BHEL Automation Migration Solution

8/12/2019 BHEL Automation Migration Solution

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Bharat Heavy Electricals LimitedElectronics Division

Bangalore

ARC - 2012



Bharat Heavy Electricals LimitedElectronics Division Bangalore

ARC - 2012

Due to aging.

Due to Obsolescence of the components/ modules of DCS - unable to repair

or replace any more

Requirement of meeting change in Environmental regulation

Installation of new systems or process or increase in capacity of the

existing plant calling for change in existing automation requirement.

Bringing most of the controls onto a single platform - for better spares and

maintenance management

Improving the operating efficiency.

Improving information flow to ease operation.Change in production schedule based on various norms and benefits

Life extension of the plant

And Many more…………………

Why Migration

igration requirement is continuous………




ARC - 2012

BEFORE AFTER

AFTER

MIGRATION

COMPLETE REPLACEMENT TRANSITIONAL UPGRADE OFELEMENTS OF THE SYSTEM

‘PLUG - IN’ SYSTEM TO OBTAINTHE ADDITIONAL FUNCTIONALITY.

Migration Possibilities




ARC - 2012

BEFORE AFTER

Developing a migration cost/benefit analysis

Leveraging existing investments

Determining functional versus value-added replacement

Reducing installation time to hours, not daysMinimizing process impact during system changeover

Avoiding costly rewiring or extra footprints

Achieving one-for-one I/O replacement

Choosing phased versus complete migration approachesEvaluating system platform openness

…………………

FEW CONSIDERATIONS




ARC - 2012

BEFORE AFTER

FEW CONSIDERATIONS

Selecting the best criteria for new partners and platforms

Handling process suites

Ensuring a solid path to long-term support

Speed, field modules, software capacity, and security.

Possibility to manage modern instrumentation

Not to lose connection with old instruments

Open systems




ARC - 2012

BEFORE AFTER

AFTER

State Of The Art Technology Higher Reliability And Availability

Better Diagnostics

Faster Response

Better accuracy and control Possibility of higher level optimization solutions

Ease Of Maintenance

Flexible For Modification

Improved Aesthetics Better Spares Availability

Remote Diagnostics And Information Availability.

And Many More……..

ADVANTAGES OF MIGRATION




ARC - 2012

BEFORE AFTER

AFTER

AUTOMATION MIGRATION IN THERMAL POWER PLANTS

……….NEED OF THE HOUR




ARC - 2012

BEFORE AFTER

AFTER

Power demand in the country is witnessing unprecedented growth creatinghigher ‘demand – supply’ mismatch.

In order to bridge this huge demand-supply gap it is imperative to operate theexisting aged power plants more efficiently and effectively and hence thenecessity to renovate and modernize these power plants.

Rapid developments in the field of automation and control systems provide thepower plant personnel with immense opportunities to achieve completeprocess/plant information access and control of multiple units from centralizedplace, thus ensuring safe, reliable and efficient operation of plant with moreinformation, data, diagnostic features at operator desk.

Technology obsolescence rate is high in field of C&I linked to electroniccomponent Obsolescence and upgrades. Spares & services are not available forolder power plants. New C&I system will equip the operator to manage and torun the plant by optimally maintaining the process parameters and hence it isthe necessary to renovate and modernize the C&I.

Conducive Environment



Potential Market

Done so for is just 2800 MWs since 1984

•

A large number of 200/250 MW & some 500 MW units majoritybeing with German / Czech technology are in operation for morethan 15 years and the control platform in last 15 years havebecome state of art which provides a high potential for lifeextension & efficiency improvement in turn to upgrades inautomation

Rating Running for> 15 Years

Running for> 20 Years

Designbasis

200/ 210 MW 53 LMZ design

200 / 210 MW 37 12 KWU Design

500 MW 12 2

• Thus a large portion of more than 25000 MW is due for R&Mupgrades

• Most of these plants are equipped either with relay+solidstatesystems or earlier version microprocessor based systems



BOILER CONTROL SYSTEMBurner Management SystemSoot Blower Control SystemSec. Air Damper Control SystemHp Bypass ControlAux. PRDS ControlReplacement of old nozzle valves & tripvalves for Burner Management System.Existing relay based/solid state andobsolete system shall be replaced with stateof art DCS and also wherever requirednecessary replacement of final actuatorsshall be done.

Scope for R&M of DCS for typical Thermal Power PlantTURBINE CONTROL SYSTEMS

(on as applicable basis)Turbine Supervisory EquipmentElectro Hydraulic Turbine GoverningTurbine Stress EvaluatorGland Steam Sealing / LP BypassAuto Turbine Run-up System/ Auto TurbineTesting

Turbine ProtectionExisting relay based/solid state and obsoletesystem shall be replaced with state of artDCS. FGMO ( Free Governing Mode of Operation)

STATION C & I CONTROL SYSTEM

Auto controls such asMaster Pressure Control, Air Flow Control, Furnace Draft, Coordinated Master control (whereverpossible), Milling Plant Control, Drum Level Control, Super heater / Reheater Temp. Control, BFPScoop Control, Cond. Level control, De-aerator Pressure / Level Control etc.

Interlock & Protection For All AuxiliariesExisting relay based/solid state and obsolete system shall be replaced with State of art DCS.

This all couple with Human Machine Interface to replace the conventional operator interface



SEE / AVR CONTROL SYSTEM

Static Excitation equipment consisting of Regulation Panel with HMI, Thyristor, Field breaker, Field Flashing Panels.

Excitation Transformer and Tap off Bus Duct.

Digital Automatic Voltage regulator (Brushless and Conventional with Exciter)

OTHER BOP SYSTEMS TO UNIFIED

PLATFORMControls for Coal Handling Plant (CHP)

Controls for Ash Handling Plant (AHP)

Controls for Water System (WS)

Controls for Make Up Water System (MU)

Controls for Stand Alone Common Systems(SAC)

Mill Reject Systems

Fuel Oil unloading and Pump house

And other off-site applications

Scope for R&M of DCS for typical Thermal Power Plant

ADD-ON OR UPGRADEOPTIMISATION SOLUTIONS

Performance Analysis and Optimisation

packages

ABT recommendation packages

Asset Management packages like CMMS

Etc………….



SYSTEM EXISTING PROPOSED ADVANTAGES

PRIMARYINSTRUMENTSTRANMITTERSCONTROL ROOMDISPLAY/RECORDINGEQUIPMENT

CONTROL DESKEQUIPMENT & POWERSUPPLY

SWAS &GAS ANALYSER

ELECTRO -MECHANICALINDICATORS ANDPOTENTIOMETRICRECORDERS

LOCAL / REMOTECONTROL THROUGHPUSH BUTTON &LAMPS

OBSOLETE

SMART TRANSMITTERSPC BASED DATAAQCUISITION SYSTEM WITHCRT DISPLAY, VIDEOPROCESS CONTROL &SCADA & REMOTE CONTROL,DATA ACQUISITION FORELECTRICAL SYSTEM,ALARMMANAGEMENT & HISTORIAN& SOE etc.

CENTRALLISED VIDEOPROCESS CONTROLWITH MINIMUM BACK UPFOR EMERGENCY SHUTDOWN.

ON-LINE STATE OFARTINSTRUMENTATION

• BETTERAESTHETICS• INFORMATIONAVAILABILIITY ATA SINGLE PLACE• ENERGY SAVINGBETTERDIAGNOSTICS• EASE INCOMMISSIONING &MAINTENANCE• BETTERAVAILABILITY OFSPARES &SERVICESUPPORT• BETTERACCURACY AND

CONTROL

Instrumentation Scope for R&M of DCS for typical Thermal Power Plant



OPTIONS OF PHASED MIGRATION IN THERMAL POWER PLANTS

Only HMI

Only Integral Controls

Add on packages

Only Station C&I Controls

Total solutions

It can togetheror phasedmanner basedon the need /shutdown /condition ofthe equipment

needs change

Only Controls retaininginstrumentation and fieldcabling





ADD-ON OR UPGRADE OPTIMISATION SOLUTIONS Performance Analysis and Optimisation packages

ABT recommendation packages

Asset Management packages like CMMS

Etc………….





System Engineering support.

Process schemes and logics availability as built to suit main equipment

Space Availability.

Scope clarity and limits.

Availability Complete Data sheet / details of existing field instruments, actuators etc.Translation of existing manual controls done by operators to auto controls to makesame look and feel.

Challenging commissioning schedule.

Erection and interface to suit the existing instruments / field wiring / JBs etc

Training of operator to quickly adopt to the changed scenario

Challenges of adopting protection.

Proving Return on investment . .

CHALLENGES




ARC - 2012

BEFORE AFTER

AFTER

AUTOMATION MIGRATION IN THERMAL POWER PLANTS

……….BHEL Experience



BHEL is the original equipment manufacturer for Boiler & TG for most of powerplants The integral Controls of the main equipment shall take care of safety andprotection of main equipment and form essential part of equipment itself.Hence it is preferred that the integral controls are supplied by the originalequipment manufacturer. The interlocks and control logics shall also form part of the main machine andthe systems like EHTC, LP Bypass, HP Bypass, Automatic Turbine Run-up andTester System etc. are designed to match the field equipment. This knowledgebase is proprietary of BHEL.BHEL has vast experience and expertise in design, supply and commissioningof these systems. Trained and experienced technical manpower in both powerplant process and control system hardware & software.

BHEL has executed R&M of C&I successfully at many places. BHEL continued to support Spares & Services for long duration due to its in-house indigenized and manufacturing capability BHEL always upgrades technology which will be current in the market andadopts to suit power plant requirements

WHY MIGRATION BY BHEL?



WHY MIGRATION BY BHEL?

BHEL has received orders for more than 500 power plants in the last 9 years andsuccessfully supplied and commissioned more than 200 units including several R&Msolutions Supplied both Analog and Digital version SEE / AVR sets for more than 1500 unitsincluding more than 200 sets of SEE /AVR for R &M. Carried out Excitation System R&Mfor both BHEL and Non-BHEL Machines including Bus-duct modifications forconverting AVR to Static Excitation equipment. BHEL has been manufacturing all electronic modules in-house at their state of the art

plant at Electronics Division, Bangalore. Complete design and engineering of theControl System is also done at BHEL EDN works. This will facilitate BHEL to providethe necessary after sales support and supply of spares. BHEL EDN is the only vendor in India to establish modern facilities to manufacture allits electronic modules and have dedicated module repair / service centre. Annualcapacity : Electronic Module 150000 & Control Panels over 6500Well spread network of service after sales centers all over the country.

Market leader with 55.8% share of market in power plant DCS business in thecountry ( as per ARC – DCS report 2009).Experience and expertise in both power plant process and control systemhardware / software. Full-fledged facilities to design, manufacture, test, install andcommission the system without the need of external support.Ability to design and engineer all the control systems for both Thermal and Hydrostations using the same hardware / software platform.Strong engineering and R&D base and R&M set up with dedicated man power



FEW R&M REFERENCESPROJECT CUSTOMER RATING SCOPE STATUSVIJAYAWADA #4 APGENCO 1X210 MW SG/TG/

Stn C&ICommissioned in Oct.2009 (Commissioningdone within 55 days )

VIJAYAWADA #1&2 APGENCO 2X210 MW (LMZTURBINE)

SG/TG/Stn C&I

Under Commissioning

IB VALLEY #1 OPGCL 1X210 MW SG/TG/Stn C&I

Commissioned in Dec.2009 (Commissioningdone within 45 days)

IB VALLEY #2 OPGCL 1X210 MW SG/TG/Stn C&I

Commissioned in Dec.2010(Synchronization completed in 33 days )

RAYALASEEMA #1&2 APGENCO 2X210 MW SG/TG/Stn C&I

Under Commissioning.

MEJIA #3 DVC 1X210 MW SG & TG Under Commissioning.

RAICHUR #1&2 KPCL 2X210 MW SG UNIT#2 commissioned NOV.2010DAHANU RIL 1X250 MW TG Commissioned in Nov.2010TROMBAY #5 (R&M

been done in stages)

TATA

POWER

1X500 MW TG Commissioned in Jan.2010

TROMBAY #6 (R&Mbeen done in stages)

TATAPOWER

1X500 MW TG Supplied & under commissioning.

TANDA#1,2,3&4 NTPC 4X110 MW Stn C&I/HMI

Commissioned.

VIZAG STEEL PLANT RINL 67.5 MW Commonheader 4 Boiler +3 TG

SG/TG/Stn C&I

Commissioned

DAMANJODI NALCO 3X18.5 MW TG Supplied.



FEW R&M REFERENCESPROJECT CUSTOMER RATING SCOPE STATUSHARIHAR Grasim Industries

Ltd.10.5 MW TG Commissioned in Jan.2010.

HAZIRA RIL 1X40 MW TG Commissioned in Nov.2008. (Tomeet the exigency due to fire,supplied & commissioned within60 days. )

JOJOBERA #1 TATA POWER 1X67.5 MW TG Under commissioning.

GGSSTP ROPAR#3 PSPGCL 1X210 MW SG/TG Commissioned.

UKAI GSECL 2X120 MW SG/TG/ StnC&I

Commissioned.

OBRA# 9 TO 13 UPRVUNL 5X200 MW SG/ Stn C&I One Unit Commissioned. OtherUnits Supply is over and undercommissioning.

PANIPAT#1 HPGCL 1X110 MW StnC&I/HMI

Commissioned.

BHATINDA # 3 &4 PSPGCL 2X110 MW SG/TG/ StnC&I Under Commissioning

PATRATU # 9 & 10 JSEB 2X110 MW SG/TG/ StnC&I

Under Commissioning

HARDUAGANJ #7 UPRVUNL 1X110 MW SG/TG/ StnC&I

Under Commissioning

BARAUNI BSEB(NTPC -consultant)

2X110 MW SG/TG/ StnC&I

Supplied



FEW R&M REFERENCESPROJECT CUSTOMER RATING SCOPE STATUSMUZAFFAR PUR KBUNL (NTPC

JV)

2X110 MW SG/TG/ Stn

C&I

Supplied

JSW ENERGY(TORANAGALLU)

JSW LTD 1 X 130 MW EHTC(TMR)/TSE/GAMP

Under Supply

GNFC BHARUCH UNITS1&2

GNFC 2 X 25 MW TG EHTC, TP &TG AUX,HMI

Under Supply

TENUGHAT#1 TVNL 1X210 MW HPBP &APRDSCONTROL

Commissioned.

TENUGHAT#1 TNVL 1x210 MW SG/TG/ StnC&I

Under Supply

R& M CARRIED OUT ON H YDRO PLAN TS WI TH SH ORT SPAN OF TI M E F OR THE PROJECTS AF F ECTED

DU E TO FL OOD.(e.g. SRI SAI LAM -7X115 M W, RANGI T-3X20 M W, KOTESHWAR-4X100 M W)

FOR MANY PROJECTS IN THERMAL/HYDRO/INDUSTRY EXCITATION SYSTEM R&M IS BEINGCARRIED OUT ON CONTINUAL BASIS.

… And Many more are being pursued



Bharat Heavy Electricals Limited Electronics DivisionBangalore ARC - 2012

BEFORE AFTER

UNIT 2• FROM CONVENTIONAL DESKTO LARGE VIDEO SCREENS

UNIT 1

AFTER



29TH MARCH 2010

BHEL ADVANTAGE



29TH MARCH 2010

BHEL ADVANTAGE



BHEL-Electronics DivisionBangalore

MIGRATION IS INEVITA B L E WE CA N GEA R UP

TO MEET THE CHAL LENGE

Documents

BHEL Automation Migration Solution