At the Ufa TETs-2, a full-scale APCS of the steam boiler st. No. 6 was created

2023

Modernization of APCS of boiler unit BKZ-320-140/GM st. No. 6 of Ufa TETs-2

Expansion was carried out to a full-scale automated process control system for a steam boiler BKZ-320-140/GM st. No. 6 of the Ufa TETs-2 of the existing automatic boiler burner control system (SAUG). NPF Krug announced this on January 26, 2024.

The Ufa TETs-2 provides heat to almost half of the residential neighborhoods of Ufa, as well as a large number of industrial enterprises.

Installed electric capacity - 519 MW, thermal - 1,528 Gcal/h. The main fuel is natural gas, the reserve fuel is fuel oil.

The boiler unit process equipment control system was created using a standard technical solution, on the basis of which similar automation systems were previously developed and successfully implemented at a number of thermal power plants in Russia and neighboring countries.

Objectives and Objectives:

• Expansion of automation system to full-scale APCS level
• Upgrade of existing CAAG boiler
• Provide CHPP personnel with timely, reliable and sufficient information on the process progress and condition of the main equipment for operational management and technical reporting
• Implementation of boiler protection and interlocking algorithms in accordance with the requirements of regulatory documents
• Improve the reliability of the equipment, the quality of regulation through the use of advanced control and control technologies.

Within the framework of the project, the following were completed:

• development of a complete set of design documentation
• dismantling of the existing system for monitoring the operation of the unit
• supply and installation of instrumentation equipment, actuators, cabinets, consoles and control panels
• complete set of engineering and commissioning works.

Modernization was also affected:

• information and measuring system (IIS)
• uninterruptible power supply system for AWS and electric drives of gas units
• process protection and interlocks system (TAiB)
• process alarm system (TS)
• remote control system for boiler valves.

The main functions of the system are:

• Measurement and monitoring of process parameters with subsequent archiving of retrospective information
• Detection, alarm and recording of deviations of parameters from established limits
• Execution of algorithms of process protections and interlocks (TAiB) of the boiler unit based on the controller with redundancy of the processor part
• Automatic ignition and control of gas burners
• Remote control of boiler equipment:
  • automated start-up
  • remote shutdown (MOC)
  • control of boiler valves

• Formation of reporting documents
• Support System Time Unity
• Delineation of access to system functions
• Logging of all events in the system, including actions of operating personnel
• and others

APCS of steam boiler operates on the basis of software and hardware (software and hardware) complex of KRUG-2000 (PAK CAS KRUG-2000) and is a three-level system.

The first (lower) level of the system includes sensors of measured parameters, shutoff and control valves together with actuators, sources of discrete information.

The second (middle) level of the system is represented by:

• Boiler control cabinet
• Burner control cabinets# 1 and# 2 with operator touch panels
• Automatic burner ignition cabinet
• Cabinet of information and measuring system.

The third (upper) level comprises:

• Two redundant boiler operator's workstations combined with servers, under the control of SCADA KRUG-2000, performing control, collection, processing, storage and visualization of data from controllers
• Boiler driver's AWS station (client) to monitor system status
• Collective use screens.

KRUG has completed turnkey work on engineering, equipment supply, engineering, installation and commissioning.

Implementation of APCS based on PAK CAS KRUG-2000 ensures compliance with all the requirements of the current regulatory documents in the field of power, leads to a significant expansion of the system functionality, an increase in the level of reliability of technological equipment and automation equipment, and a reduction in labor costs for maintenance and repair.

Modernization of the APCS of the boiler unit BKZ-320-140/GM st. No. 8 of the Ufa TETs-2

As part of the investment project, an expansion to a full-scale automated process control system (APCS) of the boiler unit BKZ-320-140/GM st. No. 8 of the Ufa TETs-2 was carried out with the modernization of the existing automatic boiler burner control system (SAUG). This was announced on July 5, 2023 by Krug.

The boiler unit process equipment control system was created using a standard technical solution implemented at a number of thermal power plants in Russia.

The APCS of the boiler and SAUG are developed on the basis of the Russian software and hardware (software and hardware) complex KRUG-2000 (PAK PTK KRUG-2000).

Modernization was also affected:

• information and measuring system (IIS)
• uninterruptible power supply system for AWS and electric drives of gas units.

KRUG has completed a complete set of turnkey works, including the design, supply of equipment and software (SCADA KRUG-2000 and IOPC).

In the Republic of Bashkortostan, on the basis of the Russian PAK PTK KRUG-2000 as of July 2023, more than 160 APCS boilers, turbine units, boiler plants, telemechanics systems, computer simulators for CHP personnel, automated dispatch control systems (ASDC) were introduced.

2021: Introduction of automated EGSR steam turbine

On March 29, 2021, it became known that the introduction of an automated EGSR steam turbine PT-65/75-130 st. No. 5 of the Ufa TETs-2 was carried out using a technical solution developed by KRUG. The EGSR subsystem was integrated into the existing APCS of the turbine, which operates on the basis of the KRUG-2000 CAS.

Introduction of automated EGSR steam turbine

As reported, a typical solution - an automated electrohydraulic control system for a steam turbine (EGSR) - is designed to optimize the level of automation of power plants taking into account modern requirements for the technological equipment of a thermal power plant.

EGSR, developed on the basis of KRUG-2000 CAS, provides:

• qualitative control of the main parameters of the steam turbine
• stable indicators with maximum possible efficiency
• optimisation of equipment operation reliability.

The cost-effectiveness of implementing EGSR is to reduce the cost of producing electric and thermal energy by:

• exclusion of the "human factor"
• long-term trouble-free operation of the equipment
• increase of inter-repair periods of equipment.

The main goal of the project was to provide turbine control, control the main turbine parameters in all permissible process modes of operation, as well as in emergency situations, is the main goal of creating a standard solution of the electrohydraulic control system.

The tasks were:

• Development of a standard solution based on CAS KRUG-2000 for building EGSR in order to obtain a single integrated turbine APCS
• Provision of a single interface to personnel for operational control of all turbine subsystems
• Provide personnel with timely, reliable and sufficient information on the process progress and condition of the main equipment
• Implementation of algorithms for diagnostics and monitoring of deviations from the normal operation mode of the turbine unit
• Optimization of equipment reliability, quality of regulation due to advanced control and control technologies.

Implementation of EGSR based on CAS KRUG-2000 ensures:

• compliance with all requirements of the current regulatory documents in the field of power
• significant expansion of functional capabilities of turbine APCS
• optimization of reliability level of process equipment and automation means
• reduced labor costs for maintenance and repair.

The main feature of the system that takes it to the next level is the implementation of a comprehensive solution for automating the turbine unit (including EGSR) on unified tools. This allows operational and maintenance personnel to see a complete integral picture of the technological process and to perform control and adjustment from one system, from one AWS.

This approach eliminates the influence of the "human factor" and minimizes the likelihood of emergency and emergency situations.

The automatic control system of the electrohydraulic system for regulating the turbine operation parameters is implemented in the form of an EGSR automation cabinet (EGSR cabinet) based on the microprocessor industrial TREI- 5B- 04 controller (PLC).

PLC includes:

• main and standby power supplies
• redundant processor modules
• protected upper-level LAN (via) switchboards Ethernet
• dedicated lower-level LAN for data mirroring
• analog and discrete input/input modules
• microprocessor positioner modules
• universal I/O modules
• main and standby turbine speed control units.

The controller performs the following tasks:

• maintaining the specified turbine rotor speed in the range from 200 to 3240 rpm with the specified non-uniformity of control by acting on the servomotor of increased pressure
• maintaining at a given level the active electric power of the generator with zero irregularity by acting on the SMPC servomotor and correcting the power setting by frequency
• maintaining the set steam pressure in the production sampling by acting on the medium pressure servomotor (SMSD)
• maintaining the set steam pressure in the heating extraction by acting on the low pressure servomotor (LMS)
• limiting control of minimum reduction of live steam pressure (by unloading the turbine)
• limiting control of the maximum steam pressure in the production extraction (by sequential opening of the control diaphragm and unloading of the turbine)
• limiting control of the maximum steam pressure in the heating extraction (by sequential opening of the control diaphragm and unloading of the turbine)
• control from signals of the plant emergency control equipment
• preliminary protection with differentiation of the turbine rotation speed value
• additional protection against failures of speed measurement channels or turbine speed exceeding 3400 rpm, protection against loss of frequency sensor signal.

Control of SMPC, SMSD, SMND servomotors of the turbine is carried out by means of microprocessor positioners of the DevLink-A10.AIO-3UI/3UI manufactured by NPF KRUG, which are connected to the master frequency control unit. The positioners are connected processor to the controller modules via the digital RS485 interface, which allows real-time communication with them, as well as configuration (without stopping the turbine).

Archival tapes are maintained directly in the processor modules of the controller to record changes in the turbine operating parameters over time.

The processor modules are combined by an additional dedicated lower-level local network for mirroring the online and archive database.

In the EGSR automation cabinet there is a local touch control panel (LCP), which provides a human-machine interface for visualizing operational information and controlling the turbine in place. The LCP communicates with the controller via Ethernet. Operational information and archives are transferred to redundant servers of the single turbine APCS.

The turbine APCS is implemented on the basis of the KRUG-2000 software and hardware complex (CAS KRUG-2000) and is represented by three hierarchical levels:

• The lower level includes sensors and actuators.
• The middle level is represented by the automation cabinet of the EGSR subsystem and the control cabinets of the subsystems of process protections and interlocks (TAiB), remote control (RC) and information and measuring system (IIS).
• The top level is represented by:
  • redundant servers combined with automated workstations of operators - ARM1, ARM2 (two-monitor), with archiving functions
  • additional ARM3 (monitoring)
  • EGSR diagnostic station.

ARM1 and ARM2 collect, process and store data coming from the middle level of the system, as well as provide visualization and control of equipment of all turbine subsystems, including EGSR.

Monitoring-client station - ARM3 is used to display the alarm board by process parameters and turbine protection states.

Structural diagram of integrated turbine APCS with EGSR subsystem (on the example of turbine PT-65/75-130)]]

Abbreviations in the scheme:

• Main Control Panel - Main Control Panel
• Missile rail launcher - emergency control panel
• CP - control panel.

Total information power of EGSR subsystem (on the example of PT-65/75-130 turbine):

• Input analog variables - 300
• Input discrete variables - 500
• Output analog variables - 35
• Output discrete variables - 140
• Manual input variables - 800
• total number of control loops - 18.

This standard solution is a joint development of LLC NPF KRUG and LLP Karaganda Turbomechanical Plant (KTMZ), which was carried out under the auspices of Bashkir Generating Company LLC.

Example of "Setters panel" mnemonic diagram

An example of the implementation of this technical solution is the EGSR of the steam turbine of the PT-65/75-130 station No. 5 of the Ufa TETs-2. The EGSR subsystem was integrated into the existing APCS of the turbine, which operates on the basis of the KRUG-2000 CAS.

The following works were performed by KRUG within the framework of this project:

• development of design documentation for EGSR automation cabinet
• Installation Supervision
• engineering works
• commissioning.