Bharat Heavy Electricals Limited
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Topics
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BHEL’s growth in Power and Industry
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DCS solutions
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Summary
Bharat Heavy Electricals Limited
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BHEL – PRODUCT PROFILE
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Power Generation
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Power transmissions & Distribution
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Industries
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Transportation
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Oil & Gas
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Renewable Energy
Bharat Heavy Electricals Limited
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BHEL – ACTIVITIES & LOCATIONS
• A ‘Navaratna’ company and a Major
Integrated Power Plant Equipment
Manufacturer in the World
GOINDWAL
CHANDIGARH
NEW DELHI
HARIDWAR
RUDRAPUR
• 15 Manufacturing units and 8
Service Centres
JAGDISHPUR
JHANSI
4 Power Sector Regional HQs
VARANASI
BHOPAL
VADODARA
NAGPUR
PATNA
KOLKATA
HYDERABAD VISAKHAPATNAM
BANGALORE

KASARAGOD
CHENNAI
RANIPET
TIRUCHIRAPALLY
Bharat Heavy Electricals Limited
• Corporate Research &
Development Division : Hyderabad
• Over 100 Project construction sites in
India & Abroad
• BHEL manufactures 180 products in 30
major product groups
 Two Subsidiaries –BHPV, Vizag & BHEL
Electrical Machines Ltd, Kasaragod
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DCS solutions from BHEL
BHEL-Electronics Division has an on-going collaboration
agreement with Metso
BHEL has established facilities and expertise for:
System engineering
Manufacturing of modules & systems
System testing & commissioning
After sales support
Bharat Heavy Electricals Limited
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UNIFIED SOUTION FOR C&I FROM BHEL
(Advantage to Customer)
THERMAL PLANTS (15 - 800MW) HYDRO PLANTS (3.67 - 200MW)
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Boiler Controls
Turbine Controls
Station C&I
HMI
Power Plant SCADA
PADO (Performance Analysis
Diagnostics & Optimisation)
• Offsite Balance Of Plant Controls
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CCPP PLANTS (21 – 1500MW)
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Other Systems
• Interlocking in Excitation Systems •
• Interlocking in FSC / CSR / SVC / •
STATCOM
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• Interlocking in VFD system
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Bharat Heavy Electricals Limited
Auto Sequencer
Governor Controls
Remote Operation
HMI
Optimization Packages
HRSG Controls
Steam Turbine Controls
Station C&I
HMI
Interface to Gas Turbines
Power Plant SCADA
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Dadri 2x490 MW Coal based Power Project –
Largest Integrated Platform
Totally maxDNA based, including
Off-site systems
Domain 1
UNIT #1
Integrated system handles >47,000
physical I/Os and >500 operator
displays
2X34 DPU4F
17000 I/Os
1 CR, 10 RIO
(SG/TG/Stn C&I)
Domain 9
Domain A
Domain B
Domain C
Domain D
COMM SYS
WTR SYS
AHP SYS
COAL SYS
MAKEUP SYS
2X11 DPU4F
4000 I/Os
5 CR, 4 RIO
2X6 DPU4F
1670 I/Os
1 CR, 3 RIO
Domain 2
UNIT #2
(SG/TG/Stn C&I)
Bharat Heavy Electricals Limited
2X11 DPU4F
4850 I//Os
5 CR, 15 RIO
2X34 DPU4F
17000 I/Os
1 CR, 10 RIO
2X8 DPU4F
3000 I//Os
1 CR, 8 RIO
2X1 DPU4F
450 I//Os
1 CR
> 200 DPUs distributed across 7
DOMAINs
> 100 maxSTATIONs distributed
across various DOMAINs / locations.
7 Domains interconnected &
geographically distributed across 20
Sq Kms
> 45 sets Remote I/O systems
Selective Interoperability across
domains
Unit#1(Domains 1,9,A,B,C,D)
Unit#2(Domains 2,9,A,B,C,D)
Common systems - Individual
domain operations (9,A,B,C,D)
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Dadri 2x490 MW Coal based Power Project –
Largest Integrated Platform
Bharat Heavy Electricals Limited
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New Applications / Solutions Developed on maxDNA
Development & Implementation of IEC 61850 Compliant HMI
for Substation Automation on maxDNA Platform
HMI
Substation
Configuration
& Engineering
Software SCL
Manager
DRIVER
HMI
HMI
Library
Client
configuration
61850
Client
Engineering
Station
HMI Station
61850/101/10
4 Protocol
Conversion
IEC 61850
Network
Gateway
To LDC
61850
Servers
61850
Servers
• Monitoring of Analog Data for a typical
220/400 kV substation
• Controlling field devices with:
 Direct control
 Direct control with enhanced security
 Select before operate
 Select before operate with enhanced
security
• Alarms and Interlocks
• Event summary
• Report control and general interrogation
61850
Servers
IEC61850 Simulation Server / Meter
Relay/BCU
Software Components in 61850 Compliant HMI
Bharat Heavy Electricals Limited
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New Applications / Solutions Developed on maxDNA
Wireless LAN & Wireless Controls on maxNET
Connects Central Control Room (CCR) with CW Pump House (CWPH) and Fuel
Oil Pump House (FOPH) through Wireless technology at 500MW TPP.
Geographic Location Details:
CCR: Central Control Room
: Latitude - 15°11'37.58"N
: Longitude - 76°43'8.40"E
: Elevation – 1575ft
Radio Modems Installed at CCR
54Mbps RF Link1
600 Mtrs
FOPH: Fuel Oil Pump House
: Latitude -15°11'46.48"N
: Longitude - 76°43'14.88"E
: Elevation – 1576ft
25Mbps Throughput
54Mbps RF Link2
400 Mtrs
25Mbps Throughput
Radio Modems Installed at
FOPH
CWPH: Cooling Water Pump House
: Latitude -15°11'45.30"N
: Longitude - 76°43'4.01"E
: Elevation – 1566ft
Radio Modems Installed at
Bharat Heavy Electricals Limited
CWPH
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New Applications / Solutions Developed on maxDNA
Alarm Analysis System – Root Cause Analysis Package on maxDNA platform
• Diagnostic tool for fault identification in power
plant for analog and digital alarms generated by
the DDCMIS.
• Provides an intelligent root cause analysis.
• The root cause analysis is performed by efficient
traversal of decision trees built by the user for
different alarm conditions.
• The operator is notified of the root cause for
various alarm conditions with Probability.
Designed and built on four Modules:
Root Cause Analysis
Alarm Management
Alarm Annunciation
Bharat Heavy Electricals Limited
1)
2)
3)
4)
Logic Tree Module
Graphic Tree Module
Probability Computation Engine
Reporting Engine
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New Applications / Solutions Developed on maxDNA
Availability Based Tariff (ABT) on maxDNA Platform
• Provides digitized linking between power
generation and revenue
maxDNA based ABT Package
ABT
Database
IMPORT
DC-Declared Capacity
SG-Scheduled Generation
UI-Tariff, Fuel Cost etc.,
EXPORT
maxDPUTools
maxNET
Download
FREEZE/
CHECK
Outputs
maxVUE
ON-LINE
Graphical Configurator
Online Logic Building
DOWNLOAD
UPLOAD
Virtual
DPU
LDC
BROWSE
/ EDIT
• Monitor the generation or power availability
continuously to ensure 90% availability
• Meets the requirements of surprise audit to
demonstrate availability
• Ensure adequate and timely maintenance of
overall infrastructure
DPU4F
ABT Display
–ABT Package Architecture –
Bharat Heavy Electricals Limited
• Improve quality of power & curtain
frequency variation/disturbance
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New Applications / Solutions Developed on maxDNA
Numerical Relay Interface – IEC-60870-5-103
maxLinks
Status, Event
and Alarm
display
(online)
Alarm
Generation
ALARM HANDLER
Status
Data
SBP
Event
Generation
EVENT SERVER
IEC-60870-5-103
PROTOCOL
IEC-60870-5-103
DLL
IEC 103
Master
RS 485
DATABASE
IEC 103
Configuration
Numerical Relays
• Software to interface Numerical Protection Relays
Bharat Heavy Electricals Limited
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Acquire time tagged events
Events are part of maxDNA’s Alarm & Events
Configuration & runtime utility
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Runs as maxLINK
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New Applications / Solutions Developed on maxDNA
PADO for Hydro Power Plants
 Simulation & Optimization package
for Hydro Power Plants
 Built-in Web Portal capability
Designed and built on following
software Modules :
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

Optimization Software
Training Simulator
Power House Intranet
Bharat Heavy Electricals Limited
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OPERATING MODE
COLD STARTUP
New Applications / Solutions Developed
on maxDNA
Training
Simulator
WARM START
HOT STARTUP
MATHEMATICAL
MODELLING OF
EQUIPMENT
PURGE READY
UNIT READY FOR TURBINE -
BOILER &
AUXILIARIES
ROLLING
UNIT READY FOR COAL FIRING
TURBINE &
AUXILIARIES
30%,60% & 100% LOAD
ANY OTHER USER DEFINED STATE
Virtual Plant
Instructor
Station
INSTRUCTOR FUNCTION
CONTROLLERS
CLASS - A CONTROLLERS
• MAIN STEAM PRESSURE
• DRUM LEVEL
• SH STEAM TEMPERATURE
• RH STEAM TEMPERATURE
• BURNER TILT
• FURNACE PRESSURE
• O2
• CMC
REST OF THE CONTROLLERS
Burner Management System (BMS)
• Oil Firing
• Coal Firing
• Unit Start up
Bharat Heavy Electricals Limited
Automatic Turbine Run-up System
(ATRS)
• Turbine
• Turbine Oil
• Evacuation
INITIAL CONDITIONS
RUN
FREEZE
MAL FUNCTIONS
LOCAL OPERATIONS
SNAP SHOTS
RECORD
REPLAY
BACK TRACK
RATE OF
SIMULATION
MALFUNCTIONS
EQUIPMENT/SYSTEM
TRIP
UNIT TRIP
ABNORMAL
PROCESS
BEHAVIOUR
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Bharat Heavy Electricals Limited
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29TH MARCH 2010
Metso DNA Architecture
Control room
Office
Operation, Maintenance, Reporting
Reporting, Enterprise integration
Remote connections
Star or ring topology
redundant Ethernet network
Controls,
Optimization,
Connectivity
and
Safety
instrumented
system
Name based communication
Automation room
Centralized or
distributed
Engineering &
Maintenance,
Asset Management,
Information services
Field
Ethernet and
serial links
No need of internal communication links
No need of internal servers
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Bharat Heavy Electricals Limited
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Salient features:
• Powerful & Reliable Controllers
with Flexible Field Options
• All type of Field buses
supported
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Build-in HART connectivity
PROFIBUS
Foundation Field Bus
Wireless
• Multi Windows
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Arrange, resize, zoom and pan windows
Multi Monitor support
• Store Picture & Desktop layout
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Based on process situations, tasks and
organizational roles
• Robust network architecture
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Ring & RSTP Topology
Handles more than one point failure.
Bharat Heavy Electricals Limited
• Dynamic function and
interlocking descriptions
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For machine and process
• History Mode - Time machine
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Replay history from any picture
• Faster analysis by single click
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Reporting, maintenance and Analysis
tools integrated with DNAuse
• Diagnostic from all levels
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Network devices and System bus
System nodes, WS
IO groups, buses,
Field devices and IO
Control software and databases
Link to third party systems
• Remote diagnostic facility
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DNA Operate – Efficient Problem
Solving - Operation Tools
Start History mode
History mode indication
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Efficient alarm analysis with
1 ms Sequence of Events
(SOE)
Replay history from any
picture, “time machine”
Drag and drop trend
analysis
Dynamic function and
interlocking descriptions for
machine and process
Integrated diary entries for
trends and loops
Select displayed moment
and replay
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Bharat Heavy Electricals Limited
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DNAtracer – trend and analysis tool
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Bharat Heavy Electricals Limited
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Use Any Time, Anywhere
Reporting and Analysis tools Summary
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All information is continuously
available throughout the enterprise
via one web portal
Informative presentation of data
– Align quality, production and
costs
Results community makes correct
decisions based on the same facts
The potential improvement targets
and deviation in process are easily
detected – Source of innovations
Environmental reporting is according
to the regulations –
No surprises
The team can focus on more value
adding tasks, since manual reporting
is eliminated
Same tools throughout The Results Community for
professionals in the Office and Control Room
Share And Increase Organization’s Knowledge
Community and Collaboration
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Global situation awareness with
discussion tools
– DNAdiary, discussion forum,
instant messaging, video
conferencing
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Integrated to process operation
– One button launch
• E.g. Video
conferencing and
instant messaging
– Fully automatic entries
• DNAdiary
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Bharat Heavy Electricals Limited
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DNAexplorer for Plant Management
Engineering and Maintenance Tools
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One powerful tool for
engineering and
maintenance of
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field devices
HW and network
documents
user interface
control application
field bus
Explore through the
network
Intuitive to use
SUMMARY
Bharat Heavy Electricals Limited
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SUMMARY
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Capability to provide control solutions for a wide
spectrum of ratings of Power plants
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Ability to provide unified solutions to meet ever increasing
customer requirements
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Availability of In-House state of art facilities & capabilities
for manufacturing
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Availability of State of art Engineering center
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Rich experience with more than 600 DCS in service
Bharat Heavy Electricals Limited
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Bharat Heavy Electricals Limited
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