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Item
Description
1.0 INTRODUCTION................................................................................5
1.1 Purpose................................................................................................................................... 5
1.2 Acronyms................................................................................................................................ 5
1.3 Glossary of Terms and Abbreviations..................................................................................5
List of Figures
Item Description
Page
List of Tables
Item Description
Page
1.0 INTRODUCTION
The automation solution offered for SIKALBAHA 225 MW +- 10% Dual Fuel Combined
Cycle Power Plant, Bangladesh, is ABB Symphony Plus for Power Generation.
1.1 Purpose
This document gives an overview of the Functional Design Specification (FDS) of Plant Life
Monitoring System (PLMS). ABBs SymphonyPlus Operations/Historian and BoilerLife (a
product from ABBs Optimax suite) is a solution for the above function. The supplied
PLMS will include features such as monitoring and issuing early warning for equipment
diagnosis.
1.2 Acronyms
DCS
HMI
MMIPIS
OWS
PLMS
SymphonyPlus
S+ Historian
S+ Operations
TNT
WHRB
Creep
Cyclic Strain
See Fatigue
Fatigue
2.1. Scope
As supplier for the DCS system for WHRB, the scope of the Plant Life Monitoring System
supplied by ABB India Ltd, is limited to monitoring of drives and thick walled components
related to the boiler. The PLMS package includes:
Boiler Life Monitoring (will be henceforth referred to as HRSG Life within this
document for the sake clarity. However the ABB product name will be BoilerLife)
Drive Life Monitoring
HRSG Life monitoring will be installed on a non-redundant workstation and will be provided
for viewing the outputs of the HRSG Life package. The current evaluated creep and fatigue
results of HRSG Life will be made available on a dedicated screen for PLMS. Additional
information including component and material details will be viewable directly only on the
dedicated workstation. The results of HRSG Life presently cannot be viewed from any OWS.
Drive Life Monitoring will be an integrated engineered functionality of the Symphony Plus
DCS and a single graphic screen will be provided on the redundant S+ Operations servers for
viewing the results (see Figure 12). The Drive Life results can be viewed from any OWS
screen.
PLMS for Gas Turbine and Steam Turbine are presently not covered in this document as
relevant information required from the respective OEM is not available.
2.2. Main Components of PLM System
The functional specifications for SymphonyPlus DCS, S+ Operations and S+ Historian are
subjects of a different Functional specification document and will not be covered in this
document. However, for the purpose of understanding the functionality of PLMS, an
introduction to S+ Historian is covered.
S+
Operations
S+
Historian
S+ Historian
Client Server
protocol
Boiler Life
Monitoring
system
HSI-Net
O-Net
SymphonyPlus DCS
rx
a. List of thick walled components that requires evaluationto be received from M/s L&T
- Materials and material property of thick walled components to be provided by M/s
L&T.
b. Component design details: Dimensions (outer diameter, inner diameter, mean
thickness), shape, design temperature and design pressure to be provided by M/s
L&T.
c. Inner wall and Middle wall metal temperature points (see Figure 4) for the identified
thick walled components from different locations.
Pressure points from the different locations for the identified thick walled components.
HRSG on/off signal
Main steam flow signal
Superheater outlet steam temperature signal
Since the Inner wall and middle wall temperature are not available, it is possible to
calculate only the creep of the component based on the steam temperature exiting the
header/component.
rm
ri
ra
ra : outer radius
ri : inner radius
rx : radius when measured near inner wall
rm : radius when measured near middle wall
HP Drum
LP Drum
HP2 SH Exchanger Inlet Header
Boiler Life
Designation
StE355
19Mn6
X10CrMoVNb9-1
10CrMo9-10
Component
Material
Number
1.0565
1.0843
1.4903
1.7380
EN
ASTM
DIN EN
SA-299 Gr. B
SA-516 Gr. 70
SA-355 P91
10028-3
10028-3
10216-2
SA-355 P22
10216-2
Only the components defined in the table above will be considered for Life time Monitoring.
Description
Value
4
5
6
IIA
1
2
HRSG ON
Main Steam flow at low load (kg/s)
Main Steam flow at full load (kg/s)
HP Drum process measurement details
HP Drum Outlet steam temperature (degC)
HP Drum steam pressure (bar)
LP Steam
03LBA71CF101
03LBA71CF102
03LBA71CF103
03HNE66CG001,
03HNE66CG002
03HNE66CG003
46.725
66.289
3HAD51 BB001
03HAD51CT001
03HAD51CP101
03HAD51CP102
S.No
.
3
4
IIB
1
2
Description
Value
03HAD51CT601
03HAD51CT602
3HAD71 BB001
03HAD71CT001
03HAD71CP101
03HAD71CP102
03HAD71CT601
03HAD71CT602
3HAH51 AC003
03HAH51CT003
03HAH51CT004
03LBA51CP101
03LBA51CP102
03LBA51CP103
03HAH51CT601
03HAH51CT602
3HAH51 AC003
03LBA51CT001
03LBA51CT002
03LBA51CT003
03LBA51CP101
03LBA51CP102
03LBA51CP103
03HAH51CT603
03HAH51CT604
Value
306.5
93
2445
2605
80
80
Value
179.9
9
2674
2702
16
16
Value
528.8
93
257.16
323.8
33.32
33.32
3
4
IIC
3
4
IID
3
4
IIIA
1
2
3
4
5
6
IIIB
1
2
3
4
5
6
IIIC
1
2
3
4
5
6
S.No
.
IIID
1
2
3
4
5
6
Description
Value
Value
552.8
93
273
323.8
25.4
25.4
M/s ABB requests M/s L&T to provide the information mentioned above.
4.5. Description of product functions & design
4.5.1. Optimax BoilerLife
The data stored in S+ Historian can be maintained and viewed by using the in-built client
applications available, viz, Navigator, Signal Explorer, etc.
BoilerLife evaluates historical process data. This archive contains data such as pressures,
metal temperatures, temperature differences as required by the algorithms. The results are
stored and accumulated to derive total stress factors. These evaluations may automatically be
executed on a daily basis or on user request. The graphic Windows surface allows quick
access to the results data of the individual components and thus allows an evaluation of the
general state of the steam-generating plant.
Component stresses in steam generators are strongly influenced by startup and shutdown
operations as well as varying load cycles in the form of varying steam pressures and high
thermal stresses. The varying loads lead to cyclic strain exhaustion. Another impact is the
flow of steam causing time dependent creeping. Service life of the pressure parts is
dependent on both cyclic loading and creeping.
The BoilerLife module can be divided into functional subsystems as evident from the
following figure.
OPTIMAX BoilerLife
OPTIMAX
BoilerLife
Server
OPTIMAX
BoilerLife
Report
Application
Database
S+ Historian
The BoilerLife application requires the Application Database for storing all data with the
exception of the raw measured values.
The Reports application is required to access the BoilerLife database after a report has been
requested. There are several predefined protocols available which can be extended and
supplemented on project-specific request.
In order to be evaluated, the measurement data are read out from the S+ Historian. Both data
sources can be alternatively used for the evaluation of stored process data. The S+ Historian
is a real-time process database specially adapted to the requirements of process monitoring,
archiving and information management.
All BoilerLife data - with the exception of the raw measured values - are stored in the
BoilerLife database. The BoilerLife database is a relational database (RDBMS) based on the
product ORACLE of the Oracle Corp. All access to the database is done via SQL or
ODBC. The BoilerLife database is made up of several data areas, each of them is assigned a
specific account. The accounts dispose of access mechanisms, i.e. access to the data in an
account is protected by a password. The following diagram illustrates the different data areas
of the BoilerLife database:
The project management database (account LMSGENERIC) contains:
Materials database
The privileged account user is entitled to modify all (project-related) data tables.
The restricted account user may view all data, initiate evaluations, and generate
reports; the user may not, however, manipulate engineering or results data. Physically
speaking, both project accounts always manage the same data. The operators and the experts
must decide for each project if and how the project databases shall additionally be protected
from unauthorized subsequent alterations to the data.
4.5.2. Evaluation
The BoilerLife evaluation function takes over the acquisition and processing of measured
values. The following diagram shows the essential tasks of this subsystem.
Subsystem Evaluation
Process data
Acquisition
Meas. Value
processing
Meas. Value
classification
Saving result
data
Component
Sheet
Component
Overview
Events report
Load cycle
report
Manual Evaluation
RDBMS
OPERATION
REPORTS
Event report
Overview report
Component sheet
Load cycle report
S+ Historian
S.No
.
1
2
3
4
5
6
7
8
Description
Boiler Feed Pump A
Boiler Feed Pump B
Cooling water Pump A
Cooling water Pump B
Cooling water Pump C
Condensate Extraction Pump A
Condensate Extraction Pump B
Condensate Extraction Pump C
Tag Name
03LAC01AP001
03LAC01AP002
03PAC01AP001
03PAC01AP002
03PAC01AP003
03LCB01AP001
03LCB01AP002
03LCB01AP003
Running Hours
Reqd (Y/N)
Y
Y
Y
Y
Y
Y
Y
Y
Switching Cycles
Reqd (Y/N)
N
N
N
N
N
N
N
N
The switch provided on the HMI will perform the following functions:
1. Reset the Preset value and Current Running hours to 0.
2. The existing Running hours after last maintenance will be added to the Total
Running hours of the drive.
5.5.4 Running hours after last Maintenance
In case a preset value (A) is entered, the preset value will be added to the output of the
current running hours logic (B). The final output of Running hours after last maintenance
will be A+B.
This signal will be provided with a Prio 3 alarm in case the value reaches 85% of the Max
running hours that was suggested by the drives OEM.
5.5.5 Total Running Hours
The total running hours will be the sum total of the running hours after last maintenance
and previously recorded total running hours.
5.5.6 Preset Value of Switching Cycles
This section has been removed in Rev 1 of this document, as there is no requirement for
monitoring switching cycles.
5.5.7 Actual Switching Cycles
This section has been removed in Rev 1 of this document, as there is no requirement for
monitoring switching cycles.
5.5.8 Results
The final results will be displayed on a graphic HMI screen as shown in figure below.
Figure 12: Sample graphic page displaying Drive Life Monitoring results