Integrated APCS of the turbo unit No. 15 of Novo-Kemerovo CHPP

Automatic process control system (APCS) of turbo unit No. 15 with a T-120-12.8 heating turbine and a generator of TVF-110-2EUZ type of Kemerovo branch (OJSC “Kuzbassenergo”). Novo-Kemerovo CHPP was manufactured by “Tornado Modular Systems” and put into operation in 2008.
The purposes of the system creation:
safe functioning;

• increase of the fail-safety level;
• increase of operating efficiency of the turbo unit;
• improvement of ecological indices of thermotechnical equipment.

All design solutions are in compliance with the current standards and technical maintenance rules, safety measures and fire safety rules, and explosion safety.

The amount of thermotechnical control and automation has been implemented in accordance with methodical instructions of amount of thermotechnical measurement, alarm system and automatic control at thermal power plants (34.35.101-2003 Organization Standard).

Efficiency criteria of the APCS and their expected changes

Running charges (repair, servicing, staff) of the turbo unit: a decrease of 3...5%.

Amortization charges: a decrease of 1...3%.

A total economic effect of the APCS adaptation (in comparison with the initial index): 5...10%.

Software and linguistic support solutions

According to the performed functions the software is divided into the following logical parts:

• Software for display of data;
• Software for data collection and storage;
• Software for data transfer;
• Software for monitoring and control of equipment.

The InTouchTM system manufactured by “Wonderware” company is used for data display. This system is an object-oriented Human-Machine interface (HMI). The InTouch system includes programming tool set for creation of the graphic elements (mimic diagrams), descriptions of its behavior, software and network interfaces, supports data exchange with most of existing programmable logic controllers via standard protocols (e.g. Modbus or OPC).

Application servers, which serve as an interface between the information display subsystem and software of technological controllers, are implemented using LabView package of “National Instruments” company.

Collection and storage of information are performed within a database, which is based on the SQL-server manufactured by “Microsoft” company. SQL language is the standard for high-performance database servers and supported by all leading DBMS1 manufacturers.

The information transfer software for minimization of overhead expenses during data transfer via the network is based on the high-level languages such as C++.

The software for control of units and devices is based on the technological programming languages of IEC 1131-3 standard.

The technological control object is the turbo unit No. 15 with T-120-12.8 heating turbine manufactured by “LMZ2” and TVF-110-2EUZ generator manufactured by “ELSIB”, Novosibirsk.

T-120-12.8 steam turbine is a single-shaft two-cylinder unit, consisting of single-flow cylinders of high and low pressure. The high pressure cylinder has a nozzle steam distribution.

The turbine is designed for operation under the following parameters (according to 89001 TU 11 02 specifications):

• Nominal absolute pressure of a fresh steam before the isolation valve: 130 kg / cm2;
• Nominal steam temperature before the isolation valve: 555 °C;
• Nominal discharge of a fresh steam: 470 t / h;
• Nominal capacity of the turbine: 120 MW;
• Maximum capacity of the turbine: 127 MW;
• Nominal thermal load: 160 Gcal / h;
• Nominal discharge of cooling water through the condenser: 8000 t / h.

Maximum capacity of the turbine (127 MW) is achieved in the condensation mode at the nominal parameters of steam and cooling water and with fully enabled regeneration.
The turbine regeneration circuit consists of three high pressure calorizators, three surface low pressure calorizators and steam condenser of the turbine labyrinth seals.
The turbine oil supply system feeds the turbine automatic control system, the bearing lubrication system of the turbine and the generator, and oil-jacking system of the rotor with oil. The oil-supply unit is designed as a general oil supply tank, which has the control pumps, lubricant pumps and lift oil pumps of the rotors. The oil supply to the control system is executed by one of two AC pumps; the oil supply to the oil supply system – by three AC pumps and one DC pump; the oil supply to the oil-jacking system of the rotors – by two AC pumps.

Control of mechanical quantities of the turbine is performed on “Vibrobit-300” hardware. Control of the information reliability and development of the security algorithms are performed in the DCS.

The 125 MW generator of TVF-110-2EUZ type with hydrogen cooling manufactured by “ELSIB”, Novosibirsk.

Thermal control of the generator is performed as a part of the APCS. A sensor set of the thermal control is supplied with the generator.

Nominal voltage in the auxiliary network is 6.0 kV (isolated neutral system) and 380/220 V (dead-earthed neutral system). The supply voltage of electric motors with power of up to 160 kV is set to be 380/220 V. If the electric motor power is 200 kV or more, the power supply voltage is 6.0 kV. Current type: AC, 50 Hz. Plant DC voltage: 220 V.

The following equipment of the turbo unit automation system is included:

• Turbine plant with a generator (APCS tasks: thermal and chemical control with alarm of exceeding the acceptable level, control and protection of the bearing vibration);
• Auxiliary equipment of a turbine thermal circuit;
• Chemical water treatment of the turbine.