JSC TGC-11 (part of the Inter RAO Group) has completed the modernization of the automated process control system (APCS) at one of the boiler units of CHP-4 in Omsk. The investment in the project amounted to 150 million rubles. Instead of previous generation controllers, new control cabinets were installed, relays, power supply and protection systems were installed, and automated workstations were organized for operators. The solution is implemented using domestic technologies as part of the strategy of import substitution of critical information infrastructure in the heat power industry.
Comprehensive replacement of controllers and control cabinets at CHP-4 in Omsk
During the modernization, the software and hardware complex that controls the operation of the boiler unit was completely replaced. The new equipment monitors parameters (pressure, temperature, fuel consumption) in real time and signals deviations. Operators were given the opportunity not only to monitor current indicators, but also to analyze historical data for up to a year in order to optimize operating modes and plan routine maintenance.
Key elements of the implemented system:
- industrial controllers of Russian production;
- new control cabinets with an integrated power supply and protection system;
- automated operator workstations with access to archives;
- real-time critical deviation alarm system.
From testing to full integration
Currently, station employees are testing the system on existing equipment. The correctness of data collection, the operation of the alarm system and interaction with the actuating mechanisms of the boiler are checked. After completion of the tests, the APCS will be fully integrated into the digital infrastructure of CHP-4.
For the energy sector, the introduction of a domestic APCS on a boiler unit means reducing dependence on foreign software and controllers, which previously prevailed in critical infrastructure. The ability to analyze historical data for a year allows us to move from reactive maintenance to predictive maintenance: predict equipment wear and plan repairs before emergency situations arise.
Investments of 150 million rubles per boiler unit demonstrate the scale of costs for the digitalization of thermal generation, which in the coming years will affect all large thermal power plants.