Metso Automation For reliable and user-friendly energy production February 2014 Matti Miinalainen Content 1. Metso Group overview 2. Metso Automation in short 3. Metso DNA for reliable energy production 4. Metso’s solution for Turbine Automation 5. Selected references – Power industry Metso DNA – for reliable and user-friendly energy production Power production applications Highlights of Metso DNA features Specialized expertise in the power industry FLUIDIZED BED BOILERS Flexible multi fuel combustion, combustion optimization with corrosion management GASIFICATION High cycle efficiency, high availability PYROLYSIS Environmentally efficiency, high availability, COAL FIRED High availability, emission minimization, combustion optimization, flexible usage COMBINED CYCLE High availability, emission minimizing, flexibility WASTE-TO-ENERGY Maximizing waste disposal, emission management, environmentally efficiency COGENERATION Flexibility, steam network management, high availability HYDRO POWER Efficiency, availability, river optimization SOLAR POWER Efficiency, availability, optimizing lifecycle maintenance costs © Metso 22 Product portfolio Metso DNA Energy Management Energy Demand Forecasting Energy Trading and Purchasing Production Optimization Plant Management Applications Metso DNA Plant Operation Monitoring Metso DNA Boiler Performance Monitoring Metso DNA Steam Turbine Performance Monitoring Metso DNA Boiler Sootblowing Manager Metso DNA Boiler Life Monitoring Metso DNA LCP Emission Monitoring Reporting & Analyzing Tools Metso DNA Historian Calculation Environment Metso DNA Report Information Services (Databases) Metso DNA Historian Metso DNA Operate – Alarms & Events Server Application databases (SQL Server) Advanced Control Applications Metso DNA 01 © Metso Metso DNA Fuel Power Compensator Metso DNA FBB Combustion Manager Metso DNA Steam Turbine Controller Metso DNA Steam Network Manager Metso DNA Training Simulator User Interaction Automated Process Secured Lifecycle One system for all automation in power generation Metso DNA 02 © Metso Metso DNA redundancy • Backup Power Supply for - control node cabinets and rack I/O’s • Optional power backup for - control room devices and servers Redundant hard disks and backup tape device Information Server Engineering Server Operator Interface Alarm Processing Redundant control room bus and process bus Back-up (BU) • Redundant power supplies and Interface controller •Redundant M120 I/O units Redundant hard disk PCS PCS PCS GTW-LIS GTW-LIS Redundant process controller Redundant PLC interface Profibus DP devices • Redundant Field Bus • Redundant I/O power supply per rack Availability up to 99,98% 03 © Metso ACN MR - powerful Metso DNA controller 5ms control cycles now possible ACN MR Servo output unit AOI3S Technology Servo outputs AIT4L Inputs • Intel Atom processor • 3 analog output channels • 4 LVDT input channels • Industry spec components • Output range -100…+100 mA • Input update interval 1 ms • 5 Ethernet ports • Settable range min and max • Settable measurement filter • installed in I/O-group • Settable dither • 16 bit A/D converter • Controller redundancy Performance • Down to 5 ms control cycles • 2 I/O-groups with < 20 ms cycles • More I/O-groups via Ethernet - Frequency 50…500 Hz AIT4CInputs - Amplitude 0…10 mA • 4 input channels 0/4-20 mA • Field loop diagnostics • Input update interval 1 ms DI for Valve shut down • Settable measurement filter • 1 digital input channel • 16 bit A/D converter • Field voltage supply 24 VDC Isolation • Current limit 40 mA • Field to system 1500 VAC • Shut down function attachable • Between channels 500 VAC to each AO channel individually • Reaction time 2 ms 04 Valve position input © Metso • Power load unbalance runback Metso DNA Operate Operation tools for efficient problem solving Start History mode • Efficient alarm analysis with 1 ms Sequence of Events (SOE) • Replay history from any picture, “time machine” • Drag and drop trend analysis • Dynamic function and interlocking descriptions for machine and process • Integrated diary entries for trends and loops Feeling of control 05 © Metso History mode indication Select displayed moment and replay Multilingual Metso DNA Control Panel • Used language can be selected per operator station • There can be several languages to choose from (these needs to be agreed already on the sales phase) 06 © Metso Typical condition monitoring measurements Boiler and Turbine-Generator Turbine generator (gas, steam or hydro) • • • • • • • • • 07 Relative shaft vibrations (x-y) x/y positions (GAP voltage) Absolute bearing vibrations (x-y-z) Axial positions (z) Differential expansions Absolute expansions Shaft eccentricity Tachometer Process parameters © Metso Process specific auxiliary equipment, e.g. • Boiler HP feed pumps • Circulation water pumps • Exhaust air fans • Fresh air fans • Primary air fans • Secondary air fans • District heating pumps • Coal / peat mill feed air fans • Booster pumps Fully integrated vibration monitoring • ACN I/O solution - ACN M120 series I/O group with AIV8V units for fast dynamic measurements Max. 128 channels per I/O group 8 measurements per I/O card => card amount depends on monitoring points • Vibration monitoring processing unit - ACN CS and ACN RT A separate or shared with controls • Application - 08 © Metso Measurement, calculations, alarm limits User Interface elements History trending if TEA or IA databases are part of the controls package Vibration levels are on alarm or warning level Fuel Power Compensator (FPC) • Compensates variations in: - fuel quality (dry/wet fuel, multiple fuels) fuel amount (unmeasured variable) • Improves combustion by supporting fuel flow controller and making corrections based on calculated fuel power • Calculates fuel power in two different ways: - flue gas oxygen method (dynamic situations) steam balance method (steady-state situations) • Stabilizes: - boiler production fuel consumption (minimizes usage) combustion variables • Recommended with Combustion Optimizer 09 © Metso Proven benefits with Advanced Control Applications CO before 1000 800 800 600 600 400 400 200 200 0 100 200 400 500 600 700 O2 before 10 0 8 6 6 4 4 2 2 100 200 300 400 500 600 700 Nox before 250 0 200 150 150 100 100 50 50 0 100 200 300 400 100 200 300 500 600 700 0 400 500 600 700 O2 after Optimization On 100 200 300 400 500 600 700 Nox after 250 200 © Metso Optimization On 10 8 0 10 300 CO after 1000 Optimization On 100 200 300 400 500 600 700 Latest in Metso DNA to boost your power generation 11 Turbine controls Pulverized coal fired combustion optimization Sootblowing optimization Condition monitoring © Metso Staying competitive in the electricity market Metso played a significant role in helping Grant Town avoid considerable cost of installing a post combustion flue gas treatment system, and met our expectations of efficient, low cost operation. Steve Friend Plant Manager American Bituminous $12 million savings resulted in reduction of 7% limestone usage over the operating range 12 © Metso Turbine Automation Customer specific approach with deep knowledge of Steam Network controls Metso DNA Turbine Controller • System - Common solution for the balance of the plant, boiler and the turbine - Special fast io-cards for 5ms cycle time • Turbine controller - All required controls and sequences - Better integration of boiler and the turbine controls in demanding industrial applications Simulator for FAT and training - • Industrial customers 14 © Metso Advanced combustion controls Model predictive steam network control Metso DNA steam turbine automation • Coordination of turbine and boiler island • Redundancy at all levels • Turbine Controller - Speed control with automatic start-up Auxiliary devices Primary and secondary control Simulator for FAT and training Complex industrial pressure controls • Turbine protection - Over speed protection Hima / DNA modules Machine protection • Machine Monitoring 15 © Metso Performance monitoring calculations Thermal stress calculations Vibration diagnostics Steam Network knowhow in CHPs Steam Turbine essential part of the steam network 16 © Metso Integrated machine monitoring Metso DNA Machine Monitoring - ACN MR - server M120 - cards 17 © Metso Metso DNA steam turbine automation Selected references • Extensive experience - Industrial turbines and large utility sized turbines With overall control strategies for power boilers, steam network management and frequency support applications Both retrofits of old installations as well as new turbine deliveries. • Experienced with the following steam turbines: Doosan-Skoda, LMZ, HangZhou, Zamech, KWU, Lang (Alstom), Bergman-Borgman, ASEA Stahl, Siemens, ABB, Lang, BHEL, AEG, Triveni. • OEM certification by LMZ (steam turbine) • OEM certification by Doosan-Skoda (steam turbine) 18 © Metso Structure of the Turbine Control and Protection ESD Process Control Station Local Operator Interface Turbine controller •Turbine run-up •Load control •Back-pressure control •Steam extraction controls •Limiting controls •Parameters for island operation Turbine protection •Diagnostics •Testing Bus Interface to Main System Status data I/O-LEVEL Monitoring Turbine protection (3-Channel) •Speed •Position •Watch-dog n > MAX Speed controller Logic •Island operation •Disturbance reserve •Load shut-off •Manual output control •Control mode •Disturbance monitoring •Protection •Limits of generator switch •Island operation Valve coordinator 4...20 mA 4...20 mA 4...20 mA 4...20 mA 4...20 mA Red. Red. Red. Red. Island operation activiated Other measurements Generator’s breaker closed 1x3 ESD 2x3 measurement X2 X2 Rotating Speed Measurement 3 channel (Protech 203 X2 Test Stop valve 19 © Metso X 1 EH G - X2 X2 X 1 EH G - X 1 EH G - X2 X 1 EH G - Control hydraulics Control Valves G Synchronizing Device Jaquet FT3000 overspeed SIL3 and Hima turbine protection SIL3 +24 VDC Overspeed 110% Speed sensor A Overspeed test A 110% Speed sensor B Overspeed test B 110% Speed sensor C Overspeed test C 110% K1 Speed puls/mA (TCS) Sensor failure A(TPS) Overspeed 110% K2 Speed puls/mA (TCS) Sensor failure B (TPS) Overspeed 110% K3 Speed puls/mA(TCS) Sensor failure C (TPS) K4 Criteria A Criteria B Criteria C K5 Criteria NN … Criteria D K6 2/3 - voted hydraulic trip block 19 © Metso 20 © Metso Unified automation system provides many benefits If the systems were from different suppliers, some of the features would definitely be lost at some point.” Kari Enwall Automation-related electrical engineering Fortum Naantali Finland © Metso Selected Power References Fluidized Bed Boilers OTSC PC Boilers Combined Cycle Power Plants Turbine Controllers Waste-to-Energy Plants Worldwide references 23 © Metso Power Combined Heat & Power Waste to Energy Flue gas desulfurization Hydro Transmission Refinery & Process Combined Cycle Solar Wave Surge Automating the world’s largest FBB plants Nacogdoches 100MW – Largest biomass boiler in US Alholmens240MW – World’s largest multifuel boiler Sha Lang Tan 300MW – China’s largest FBB Neyveli Lignite 250MW – India’s largest FBB © Metso Lagisza 460MW – World’s largest FBB – OT CFB Selected references in CFB Plants Capacity MWth 1200 Lagisza 1000 800 Jing Hai x2 600 Eesti Balti Kaukas 400 Keljonlahti Toppila I Ostroleka 200 0 EC Tychy Rovaniemi Kokkola Toppila II Tornio Rauma Pori Langerbrugge Kauttua 0 5 10 Bold = Foster Wheeler references © Metso Alholmen 15 20 25 PKE Elektrownia Lagisza S.A. Poland • Worlds largest super-critical CFBC Boiler • 460 MWe • Foster Wheeler • July 2009 start-up • Total Plant Controls • > 20,000 I/O’s 26 © Metso Date Author Title 100 0 27 © Metso 200 MWth 300 400 Cikarang 1 Cikarang 2 Nacogdoches Gainesville Kymin voima Sczcecin PGE Porin Prosessi Ostroleka RWE TullisRussel Kuopion Energia Edenderry Övik Energi Eneco Delfzijl Langerbrugge Dalkia Facture Celbi Rauman Voima Wrochlaw Kalmar Energi UPM Chapelle UPM Shotton Swiecie AS Tartu Keravan LV Savonlinna Martinska HAM Cogen Launkalne Helme 500 Alholmen Metso Power & Automation together 600 Selected references in BFB plants Capacity MWth 300 250 Capacity 200 150 100 50 0 0 5 10 15 20 Units 28 © Metso 25 30 35 40 References - China Beijing,Liulihe Cement Cogen Beijing, Sanhe Liaoning, Dalian Chemical Hebei, Zhangjiakou Hebei, Qinghuangdao Shandong, Lunan Cement Cogen Zhangqiu Henan,Xinxiang Gucheng Henan, Xingxiang Baoshan Henan, Xingyang Shanxi, Shentou I Neimenggu, Jinghai Neimengtu, Dengkou Jiangsu, Xutang I&II Jiangsu, Pengcheng I&II Jiangsu, Yizheng Chemical Meishan Iron&Steel Jiangsu, Xiaguan Hunan, Lianyuan Hubei, Xiangfan Chongqing 1,2,3 Zhejiang, Qianqing Sichuan, Yibin Anhui, Tianjiaan Anhui Tongling Anhui, Anqing Anhui, Ma’anshan Guizhou, Jinsha GuiZhou, Qianbei Guizhou, Yaxi Power Cogeneration Waste-to-Energy Flue gas desulfurization © Metso Shanghai, Waigaoqiao Shanghai, Minhang Yunnan, Qujing Yunnan, Kunming 1&2 Yunnan, Xiaolongtan 1&2 Yunnan, Xuanwei V,VI, VII Yunnan, Xunjiansi Jiangxi, Jiujiang Chemical Jiangxi, Guixi Jiangxi, Fengcheng I&II Jiangxi, Fengyi Guangzhou, Nansha CCPP Huadian Jurong Power Plant, China • 2 x 1000 MWe Ultra-supercritical coal fired TPP • Start-up: 2013 • Total BTG Controls • 27,360 I/O’s • Delivered by Metso SAC JV: © Metso Main control system, Furnace safety surpervision system Data acquisition system Steam turbine digital electro-hydarulic control system (DEH) FGD plant control system and SCR controls Fengcheng Power Plant, China • 2 X 700 MW OTSC • Start-up: January 2007 • Shanghai Electric Co., China 31 • Total BTG Controls • 23,300 I/O’s © Metso Maanshan Power Plant, China • 2 X 660 MW OTSC • Dec 2008 start-up • Harbin Power Engineering, China 32 • Total BTG Controls • 24,200 I/O’s © Metso THERMAL POWER PLANTS Metso Automation in India NTPC UNCHAHAR 1x210 MW 2 BALCO 3 RENUSAGAR #9 1x67 MW 4 GEB KUTCH LIGNITE 1x75 MW 5 PARICHHA 1 & 2 2x210 MW 6 NTPC RAMAGUNDAM 1x500 MW 7 MAHAGENCO KHAPERKHEDA 1x500 MW 8 ANPARA 4 & 5 2x500 MW 9 PIPAVAV TPP 2X600 MW 10 PRAYAGRAJ STPP 3X660 MW 11 GIRAL 1x125 MW 12 LEHRA MOHABAT 2x250 MW 13 NTPC RIHAND STGII 2x500 MW 14 KOTA - 6 1x195 MW 15 NTPC SIPAT 2x500 MW 7 16 TAU DEVILAL PANIPAT 7 & 8 2x250 MW 9 17 SGTPS BIRSINGHPUR 1x500 MW 4 18 NTPC KAHALGAON 1x500 MW 2 19 KPCL BELLARY 1x500 MW 33 20 DVC MEJIA 1x210 MW 26 21 NTPC VINDHYACHAL STGII 2x500 MW 22 APGENCO RAYALASEEMA 2x210 MW 23 MS EB PARLI 1x250 MW 24 CS EB KORBA EAST 2x250 MW 25 KAHALGAON STGII 2x500 MW 26 PARAS #1 1x250 MW 27 MEJIA 5&6 2x250 MW 28 CHANDRAPURA 2x250 MW 29 SANTALDIH 1x250 MW 30 JINDAL RAIGARH 4x250 MW 31 AMARKANTAK V 1x210 MW 32 BAKRESWAR 4&5 2x210 MW 33 UKAI 1&2 2x120 MW 34 TANDA (R&M) 3x110 MW 35TENUGHAT (R&M) 1x210 MW 36 MAHAGENCO BHUSAWAL 2X500 MW 37 NTPC SIMHADRI II 2X500 MW 38 OP JINDAL STPP 4X600 MW 1 © Metso 10 1 8 12 5 6 16 7 9 CAPTIVE POWER PLANT 14 1 13 1 34 21 11 4 10 13 3 4 10 5 9 2 COMBINED CYCLE POWER PLANTS 1 KUTTALAM CCPP 101 MW 2 DHUVARAN CCPP 107 MW 3 GMR KAKINADA 230 MW 4 GMR VASAVI CCPP 4X50 5 MW 6 BHUSHAN CCPP 1x60 MW 7 BHADRACHALAM1x21MW 8 DHOLPUR CCPP 330 MW 9 BHILAI STEEL 1x15 MW 10 BHUSHAN 60 MW RAICHUR (R&M) 3 6 35 8 17 31 9 24 8 5 13 12 30 38 2 36 12 7 11 37 9 2 10 19 3 2 3 4 5 6 7 8 9 10 11 6 7 20 25 3 27 18 32 15 28 29 8 11 5 23 1 12 13 6 ADITYA CEMENT 1x23 MW RIL, HAZIRA 40 MW TISCO JOJOBERA 1x120 MW HINDUSTAN ZINC LTD. 2x77 MW RAIGARH 55 MW HINDALCO 1x35 & 1x6 MW ITC BHADRACHALAN 1x18.5 MW BHUSHAN LTD. 1x77 & 1x30.75 MW MONET ISPAT 1x80 MW NALCO ANGUL 2X120 MW GNFC 2x25 MW TISCO JAMSHEDPUR 1x30 MW SPB ERODE 21 MW HYDRO POWER PLANTS 22 14 1 1 3 2 4 4 5 6 7 8 9 10 11 12 13 NHPC PARBATI HEP 4x200 MW KPCL ALMATTI HEP 5x55 & 1x15 MW NEEPCO TURIAL HEP 2x30 MW MPEB MADHIKEDA HEP 2x20 MW THDC KOTESHWAR HEP 4x100 MW MANERI BHALI HEP 4x76 MW ROLEP HEP 2x18 MW MUKERION HEP 2x9 MW KOLDAM HEP 4x200 MW SEWA 3x40 MW CHIPLIMA HEP 1x25 MW MADHIKHEDA HEP 1x20 MW KAMENG HEP 4x150 MW OP Jindal Super Thermal Power Plant, India 34 • 4 x 250 MW • BHEL • Sept 2008 start-up • Total BTG Controls • ~ 50,000 I/O’s © Metso National Thermal Power Corporation, Ramagundam Unit 7, India 35 • First “Unified Automation Solution” in India • BHEL 1 x 500 MW • Start-up: August 2004 • Total BTG Controls • ~ 21,000 I/O’s © Metso Selected automation references: Hydro Power Plants Location Djerdap- 1 HPP Irganayskaya HPP Baksan HPP Ilarion HPP Nho Que 3 Anjalankoski Anjalankoski Peniche Vuokskij kaskad Tuyen Quang Se San 3A Chukka HEP ROLEP 1 & 2 Koteshwar 1 to 4 Maneribhali 1 to 4 Turial 1 & 2 Almatti Units 1 to 6 Madhikheda 1 & 2 Almatti Units 1 to 6 Bihai Parbati Can Don Kyröskoski Anjalankoski Kyröskoski Tammerkoski 36 © Metso Country Serbia Russia Russia Greece Vietnam Finland Finland Portugal Russia Vietnam Vietnam India India India India India India India India Taiwan India Vietnam Finland Finland Finland Finland Capacity MW e 5 x 201MW 2 x 205 MW 3 x 8,3MW 2x70MW, +5MW 2x55 MW 14,5 MW 3x4,5 MW 300kW 8x27MW 3X114 2X55 4x85 2x18.5 4x100 4x76 2x30 5 X 55, 1 X 15 2x20 5 X 55 1 X 15 1x62.5 4x200 2 x 38.8 15 5x 2x 4,3 Start up Year 2013 2012 2012 2012 2012 2012 2012 2011 2011 2008 2006 2006 2005 2005 2004 2004 2004 2004 2004 2003 2003 2003 1997 1994 1992 1992 Selected automation references: Combined Cycle Power Plants 2008 DATE SIME LAEM CHABANG POWER CO. LTD, LAEM CHABANG, THAILAND • Electrical output 60 MWe, process steam 45 t/h • Fuel: natural gas • Combined cycle 2010 ENERJI SA BANDIRMA, TURKEY • Electrical power 900 MWe • Fuel: natural gas • Combined cycle (2xGT+2xHRSG+1xST) 2011 KOJUHOVO HETAINH POWER PLANT, MOSCOW, RUSSIA • Electrical output 170 MWe • Fuel: natural gas • Gas turbine & HRSG 2008 FORTUM POWER AND HEAT, SUOMENOJA, ESPOO, FINLAND • Electrical output 234 MWe, District heat 214 MW • Fuel: natural gas • Combined cycle 2008 SEMBCORB UTILITIES, TEESSIDE, UNITED KINGDOM • Electrical output 40 MWe • Fuel: natural gas • Gas turbine & HRSG 37 © Metso Title/Author 2012 OMV SAMSUN ELEKTRIK URETIM SAN. VE TIC. A.S, TURKEY • Electrical output 880 MWe • Fuel: natural gas • Combined Cycle 2013 AGE ENERJI, DENIZLI, TURKEY • Electrical output 205 MWe • Fuel: natural gas • Combined Cycle Experience with the technology providers Gas turbine manufactures • Gas turbine control system connected to Metso DNA through link - Monitoring and operation through Metso DNA operator interface - Typical link protocols: GE´s Mark II-VI GSM, Modbus TCP/IP, Profibus DP, OPC Start-up and shutdown sequences in Metso DNA MW setpoints for the GT´s from the main load controller or AGC in Metso DNA in pre-selected control mode GT manufactures GE ABB Alstom Ansaldo • BHEL EGT Fiat Hanjung Mitsubishi PG Rolls-Royce Siemens Gas turbine control system done with Metso DNA GT manufactures GE AEG 38 © Metso Alstom Fiat PR&GEC Siemens Thomanssen Tuma Turbomach Westinghouse Experience with the technology providers Steam turbine manufactures • Steam turbine control system connected to Metso DNA through link - Monitoring and operation through Metso DNA operator interface Start-up and shutdown sequences in Metso DNA Typical link protocols: Modbus TCP/IP, Profibus DP, OPC,Mauell PLC interface, GE´s Mark II-VI GSM, Siemens S7 SAPI Ethernet TCP/IP ST manufactures LMZ Alstom Prvni Brnenska Strojirna Siemens • ABB GE Ansaldo Franco Tosi BHEL Blohm+Voss Ekol Fuji KWU Lang MAN Mitsubishi Steam turbine control system done with Metso DNA ST manufactures Skoda LMZ HangZhou Zamech 39 © Metso KWU Lang (Alstom) Bergman-Borsig ASEA Stahl Siemens ABB BHEL AEG NEI Parson Siemens Skoda STT Thermodyn Urals Turbine Works Zamech Experience with the technology providers Heat recovery steam generator manufactures • HRSG automated with Metso DNA HRSG manufactures Adato SES Tlmace Rafako Podolsk 40 © Metso Ahlstrom Babcock&Borsig CMI Belgium Alstom Stork Energy Kvaerner Idrotermici Standard Fasel Schelde Breda Foster Wheeler Senior thermal Oschatz Mech. de la Pena Vogt Zurn Deltak SGP Tampella Power Metso Nooter/Eriksen 41 © Metso References Europe Finland • Westenergy Oy Ab, Vaasa Norway • BIR Avallsenergi, Bergen Sweden •Åmotfors Energi Ab Estonia UK • Eesti Energi AS, Tallinn • Ineos Runcorn, Manchester phase 1 • Ineos Runcorn, Manchester phase 2 • MES Environmental, Dudley • MES Environmental, Wolverhampton • Waste Recycling Group, Lincolnshire • Veolia Environmental Services, Staffordshire • Cory Environmental, Riverside London • Veolia Environmental Services, Newhaven • Sita, Cleveland 4&5 • Dundee Energy Recycling, Dundee • RWE Markinch, Glenrothers • London Waste, London Austria • A.S.A., Zistersdorf • AVE Wels II • AVE Wels I • AVE Lenzing Italy Hitachi Zosen Inova (former Von Roll Inova) Keppel Seghers CNIM Metso Power Other Technology or Automation Replacement Projects in execution are mentioned in bold/italic 42 © Metso •Trattamento Rifiuti Metropolitani, Turin • Veolia, Piacenza • Veolia, Energonut © Metso
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