CONTROLS & INSTRUMENTATION

FOR

660 MW SUPERCRITICAL UNIT @ Tiroda

1/16/2012 1
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

• Steam flow Deg. of Super Heat T

m
Ts-Tsat
T

P T

Level

Feedwater WW
control

Eco Eva
Eco
BCP
Feedwater
control

FW FW

008 406p
 Feed Water Control

SUBCRITICAL (DRUM) SUPERCRITICAL (ONCE-THRU)

Low Load Wet Mode

• Single Element Level Control • BCP in recirculation mode for Load < 30 %

Higher Load • Levelling Vessel Level Control

• Three Element 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 From
Water Wall Water Wall
O/L O/L

Levelling Vessel

To SH Spray To Condensor

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 by-
From Separator-A From Separator-B

Levelling Vessel

CV to 1st stage DSH water Drain CVs to

Condensor

BCP
Drain CVs to
BCP Discharge OAC/Waste
CV to Eco. I/L
 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 Separator O/L

Press Temperature - Ts

PV

Deg of SH + Tsat SP
F1(x) PID
X Y
0 120
12 340
19.5 377
. . Feedwater Flow
. .
PV

Desired FW Flow
Temp Correction SP
Fuel Flow F2(x) PID
block
X Y
0 0
103 663
236 1638
320 2285 TDBFP Master
. . Command
. .
AUTOMATION TECHNOLOGIES
 AUTOMATION TECHNOLOGIES

Conventional Latest

• PLC • Advanced PLCs

• DCS with local IO & limited • DCS with remote IO

processing capabilities Capability **

• Speed limited to backplane • TCP/IP communication upto

communication 1Gbps
• Server Based architecture • Mesh Topology for reliable
network
• Statement based Logic
configuration • 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 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.
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…!!