DCS solutions from BHEL - ARC Advisory Group

Bharat Heavy Electricals Limited 

Brightening Lives .. Powering Progress.. 

Touching Every Indian Home…

Topics 

• BHEL’s growth in Power and Industry 

• DCS solutions 

• Summary 




BHEL – PRODUCT PROFILE 

• Power Generation 

• Power transmissions & Distribution 

• Industries 

• Transportation 

• Oil & Gas 

• Renewable Energy 


Brightening Lives .. .. Powering Progress.. 


BHEL – ACTIVITIES & LOCATIONS 

CHANDIGARH 

NEW DELHI 

JHANSI 

BHOPAL 

VADODARA 

BANGALORE 

HYDERABAD 

 

KASARAGOD 

GOINDWAL 

HARIDWAR 

VARANASI 

NAGPUR 

RUDRAPUR 

RANIPET 

JAGDISHPUR 

PATNA 

VISAKHAPATNAM 

CHENNAI 

TIRUCHIRAPALLY 

KOLKATA 

• A ‘Navaratna’ company and a Major 

Integrated Power Plant Equipment 

Manufacturer in the World 

• 15 Manufacturing units and 8 

Service Centres 

4 Power Sector Regional HQs 

• Corporate Research & 

Development Division : Hyderabad 

• Over 100 Project construction sites in 

India & Abroad 

• BHEL manufactures 180 products in 30 

major product groups 

Two Subsidiaries –BHPV, Vizag & BHEL 

Electrical Machines Ltd, Kasaragod 




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 




UNIFIED SOUTION FOR C&I FROM BHEL 

(Advantage to Customer) 

THERMAL PLANTS (15 - 800MW) 

• Boiler Controls 

• Turbine Controls 

• Station C&I 

• HMI 

• Power Plant SCADA 

• PADO (Performance Analysis 

Diagnostics & Optimisation) 

• Offsite Balance Of Plant Controls 

Other Systems 

• Interlocking in Excitation Systems 

• Interlocking in FSC / CSR / SVC / 

STATCOM 

• Interlocking in VFD system 


HYDRO PLANTS (3.67 - 200MW) 

• Auto Sequencer 

• Governor Controls 

• Remote Operation 

• HMI 

• Optimization Packages 

CCPP PLANTS (21 – 1500MW) 

• HRSG Controls 

• Steam Turbine Controls 

• Station C&I 

• HMI 

• Interface to Gas Turbines 

• Power Plant SCADA 



Dadri 2x490 MW Coal based Power Project – 

Largest Integrated Platform 

Domain 1 

UNIT #1 

(SG/TG/Stn C&I) 

2X34 DPU4F 

17000 I/Os 

1 CR, 10 RIO 

Totally maxDNA based, including 

Off-site systems 

Integrated system handles >47,000 

physical I/Os and >500 operator 

displays 

Domain 9 

COMM SYS 

2X11 DPU4F 

4000 I/Os 

5 CR, 4 RIO 

Domain A 

WTR SYS 

2X6 DPU4F 

1670 I/Os 

1 CR, 3 RIO 

Domain B 

AHP SYS 

2X11 DPU4F 

4850 I//Os 

5 CR, 15 RIO 

Domain C 

COAL SYS 

2X8 DPU4F 

3000 I//Os 

1 CR, 8 RIO 

Domain D 

MAKEUP SYS 

2X1 DPU4F 

450 I//Os 

1 CR 

> 200 DPUs distributed across 7 

DOMAINs 

> 100 maxSTATIONs distributed 

across various DOMAINs / locations. 

7 Domains interconnected & 

geographically distributed across 20 

Sq Kms 

> 45 sets Remote I/O systems 

Domain 2 

UNIT #2 

(SG/TG/Stn C&I) 

2X34 DPU4F 

17000 I/Os 

1 CR, 10 RIO 

Selective Interoperability across 

domains 

Unit#1(Domains 1,9,A,B,C,D) 

Unit#2(Domains 2,9,A,B,C,D) 

Common systems - Individual 

domain operations (9,A,B,C,D) 




Dadri 2x490 MW Coal based Power Project – 

Largest Integrated Platform 




New Applications / Solutions Developed on maxDNA 

Development & Implementation of IEC 61850 Compliant HMI 

for Substation Automation on maxDNA Platform 

HMI 

Library 

HMI 

Client 

configuration 

HMI Station 

61850 

Servers 

DRIVER 

HMI 

IEC 61850 

Network 

61850 

Servers 

61850 

Client 

61850 

Servers 

Substation 

Configuration 

& Engineering 

Software SCL 

Manager 

Engineering 

Station 

61850/101/10 

4 Protocol 

Conversion 

Gateway 

To LDC 

• Monitoring of Analog Data for a typical 

220/400 kV substation 

• Controlling field devices with: 

• Direct control 

• Direct control with enhanced security 

• Select before operate 

• Select before operate with enhanced 

security 

• Alarms and Interlocks 

• Event summary 

• Report control and general interrogation 

IEC61850 Simulation Server / Meter 

Relay/BCU 

Software Components in 61850 Compliant HMI 





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 - 15°11'37.58"N 

: Longitude - 76°43'8.40"E 

: Elevation – 1575ft 

FOPH: Fuel Oil Pump House 

: Latitude -15°11'46.48"N 

: Longitude - 76°43'14.88"E 


CWPH: Cooling Water Pump House 

: Latitude -15°11'45.30"N 

: Longitude - 76°43'4.01"E 


Wireless LAN & Wireless Controls on maxNET 

Radio Modems Installed at CCR 

400 Mtrs 

54Mbps RF Link2 

25Mbps Throughput 

54Mbps RF Link1 

25Mbps Throughput 

600 Mtrs 

Radio Modems Installed at 

FOPH 


Radio Modems Installed at 

CWPH Brightening Lives .. Powering Progress.. 



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: 


Root Cause Analysis 

Alarm Management 

Alarm Annunciation 

1) Logic Tree Module 

2) Graphic Tree Module 

3) Probability Computation Engine 

4) Reporting Engine 




Availability Based Tariff (ABT) on maxDNA Platform 

maxNET 

Download 

FREEZE/ 

CHECK 

Outputs 

maxDNA based ABT Package 

ABT 

Database 

IMPORT 

maxDPUTools 

DOWNLOAD 

UPLOAD 

DPU4F 

Virtual 

DPU 

DC-Declared Capacity 

SG-Scheduled Generation 

UI-Tariff, Fuel Cost etc., 

EXPORT 

BROWSE 

/ EDIT 

maxVUE 

ON-LINE 

Graphical Configurator 

Online Logic Building 

ABT Display 

–ABT Package Architecture – 

LDC 

• Provides digitized linking between power 

generation and revenue 

• Monitor the generation or power availability 

continuously to ensure 90% availability 

• Meets the requirements of surprise audit to 

demonstrate availability 

• Ensure adequate and timely maintenance of 

overall infrastructure 

• Improve quality of power & curtain 

frequency variation/disturbance 





Numerical Relay Interface – IEC-60870-5-103 

maxLinks 

Status, Event 

and Alarm 

display 

(online) 

ALARM HANDLER 

SBP 

Alarm 

Generation 

Status 

Data 

IEC-60870-5-103 

DLL 

EVENT SERVER 

Event 

Generation 

IEC-60870-5-103 

PROTOCOL 

IEC 103 

Master 

RS 485 

DATABASE 

IEC 103 

Configuration 

Numerical Relays 


• Software to interface Numerical Protection Relays 

• Acquire time tagged events 

• Events are part of maxDNA’s Alarm & Events 

• Configuration & runtime utility 

• Runs as maxLINK 




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 




OPERATING MODE 

COLD STARTUP 

WARM START 

HOT STARTUP 

PURGE READY 

UNIT READY FOR TURBINE - 

ROLLING 

UNIT READY FOR COAL FIRING 

30%,60% & 100% LOAD 

ANY OTHER USER DEFINED STATE 

New Applications / Solutions Developed 

on maxDNA 

MATHEMATICAL 

MODELLING OF 

EQUIPMENT 

BOILER & 

AUXILIARIES 

TURBINE & 

AUXILIARIES 

Training 

Simulator 

Virtual Plant 

Instructor 

Station 

INSTRUCTOR FUNCTION 

CONTROLLERS 

CLASS - A CONTROLLERS 

• MAIN STEAM PRESSURE 

• DRUM LEVEL 

• SH STEAM TEMPERATURE 

• RH STEAM TEMPERATURE 

• BURNER TILT 

• FURNACE PRESSURE 

• O2 

• CMC 

REST OF THE CONTROLLERS 

INITIAL CONDITIONS 

RUN 

FREEZE 

MAL FUNCTIONS 

LOCAL OPERATIONS 

SNAP SHOTS 

RECORD 

REPLAY 

BACK TRACK 

RATE OF 

SIMULATION 

MALFUNCTIONS 

EQUIPMENT/SYSTEM 

TRIP 

UNIT TRIP 


Burner Management System (BMS) 

• Oil Firing 

• Coal Firing 

• Unit Start up 

Automatic Turbine Run-up System 

(ATRS) 

• Turbine 

• Turbine Oil 

• Evacuation 

ABNORMAL 

PROCESS 

BEHAVIOUR 






Metso DNA Architecture 

Control room 

Operation, Maintenance, Reporting 

Office 

29TH MARCH 2010 

Reporting, Enterprise integration 

Remote connections 

Star or ring topology 

redundant Ethernet network 

Controls, 

Optimization, 

Connectivity 

and 

Safety 

instrumented 

system 

Automation room 

Centralized or 

distributed 

Name based communication 

Engineering & 

Maintenance, 

Asset Management, 

Information services 

17 

Ethernet and 

serial links 


Field 

No need of internal communication links 

No need of internal servers 



Salient features: 

18 

• Powerful & Reliable Controllers 

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. 


• Dynamic function and 

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 



DNA Operate – Efficient Problem 

Solving - Operation Tools 

Start History mode 

History mode indication 

19 

• 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 



DNAtracer – trend and analysis tool 

20 




Use Any Time, Anywhere 

Reporting and Analysis tools Summary 

21 

• 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 – 

No surprises 

• The team can focus on more value 

adding tasks, since manual reporting 

is eliminated 

Same tools throughout The Results Community for 

professionals in the Office and Control Room

Share And Increase Organization’s 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 

22 




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 

23

SUMMARY 




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

DCS solutions from BHEL - ARC Advisory Group

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