Table of Content

Item Description Page

1.0 INTRODUCTION................................................................................51.1 Purpose................................................................................................................................... 5

1.2 Acronyms................................................................................................................................ 5

1.3 Glossary of Terms and Abbreviations..................................................................................5

2.0 SYSTEM OVERVIEW.........................................................................62.1. Scope........................................................................................................................................ 6

2.2. Main Components of PLM System.........................................................................................6

3.0 SYMPHONYPLUS HISTORIAN.........................................................83.1. Process Data Management (Server)......................................................................................8

3.2. Process Data Acquisition (Scanner)......................................................................................8

3.3. Process Data Evaluation (Client)...........................................................................................8

3.3.1 Navigator................................................................................................................................ 93.3.2 Signal Explorer...................................................................................................................... 9

4.0 BOILER LIFE MONITORING...........................................................104.1. Introduction........................................................................................................................... 10

4.2. Purpose.................................................................................................................................. 10

4.3. Scope...................................................................................................................................... 10

4.4. Information Used...................................................................................................................11

4.5. Description of product functions & design.........................................................................14

4.5.1. Optimax® BoilerLife...........................................................................................................144.5.2. Evaluation........................................................................................................................... 164.5.3. Reports................................................................................................................................ 164.5.4. Data Flow............................................................................................................................ 174.5.5 Evaluation Results: Classification.....................................................................................174.5.6 Evaluation Results: Exhaustion.........................................................................................18

5.0 DRIVE LIFE MONITORING..............................................................195.1. Introduction........................................................................................................................... 19

5.2. Purpose.................................................................................................................................. 19

5.3. Scope...................................................................................................................................... 19

5.4. Information Used...................................................................................................................19

5.5. Description of product function...........................................................................................20

5.5.1 Preset Value of Running hours..........................................................................................205.5.2 Current Running Hours.......................................................................................................205.5.3 Perform Maintenance..........................................................................................................205.5.4 Running hours after last Maintenance..............................................................................205.5.5 Total Running Hours...........................................................................................................205.5.6 Preset Value of Switching Cycles......................................................................................215.5.7 Actual Switching Cycles.....................................................................................................215.5.8 Results................................................................................................................................. 21

List of FiguresItem Description Page

Figure 1: Block diagram representation of interaction between components used in PLMS.................................7Figure 2: S+ History client application: Navigator..................................................................................................9Figure 3: S+ History client application: Signal Explorer......................................................................................10Figure 4: Temperature measurement locations in monitored component.............................................................11Figure 5: Functional sub systems of BoilerLife....................................................................................................14Figure 6: BoilerLife database structure.................................................................................................................15Figure 7: Tasks involved in BoilerLife evaluation................................................................................................16Figure 8: Reports available in BoilerLife..............................................................................................................16Figure 9: Data flow in BoilerLife..........................................................................................................................17Figure 10: Sample Creep rupture classification in terms of dwell time................................................................18Figure 11: Exhaustion trend from BoilerLife........................................................................................................18Figure 12: Sample graphic page displaying Drive Life Monitoring results..........................................................21

List of TablesItem Description Page

Table 1: Monitored components and the materials used at Sikalbaha...................................................................12Table 2: Inputs required for BoilerLife engineering..............................................................................................12Table 3: List of Drives to be monitored at Sikalbaha............................................................................................19

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). ABB’s SymphonyPlus Operations/Historian and BoilerLife (a product from ABB’s 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 Distributed Control SystemHMI Human Machine InterfaceMMIPIS Man Machine Interface & Plant Information SystemOWS Operator WorkstationPLMS Plant Life Monitoring SystemSymphonyPlus ABB’s Symphony Plus DCSS+ Historian Symphony Plus Operations HistoryS+ Operations Symphony Plus Operations HMITNT Tenore NT (ABB’s legacy HMI on which S+ Operations is based)WHRB Waste Heat Recovery Boiler

1.3 Glossary of Terms and Abbreviations

Creep

Creep is the tendency of a solid material to move slowly or deform permanently under the influence of thermal / mechanical stresses, for example pressure at high temperatures. It can occur as a result of long-term exposure to high levels of stress that are still below the yield strength of the material.

Cyclic Strain See ‘Fatigue’

FatigueFatigue is the weakening of a material caused by repeatedly applied loads. It is the progressive and localized structural damage that occurs when a material is subjected to cyclic loading.

2.0 SYSTEM OVERVIEW

As a solution to the required functionalities of PLMS, ABB shall use the engineering solutions of Symphony Plus DCS to implement Drive Life Monitoring and S+ Historian server as a platform for BoilerLife which is covered later on.

Some of the aspects of Plant Life Monitoring system are:

Decentralized and distributed data acquisition. Automatic acquisition of detailed status information from the lower-level systems. Automatic transfer of signal attributes from most of the control systems. Data validation. Value counters for running hours and switching cycles. Temporary decentralized data storage. Life monitoring of Thick walled components.

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

SymphonyPlus DCS incl. S+ Operations (with integrated S+ Historian) HRSG Life

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.

Figure 1: Block diagram representation of interaction between components used in PLMS

S+ Historian

S+ Operations

Boiler Life Monitoring

system

Data Transfer via Scanner

S+ Historian Client Server protocol

HSI-Net

O-Net

SymphonyPlus DCS

3.0 SYMPHONYPLUS HISTORIAN

S+ Historian includes Information Management functions that are inherent to ABB's Industrial IT system. Historical process data is collected from available sources and stored securely. The data is transformed into meaningful information, which is presented to each decision maker in a manner that is easy to understand. S+ Historian is completely operable on the Windows Operating System. Using the latest development tools and currently available system environments, proven and well-known standard PC hardware and software, S+ Historian meets the requirements of an efficient and plant-wide process information management system.

3.1. Process Data Management (Server)

S+ Historian includes a process data server to store:

• Signal descriptions.• Current process data (real-time data).• Historical process data (long-term storage).• Messages (events).

The following information is stored for all process data:• The time of acquisition, as stamped by the DCS hardware.• The physical value.• Detailed status information (for example measured value disturbed).

For the purpose of PLMS, the database will be configured to store measured process value information. The data stored in S+ Historian is based on exception. The exception rate will be configured as 0.5% of the span of the signal. The specific signal information that shall be used for HRSG Life will be made available for a maximum of 3 yrs after which the data will be deleted based on a FIFO basis.

3.2. Process Data Acquisition (Scanner)

To acquire the process data, in built ‘scanners’ are available.

S+ Historian is designed to pick data from the S+ Operations via an in built scanner called TNT scanner. TNT also referred to as Tenore NT scanner has retained its name from the legacy ABB HMI (TNT/PGP/S+ Operations) scanner name.

3.3. Process Data Evaluation (Client)

The S+ History client consists of various applications that are used viewing and evaluating the data stored in S+ Historian.

3.3.1 Navigator

The S+ History Navigator is the user-friendly client interface for open message views, reports, technical calculations and trend analyses.

Figure 2: S+ History client application: Navigator

3.3.2 Signal Explorer

The SignalExplorer lists the available signals in a S+ History system. Signals can be used within other applications using drag-and-drop operations from the SignalExplorer. It is possible, for example, to write modules in the technical calculations, or to configure a trend display.

The SignalExplorer is not only used for the configuration of S+ Operations History client applications; it is also a tool to help configure the S+ Operations History system.

Figure 3: S+ History client application: Signal Explorer

4.0 HRSG LIFE MONITORING

4.1. Introduction

The HRSG Life is state of art lifetime monitoring package for boilers. It improves maintenance planning, shows creep, cyclic stress and material exhaustion of pressure parts. The HRSG life assessment tool provides online manual analyses of stress, in the form of creep and fatigue, for the thick-walled components in the boiler which are subjected to pressure and temperatures under consideration of the defined parameters in TRD 301 and TRD 508 plants.

4.2. Purpose

The purpose of this section is to describe the design specifications of HRSG Life system for a HRSG of Sikalbaha Power Plant.

4.3. Scope

The Optimax® BoilerLife Product is used to calculate the total degree of exhaustion of thickwalled steam-generating components which are subject to pressure and temperature. It helps in determining general degree of exhaustion of thick-walled steam generating components which are subject to pressure and temperatures under defined parameters as per TRD.

4.4. Information Used

Information required to implement the HRSG Life is as below P&ID OEM Data of HRSG related to thick walled components

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.

ra : outer radiusri : inner radiusrx : radius when measured near inner wallrm : radius when measured near middle wall

Figure 4: Temperature measurement locations in monitored component

Table 1: Monitored components and the materials used at Sikalbaha

ComponentBoiler Life Designation

Material Number

ASTM DIN EN

HP Drum StE355 1.0565 SA-299 Gr. B 10028-3LP Drum 19Mn6 1.0843 SA-516 Gr. 70 10028-3HP2 SH Exchanger Inlet Header X10CrMoVNb9-1 1.4903 SA-355 P91 10216-2HP2 SH Exchanger Outlet Header 10CrMo9-10 1.7380 EN SA-355 P22 10216-2

rx

rm

ra

ri

Only the components defined in the table above will be considered for Life time Monitoring.

Table 2: Inputs required for HRSG Life engineering

S.No. Description ValueI HRSG details for statistics Tag Name / Value1 HRSG tag name  HRSG_ 30137

2 Main Steam Temperature

HP Steam03LBA51CT00103LBA51CT00203LBA51CT003

LP Steam03LBA71CT00103LBA71CT00203LBA71CT003

3 Main Steam Flow

HP Steam03LBA51CF10103LBA51CF10203LBA51CF103

LP Steam03LBA71CF10103LBA71CF10203LBA71CF103

4 HRSG ON03HNE66CG001, 03HNE66CG002 03HNE66CG003

5 Main Steam flow at low load (kg/s) 46.7256 Main Steam flow at full load (kg/s) 66.289

IIA HP Drum process measurement details 3HAD51 BB0011 HP Drum Outlet steam temperature (degC) 03HAD51CT001

2 HP Drum steam pressure (bar)03HAD51CP10103HAD51CP102

3 HP Drum Inner Wall metal temperature (degC) 03HAD51CT6014 HP Drum Middle Wall metal temperature (degC) 03HAD51CT602

IIB LP Drum process measurement details 3HAD71 BB0011 LP Drum Outlet steam temperature (degC) 03HAD71CT001

2 LP Drum steam pressure (bar)03HAD71CP10103HAD71CP102

3 LP Drum External Wall metal temperature (degC) 03HAD71CT6014 LP Drum Middle Wall metal temperature (degC) 03HAD71CT602

IIC HP2 SH I/L HDR process measurement details 3HAH51 AC003

1 HP2 SH I/L HDR Outlet steam temperature (degC)03HAH51CT00303HAH51CT004

2 HP2 SH I/L HDR steam pressure (bar)03LBA51CP10103LBA51CP10203LBA51CP103

3 HP2 SH I/L HDR External Wall metal temperature (degC) 03HAH51CT6014 HP2 SH I/L HDR External Wall metal temperature (degC) 03HAH51CT602

IID HP2 SH O/L HDR process measurement details 3HAH51 AC003

S.No. Description Value

1 HP2 SH O/L HDR Outlet steam temperature (degC)03LBA51CT00103LBA51CT00203LBA51CT003

2 HP2 SH O/L HDR steam pressure (bar)03LBA51CP10103LBA51CP10203LBA51CP103

3 HP2 SH O/L HDR External Wall metal temperature (degC) 03HAH51CT6034 HP2 SH O/L HDR External Wall metal temperature (degC) 03HAH51CT604

IIIA HP Drum design details Value1 HP Drum design temperature (degC)  306.52 HP Drum design pressure (bar)  933 HP Drum Inner diameter (mm)  24454 HP Drum Outer diameter (mm)  26055 HP Drum thickness (mm)  806 HP Drum mean thickness (mm)  80

IIIB LP Drum design details Value1 LP Drum design temperature (degC) 179.92 LP Drum design pressure (bar) 93 LP Drum Inner diameter (mm) 26744 LP Drum Outer diameter (mm) 27025 LP Drum thickness (mm) 166 LP Drum mean thickness (mm) 16

IIIC HP2 SH I/L HDR design details Value1 HP2 SH I/L HDR design temperature (degC) 528.82 HP2 SH I/L HDR design pressure (bar) 933 HP2 SH I/L HDR Inner diameter (mm) 257.164 HP2 SH I/L HDR Outer diameter (mm) 323.85 HP2 SH I/L HDR thickness (mm) 33.326 HP2 SH I/L HDR mean thickness (mm) 33.32

IIID HP2 SH O/L HDR design details Value1 HP2 SH O/L HDR design temperature (degC) 552.82 HP2 SH O/L HDR design pressure (bar) 933 HP2 SH O/L HDR Inner diameter (mm) 2734 HP2 SH O/L HDR Outer diameter (mm) 323.85 HP2 SH O/L HDR thickness (mm) 25.46 HP2 SH O/L HDR mean thickness (mm) 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.

Figure 5: Functional sub systems of BoilerLife

The BoilerLife Server application is used for the manual and automatic evaluation of data. It takes care of the cyclic collection and processing of the measured values, the calculation of creep and cyclic strain exhaustion and writing the results to the BoilerLife database.

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:

OPTIMAX® BoilerLife

OPTIMAXBoilerLife

Server

OPTIMAXBoilerLife

Report

Application Database S+ Historian

• All information concerning the existing project databases.• Catalogues for the BoilerLife Browser (e.g. possible types of components).

Figure 6: BoilerLife database structure

The materials database (account: LMSPROJ_W) contains all the materials data available in the system.

All maintenance and operating functions of BoilerLife can be controlled through the BoilerLife Browser. The user is thus in a position e.g. to compile the data for components, materials, or measuring points, generate reports, control evaluations and watch results without difficulty.

Access Protection:All accounts described above are protected from unauthorized access by means of passwords.

Each project database is additionally equipped with two access protection levels (accounts):• 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.

Figure 7: Tasks involved in BoilerLife evaluation

4.5.3. Reports

Subsystem Evaluation

Process data Acquisition

Meas. Value processing

Meas. Value classification

Saving result data

Materials databaseProject Management

database

OPTIMAX® SERVER with ORACLE DB

The results of the BoilerLife evaluation are stored in the BoilerLife database. When a report is requested, the BoilerLife reports function accesses the database. The following diagram shows some of the currently available reports.

Figure 8: Reports available in BoilerLife

4.5.4. Data Flow

The following diagram illustrates the dataflow between the individual subsystems. Most of the communication is done via the BoilerLife database:

Figure 9: Data flow in BoilerLife

4.5.5 Evaluation Results: Classification

In order to indicate the distribution of the calculated loads, the creep rupture and cyclic strain classification matrixes are displayed.

Subsystem Reports

Component Sheet

Component Overview

Events report Load cycle report

Manual Evaluation

S+ Historian

Load cycle report

Component sheet

Overview report

Event reportREPORTS

OPERATION

RDBMS

EVALUATIONCalculation Kernel TRD

OPTIMAX ® BoilerLife (All the boxes indicated within this box is available only on the dedicated PLMS machine)

Measured data, archived data Calculation results

The classification of the data ensues by classifying it in temperature and pressure ranges (creep exhaustion), i.e. in temperature and stress-range ranges (cyclic strain exhaustion). At the same time, the exhaustion of the component is calculated directly for every measurement cycle and added to an exhaustion counter ("exhaustion without classification").

The time spent in specific operating conditions and the operating conditions in which cyclic strain is recognized are stored in classification tables. Separate tables for creep rupture monitoring and cyclic strain monitoring have been provided for each component.

The advantage of storing data in classification tables is the high degree of transparency of the calculation results. The entries in the classification tables can be compared with other operating data and checked for plausibility.

Figure 10: Sample Creep rupture classification in terms of dwell time

4.5.6 Evaluation Results: Exhaustion

The exhaustion is displayed in the form of a trend over time as percentage value. The period can be set either by entering the times into the corresponding fields (confirm with 'Return') or with the arrow keys (+/- 1 month).

In addition, the identification of the selected component, its designation, the degree of exhaustion as a numerical percentage, and the time of the last evaluation are provided.

Figure 11: Exhaustion trend from BoilerLife

5.0 DRIVE LIFE MONITORING

5.1. Introduction

DriveLife Monitoring is used to continuously evaluate the total running time and number start/stops of unidirectional drive. The runtime information is compared with the manufacturer’s specification to advise operator/maintenance personnel on the drive’s operation and need for maintenance.

5.2. Purpose

The purpose of this section is to describe the design specifications of Drive Life Monitoring system for drives related to the boiler of Sikalbaha Power Plant.

5.3. Scope

A specified list of drives shall be monitored for its operational hours and switching cycles. The required counters shall be implemented in logic form in the Symphony Plus DCS. The output of these counters will be displayed on a single HMI graphic screen.

5.4. Information Used

Information required to implement the Drive Life is as below List of Drives to be monitored under Drive Life monitoring to be provided. Drives OEM’s suggested number of max start and stops before maintenance to be

provided.

Table 3: List of Drives to be monitored at Sikalbaha

S.No. Description Tag NameRunning Hours Reqd (Y/N)

Switching Cycles Reqd (Y/N)

1 Boiler Feed Pump A 03LAC01AP001 Y N2 Boiler Feed Pump B 03LAC01AP002 Y N3 Cooling water Pump A 03PAC01AP001 Y N4 Cooling water Pump B 03PAC01AP002 Y N5 Cooling water Pump C 03PAC01AP003 Y N6 Condensate Extraction Pump A 03LCB01AP001 Y N7 Condensate Extraction Pump B 03LCB01AP002 Y N8 Condensate Extraction Pump C 03LCB01AP003 Y N

5.5. Description of product function

5.5.1 Preset Value of Running hours

An option for entering the preset value for a drives’ running hours will be provided. This shall help in setting a desired value into the DCS in the following cases:

1. The current working hours were set to zero by controller initialisation.2. To have an option of considering a drive that was in operation before the

commissioning of Drive Life Monitoring package.

The preset value will be automatically set to ‘0’ in case a drive maintenance is done. For more information on Drive maintenance, please see section 5.5.3.

5.5.2 Current Running Hours

The current running hours of drives shall be evaluated based on the monitoring of a drives ON feedback. A monitoring logic will be implemented in the Symphony Plus DCS.

The current running hours will be set to ‘0’ in case a drive maintenance is carried out.

5.5.3 Perform Maintenance

The operator will be provided an operable HMI switch to perform drive maintenance. Drive maintenance is intended to be done only in case an actual maintenance of the drive has been carried out in the field. No interlocks between actual maintenance in the field and HMI maintenance switch is envisaged.

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