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 • Multivariable Transmitter

measurement
• HART
• 4-20 Ma
• Fieldbus
• Local Calibration
• Remote Calibration & Health
• No health monitoring 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 • Magnetic Type

• Mechanical ( turbine ) 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 & • Configurable limit switches (
feedback NO/NC ) and position feedback

• Mechanical zero and span setting • 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 Limit
Switch Oil Gun
Cylinder Body

Air Junction
Supply Box
Swirler
Apron Flange
ADANI POWER MAHARASHTRA LTD, TIRORA
Technology vs. Application
Technology Application
High Precision Digital C&I Lab Test Bench
Pressure Indicator
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 Boiler Flame & other critical

areas
HART 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
• Steam flow
m T
Enthalpy
T

P T

Level

Feedwater
Eva
control
Eco Eva

Feedwater
control
Eco
Feedwater Feedwater

008 406p
 ADANI POWER MAHARASHTRA LTD, TIRORA
Feedwater Control
SUBCRITICAL (DRUM) SUPERCRITICAL (ONCE-THRU)
Feedwater to Coal Flow ratio = 7 to 9
• Three Element Drum Level • BCP in recirculation mode for BMCR load < 30 %
Control • 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 • 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 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
Engineering S/W –
Ash Handling Plant GE make – PAC-Rx3i
Machine Addition 6.0
Mill Reject system GE make – PAC-Rx3i
Aux. Boiler ABB make - PM590 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 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.
ADANI POWER MAHARASHTRA LTD, TIRORA

Thank You…!!