hermal Power Plant DCS/PLC Control Solutions
Thermal power generation demands highly reliable control systems to ensure safe, efficient, and continuous operation. Modern power plants rely extensively on distributed control systems (DCS) and programmable logic controllers (PLC) to manage complex processes from fuel combustion to electricity generation.
Boiler Management System (BMS) Control
The Boiler Management System serves as the critical safety backbone for combustion control in thermal power plants. The BMS controls the complete firing sequence including firebox purging before initial light-off, pilot ignition, and main burner control according to NFPA 85 standards. These systems can be implemented using dedicated PLCs or integrated within the plant’s main DCS architecture. ABB Bailey INFI 90 systems have been extensively deployed in coal-fired power plants where they successfully operate in harsh environments characterized by high dust levels, heat, and vibration.
Digital Electrohydraulic (DEH) Turbine Control
Steam turbine control systems manage critical functions including valve positioning, speed regulation, and load control to optimize power generation efficiency. The turbine control interface with the main DCS requires high-speed, reliable communication to coordinate steam flow with boiler output. Proper maintenance of turbine control components, including valve actuators and seal systems, is essential during scheduled outages to prevent unplanned downtime.
Auxiliary Equipment Control
Beyond primary combustion and turbine systems, DCS platforms control numerous auxiliary systems including feedwater pumps, condensate systems, cooling water circulation, coal handling, and ash removal equipment. The scalability of systems like ABB Bailey INFI 90/NET 90 allows integration of these diverse control requirements into a unified platform with redundant design for maximum availability.
Critical Role of Spare Parts
Many thermal power plants worldwide operate ABB Bailey INFI 90 and NET 90 systems that were installed in the late 1980s and 1990s. These facilities, now exceeding 20 years of continuous operation, face significant challenges as original equipment manufacturers have discontinued production of legacy components.
Legacy System Support Requirements
Power plants running INFI 90/NET 90 platforms depend critically on sourcing genuine spare parts to maintain system integrity. Key spare components include controller modules for executing control logic, input/output modules for field device connectivity, communication modules for data exchange, and human-machine interface components. Periodic replacement of aging components during scheduled maintenance windows prevents unexpected failures that could force costly plant shutdowns.
Migration and Sustainability Strategy
While ABB offers migration paths to modern Symphony Plus systems with backward compatibility to INFI 90 generations, many plants continue operating legacy systems due to budget constraints or operational considerations. For these facilities, maintaining an adequate inventory of tested, genuine spare parts becomes essential for long-term operational availability. Strategic spare parts management, based on historical failure data and condition assessments, enables plant operators to minimize downtime and extend the service life of proven control infrastructure.
