From May to December 2018, employees of INCONTROL LLC carried out work on the adjustment of the SPPA-T3000-based I&C DCS of the Pregolskaya TPP. The power plant is located in the Kaliningrad region and built by order of the government of the Russian Federation to ensure the energy independence of the region. The plant consists of 4 PGU-110 power units consisting of one gas turbine unit of type PG6111 (FA) manufactured by Russian Gas Turbines LLC, with TF-90G-2UZ generator manufactured by ELSIB CJSC, one Е-113.8/15.7-8.3/0.75-542/220 (PK-116) waste-heat boiler manufactured by Podolsk Machine-Building Factory OJSC (OJSC ZIO) and one K-38-8.0 steam turbine manufactured by Kaluga Turbine Plant OJSC with a DFT-40-2NU3 generator manufactured by Electrosila plant. Working load range is from 38MW to 110MW.
In accordance with the order, the commissioning of the last fourth power unit of the Pregolskaya TPP was to take place on April 1, 2019. The General contractor represented by inter RAO – Engineering LLC made a decision on early commissioning of the last power unit No. 4 in December 2018, that is, 4 months earlier than the planned date. With such a short time, it was decided to work on the setting up of DCS of the power units in parallel. So, it turned out that with the uncompleted commissioning of the DCS of the 1st power unit, work on the commissioning of the DCS of the power unit No. 3 was already taking place, and the adjustment of the DCS of the power unit No. 2 was fully carried out. To fulfill these commitments, in May 2019, the specialists of INCONTROL LLC carried out the adjustment and commissioning of the DCS of the plant-wide electrical and thermal equipment, and the commissioning of 4 PGU-110 power units began in September 2018 and was completed in record time – for 4 months. All DCS functions necessary for operation of all generating capacities of the power plant in the market were adjusted in full. Even at the stage of complex adjustment, all critical automatic control systems were enabled, such as: CS drum level control, automatic operation of the fast-response pressure-reducing and desuperheating station in the modes of steam discharge into the condenser, maintaining the total power of the power unit within the specified limits, and more.
In addition to adjusting the main functions of the DCS, in the same period, work was completed on integrating the unit- and plant-wide levels of all local systems supplied complete with process equipment into the I&C distributed control system: LCSs for GE-supplied gas turbines based on Mark VIe DCS, LCSs based on Simatic PSC7: steam turbine electrical hydraulic system electronic control elements, gas conditioning station LCS, rotor turning gear LCS, boosting compressor station LCS. In addition, all digital devices and systems of electrical equipment were fully integrated into the DCS. The timely solution of these problems allowed to ensure complete control of all process objects of the power plant from the single SPPA-T3000 DCS interface by the time of complex testing, which made it possible to carry out the process adjustment of the main and auxiliary equipment of the power plant in record time.