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Guangzhou Pearl River Power Plant #1 unit completed the DCS integration transformation in the beginning of 2001 using the unit overhaul time and achieved satisfactory results. Now I will give a brief report on the transformation of #1 unit DCS:
1. Pre-retrofit equipment condition The Guangzhou Zhujiang Power Plant installed a 4×300MW coal-fired turbine generating unit, and the #1 unit was put into operation in March 1993. The three main engines were supplied by the Harbin Sanda Power Plant. Subcritical intermediate reheat natural circulation drum furnace, uniaxial subcritical reheat condensing steam turbine, medium speed mill positive pressure direct blowing system, two 50% MCR steam feed pumps, one 50% MCR electric Feed pump and 40% high and low voltage secondary bypass.
The control system was at the mid-eighties level. The decentralized control system used the Westinghouse WDPF-II system, including machine/furnace/electrical data acquisition (DAS), machine/furnace analog control (MCS) functions, and machine/furnace sequence control ( The SCS) function can only achieve remote control of the CRT/KB, but all of the functions of interlock protection and program control of the main and auxiliary machines are hard-wired by the conventional relays. The FSSS system uses the American Forney AFS-1000 system. The DEH system adopts DEH-III digital anti-fuel anti-fuel digital pure electronic modulation provided by Shanghai Xinhua Company. The connection signal between DEH and DCS adopts hard wiring. The MEH system is also provided by Shanghai Xinhua Company. The bypass control system uses the Swiss Sulzer AV6 system. The turbine monitoring system uses the TSI-3300 system of Bentley Corporation. The program control system of domestic ETS system and fixed row, soot blower, air preheater air leakage, ash removal, slag discharge, and rubber ball cleaning are completed by conventional relays or PLC hard wiring. The monitoring and control methods of the electric-transformer and factory electrical equipment are based on conventional monitoring equipment. Some of the parameters are entered into the DCS for data acquisition.
2. The reasons for the transformation 2.1 The cost of spare parts is considerable Due to the control system provided by a number of companies, hardware and software are not universal, resulting in a large number of spare parts and varieties. With the ever-increasing operation time of equipment, the failure caused by the gradual aging of equipment has increased year by year. Every year requires a lot of manpower and material resources to maintain the equipment system. The cost of equipment repair is high, and the annual maintenance costs are increasing.
2.2 Since the original control system consists of several devices, there is a gap in service.
2.3 Due to the low technical level of the designed control system and the poor degree of integration, data communication problems cannot be well resolved among the various systems. Sampled data cannot be shared. It will be difficult or even impossible to achieve the automatic coordination control of the unit when the load is changed rapidly during peak load adjustment with the existing equipment technology, and it is impossible to realize the automatic start-stop control of the unit. Seriously restricted the further improvement of the level of regulation of the automatic control system. In order to adapt to the current competition in the power market for competitive bidding and the creation of a "world-class" power plant, it is necessary to upgrade the control system.
After the project was established, our factory decided to adopt the "XDPS-400 hardware and 2.0 application software system produced and developed by Xinhua Control Engineering Co., Ltd." to achieve the integrated transformation of the DCS system of the #1 unit in Zhujiang Power Plant after a close investigation.
3. Scope and Objectives of the Transformation 3.1 Scope of Transformation The integrated transformation of the DCS unit #1 includes the main control systems for thermal control: CCS, BMS, DAS, ETS, DEH, MEH, SCS (including boiler soot blowing, fixed row, continuous row , air preheater air leakage control, steam turbine secondary filter, small machine on the site, minimum flow valve, rubber ball cleaning and other program control system); the original 36 sets of base regulator into the DCS system; cancel the original temperature meter, the information into the DCS Electrical ECS system (including monitoring of electrical 220kV systems and operation and monitoring of 6kV and 380V power supply systems for the plant); Centralized control of all indoor equipment modifications: Removal of BTG trays, operator stations, setting up of large-screen display systems, and two industrial Television and 9 hard-wired operation buttons set up a voice alarm system.
The original site of a meter and components in addition to the base-type adjustment system actuator pneumatic valve positioner to electric / gas valve positioner, basically unchanged, maintain the original situation.
3.2 Rebuild target The DCS system reaches the level of the unit-level program-controlled start-stop level, through Aus (AutoUnitSequence) sequence control system, according to the different working conditions of the unit (cold, hot, extremely hot state) using the corresponding sequential control logic to achieve from System cleaning, boiler feedwater, establishment of wind smoke, boiler ignition, feedwater bypass and main road switching, single impulse and three impulses switching, steam turbine automatic speed increase, valve switching automatic grid load, factory power Switching, small machine self-start and stop, high and low self-input and other automatic control.
After the transformation, the DCS system is connected with the MIS system through Ethernet. All DCS measurement points can be sent to the MIS system. The MIS system can display real-time measurement point information through a browser. Large screen displays and new operator stations are located in the unit control room. The flame industrial TV and water level TV use flat-screen color CRT independent display. Drum electric contact level gauge signal directly into the DCS is displayed on the CRT. The large screen has all the screen display functions of the operator station, including flow chart display, trend display, alarm, etc. It can also display the water level, soft alarm light card and so on.
4. Careful organization and meticulous construction The entire DCS system renovation project is under the responsibility of Shanghai Xinhua Company's technology and is designed by the Guangdong Electric Power Design Institute. The power plant is responsible for the overall coordination of the construction process and the control of cable laying, cabinet disassembly and assembly, and commissioning of the control system. Due to the large amount of work and time constraints, we have adopted a technical construction staff to solve this problem. At the same time, from the perspective of standardized management, we have hired Huainan Zhongfa Power Co., Ltd. as the quality supervision unit to provide quality supervision for the entire project.
The DCS integration transformation of #1 unit of Zhujiang Power Plant began on February 1, 2001, and completed on April 6, 2001. The unit lasted for 65 days. On April 9, the unit started once and was successfully connected to the network and transferred to the automatic control system. Commissioning and commissioning work. On April 25, the coordinated control system was put into operation. From May 21 to May 22, the DEH test was used to measure the turbine valve flow curve. On the 24th, the valve switching test was performed based on the measured curve correction parameters. The result was satisfactory. On May 30th, a test of changing conditions of one set of five pulverizers was completed. On June 1st, two sets of five coal mill tripping tests were completed. On June 5, the disturbance test of a single steam-feed pump trip was completed. On October 25th, through the joint efforts of all parties involved in operation, maintenance, and thermal control, the burner swing angle was automatically put into operation.
Since then, in terms of system functions, the protection has been fully put into operation, the input rate is 100%, and 100 sets of automatic adjustment systems have been used. The input rate is 100%; all DAS measuring points have been invested, and the input rate is 100%. The first phase of the functional goals has been fully realized. In the next stage, the RB conditions and the logic of the AUS system (namely, the unit-level program-controlled phase-by-phase automatic start-stop system) will be tested and the tuning performance will be further optimized and the performance calculation will be improved.
5. Evaluation of DCS system operation Since starting up on April 9, the unit operation is basically normal and the control system is stable. During the entire debugging period, no trip failure due to system or debugging has occurred. Through more than one year of operation, we believe that the XDPS-400 system has the following features compared to the original system:
5.1 Each subsystem adopts the same hardware and software platform and is connected on the same information highway. This simplifies the interface between subsystems and facilitates the sharing of information among subsystems. This saves a lot of information. The internal cable of the system not only saves the cost of the interface hardware, but also facilitates maintenance.
5.2 Abolished the hard handle operation originally distributed on the BTG disk. Using the same human interface station, the process flow is displayed on the CRT. The position and status of the equipment in the process system are clear at a glance. All operations can be used on the CRT soft. The completion of the manual operation facilitates the centralized monitoring of the crew by the operating personnel.
5.3 The SCS control of the original system is a hard logic built by relays. The system wiring is complicated and the logic is difficult to modify. If the device trips, the reason is also difficult to find and the system is inconvenient to maintain. After the transformation, all state signals and interlocking and tripping conditions of the equipment can be recorded by the computer to facilitate accident analysis. Due to the use of computer configuration, the control logic can be easily modified without any additional hardware costs.
5.4 The integration of the electrical control into the DCS system has increased the means of monitoring these equipment and has also made it possible to start and stop program-controlled units at the unit level.
The XDPS-400 system also encountered some problems during the operation of our plant. Some of them have yet to be resolved. For example, DPU initialization during operation, DPU drop-out, and OPU shrinking in the unmanned operation. In the DCS system reconstruction of #3 unit completed in March of this year, the Xinhua Company's latest 2.05R software was adopted. Xinhua Company promised to solve the above problems and the actual effect needs further observation. RB operating conditions and AUS system (ie, unit-level program-controlled, phase-by-phase automatic start-stop system) logic tests and performance calculations have not yet been implemented, and the tuning performance needs to be further optimized. Due to the short time, some problems may not have been exposed. However, on the whole, the DCS rebuild of Unit #1 was successful, which has brought the automation level of our plant forward one step further.
Reasons and Experiences of Transforming Westinghouse WDPF with Xinhua XDPS-400
Leaders, experts: