1/16/2012 1

CONTROLS & INSTRUMENTATION

FOR

660 MW SUPERCRITICAL UNIT @ Tiroda

Road Map

Instrumentation at Tiroda Power Plant

Feedwater Control

Automation technologies

IT Integration

INSTRUMENTATION @ TIRODA

Technology ApplicationSMART / HART Transmitter / Positioners

IR sensors Flame Scanner & CHP Conveyor fire detection

Piezoelectric sensors Compressor system

3D Imaging level meas Bunker level Meas

CCTV Flame Monitoring

Acoustics Sensor BTLDS

Wireless Transmitter Remote flow meas

MODBUS/OPC Third Party Interface

Application of Technology

Boiler Tube Leakage Detection System :Available Schemes :- Accoustic- Conductivity- Mass Balance

Accoustic Detection @ Tiroda- Enhanced Sensors for Noise signal measurement and elimination

- Boiler tube leak prediction through an analysis of acoustic frequency spectrum by Quick Fourier Transformation

-Location and intensity of leak identification Operator to take measures immediately to prevent the accident from worsening thereby reduce the time and cost spent on the repair

- High temperature resistant optical system consists of quartz and corundum, which can be normally operated in a certain amount of purging air.

- Screen menu setting, remote control in central control room, for forward and retract movement of camera.

- Horizontal mounting and large field angle probe

- System is equipped with automatic forward and backward protection device, which can automatically withdraw from furnace when no pressure in cooling air.

Furnace TV :

FEEDWATER CONTROL

The key differentiator between subcritical and supercritical…

008 406p

Natural circulation boiler Once-through boiler

Feedwatercontrol

Level

FW

Steam flowm•

EvaEco

TTs-Tsat

TDeg. of Super Heat

Feedwatercontrol

FW

TP

Feed Water Control

WW

EcoBCP

SUBCRITICAL (DRUM)

Low Load• Single Element Level Control

Higher Load• Three Element Level Control

SUPERCRITICAL (ONCE-THRU)

Wet Mode• BCP in recirculation mode for Load < 30 %

• Levelling Vessel Level Control

• Feedwater to Coal Flow ratio = (7 to 9) : 1

Dry Mode• BCP stopped for Load > 40%

• Feedwater to Coal Flow ratio = (7 to 9) : 1

• Flow control based on degree of superheat (21-35 deg)

Feed Water Control

Feed Water Control

From Water Wall O/L

From Water Wall O/L

Separator Tank – A

Levelling Vessel

To Superheater To Superheater

To BCP

To CondensorTo SH SprayTo SH Spray

Separator Tank - B

Main objective in Super Critical Boiler FW control system is –

a) To maintain Level of the Levelling Vessel at Wet Mode

b) To maintain Deg. Of Superheat at Separator Outlet

c) To maintain FW flow to Fuel Flow Ratio

Feed Water Control

Levelling Vessel Level Control by-

Feed Water Control

BCP

CV to 1st stage DSH water Drain CVs to

Condensor

From Separator-B

BCP Discharge

CV to Eco. I/L

Levelling Vessel

From Separator-A

Drain CVs to

OAC/Waste

Degree of Superheat is maintained in the separator outlet in the range of 21 - 35 degC

Why Degree of Superheat ?> 35 deg C : May lead to overheating of water wall tubes.

< 21 deg C : May lead to flow of wet steam to SH coils.

Note : Bias for degree of superheat > 21 degC is in Operators control

Feed Water Control

Separator O/L Temperature Control

PID

Separator O/L Temperature - Ts

Separator O/L Press

F1(x)

PID

TDBFP MasterCommand

Feedwater Flow

Fuel Flow F2(x) Temp Correctionblock

X Y0 12012 34019.5 377

. .

. .

X Y0 0103 663236 1638320 2285

. .

. .

Deg of SH + Tsat

PV

PV

SP

SPDesired FW Flow

AUTOMATION TECHNOLOGIES

AUTOMATION TECHNOLOGIES

Conventional

• PLC

• DCS with local IO & limited processing capabilities

• Speed limited to backplane communication

• Server Based architecture

• Statement based Logic configuration

Latest

• Advanced PLCs

• DCS with remote IO

Capability **

• TCP/IP communication upto 1Gbps

• Mesh Topology for reliable network

• Graphical Drag and Drop facility for logic configuration

** Used for Metal Temperature Thermocouples,CWPH, CT, FOPH, Compressor system

MESH NETWORK

DCS DETAILS

Foxboro Invensys IA System with IACC

Controller : FCP270 with Direct 100 Mbps Ethernet fiber connection and fault tolerant configuration. Number of Controllers : 27 per Unit

IO Modules : Supports all types of measurement inputs with optical isolation integrated in applicable cases. Number of IO Modules : 1400+ per Unit

Termination Assemblies : Field signal connection modules, which provide optional signal conditioning and circuit protection

Logic Configuration Software : Uses IA configuration component which is graphical based user interface

BOILER MFT

• TRICONEX

• TRIPLE MODULAR REDUNDANT SYSTEM

• HARD WIRED BACKUP RELAY PANEL

• TUV SIL3 CERTIFIED

• PROGRAMMING SOFTWARE : (Tristation 1131 Standard Programming) Class (IEC61131-3 )

1. Availability of online data-

a) For Operator

b) For Management at Tiroda

c) Corporate Office

d) Other OEMs for analysis purpose of their equipments

2. Resulting in better analysis of problems by experts and quicker solutions.

3. Improved efficiency due to high speed processing of various I/Os.

4. Reduction in outages due to highly automated and reliable control system, leading to increased PLF and availability.

5. Online performance calculation of 660MW Unit.

6. Latest technology enables predictive maintenance.

7. Reduction in Man/Megawatt Ratio.

Benefits of Latest Technology

IT INTEGRATION

IT INTEGRATION

Management Information System ( MIS ) interface with external world and office automation system

Remote access/troubleshooting of vibration monitoring system

Integration with SAP

SMS alerts on Equipment Trip / Alarms

Thank You…!!