Advanced Control System

ADANI POWER MAHARASHTRA LTD, TIRORA
ADVANCED CONTROL SYSTEM

660 MW SUPERCRITICAL UNIT @ Tiroda
1/16/2012
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
Advancements in Process Measurement technology
Field Instrumentation ..

TRANSMITTERS
Conventional Sensors Strain Gauge Potentiometer Capacitance Type Latest Sensors Capsule Piezoelectric Magnetic type
Optical type
Silicon Resonant

PROCESS MEASUREMENT Conventional Protocols One Transmitter for one type of measurement 4-20 Ma Fieldbus Local Calibration No health monitoring Remote Calibration & Health Monitoring HART Settings Latest Protocols
Multivariable Transmitter
HART
Multivariable transmitters ( measures, temp, press etc. )

TEMPERATURE MEASUREMENT Conventional RTD Thermocouple Latest RTD/Thermcouple Wireless IR
Thermistor
Thermal Imaging
Head Mounted integrated sensor/transmitter
Thermal Imaging

LEVEL MEASUREMENT Conventional Capacitance Type Inductance Type
Latest
Radar Ultrasonic 3D Level Scanner
Radar Type
3D Type

FLOW MEASUREMENT Conventional DP Type using Orifice, Venturi etc Mechanical ( turbine ) type Latest Magnetic Type Ultrasonic
Coriolis Type for Mass Flow

Positive Displacement type DP Type Magnetic Type

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

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

Furnace TV : 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.
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
Cylinder
Limit Switch Oil Gun Body
Air Supply
Junction Box
Swirler
Apron
Flange
Technology vs. Application

Technology
High Precision Digital Pressure Indicator Accoustic sensor IR sensors
Application
C&I Lab Test Bench Boiler Tube Leakage Detection System Flame Scanner & CHP Conveyor fire detection POSITIONERS Compressor system
SMART technology Piezoelectric sensors
3D Imaging level meas

CCTV
CHP/AHP bunker level

Boiler Flame & other critical areas Transmitters Third Party / IT Interface
HART
MODBUS / OPC
CONTROLS
Sub Critical vs. Super Critical
Natural circulation boiler Once-through boiler
Feedwater Control
m T Steam flow
Enthalpy
Level
Feedwater control
Eva
Eco
Eva
Feedwater control
Eco Feedwater Feedwater
008 406p
Feedwater Control
SUBCRITICAL (DRUM)
SUPERCRITICAL (ONCE-THRU)
Three Element Drum Level Control
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)
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
DCS HARDWARE ARCHITECTURE

Offsite PLC Interface through Modbus, OPC etc

MESH NETWORK
DCS DETAILS
Foxboro Invensys IA System with IACC Controller : FCP270 with 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
DCS Configuration
Number of I/Os per unit : 9000 + Number of I/O Modules : 1400+ Number of I/O cabinets : 66
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 )
Various PLC systems used for BTG / Offsite Systems
BTG/Offsite System ETS Intake Water FOPH
PLC Hardware GE Fanuc 90-70
Software Invensys
AllenBradley make RX Logic 5000 Logix L32E GE make PAC-Rx3i
CHP
DM Plant Ash Handling Plant Mill Reject system Aux. Boiler
GE make PAC-Rx3i SCADA - Cimplicity

GE make PAC-Rx3i GE make PAC-Rx3i GE make PAC-Rx3i ABB make - PM590 Code-Sys
Engineering S/W Machine Addition 6.0
Total Plant Automation
Coordinated Master Control (CMC) / Coordindated Control System (CCS) Free Governor Mode of Operation (FGMO)
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
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.
Thank You!!

Advanced Control System

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ADANI POWER MAHARASHTRA LTD, TIRORA