Automation of boilers, burners, and balance of plant facilities and changeover to a new boiler combustion systemTo meet the customer's requirements for changing the old indirect combustion system to a direct combustion system, a Yokogawa project team of Russian, English, Mongolian, and Japanese speakers conducted a detailed investigation of the original boiler combustion control system and coordinated its activities with a new burner vendor. They had to crawl around every nook and cranny of this plant to create a piping & instrument diagram (P&ID) and a cabling drawing that accurately described the plant configuration. This was dirty and challenging work and it took many days to complete. Finally, they succeeded in bringing together the documentation needed to design the automation for the plant's boilers, burners, and balance of plant facilities and change to a direct firing boiler combustion system. Replacement of conventional analog control system with state-of-the-art digital control systemWith the completion of both phases of this project, the control of all eight boilers has been integrated with a Yokogawa CENTUM CS 3000 DCS. The operator stations were changed over from conventional analog panels to a modern graphical user interface, and this has improved the efficiency and safety of plant operations. In addition, a Yokogawa Exaquantum Plant Information Management System was installed to enable remote monitoring of all boiler operations from the administration building, which contributes to correct and prompt plant operation management. As for the system architecture, a redundant remote optical network was used for the I/O system to reduce the cabling cost and improve safety and reliability. Power plant simulator improves skills and eases transition to screen-based operationsTogether with a state-of-art DCS, a power plant simulator was provided that operators can use to upgrade their skills. This made possible a smooth transition from the conventional analog control panels to an all-new graphical user interface.In addition, there were just a few of the original blueprints dating back to when the plant was built in the 1980s, and none showed the boiler design in detail. As a result, no one completely understood the actual workings of the plant.However, the Mongolian government had an urgent need to rehabilitate this large plant and thereby secure this major lifeline for its people. The customer's specific requirements were as follows:1. Full automation of the boilers, burners, and balance of plant facilities2. Change from an analog control system to a modern digital control system3. Use of a power plant simulator to train operators and achieve a smooth transition to screen-based operations.An original boiler control panelAn old plant drawing26The ChallengesThe original combustion system used indirect firing, with pulverized coal being transferred from a storage silo whenever the boiler was started up. With the exception of feed water control, all the boilers and mill burners were manually controlled by operators. There were many equipment problems, a high risk of explosions, and extremely low combustion efficiency.The SolutionsFirst of all, information had to be gathered that would provide a starting point for the automation design. This was followed by conversion to a direct firing boiler combustion system in which pulverized coal is directly loaded into the boilers and the replacement of the old mill burner control systems with a Yokogawa DCS.Ulaanbaatar TPP4 / Mongolia
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