This is the first high level project of our plant in which we planned, design, develop and commissioned the system without any support from OEM.
The control of drum level on full load was excellent and drum level was with in 10mm band and control frequency was within 0.6 Hz range. At stable load, feed water flow standard deviation remained within 2%. The total deviation in the frequency control signal was 0.8 Hz at stable load which is a smooth signal for VVVF drive and pump operation also.
The results of the control logic was very successful. Based on the process behavior, first time adaptive control was used for drum level control via VVVF drives.
The drum volume, hold time and other controlling parameters were also calculated. The control and protections parameters were calculated as there was no data available from pumps OEM for VVVF drives operations. The logic development was planned according to the control philosophy. My responsibility in this task of execution team was to design, develop, test and commission the following systems for new VVVF drives including Graphic User Interface (GUI), Protection system, pump sequence control system, VVVF drive bypass system, speed control system, drum level control via VVVF drives, PID controller tuning without any support from Original Equipment Manufacturer (OEM). To reduce plant electrical house load plant performance team suggested to install VVVF drives on motors for boiler feed water pumps. The boiler has a design capacity of 1200 T/H super-heated steam. It has one Generator Step-up Transformer (24 KV to 220 KV), one start-up transformer (220 KV to 11 KV), one auxiliary transformer (24 KV to 11 KV). The power plant is electrically connected with Water and Power Development Authority (WAPDA) system at 220 KV grid. It is situated Near Mahmud Kot, Tehsil Kot Addu, District Muzaffargarh, in the Province of Punjab, Pakistan. The Lalpir Power Limited is an HFO fired thermal power plant having gross capacity of 365MW. It includes the planning, execution, calculations, simulation, testing and commissioning of the VVVF (variable voltage & variable frequency) drives. This is a technical report on the implementation of variable frequency drives (VFDs) for the boiler feed water pumps. Results & Achievements: Executive Summary:
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