Advanced Control System.ppt

CONTROL

1. ADANI POWER MAHARASHTRA LTD, TIRORA ADANI 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

2. ADANI POWER MAHARASHTRA LTD, TIRORA
Road Map
Advancements in Power Plant process measurement
technology
Field Instrumentation ( pressure, level etc )
Latest Trends in C&I
Feedwater Control
Automation technologies
IT Integration

3. ADANI POWER MAHARASHTRA LTD, TIRORA
Advancements in Process
Measurement technology
Field Instrumentation …..

4. ADANI POWER MAHARASHTRA LTD, TIRORA
TRANSMITTERS
Conventional Sensors
•Strain Gauge
•Potentiometer
•Capacitance Type
Latest Sensors
•Capsule
•Piezoelectric
•Magnetic type
•Optical type
•Silicon Resonant

5. 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

6. 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

7. ADANI POWER MAHARASHTRA LTD, TIRORA
LEVEL MEASUREMENT
Conventional
•Capacitance Type
•Inductance Type
Latest
•Radar
•Ultrasonic
•3D Level Scanner
Radar Type
3D Type

8. 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

9. 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 POSITIONERS
SADC

10. 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 boiler
operation.
-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

11. ADANI POWER MAHARASHTRA LTD, TIRORA
-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, and forward and
backward of image and propeller.
-Horizontal mounting and large field angle probe are suitable for boilers with various
models.
-System is equipped with automatic forward and backward protection device, which
can automatically withdraw from furnace when no pressure in cooling air.
Furnace TV :

12. 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
SwitchOil Gun
Body

13. 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

14. ADANI POWER MAHARASHTRA LTD, TIRORA
008 406p
Natural circulation boiler Once-through boiler
Feedwater
control
Level
Feedwater
Steam flow
m
•
EvaEco
T
T
Enthalpy
Feedwater
control
Feedwater
TP
Eco
Eva
CONTROLS
Sub Critical vs. Super Critical
Feedwater Control

15. ADANI POWER MAHARASHTRA LTD, TIRORA
Feedwater Control
SUBCRITICAL (DRUM)
•Three Element Drum Level
Control
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)

16. 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 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 Thermcouples,
CWPH, CT, FOPH, Compressor system

17. ADANI POWER MAHARASHTRA LTD, TIRORA
DCS HARDWARE ARCHITECTURE
Offsite PLC Interface
through Modbus,
OPC etc

18. ADANI POWER MAHARASHTRA LTD, TIRORA
MESH NETWORK

19. ADANI POWER MAHARASHTRA LTD, TIRORA
DCS DETAILS
Foxboro Invensys IA System with IACC
Controller: FCP270with Direct 100 Mbps Ethernet fiber connection
and fault tolerant configuration
IO Modules : Supports all types of measurement inputs with optical
isolation integrated in applicable cases
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

20. 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

21. ADANI POWER MAHARASHTRA LTD, TIRORA
BOILER MFT
•TRICONEX TRIPLE MODULAR REDUNDANT (TMR) SYSTEM USED FOR
BOILER MASTER FUEL TRIP INITIATION
•TUV SIL3 CERTIFIED
•PROGRAMMING SOFTWARE :
Tristation 1131 Standard Programming
Class ( IEC61131-3 )

22. ADANI POWER MAHARASHTRA LTD, TIRORA
BTG/Offsite SystemPLC 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 PlantGE make –PAC-Rx3i
Mill Reject systemGE make –PAC-Rx3i
Aux. Boiler ABB make -PM590 Code-Sys
ADANI POWER MAHARASHTRA LTD, TIRORA
Various PLC systems used for BTG / Offsite Systems

23. ADANI POWER MAHARASHTRA LTD, TIRORA
Total Plant Automation
Coordinated Master Control (CMC) /
Coordindated Control System (CCS)
Free Governor Mode of Operation (FGMO)

24. ADANI POWER MAHARASHTRA LTD, TIRORA
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

25. 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.

26. ADANI POWER MAHARASHTRA LTD, TIRORA
Thank You…!!