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ADANI POWER MAHARASHTRA LTD, TIRORAADANI POWER MAHARASHTRA LTD, TIRORA
1/16/2012 1
ADVANCED CONTROL SYSTEM
660 MWSUPERCRITICAL UNIT @ Tiroda
Mr. N. D. Prasad
Mr. Shriram Pimplikar
Mr. Rakesh Dash
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ADANI POWER MAHARASHTRA LTD, TIRORA
Road Map
Advancements in Power Plant process measurementtechnology
Field Instrumentation ( pressure, level etc )
Latest Trends in C&I
Feedwater Control
Automation technologies
IT Integration
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ADANI POWER MAHARASHTRA LTD, TIRORA
Advancements in ProcessMeasurement technology
Field Instrumentation ..
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ADANI POWER MAHARASHTRA LTD, TIRORA
TRANSMITTERS
Conventional Sensors
Strain Gauge
Potentiometer
Capacitance Type
Latest Sensors
Capsule
Piezoelectric
Magnetic type
Optical type
Silicon Resonant
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ADANI POWER MAHARASHTRA LTD, TIRORA
PROCESS MEASUREMENT
Conventional Protocols
One Transmitter for one type of
measurement
4-20 Ma
Local Calibration
No health monitoring
Latest Protocols
Multivariable Transmitter
HART
Fieldbus
Remote Calibration & Health
Monitoring
Multivariable transmitters
( measures, temp, press etc. )
HART Settings
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ADANI POWER MAHARASHTRA LTD, TIRORA
TEMPERATURE MEASUREMENT
Conventional
RTD
Thermocouple
Thermistor
Latest
RTD/Thermcouple
Wireless IR
Thermal Imaging
Head Mounted integrated
sensor/transmitter
Thermal Imaging
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ADANI POWER MAHARASHTRA LTD, TIRORA
LEVEL MEASUREMENT
Conventional
Capacitance Type
Inductance Type
Latest
Radar
Ultrasonic
3D Level Scanner
Radar Type
3D Type
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ADANI POWER MAHARASHTRA LTD, TIRORA
FLOW MEASUREMENT
Conventional
DP Type using Orifice, Venturi etc
Mechanical ( turbine ) type
Latest
Magnetic Type
Ultrasonic
Coriolis Type for Mass Flow
Positive Displacement type
Magnetic Type
DP Type
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ADANI POWER MAHARASHTRA LTD, TIRORA
CONTROL VALVE POSITIONER
Conventional
Separate I/P converter
Separate mechanical type
positioner with limit switches &
feedback
Mechanical zero and span setting
Latest
SMART Positioners
integrated with I/P converter
Configurable limit switches (
NO/NC ) and position feedback
Auto Calibration for zero and
span, Fail Safe condition
Configurable for valve
characteristic
SMART POSITIONERSSADC
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ADANI POWER MAHARASHTRA LTD, TIRORA
Boiler Tube Leakage System :
-Noise signal of the boiler tube leak is capturedby the Enhanced Sensors.
-Next a variety of noise disturbance is eliminated occurring during the boileroperation.
- Finally the boiler tube leak is predicted through an analysis of acoustic frequency
spectrum got by Quick Fourier Transformation on computer.
- Moreover, the location and intensity of leak can be identified.
In this way, the operator can take some measures immediately to prevent the
accident from worsening, reduce the time and cost spent on the repair
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ADANI POWER MAHARASHTRA LTD, TIRORA
Advanced Type of Oil Gun/Ignitor System
Basic Components :
- Oil Gun Assy. With Cylinder and Limit Switch
- Solenoid Valve Box
- Power pack with 20J HESI
- High Energy Cable
Swirler
Apron Flange
Junction
Box
Air
Supply
Cylinder
Limit
Switch Oil Gun
Body
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ADANI POWER MAHARASHTRA LTD, TIRORA
Technology Application
High Precision Digital
Pressure Indicator
C&I Lab Test Bench
Accoustic sensor Boiler Tube Leakage
Detection System
IR sensors
SMART technology
Flame Scanner & CHP
Conveyor fire detection
POSITIONERS
Piezoelectric sensors Compressor system
3D Imaging level meas CHP/AHP bunker level
CCTV
HART
MODBUS / OPC
Boiler Flame & other critical
areas
Transmitters
Third Party / IT Interface
Technology vs. Application
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ADANI POWER MAHARASHTRA LTD, TIRORA
008 406p
Natural circulation boiler Once-through boiler
Feedwatercontrol
Level
Feedwater
Steam flowm
EvaEco
T
T
Enthalpy
Feedwatercontrol
Feedwater
TP
Eco
Eva
CONTROLS
Sub Critical vs. Super Critical
Feedwater Control
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ADANI POWER MAHARASHTRA LTD, TIRORA
Feedwater ControlSUBCRITICAL (DRUM)
Three Element Drum LevelControl
SUPERCRITICAL (ONCE-THRU)
Feedwater to Coal Flow ratio = 7 to 9
BCP in recirculation mode for BMCR load < 30 %
BCP stopped for BMCR load > 40%
Flow control based on degree of
superheat (22-35 deg)
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ADANI POWER MAHARASHTRA LTD, TIRORA
AUTOMATION TECHNOLOGIES
Conventional
PLC
DCS with local IO & limited
processing capabilities
Speed limited to backplane
communication
Server Based architecture
Statement based Logicconfiguration
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 Thermcouples,
CWPH, CT, FOPH, Compressor system
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ADANI POWER MAHARASHTRA LTD, TIRORA
DCS HARDWARE ARCHITECTURE
Offsite PLC Interface
through Modbus,OPC etc
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ADANI POWER MAHARASHTRA LTD, TIRORAMESH NETWORK
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ADANI POWER MAHARASHTRA LTD, TIRORA
DCS DETAILS
Foxboro Invensys IA System with IACC
Controller: FCP270 with Direct 100 Mbps Ethernet fiber connectionand fault tolerant configuration
IO Modules : Supports all types of measurement inputs with opticalisolation integrated in applicable cases
Termination Assemblies : Field signal connection modules, whichprovide optional signal conditioning and circuit protection
Logic Configuration Software : Uses IA configuration componentwhich is graphical based user interface
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ADANI POWER MAHARASHTRA LTD, TIRORA
DCS Configuration
Number of I/Os per unit : 9000 +
Number of I/O Modules : 1400+
Number of I/O cabinets : 66
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ADANI POWER MAHARASHTRA LTD, TIRORA
BOILER MFT
TRICONEX TRIPLE MODULAR REDUNDANT (TMR) SYSTEM USED FORBOILER MASTER FUEL TRIP INITIATION
TUV SIL3 CERTIFIED
PROGRAMMING SOFTWARE :
Tristation 1131 Standard ProgrammingClass ( IEC61131-3 )
ADANI POWER MAHARASHTRA LTD TIRORA
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BTG/Offsite System PLC Hardware Software
ETS GE Fanuc 90-70 Invensys
Intake Water AllenBradley make
Logix L32E
RX Logic 5000
FOPH GE make PAC-Rx3i
SCADA - Cimplicity
Engineering S/W
Machine Addition 6.0
CHP GE make PAC-Rx3i
DM Plant GE make PAC-Rx3i
Ash Handling Plant GE make PAC-Rx3i
Mill Reject system GE make PAC-Rx3i
Aux. Boiler ABB make - PM590 Code-Sys
ADANI POWER MAHARASHTRA LTD, TIRORA
Various PLC systems used for BTG / Offsite Systems
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ADANI POWER MAHARASHTRA LTD, TIRORA
Total Plant Automation
Coordinated Master Control (CMC) /
Coordindated Control System (CCS)
Free Governor Mode of Operation (FGMO)
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ADANI POWER MAHARASHTRA LTD, TIRORA
IT INTEGRATION
Management Information System ( MIS )interface with external world and officeautomation system
Remote access/troubleshooting of vibrationmonitoring system
Integration with SAP
SMS alerts on Equipment Trip / Alarms
ADANI POWER MAHARASHTRA LTD TIRORA
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ADANI POWER MAHARASHTRA LTD, TIRORA
Benefits of Latest Technology:-
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.
ADANI POWER MAHARASHTRA LTD TIRORA
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Thank You!!