SUPER CRITICAL POWER PLANTS

CONTROL & AUTOMATION ASPECTS

FOR

RELIABILITY OF SUPER-CRITICAL UNITS

Sandeep M. Patel
BHEL-Electronics Division
patelsm@bheledn.co.in

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Market requirements

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FUEL
Coal & Lignite

Abundant Availability

Lower Cost
Will continue as main
source of fuel

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EXPECTATIONS FROM GENERATION UNITS

Increased Plant Efficiency & Lower Heat rate
High Reliability and Availability of Plant
Ability to use different quality of Fuel

Ability to operate under adverse grid conditions

Minimum Pollution
Lowest cost

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Parameters to Increase Cycle Efficiency

Increase in Main Steam Pressure
Increase in Superheat and Reheat Temperatures
Increase in Condenser Vacuum

Increase in Feed water Temperature

.. and many more

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Measures to Improve Plant Efficiency

Overall Efficiency can be increased by
Improving internal efficiency
Adoption of advance steam parameters

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Measures to Improve Plant Efficiency

As the fluid pressure increases,

Latent Heat ( Enthalpy of Steam
Enthalpy of Water) reduces.

At Critical point it becomes zero.

In physical terms, at this pressure
water transforms to steam

spontaneously.

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Measures to Improve Plant Efficiency

Improvement

PARAMETERS ABOVE CRITICAL STATE

STEAM PRESSURE
> 221.2 BAR

STEAM TEMPERATURE > 374.15 Deg C

ULTRA SUPERCRITICAL PRESSURE( 300 BAR)
4.3 %
45
40
35
30
25
20
15
10
5
0

500 MW

Sub critical
170ata / 537 C / 537 C

660 MW

Super Critical
247ata / 565 C / 593 C

INCREASE IN PRESSURE AND MAIN & REHEAT TEMP. > 537 Deg C
RESULTS IN SIGNIFICANT IMPROVEMENT IN EFFICIENCY

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Measures to Improve Plant Efficiency

Steam Power plant efficiency increases with
increase in steam pressure and temperature.
Power plant Cycles operating above critical
pressure (221.2 bar) are classified as Supercritical
cycles.
With higher cycle efficiency, the supercritical cycle
offers the advantage of burn less fuel for the
same output and lower emission.

Lesser Pollutants SOX , NOX & CO2

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Expectations from C&I

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Power Plant Objectives

Optimum Performance
Reliable and Secure Operation
Simplicity in Operation

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Power Plant Control Requirement

Efficient and Effective Control Strategy
Reliable , Precise and Flexible Execution
Well Designed Operating Aids
Increased Level of Automation
Ability to cover all areas of a power plant
Integrated Automation and Information
Management
Central Control Room for Total Power Plant

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Added Features
Expert System Based Tools
Performance Analysis, Diagnosis and Optimization
System ( PADO)
Boiler Flame Analysis System for Combustion
Optimisation
Root Cause Analysis System

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Responsibility of C&I
To provide a system, which is
Safe
Reliable
Highly Available
Efficient
Easy to Operate

----------------->>>>

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Responsibility of C&I
To provide a system, which is

Expandable
Informative
Guide To Operator and Maintenance
Personnel
Assistant to Operator/ Maintenance
Group

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Responsibility of C&I

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How it is Achieved
Highly reliable and rugged control system
Well designed Control Strategies
Fast, Accurate and Efficient Processing,
Calculations and Decision making
Built-in Redundancies at every level
Easily maintainable for Minimum Down time

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How it is Achieved
Better Information Management & Presentation
System
Operator Guidance
Better Diagnostic and Maintenance Tools
for Machine as well as for Control Electronics

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Changes in C&I due to Super-Critical

Technology
Even Though Machines have changed but Major
Sub-systems remain same/similar

All major Control Requirements remain Same

No major change in Controlled Field Devices and
Equipment
Control Strategies will change to suit Process
requirement, which is possible to be realized in
existing Control System

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Power Plants are either

Sub-Critical OR Super-Critical
There is no Critical Plant

But for C&I

Every Plant is CRITICAL

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THANKS