Bharat Heavy Electricals Limited

Electronics Division
Bangalore

ARC - 2012

Why Migration?
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

Migration requirement is continuous

Bharat Heavy Electricals Limited
Electronics Division Bangalore

ARC - 2012

Migration Possibilities
COMPLETE REPLACEMENT

TRANSITIONAL UPGRADE OF
ELEMENTS OF THE SYSTEM

AFTER

BEFORE
MIGRATION

AFTER
PLUG - IN SYSTEM
TO OBTAIN
THE ADDITIONAL FUNCTIONALITY.
Bharat Heavy Electricals Limited
Electronics Division Bangalore

ARC - 2012

FEW CONSIDERATIONS
Developing a migration cost/benefit analysis
Leveraging existing investments
Determining functional versus value-added replacement

Reducing installation time to hours, not days

Minimizing process impact during system changeover
AFTER
BEFORE
Avoiding costly rewiring or extra footprints

Achieving one-for-one I/O replacement

Choosing phased versus complete migration approaches
Evaluating system platform openness

Bharat Heavy Electricals Limited

Electronics Division Bangalore

ARC - 2012

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.
AFTER
BEFORE
Possibility
to manage modern instrumentation
Not to lose connection with old instruments
Open systems

Bharat Heavy Electricals Limited

Electronics Division Bangalore

ARC - 2012

ADVANTAGES OF MIGRATION
State Of The Art Technology

Higher Reliability And Availability

Better Diagnostics
Faster Response
Better accuracy and control

Possibility of higher level optimization

solutions
AFTER
BEFORE

Ease Of Maintenance
Flexible For Modification

Improved Aesthetics
Better Spares Availability
Remote Diagnostics And Information Availability.

And Many More..

AFTER
Bharat Heavy Electricals Limited
Electronics Division Bangalore

ARC - 2012

AUTOMATION MIGRATION IN THERMAL POWER PLANTS

.NEED OF THE HOUR

AFTER

BEFORE

AFTER
Bharat Heavy Electricals Limited
Electronics Division Bangalore

ARC - 2012

Conducive Environment

Power demand in the country is witnessing unprecedented growth creating

higher demand supply mismatch.

In order to bridge this huge demand-supply gap it is imperative to operate the

existing aged power plants more efficiently and effectively and hence the
necessity to renovate and modernize these power plants.

Rapid developments in the field of automation and control systems provide the
power plant personnel with immense opportunities to achieve complete
AFTERunits from centralized
process/plant
information access and control of multiple
BEFORE
place, thus ensuring safe, reliable and efficient operation of plant with more
information, data, diagnostic features at operator desk.

Technology obsolescence rate is high in field of C&I linked to electronic

component Obsolescence and upgrades. Spares & services are not available for
older power plants. New C&I system will equip the operator to manage and to
run the plant by optimally maintaining the process parameters and hence it is
the necessary to renovate and modernize the C&I.

AFTER
Bharat Heavy Electricals Limited
Electronics Division Bangalore

ARC - 2012

Potential Market
A large number of 200/250 MW & some 500 MW units majority
being with German / Czech technology are in operation for more
than 15 years and the control platform in last 15 years have
become state of art which provides a high potential for life
extension & efficiency improvement in turn to upgrades in
automation
Rating

Running for
> 15 Years

200/ 210 MW

Running for
> 20 Years

Design
basis

53

LMZ design
KWU Design

200 / 210 MW

37

12

500 MW

12

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

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

Done so for is just 2800 MWs since 1984

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

BOILER CONTROL SYSTEM
Burner Management System
Soot Blower Control System
Sec. Air Damper Control System
Hp Bypass Control
Aux. PRDS Control
Replacement of old nozzle valves & trip
valves for Burner Management System.
Existing relay based/solid state and
obsolete system shall be replaced with state
of art DCS and also wherever required
necessary replacement of final actuators
shall be done.

TURBINE CONTROL SYSTEMS

(on as applicable basis)
Turbine Supervisory Equipment
Electro Hydraulic Turbine Governing
Turbine Stress Evaluator
Gland Steam Sealing / LP Bypass
Auto Turbine Run-up System/ Auto Turbine
Testing
Turbine Protection
Existing relay based/solid state and obsolete
system shall be replaced with state of art
DCS.
FGMO ( Free Governing Mode of Operation)

STATION C & I CONTROL SYSTEM

Auto controls such as
Master Pressure Control, Air Flow Control, Furnace Draft, Coordinated Master control (wherever
possible), Milling Plant Control, Drum Level Control, Super heater / Reheater Temp. Control, BFP
Scoop Control, Cond. Level control, De-aerator Pressure / Level Control etc.

Interlock & Protection For All Auxiliaries

Existing 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

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

OTHER BOP SYSTEMS TO UNIFIED
PLATFORM

ADD-ON OR UPGRADE
OPTIMISATION SOLUTIONS

Controls for Coal Handling Plant (CHP)

Controls for Ash Handling Plant (AHP)
Controls for Water System (WS)

Performance Analysis and Optimisation

packages

Controls for Make Up Water System (MU)

ABT recommendation packages

Controls for Stand Alone Common Systems

Asset Management packages like CMMS

(SAC)
Mill Reject Systems

Etc.

Fuel Oil unloading and Pump house

And other off-site applications

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)

Instrumentation Scope for R&M of DCS for typical Thermal Power Plant
SYSTEM
PRIMARY
INSTRUMENTS
TRANMITTERS
CONTROL ROOM
DISPLAY/RECORDING
EQUIPMENT

CONTROL DESK
EQUIPMENT & POWER
SUPPLY

SWAS &
GAS ANALYSER

EXISTING
ELECTRO MECHANICAL
INDICATORS AND
POTENTIOMETRIC
RECORDERS

LOCAL / REMOTE
CONTROL THROUGH
PUSH BUTTON &
LAMPS

OBSOLETE

PROPOSED
SMART TRANSMITTERS
PC BASED DATA
AQCUISITION SYSTEM WITH
CRT DISPLAY, VIDEO
PROCESS CONTROL &
SCADA & REMOTE CONTROL,
DATA ACQUISITION FOR
ELECTRICAL SYSTEM,ALARM
MANAGEMENT & HISTORIAN
& SOE etc.

CENTRALLISED VIDEO
PROCESS CONTROL
WITH MINIMUM BACK UP
FOR EMERGENCY SHUT
DOWN.

ON-LINE STATE OF
ART
INSTRUMENTATION

ADVANTAGES
BETTER
AESTHETICS
INFORMATION
AVAILABILIITY AT
A SINGLE PLACE
ENERGY SAVING
BETTER
DIAGNOSTICS
EASE IN
COMMISSIONING &
MAINTENANCE
BETTER
AVAILABILITY OF
SPARES &
SERVICE
SUPPORT
BETTER
ACCURACY AND
CONTROL

OPTIONS OF PHASED MIGRATION IN THERMAL POWER PLANTS

Only HMI
Only Integral Controls
Only Station C&I Controls
Only Controls retaining
instrumentation and field
cabling

Add on packages
Total solutions

It can together
or phased
manner based
on the need /
shutdown /
condition of
the equipment
needs change

ADD-ON OR UPGRADE OPTIMISATION SOLUTIONS

Performance Analysis and Optimisation packages
ABT recommendation packages
Asset Management packages like CMMS
Etc.

ADVANTAGES OF UNIFIED AUTOMATION

Coordinated Master Control (as applicable).

Unified Information Management.

Unified Man-Machine Interface.
Unified Diagnostics.

Unified Training for O&M personnel and Better resource / Spares Management.
Better immunity to noise.
Better structuring and flexibility.

Comprehensive diagnostics
Ergonomic and utilization based Man-Machine interface System
Better response times.

Better compatibility within the system.

Unified solution for back-up control task.

CHALLENGES
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 make
same 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. .

AUTOMATION MIGRATION IN THERMAL POWER PLANTS

.BHEL Experience
AFTER

BEFORE

AFTER
Bharat Heavy Electricals Limited
Electronics Division Bangalore

ARC - 2012

WHY MIGRATION BY BHEL?

BHEL is the original equipment manufacturer for Boiler & TG for most of power
plants
The integral Controls of the main equipment shall take care of safety and
protection of main equipment and form essential part of equipment itself.
Hence it is preferred that the integral controls are supplied by the original
equipment manufacturer.
The interlocks and control logics shall also form part of the main machine and
the systems like EHTC, LP Bypass, HP Bypass, Automatic Turbine Run-up and
Tester System etc. are designed to match the field equipment. This knowledge
base is proprietary of BHEL.
BHEL has vast experience and expertise in design, supply and commissioning
of these systems. Trained and experienced technical manpower in both power
plant 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 inhouse indigenized and manufacturing capability
BHEL always upgrades technology which will be current in the market and
adopts to suit power plant requirements

WHY MIGRATION BY BHEL?

BHEL has received orders for more than 500 power plants in the last 9 years and
successfully supplied and commissioned more than 200 units including several R&M
solutions
Supplied both Analog and Digital version SEE / AVR sets for more than 1500 units
including more than 200 sets of SEE /AVR for R &M. Carried out Excitation System R&M
for both BHEL and Non-BHEL Machines including Bus-duct modifications for
converting 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 the
Control System is also done at BHEL EDN works. This will facilitate BHEL to provide
the necessary after sales support and supply of spares.
BHEL EDN is the only vendor in India to establish modern facilities to manufacture all
its electronic modules and have dedicated module repair / service centre. Annual
capacity : Electronic Module 150000 & Control Panels over 6500
Well 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 the
country ( as per ARC DCS report 2009).
Experience and expertise in both power plant process and control system
hardware / software. Full-fledged facilities to design, manufacture, test, install and
commission the system without the need of external support.
Ability to design and engineer all the control systems for both Thermal and Hydro
stations using the same hardware / software platform.
Strong engineering and R&D base and R&M set up with dedicated man power

FEW R&M REFERENCES

PROJECT
VIJAYAWADA #4

CUSTOMER RATING
APGENCO 1X210 MW

SCOPE
SG/TG/
Stn C&I
2X210 MW (LMZ SG/TG/
TURBINE)
Stn C&I
1X210 MW
SG/TG/
Stn C&I

VIJAYAWADA #1&2

APGENCO

IB VALLEY #1

OPGCL

IB VALLEY #2

OPGCL

STATUS
Commissioned in Oct.2009 (Commissioning
done within 55 days )
Under Commissioning
Commissioned in Dec.2009 (Commissioning
done within 45 days)

1X210 MW

SG/TG/ Commissioned in Dec.2010

Stn C&I (Synchronization completed in 33 days )

RAYALASEEMA #1&2 APGENCO

2X210 MW

MEJIA #3

DVC

1X210 MW

SG/TG/ Under Commissioning.

Stn C&I
SG & TG Under Commissioning.

RAICHUR #1&2
DAHANU
TROMBAY #5 (R&M
been done in stages)
TROMBAY #6 (R&M
been done in stages)
TANDA#1,2,3&4

KPCL
RIL
TATA
POWER
TATA
POWER
NTPC

2X210 MW
1X250 MW
1X500 MW

SG
TG
TG

UNIT#2 commissioned NOV.2010

Commissioned in Nov.2010
Commissioned in Jan.2010

1X500 MW

TG

Supplied & under commissioning.

VIZAG STEEL PLANT RINL

DAMANJODI

NALCO

4X110 MW

Stn C&I/ Commissioned.

HMI
67.5 MW Common SG/TG/ Commissioned
header 4 Boiler + Stn C&I
3 TG
3X18.5 MW
TG
Supplied.

FEW R&M REFERENCES

PROJECT
HARIHAR

SCOPE
TG

STATUS
Commissioned in Jan.2010.

HAZIRA

CUSTOMER
RATING
Grasim Industries 10.5 MW
Ltd.
RIL
1X40 MW

TG

JOJOBERA #1

TATA POWER

1X67.5 MW

TG

Commissioned in Nov.2008. (To

meet the exigency due to fire,
supplied & commissioned within
60 days. )
Under commissioning.

GGSSTP ROPAR#3
UKAI

PSPGCL
GSECL

1X210 MW
2X120 MW

OBRA# 9 TO 13

UPRVUNL

5X200 MW

PANIPAT#1

HPGCL

1X110 MW

BHATINDA # 3 &4

PSPGCL

2X110 MW

PATRATU # 9 & 10

JSEB

2X110 MW

HARDUAGANJ #7

UPRVUNL

1X110 MW

BARAUNI

BSEB
(NTPC consultant)

2X110 MW

SG/TG
Commissioned.
SG/TG/ Stn Commissioned.
C&I
SG/ Stn C&I One Unit Commissioned. Other
Units Supply is over and under
commissioning.
Stn
Commissioned.
C&I/HMI
SG/TG/ Stn Under Commissioning
C&I
SG/TG/ Stn Under Commissioning
C&I
SG/TG/ Stn Under Commissioning
C&I
SG/TG/ Stn Supplied
C&I

FEW R&M REFERENCES

PROJECT
MUZAFFAR PUR

CUSTOMER
KBUNL (NTPC
JV)

RATING
2X110 MW

SCOPE
STATUS
SG/TG/ Stn Supplied
C&I

JSW ENERGY
(TORANAGALLU)

JSW LTD

1 X 130 MW

EHTC
Under Supply
(TMR)/
TSE/GAMP

GNFC BHARUCH UNITS

1&2

GNFC

2 X 25 MW TG

EHTC, TP & Under Supply

TG AUX,
HMI

TENUGHAT#1

TVNL

1X210 MW

HPBP &
Commissioned.
APRDS
CONTROL

TENUGHAT#1

TNVL

1x210 MW

SG/TG/ Stn Under Supply

C&I

R&M CARRIED OUT ON HYDRO PLANTS WITH SHORT SPAN OF TIME FOR THE PROJECTS AFFECTED
DUE TO FLOOD.(e.g. SRISAILAM-7X115 MW, RANGIT-3X20 MW, KOTESHWAR-4X100 MW)
FOR MANY PROJECTS IN THERMAL/HYDRO/INDUSTRY EXCITATION SYSTEM R&M IS BEING
CARRIED OUT ON CONTINUAL BASIS.

And Many more are being pursued

UNIT 1

BEFORE

AFTER

FROM CONVENTIONAL DESK

TO LARGE VIDEO SCREENS

UNIT 2

AFTER

Bharat Heavy Electricals Limited

Electronics Division
Bangalore

ARC - 2012

29TH MARCH 2010

BHEL ADVANTAGE

29TH MARCH 2010

BHEL ADVANTAGE

MIGRATION IS INEVITABLE WE CAN GEAR UP

TO MEET THE CHALLENGE
BHEL-Electronics Division
Bangalore