CONTROLS & INSTRUMENTATION

FOR
660 MW SUPERCRITICAL UNIT @ Tiroda

1/16/2012

Road Map

Instrumentation at Tiroda Power Plant

Feedwater Control

Automation technologies

IT Integration

INSTRUMENTATION @ TIRODA

Application of Technology
Technology

Application

SMART / 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

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

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, 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.

FEEDWATER CONTROL

The key differentiator between subcritical and supercritical

Feed Water Control

Natural circulation boiler

Once-through boiler
Deg. of Super Heat

Steam flow

Ts-Tsat

Level
Feedwater
control

Eco

Eva

Eco
BCP

Feedwater
control

FW

008 406p

WW

FW

Feed Water Control

SUBCRITICAL (DRUM)

SUPERCRITICAL (ONCE-THRU)

Low Load
Single Element Level Control

Wet Mode
BCP in recirculation mode for Load < 30 %

Higher Load
Three Element Level Control

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

To Superheater

To Superheater

Separator Tank A

Separator Tank - B
From
Water Wall
O/L

From
Water Wall
O/L

Levelling Vessel

To Condensor

To SH Spray
To BCP

Feed Water Control

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 byFrom Separator-A

From Separator-B

Levelling Vessel

Drain CVs to
Condensor

CV to 1st stage DSH water

BCP

BCP Discharge
CV to Eco. I/L

Drain CVs to
OAC/Waste

Feed Water Control

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

Separator O/L Temperature Control

Separator O/L
Press

Separator O/L
Temperature - Ts
PV

Deg of SH + Tsat
X
0
12
19.5

Y
120
340
377

.
.

.
.

SP

F1(x)

PID

Feedwater
Flow
PV
Desired FW Flow

F2(x)

Fuel Flow
X
0
103
236
320

Y
0
663
1638
2285

.
.

.
.

Temp Correction
block

SP

PID

TDBFP Master
Command

AUTOMATION TECHNOLOGIES

AUTOMATION TECHNOLOGIES
Conventional

Latest

PLC

Advanced PLCs

DCS with local IO & limited

processing capabilities

DCS with remote IO

Speed limited to backplane

communication

TCP/IP communication upto

1Gbps

Server Based architecture

Mesh Topology for reliable

network

Statement based Logic

configuration

Capability **

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 )

Benefits of Latest Technology

1. Availability of online dataa) 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.

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!!