Yokogawa's Vigilant Plant | Success Stories | Power industry

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Collection of Yokogawa's Success Stories for Vigilant Plant within the Power Industry.

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<ul><li>1.VigilantPlant Success Story Collection&amp; AFRICA B.S.C.(c)Trademarks All brand or product names of Yokogawa Electric Corporation in this bulletin are trademarks or registered trademarks of Yokogawa ElectricCorporation. All other company brand or product names in this bulletin are trademarks or registered trademarks of their respective holders.2010 0530500A01A53-01E</li></ul><p>2. Vigilan tPlant Su ccess StoriesThis is a showcase of success stories from our customers worldwide. Many leading companies are using Yokogawa products to manage their plants and processes. 3. Power ContentsVigilantPlant Success Stories01Eraring Energy29Australian Gas Light Company03The City Utilities of Springeld31Greater Toronto Airports Authority05Pha Lai 2 Thermal Power Joint Stock Company33District Cooling System and Power Plant Co., Ltd.07The 4th Thermal Power Plant35Kraftszer Kft11Macquarie Generation37PetroChina Company Limited13Tachibanawan Thermal Power Station39Energy Brix Australia Corporation15Itoigawa Power Plant41PNOC-EDC17Tuas Power Station43Australian National University19Korea South East Power Co., Ltd.45NEP SOLAR Pty Ltd.21Bahia de Bizkaia Electricidad, Bahia de Bizkaia Gas47A.T. Biopower Co., Ltd.23SC Electrocentrale Bucuresti SA49Japan Wind Development Co., Ltd.25EGCO Cogeneration Co., Ltd.51Lakeside EFW27Samutprakarn Cogeneration Co., Ltd.Making critical plant information fully visible is just the beginning of the vigilant cycle. The clear path to operational excellence Envision a plant where people are watchful and attentive while your business responds to change quickly and efciently. Now picture an operation that delivers non-stop production while condently expanding your capabilities into the future. Imagine no further. This is the vision and promise behind VigilantPlant, the clear path to operational excellence.Seeing clearly gives you the knowledge necessary to anticipate the changes required in your process. Knowing in advance brings you the speed and exibility to optimize your plant in real time. And by acting with agility, you are able to adapt to the ups and downs of your business environment. VigilantPlant excels at bringing out the best in your plant and your people - keeping them fully aware, well informed, and ready to face the next challenge. 4. 1AustraliaPowerHighly Integrated Control and Monitoring Systems Solution for Australias Largest Power Station Plant Information Plant Information Plant name:Plant name: Eraring Power Station Location: Location: Project type: New South Wales, Australia Project type: Plant revamping Plant type: Plant type: Coal-fired power plant Output: Output: Order date: 4 x 660MW Order date: 2003 Completion: Completion: August 2004-2005Eraring Energy Yokogawa met these requirements for integrated device management across the HART protocol with a combination of its CENTUM CS 3000 DCS and its Plant Resource Manager (PRM) software. The new system integrates all eld information into a single database on a PRM server and allows real-time, remote maintenance of many hundreds of devices, including around 500 EJA transmitters, via the DCS networks and HART I/O modules. The open architecture of PRM will also allow the diagnostics of smart Fisher valve positioners via the Yokogawa DCS just by loading diagnostic plug-in software onto the PRM server. This integrated maintenance solution helped Erarings maintenance crew streamline plant maintenance work.Minimum plant outage Another challenge was the tight commissioning schedule. The rst outage was planned 15 months after the initial order. To minimize the time taken for the control system replacement, Yokogawa proposed a unique solution making full use of the capabilities of the Yokogawa DCS and simulator. The CENTUM has a unique engineering test function that enables an application functional test on a general-purpose PC without any real controller hardware. Yokogawa afliate TechComm Simulation developed the high-delity simulation system based on the detailed plant documentation supplied by the customer. Combining these capabilities, Yokogawa engineers were able to very extensively test the new control system on the simulator prior to DCS commissioning, thereby minimizing the nal tuning work once the unit returned to service. Eraring plant operators were well trained in the new control system utilizing the simulator. This avoided mistakes that could have occurred if they had not been familiar with the new system, ensuring a smooth plant commissioning process.The Results Background Eraring Power Station, located just north of Sydney, is one of the largest power stations in Australia, comprising four 660MW coal-red units. The power station has operated reliably since 1981. To ensure continued reliability for the next few decades, Eraring Energy, the owner of the power plant, decided to replace the original hard-wired control equipment with a modern integrated control and monitoring system (ICMS). Signicant project drivers were the requirements to maintain plant reliability and to gain operational improvements in order to ensure the competitiveness in the deregulated Australian power market. The re-instrumentation work started in early 2003 under the leadership of Yokogawa Australia, which teamed up with TechComm Simulation, a wholly owned Yokogawa subsidiary.The Challenges and the Solutions The customer required an integrated system to control the operation of the boilers, turbines, generators and other balance of plant equipment. Yokogawa proposed an integrated solution comprised of a distributed control system (DCS), plant information management system, eld device management system, full-replica training simulator and eld instruments together with strong local support.System maintainability Another important issue to be considered was system maintainability. From the late 1990s (before the control system replacement), the customer had progressively upgraded its analog eld instruments selecting Yokogawa DPharp EJA transmitters as well as other vendors devices. A further requirement was to upgrade the original paper-based eld device management system to a Windows-based, user-friendly tool which integrates various data from multivender HART and analogue devices into a single database. The customer wanted system compatibility with the DCS and used the opportunity of the plant revamping to achieve tight integration of the eld device management system into the DCS.Faster commissioning The four units at Eraring are being retrotted progressively, with the rst changeover in August 2004 and the second unit being completed at the beginning of 2005. The customer was very pleased that Yokogawa has completed return to service of the rst unit ahead of schedule, with the second unit approximately two weeks early and similar results expected for the third and fourth units. Efcient operation ensuring high reliability The renovated units give very stable, and at the same time more exible operation than before. After the revamping, the customer now makes everyday load changes at a rate faster than with the previous control system. This can provide nancial benets in the competitive Australian electricity market. Efcient maintenance Integrated device management enables predictive maintenance, reducing routine maintenance work. Jeff Hogan, Power Station Technicians Supervisor of Eraring Energy said, The upgrading of eld instrument is still in progress but PRM has provided access from our workshop to all smart instruments on site. When a plant problem occurs we are able to verify the validity of reading and conguration settings of the associated instrument within a couple of minutes. A great diagnostic tool which enhances the Yokogawa CS3000 System.Operational improvements ensuring plant reliabilitySystem DetailsThe Eraring plant has four large units with a total system input/output (I/O) count of more than 40,000 as well as 25,000 interfaces to other plant auxiliary systems. Yokogawas CENTUM CS 3000 R3 DCS supported this large application in a single architecture while ensuring reliable plant operation with itspair&amp;spare non-stop controller technology.Distributed control system, Burner management system: Plant information management system: Integrated plant resource management system: Simulator: Field devices: Project includes:To satisfy the need for further operational improvement, a Yokogawa Exaquantum plant information management system was used for longterm data storage, data and alarm logging, and performance calculation. The users can monitor the graphical data for both current and historical plant information in an Exaquantum window at their own PCs using the Eraring wide area network. This makes it easier for operators and plant managers to keep informed and to make decisions for future plant operation. The customer also desired to improve plant operation in the aspects of human resources and operating environment. Yokogawas high delity, full-replica simulator enabled custom-made operator training that fully replicated the characteristics of the Eraring Power Station. This allowed the operators to be familiar with all aspects of plant operation using the new control system before running the real plant. The original analog-based control room was replaced with a new control room which is based on the latest ergonomic design, securing operators higher performance.2CENTUM CS3000 R3 Exaquantum Plant Resource Manager (PRM) TechComm full-replica training simulator EJA series electronic pressure transmitters, GD series gas density meters Full functional requirements design, control system software development, factory acceptance, installation, commissioning &amp; tuning 5. 3USAPowerJames River Power Plant Replaces Legacy Control System Plant Information Plant name: Location: Project type: Plant type: Output:James River Power Plant Springfield, MO, USA Control system revamping Coal and gas fired power plant 253 MW (2 x 22 MW, 1 x 44 MW, 1 x 60 MW and 1 x 105 MW) Order date: March 2006 Completion: April 2007The City Utilities of Springfield Scope We decided to handle all the new-system installation in-house, said Stodden. That way our personnel would be very familiar with everything involved. We were delighted with how smoothly the entire procedure went, and we completed installation in only six weeks. We had virtually no problems with the CS 3000 hardware or software. Our biggest obstacle was moving the electrical interlocks required to combine the two control rooms into one. If the Yokogawa system had not worked so well, we would never have made our startup dates. Originally, he continued, Units 1 and 2 were housed in one control room, while Units 3, 4 and 5 were housed in a separate control room. As part of this project, we combined these into one. The new system has worked so well, that we now utilize one control operator to run both Units 1 and 2, where before each unit had a dedicated control operator assigned to each unit. Units 3, 4 and 5 use a hybrid conguration. These units are equipped with an older control system platform, utilizing Hand-Auto Stations for operator interface. This control system, while dated, is still supported. Therefore, as a step toward uniformity among the units, we utilize the Yokogawa Operator Console Platform to communicate with the older control system hardware already in place. The operators see the same style of operator screens as Units 1 and 2, without realizing that it is utilizing a completely different control system. Annunciators and selected other functions work directly from the CS 3000 control; control loops are displayed on the CS 3000 screens but are processing existing control loops through an interface. When asked about acceptance by operators of the new electronic system, Stodden illustrated by quoting one of the men who initially said he thought the new system was the worst decision we had ever made. But within two months after startup, the same operator asked When are we going to do the other three units? Sufce it to say that by now our operators are very comfortable and pleased.Background In 1957, the City Utilities of Springeld, MO, commissioned a pneumatic distributed control system for its James River Power Plant. At that time, the plant was considered very advanced because it utilized a centralized control room for operations, instead of a series of separate control stations located throughout the facility. Through the years since, explained Maintenance Manager Steve Stodden, we had attempted to keep the existing systemfunctional, but maintaining a 50-year-old system has proven difcult. Several years ago we started discussions with all plantpersonnel involved about upgrading the old control system to improve the safety of the plant and to take advantage of modern digital technology. The result is that we now operate our ve generating units with varying stages of a new CS 3000 control system from Yokogawa.The CS 3000 system has provided the ability for automatic control sequences not previously practical. For example, shutting down a coal feeder used to require many control manipulations to maintain safe operation of the boiler. The entire sequence is now automatic. We just hit a key and sit back to watch everything progress through the control sequence, said Stodden with a satised smile.Notes on James River Power Plant The plant, which celebrated its 50th anniversary in 2007, consists of ve coalred boilers equipped with steam turbines and two natural-gas-red turbines. The plant initially was designed to utilize natural gas as its primary fuel, with coal as a winter backup fuel. This switched during the late 1970s driven by the Power Plant and Industrial Fuel Use Act of 1978. The station now utilizes less than 1% natural gas for fuel for the steam boilers. Ultra low-NOX burners and overre air(OFA) were introduced later to greatly reduce nitrogen oxide emissions in preparation for EPA standards that went into effect in 2009. All units of the James River Power Station remain capable of burning either 100% coal or 100% natural gas in order to produce electricity.Evaluating the Choices Our evaluation of competing vendors was based on consideration of a combination of factors with the awareness that the new system will probably be in place for decades until the current facility is retired, said Stodden. We had to be condent of the vendors support during this extended future time period.The plant currently supplies slightly more than half of the electricity generated by City Utilities. Forced outages at the plant have averaged slightly more than 1%, which is approximately one-fth of the national average.With the vendor selected, system details were then examined. The initial bid was based on 4-20 mA protocol but replaced by FOUNDATION fieldbus (FF) as advantages of FF emerged. The plant has ve generating units with a total capacity of 253 MW (two 22 MW, one 44 MW, one 60 MW, and one 105 MW).4CENTUM CS 3000System CongurationSy...</p>