"The southern Sakhalin CHPP-1" completed implementation of the PCS of two power units

On December 15, 2016 the press service of Tornado Modular Systems company announced implementation as a management system of the PCS of the Tornado-N software and hardware complex on 4 and 5 power units of the Southern Sakhalin CHPP-1. The SZIK Ltd company acted as the PTK system integrator.

Project Tasks

The southern Sakhalin CHPP-1 the large producer of electrical and thermal energy in the Sakhalin region. Provides with the electric power 60% of the population of the region and the regional center – the city of Yuzhno-Sakhalinsk. Electric power of combined heat and power plant is 455 MW, thermal – 761 Gcal/h. The CHPP-1 works in specific and difficult conditions: all power supply system of the Sakhalin region is independent of an integrated power grid of Russia, and on the island of Sakhalin it is separated into three autonomous energorayon. These territories are considered as seismically dangerous and differ in the increased level of the adverse phenomena of climatic character.

Southern Sakhalin CHPP-1, (2016)

All this conducts to an accelerated wear of nodes and mechanisms, the raised costs for routine maintenance and overhaul repairs. The main fuel of the station – gas, reserve – coal.

Input in a system of 4 and 5 power units equipped with the innovation automated control system and using natural gas provided power supply system of the island with a necessary reserve of power (before input of power units the reserve made only 30 MW that at constantly growing consumption was explicit insufficiently, and any violation in work of power facilities led to forced restriction of consumers).

Stages of project implementation of automation of the 4th and 5th power units of the Southern Sakhalin CHPP-1

On August 29, 2012 RAO ES of the East put into operation the 5th power unit of the Southern Sakhalin CHPP-1 based on two gas turbine units of General Electric with a total power of 91.2 MW. It is the largest input of new capacities in thermal generation on Sakhalin in 30 years. Project implementation allowed to display gradually outdated capacities of the Sakhalin state district power plant and provided a necessary reserve of power in power supply system (having increased it up to 109 MW). In 2013 the 4th power unit as a part of three gas turbine units of General Electric is started (electric power of the block was 139.1 MW, thermal — 133.5 Gcal/hour).

Within construction of the 5th and 4th power units of combined heat and power plant the implementation project of the modern automated control system which covered the all-packaged and electrotechnical equipment, the system of gas supply is executed and integrated local management systems for the equipment of different producers from which the main are SAU of gas turbine units General Electric.

In development process of documentation designers formulated requirements to the PCS of power units:

• reliability augmentation, profitability, security and durability of the equipment owing to reduction of intensity of accidental waves of parameters of technology process,
• implementation of more difficult control algorithms and regulation,
• expansion of information and diagnostic functions of a management system,
• improvement of conditions and standard of work of service staff,
• prevention of wrong actions of personnel.

As a result of competitive procedures, the tender for design and supply of equipment of the PCS of power units was won by "Northwest engineering corporation". As the software and hardware complex (SHC) PTK "Tornado-N" of production of Tornado Modular Systems company is selected.

SZIK Ltd acted in this project as the PTK "Tornado-N" system integrator. Specialists of the company integrator underwent profound training in Novosibirsk, in training center of Tornado Modular Systems company, having studied the principles of creation of PTK:

• its structure,
• basic elements,
• constructive solutions,
• organization of internal network and communications,
• power supply,
• structure and structure of the software.

Design engineers of SZIK mastered rules of development of design documentation of cabinets of PTK on the basis of which assembly of cabinets is performed, and programmers using specialists of Tornado studied technology programming in the environment of ISaGRAF, work with SCADA InTouch, with the system and application software of development of Tornado. Also transferred to Tornado in SZIK the large volume of examples of operational documentation on PTK:

• description of programs,
• instructions for operational and system service,
• operation manuals on cabinets, modules USO, power sources,
• instruction for change and expansion of a system
• many others.

Project Progress

Designers SZIK executed the project of the PCS field level and the project regarding PTK by all types of providing: technical, mathematical (algorithms of control and management), information, program. All documentation went to check to Tornado Modular Systems, then was adjusted according to notes and transferred to work. On the platform "Tornado" all is collected by PTK (cabinets, the automated jobs), "is filled in" and the software of controllers is debugged.

Upon termination of assembly and adjustment before shipment of the equipment on the Southern Sakhalin CHPP-1 integration test – testing of technical and software tools, check of operability of a complex in general is carried out. On an object specialists of SZIK and Tornado jointly executed adjustment of PTK, the PCS and put an object in operation.

Project Results

With input of the 4th and 5th power units at the station:

• modern production is arranged,
• advanced technologies are applied,
• working conditions improved.

In 2016 specialists of Tornado Modular Systems company left on the Southern Sakhalin CHPP-1 with the purpose to inspect a status of PTK PCS of the 5th and 4th power units. Within this trip notes of operation personnel of combined heat and power plant are collected, magazines of different incidents are studied, copies of programs and files of databases are collected. Together with the management and personnel of the station service actions for system maintenance and upgrade of technical and software tools of a complex are planned.