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APCS of the boiler unit No. 5 of CHPP-1 (JSC “Astana-Energy”)

The modern full-scale functions of monitoring and control of technological processes and operating modes of the thermotechnical and electrotechnical equipment of the boiler unit are assigned to the APCS.


Tasks, which implement data processing functions

Purpose and brief description of the task

Collection, primary and special processing of data

Collection, primary and special processing of data coming from the sensors of analog and discrete signals. The task is automatically launched when power is supplied to the system and executed at the lower (controller) level in all operating modes of the system with the operating cycle, which is set for each channel individually. The output data are processed parameter values with corresponding flags of performed control and processing registered in the instantaneous value database.

Data representation, including information on alarms

Issue of information for the operating staff on current values of the parameters, position of the control and shutoff valves, condition of the main and auxiliary technological equipment and control system, alarm of the technological process violations and representation of the reference data on displays in a user-friendly form, accepting requests of an operator of the boiler unit to the system, and printing of the necessary information. Communication between the operator of the boiler unit and the system is performed in dialogue mode.

Emergency events recording

Data registration and processing over the pre-emergency and emergency periods, and forming the data files ready for representation to an operator of the boiler unit in a form of report that allows analyzing the registered process of emergence, development and containment of emergency condition.

Registration of parameters deviation

Registration of deviation of values of the analog parameters from the given boundary values of warning and alarm signaling, interlocks and technological protections. Registration of the technological process violations based on condition of the discrete parameters. Collection of the shift reports based on the results.

Daily report generation

Generation of reports to display on the service automated workstation of the APCS and for printing. The report shows the values of the technological parameters, which allow assessing the quality of the technological process of the boiler unit. The report contains information on the primary parameters per each hour of a day and the calculated parameters per each shift and 24-hour period.

Automatic monitoring of commands execution

Forming of messages for an operator of the boiler unit about unexecuted commands given by the control subsystems (technological protections, interlocking, remote and functional & group control) to the shutoff valves with motor drive, solenoid valves and auxiliary devices.

Calculation of technical & economic indices

Automated calculation and preparation of reporting documentation on technical & economic indices for correction of the equipment operation control, equipment condition analysis, assessment of the quality of work of the night watch staff.

Data storage history (Archive)

Automatic generation of a long-term archive, which contains a history of changes of analog and discrete parameters of the technological equipment, as well as the events of the system and local control system (LCS), staff actions and diagnostics of hardware components set (HCS).

Metrological certification of measuring channels

Automated calibration of measuring channel modules of the DCS and system and formation of documentation according to the metrological measuring channel certification of thermotechnical and electrotechnical equipment.


The system is implemented as technically distributed system, which follows the principle of centralized automated monitoring and control of the boiler unit from the control desk involving the operational staff.

An emergency button on one of the DCS cabinets is provided for fail-safe shutdown of the boiler unit in case of the failure of the DCS hardware, which excludes automated control.

The central part of the APCS is the DCS (distributed control system) “TORNADO-N”, which includes programmable automation devices and other computer equipment.


THE AUTOMATION OBJECT CHARACTERSTICS

The automation object is a hot-water boiler No. 5 of KV-T-128-150 type (BKZ KV-110 K-1-model).

Brief characteristics of boiler No. 5:


3.1. Main fuel: Ekibastuz coal.

The liquid fuel (fuel oil) is used for the boiler kindling and sustaining the pulverized fuel flame.


3.2 Technical data of the boiler unit No. 5:

#

Number

Characteristic

Parameter

1

Nominal thermal performance, MW

127.9

2

Nominal water temperature at the outlet of the boiler, t °C

150

3

Nominal difference of water temperature at the outlet and inlet of the boiler, °C

80

4

Nominal discharge of water through the boiler, Gnom, t / h

1362

5

Flow resistance of water path of the boiler unit, Phydr, no more than, MPa

0.2

6

Underheating of water at the outlet of the boiler unit below saturation temperature, at least, °C

30

7

Calculated excess pressure, RCalc, MPa

2.45


Maximal permissible parameters of the boiler at which it must be shut down:

#

Number

Characteristic

Parameter

1

Maximum water temperature at the outlet of the boiler, °C

155

2

Minimum discharge of water through the boiler, Gmin, t / h

1226

3

Minimum excess pressure at the outlet of the boiler, Pmin, MPa

1.03

4

Maximum excess pressure at the outlet of the boiler, Pmin, MPa

2.25


3.4. The boiler has a gastight design and has the following equipment:

  • Forced blower fans: 2 pcs;
  • Exhausters: 2 pcs;
  • Coal-pulverization systems with hammer mills: 2 pcs;
  • Direct-flow pulverized-coal burner: 4 pcs;
  • Liquid fuel injector: 4 pcs;
  • Ignition safety devices (ISDs): 4 pcs;
  • Group of bottom blowing air nozzles;
  • Slag-disposal and ash removal systems;
  • Systems of exhaust gases drying using excess air.


3.5. The coal-pulverization system is based on the direct firing scheme. The fuel is dried with hot air, and in some modes with hot air with cold air from the blower fan head. Transportation of coal dust to the burners is performed using a drying agent.

3.6. The pulverized-coal burners are arranged tangentially in one layer. The liquid fuel injector and ISDs are integrated into the air register, which is set under the pulverized-coal burners.

The injectors are equipped with valves and ISD in accordance with the normative & technical documentation (NTD). As specified in the NTD, installation of a shutoff device with the manual drive and a shutoff device with the electrical drive is prescribed at the liquid fuel input of each injector. An electromagnetic valve on the bypass of the shutoff device with electric drive is set at the liquid fuel input to each flame safety injector in addition to two shutoff devices.

The four injectors provide the kindling load of the boiler equal to 30% of the nominal one. These injectors are used for firing of the pulverized-coal burners.

When the boiler unit is operating on the pulverized coal two injectors are switched on by “Dimming of the pulverized coal flame” automatic protection or by the protection on the boiler load reduction to 60% of the nominal one – for “pickup” of the pulverized fuel flame.

The fuel oil injectors of flame safety are switched on automatically and without the igniter only in these two cases as a quick switch is required. However, if the injectors flame is not fixed by a protection device the protection will switch these injectors off. An operator of the boiler performs switching off of the injectors switched on by the protection after stabilization of a pulverized fuel flame.

3.7. Remote switching on of the ignition devices and liquid fuel injectors must be provided for the safe execution of the kindling operations, and the control of this devices and injectors on site (from the service platforms of the boiler) is used only for adjustment work.

Explosion prevention during kindling is provided by interlocking of the furnace ventilation and protection that switches off the liquid fuel supply in the injector when the injector’s flame does not ignite or goes out.

According to the explosion hazard requirements, the kindling of the boiler with the use of the liquid fuel may start with ignition of any injector and is executed in sequence specified in the operating instruction of the boiler plant.

3.8. Hot air is supplied to the bottom blowing air nozzles, which are located on the front and back slopes of the ash hopper. One control valve and one restrictive orifice are set on each of the two air inputs to the bottom blowing air nozzles.

Secondary air admitted to the air channel of the pulverized-coal burner and to the air register of the injector is supplied through its own valves. Before the injector switches on, the valve at the air input to the register must be opened. Before the mill switches on, all the valves at the air input to all the pulverized coal burners must be opened.

Additive of the hot (excess) air is used to increase the temperature and reduce humidity of exhaust gases before the exhauster. This air is selected after the air preheater and supplied via two lines to the path of the exhaust gases after the ash removal devices. One control valve and one restrictive orifice are set on each of the two air inputs.

3.9. If the fuel supply switch is in the “Уголь1” position, the main fuel is coal. If the fuel supply switch is in the “М2” position, then kindling of the KV-T-128-150 boiler is fuel oil based. 


1 Coal.

2 Fuel oil (rus. “Мазут”).



 

 


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