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 Topics

BHELs growth in Power and Industry

DCS solutions
Summary

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 BHEL PRODUCT PROFILE

Power Generation
Power transmissions & Distribution
Industries
Transportation
Oil & Gas
Renewable Energy

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 BHEL ACTIVITIES & LOCATIONS

A Navaratna company and a Major

GOINDWAL
Integrated Power Plant Equipment
CHANDIGARH Manufacturer in the World
HARIDWAR
NEW DELHI
RUDRAPUR 15 Manufacturing units and 8
JAGDISHPUR
Service Centres
JHANSI
VARANASI 4 Power Sector Regional HQs
BHOPAL KOLKATA Corporate Research &
PATNA
VADODARA Development Division : Hyderabad
NAGPUR
Over 100 Project construction sites in
HYDERABAD VISAKHAPATNAM India & Abroad
BHEL manufactures 180 products in 30
BANGALORE CHENNAI major product groups

RANIPET Two Subsidiaries BHPV, Vizag & BHEL
KASARAGOD TIRUCHIRAPALLY
Electrical Machines Ltd, Kasaragod
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 DCS solutions from BHEL

BHEL-Electronics Division has an on-going collaboration

agreement with Metso
BHEL has established facilities and expertise for:
System engineering
Manufacturing of modules & systems
System testing & commissioning
After sales support

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 UNIFIED SOUTION FOR C&I FROM BHEL
(Advantage to Customer)
THERMAL PLANTS (15 - 800MW) HYDRO PLANTS (3.67 - 200MW)
Boiler Controls Auto Sequencer
Turbine Controls Governor Controls
Station C&I Remote Operation
HMI HMI
Power Plant SCADA Optimization Packages
PADO (Performance Analysis CCPP PLANTS (21 1500MW)
Diagnostics & Optimisation)
Offsite Balance Of Plant Controls HRSG Controls
Other Systems Steam Turbine Controls
Interlocking in Excitation Systems Station C&I
Interlocking in FSC / CSR / SVC / HMI
STATCOM Interface to Gas Turbines
Interlocking in VFD system Power Plant SCADA
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 Dadri 2x490 MW Coal based Power Project
Largest Integrated Platform

Totally maxDNA based, including

Off-site systems
Domain 1 2X34 DPU4F Integrated system handles >47,000
UNIT #1
17000 I/Os physical I/Os and >500 operator
1 CR, 10 RIO
displays
(SG/TG/Stn C&I)

> 200 DPUs distributed across 7

DOMAINs
> 100 maxSTATIONs distributed
Domain 9 Domain A Domain B Domain C Domain D across various DOMAINs / locations.
COMM SYS WTR SYS AHP SYS COAL SYS MAKEUP SYS 7 Domains interconnected &
2X8 DPU4F
geographically distributed across 20
2X11 DPU4F 2X6 DPU4F 2X11 DPU4F 2X1 DPU4F
4000 I/Os 1670 I/Os 4850 I//Os 3000 I//Os 450 I//Os Sq Kms
5 CR, 4 RIO 1 CR, 3 RIO 5 CR, 15 RIO 1 CR, 8 RIO 1 CR > 45 sets Remote I/O systems
Selective Interoperability across
domains
Domain 2 2X34 DPU4F
17000 I/Os
Unit#1(Domains 1,9,A,B,C,D)
UNIT #2 1 CR, 10 RIO Unit#2(Domains 2,9,A,B,C,D)
(SG/TG/Stn C&I) Common systems - Individual
domain operations (9,A,B,C,D)

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 Dadri 2x490 MW Coal based Power Project
Largest Integrated Platform

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 New Applications / Solutions Developed on maxDNA

Development & Implementation of IEC 61850 Compliant HMI

for Substation Automation on maxDNA Platform

HMI
Substation
Configuration
Monitoring of Analog Data for a typical
DRIVER
HMI & Engineering
Software SCL
220/400 kV substation
Controlling field devices with:
HMI
Library
Manager
61850
Client
Client
Engineering
Direct control
configuration

HMI Station
Station Direct control with enhanced security
Select before operate
Select before operate with enhanced
IEC 61850
61850/101/10 security
4 Protocol
Network Conversion Alarms and Interlocks
Event summary
Gateway
Report control and general interrogation
To LDC
61850 61850 61850
Servers Servers Servers

IEC61850 Simulation Server / Meter

Relay/BCU

Software Components in 61850 Compliant HMI Brightening Lives .. Powering Progress..

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 New Applications / Solutions Developed on maxDNA
Wireless LAN & Wireless Controls on maxNET
Connects Central Control Room (CCR) with CW Pump House (CWPH) and Fuel
Oil Pump House (FOPH) through Wireless technology at 500MW TPP.
Geographic Location Details:
CCR: Central Control Room
: Latitude - 1511'37.58"N
: Longitude - 7643'8.40"E Radio Modems Installed at CCR
: Elevation 1575ft
54Mbps RF Link1
600 Mtrs
FOPH: Fuel Oil Pump House 25Mbps Throughput

: Latitude -1511'46.48"N 54Mbps RF Link2

400 Mtrs
: Longitude - 7643'14.88"E 25Mbps Throughput
: Elevation 1576ft
Radio Modems Installed at
CWPH: Cooling Water Pump House FOPH

: Latitude -1511'45.30"N
: Longitude - 7643'4.01"E
: Elevation 1566ft
Radio Modems Installed at
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 New Applications / Solutions Developed on maxDNA

Alarm Analysis System Root Cause Analysis Package on maxDNA platform

Diagnostic tool for fault identification in power

plant for analog and digital alarms generated by
the DDCMIS.
Provides an intelligent root cause analysis.
The root cause analysis is performed by efficient
traversal of decision trees built by the user for
different alarm conditions.
The operator is notified of the root cause for
various alarm conditions with Probability.

Designed and built on four Modules:

1) Logic Tree Module

Root Cause Analysis
Alarm Management
Alarm Annunciation
Bharat Heavy Electricals Limited
2) Graphic Tree Module
3) Probability Computation Engine
4) Reporting Engine
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 New Applications / Solutions Developed on maxDNA

Availability Based Tariff (ABT) on maxDNA Platform

Provides digitized linking between power

maxDNA based ABT Package generation and revenue
DC-Declared Capacity
SG-Scheduled Generation LDC
ABT
Database
UI-Tariff, Fuel Cost etc., Monitor the generation or power availability
IMPORT EXPORT
maxVUE
continuously to ensure 90% availability
maxDPUTools ON-LINE
Graphical Configurator
maxNET

Meets the requirements of surprise audit to

Online Logic Building
DOWNLOAD
Download UPLOAD
FREEZE/
CHECK Virtual
demonstrate availability
Outputs DPU
BROWSE
/ EDIT
Ensure adequate and timely maintenance of
DPU4F
overall infrastructure
ABT Display

ABT Package Architecture Improve quality of power & curtain

frequency variation/disturbance

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 New Applications / Solutions Developed on maxDNA
Numerical Relay Interface IEC-60870-5-103

maxLinks
Status, Event Alarm
and Alarm ALARM HANDLER Generation
display
Status IEC-60870-5-103
(online) Data
SBP DLL

Event
EVENT SERVER Generation

IEC-60870-5-103
IEC 103
PROTOCOL
Master

RS 485
DATABASE IEC 103
Configuration

Numerical Relays

Software to interface Numerical Protection Relays

Bharat Heavy Electricals Limited
Acquire time tagged events
Events are part of maxDNAs Alarm & Events
Configuration & runtime utility
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 New Applications / Solutions Developed on maxDNA

PADO for Hydro Power Plants

Simulation & Optimization package

for Hydro Power Plants

Built-in Web Portal capability

Designed and built on following

software Modules :

Optimization Software
Training Simulator
Power House Intranet

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 New Applications / Solutions Developed
OPERATING MODE
COLD STARTUP
on maxDNA
Training
WARM START

HOT STARTUP
MATHEMATICAL

Simulator
PURGE READY MODELLING OF
UNIT READY FOR TURBINE - EQUIPMENT
ROLLING BOILER &
AUXILIARIES
UNIT READY FOR COAL FIRING

30%,60% & 100% LOAD TURBINE &

AUXILIARIES
ANY OTHER USER DEFINED STATE

Virtual Plant
Instructor
Station
INSTRUCTOR FUNCTION

INITIAL CONDITIONS
RUN
FREEZE
MAL FUNCTIONS
CONTROLLERS LOCAL OPERATIONS
SNAP SHOTS
RECORD
CLASS - A CONTROLLERS REPLAY
MAIN STEAM PRESSURE BACK TRACK
DRUM LEVEL RATE OF
SH STEAM TEMPERATURE SIMULATION
RH STEAM TEMPERATURE
BURNER TILT MALFUNCTIONS
FURNACE PRESSURE
O2 EQUIPMENT/SYSTEM
CMC TRIP

REST OF THE CONTROLLERS UNIT TRIP

Burner Management System (BMS) Automatic Turbine Run-up System ABNORMAL

(ATRS) PROCESS
Oil Firing BEHAVIOUR
Coal Firing Turbine
Unit Start up Turbine Oil
Evacuation
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 Brightening Lives .. Powering Progress..
Bharat Heavy Electricals Limited
Touching Every Indian Home
 29TH MARCH 2010
Metso DNA Architecture
Control room Office
Operation, Maintenance, Reporting Reporting, Enterprise integration

Remote connections

Star or ring topology

redundant Ethernet network Name based communication

Controls, Automation room

Optimization, Engineering &
Connectivity Maintenance,
Centralized or
and Asset Management,
distributed
Safety Information services
instrumented
system

Field
Ethernet and No need of internal communication links
serial links No need of internal servers

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 Salient features:

Powerful & Reliable Controllers Dynamic function and

with Flexible Field Options
All type of Field buses
supported
Build-in HART connectivity
PROFIBUS
Foundation Field Bus
Wireless
Multi Windows
Arrange, resize, zoom and pan windows
Multi Monitor support
Store Picture & Desktop layout
Based on process situations, tasks and
organizational roles
Robust network architecture
Ring & RSTP Topology
Handles more than one point failure.
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Bharat Heavy Electricals Limited
interlocking descriptions
- For machine and process
History Mode - Time machine
- Replay history from any picture
Faster analysis by single click
- Reporting, maintenance and Analysis
tools integrated with DNAuse
Diagnostic from all levels
- Network devices and System bus
- System nodes, WS
- IO groups, buses,
- Field devices and IO
- Control software and databases
- Link to third party systems
Remote diagnostic facility
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 DNA Operate Efficient Problem
Solving - Operation Tools
Start History mode
History mode indication

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
Select displayed moment
and replay
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 DNAtracer trend and analysis tool

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 Use Any Time, Anywhere
Reporting and Analysis tools Summary

All information is continuously

available throughout the enterprise
via one web portal
Informative presentation of data
Align quality, production and
costs
Results community makes correct
decisions based on the same facts
The potential improvement targets
and deviation in process are easily
detected Source of innovations
Environmental reporting is according
to the regulations Same tools throughout The Results Community for
professionals in the Office and Control Room
No surprises
The team can focus on more value
adding tasks, since manual reporting
21 is eliminated
 Share And Increase Organizations Knowledge
Community and Collaboration

Global situation awareness with

discussion tools
DNAdiary, discussion forum,
instant messaging, video
conferencing
Integrated to process operation
One button launch
E.g. Video
conferencing and
instant messaging
Fully automatic entries
DNAdiary

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 DNAexplorer for Plant Management
Engineering and Maintenance Tools

One powerful tool for

engineering and
maintenance of
- field devices
- HW and network
documents
- user interface
- control application
- field bus
Explore through the
network
Intuitive to use

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 SUMMARY

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 SUMMARY

Capability to provide control solutions for a wide

spectrum of ratings of Power plants
Ability to provide unified solutions to meet ever increasing
customer requirements
Availability of In-House state of art facilities & capabilities
for manufacturing
Availability of State of art Engineering center
Rich experience with more than 600 DCS in service

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