ADANI POWER MAHARASHTRA LTD, TIRORA
ADVANCED CONTROL SYSTEM
660 MW SUPERCRITICAL UNIT @ Tiroda
Mr. N. D. Prasad
Mr. Shriram Pimplikar
Mr. Rakesh Dash
1/16/2012
1
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
ADANI POWER MAHARASHTRA LTD, TIRORA
Advancements in Process
Measurement technology
Field Instrumentation …..
ADANI POWER MAHARASHTRA LTD, TIRORA
TRANSMITTERS
Conventional Sensors
Latest Sensors
• Strain Gauge
• Capsule
• Potentiometer
• Piezoelectric
• Capacitance Type
• Magnetic type
• Optical type
• Silicon Resonant
ADANI POWER MAHARASHTRA LTD, TIRORA
PROCESS MEASUREMENT
Conventional Protocols
Latest Protocols
• One Transmitter for one type of
measurement
• Multivariable Transmitter
• HART
• 4-20 Ma
• Fieldbus
• Local Calibration
• No health monitoring
• Remote Calibration & Health
Monitoring
HART Settings
Multivariable transmitters
( measures, temp, press etc. )
ADANI POWER MAHARASHTRA LTD, TIRORA
TEMPERATURE MEASUREMENT
Conventional
Latest
• RTD
• RTD/Thermcouple
• Thermocouple
• Wireless IR
• Thermistor
• Thermal Imaging
• Head Mounted integrated
sensor/transmitter
Thermal Imaging
ADANI POWER MAHARASHTRA LTD, TIRORA
LEVEL MEASUREMENT
Conventional
Latest
• Capacitance Type
• Radar
• Inductance Type
• Ultrasonic
• 3D Level Scanner
Radar Type
3D Type
ADANI POWER MAHARASHTRA LTD, TIRORA
FLOW MEASUREMENT
Conventional
Latest
• DP Type using Orifice, Venturi etc
• Mechanical ( turbine ) type
• Magnetic Type
• Ultrasonic
• Coriolis Type for Mass Flow
• Positive Displacement type
DP Type
Magnetic Type
ADANI POWER MAHARASHTRA LTD, TIRORA
CONTROL VALVE POSITIONER
Conventional
Latest
• Separate I/P converter
• SMART Positioners
integrated with I/P converter
• Separate mechanical type
positioner with limit switches &
feedback
• Mechanical zero and span setting
• Configurable limit switches (
NO/NC ) and position feedback
• Auto Calibration for zero and
span, Fail Safe condition
• Configurable for valve
characteristic
SMART POSITIONERS
SADC
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
ADANI POWER MAHARASHTRA LTD, TIRORA
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.
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
Cylinder
Air
Supply
Swirler
Apron
Flange
Limit
Switch Oil Gun
Body
Junction
Box
ADANI POWER MAHARASHTRA LTD, TIRORA
Technology vs. Application
Technology
Application
High Precision Digital
Pressure Indicator
C&I Lab Test Bench
Accoustic sensor
Boiler Tube Leakage
Detection System
IR sensors
Flame Scanner & CHP
Conveyor fire detection
SMART technology
POSITIONERS
Piezoelectric sensors
Compressor system
3D Imaging level meas
CHP/AHP bunker level
CCTV
HART
Boiler Flame & other critical
areas
Transmitters
MODBUS / OPC
Third Party / IT Interface
ADANI POWER MAHARASHTRA LTD, TIRORA
CONTROLS
Sub Critical vs. Super Critical
Natural circulation boiler
Once-through boiler
Feedwater Control
•
m
Steam flow
T
Enthalpy
T
P
T
Level
Feedwater
control
Eco
Eva
Feedwater
control
Eco
Feedwater Feedwater
008 406p
Eva
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)
ADANI POWER MAHARASHTRA LTD, TIRORA
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 Thermcouples,
CWPH, CT, FOPH, Compressor system
ADANI POWER MAHARASHTRA LTD, TIRORA
DCS HARDWARE ARCHITECTURE
Offsite PLC Interface
through Modbus,
OPC etc
ADANI POWER MAHARASHTRA LTD, TIRORA
MESH NETWORK
ADANI POWER MAHARASHTRA LTD, TIRORA
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
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

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 )
ADANI POWER MAHARASHTRA LTD, TIRORA
Various PLC systems used for BTG / Offsite Systems
BTG/Offsite System
PLC Hardware
Software
ETS
GE Fanuc 90-70
Invensys
Intake Water
AllenBradley make – RX Logic 5000
Logix L32E
FOPH
GE make – PAC-Rx3i
CHP
GE make – PAC-Rx3i SCADA - Cimplicity
DM Plant
GE make – PAC-Rx3i
Ash Handling Plant
GE make – PAC-Rx3i
Mill Reject system
GE make – PAC-Rx3i
Aux. Boiler
ABB make - PM590
Engineering S/W –
Machine Addition 6.0
Code-Sys
ADANI POWER MAHARASHTRA LTD, TIRORA
Total Plant Automation

Coordinated Master Control (CMC) /
Coordindated Control System (CCS)

Free Governor Mode of Operation (FGMO)
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
ADANI POWER MAHARASHTRA LTD, TIRORA

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.
ADANI POWER MAHARASHTRA LTD, TIRORA
Thank You…!!