The Large Combustion Plant Directive (LCPD) (2001/80/EC) aims to reduce acidification, ground level ozone and
particles throughout Europe by controlling emissions of sulphur dioxide (SO2), oxides of nitrogen (NOx) and dust
(particulate matter (PM)) from large combustion plants.
In compliance with these regulations International Power (IPR) have
installed Flue Gas Desulphurisation (FGD) plant at their coal-fired
power station in Rugeley, Staffordshire. A turn-key EPC contract was
awarded to Lentjes UK in 2006, who were responsible for the design,
construction and commissioning of the FGD plant and its integration
into the existing power station.
Lentjes appointed Capula in 2007 as the control systems supplier
for this project, with the scope of work including:
> PLC and SCADA based control systems
> Safety and protection systems
> Field Instrumentation supply and installation
> Installation of field cabling
> Local man-machine interface equipment
> Cable marshalling equipment
> Integration of the new control systems into existing generating unit
The contract was awarded in 2007, and commissioning of the plant
was successfully achieved with flue gas scrubbing operational in mid-
2009, removing approximately 96%of the SO2.
The new FGD plant receives flue gases from the existing boiler
plant. Therefore, the FGD control systems had to integrate with the
generating unit control systems at the power station to safely control
the flue gas path through the entire plant.
Furthermore, IPR required that the operator control facilities were
fully integrated into the existing power plant control room to enable
the safe, efficient control of the boiler and FGD plant. Capula was
challenged with creating an innovative solution and system designs
which would allow this seamless integration, both during installation
and commissioning and following project completion.
International Power plc
Rugeley Power Station Flue Gas Desulphurisation
Business benefits delivered
> Skilled assistance to Lentjes on applying
Rugeley and UK engineering standards
> Local integrator able to provide good
> Experienced system integrator able to
handle major project implementation on a
> Experienced FGD control systems integrator
> Dedicated and able to meet the tight
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A large number of field instruments (approximately 350) were supplied for the measurement of the
process parameters (ie. flows, pressure, temperature, levels, chemical composition etc).
The FGD control system relies on precise measurement and control of the process, and Capula was
responsible for the specification, supply, installation, fitting and commissioning of each instrument.
The timescales of the project were also a significant challenge. It involved major plant design and
construction whilst minimising the disruption on the power station.
Major outage tie-ins were provided, but much of the installation and commissioning had to be
carried out whilst the power plant was operational. This exerted significant pressure on the design
and site commissioning teams, but careful planning and co-ordination on the part of Lentjes and
all sub-suppliers, including Capula, allowed the project to be successfully completed.
Capula was chosen because of the company’s extensive experience on the boiler control systems
at Rugeley, which is based on APACS and APMS, and there are only a limited number of companies
who can provide this level of support for these systems.
The ability to work closely with the main contractor on this project, together with their
responsiveness and delivery ethos, all contributed to the success.
International Power plc
International Power plc (IPR) is
a growing independent power
generation company with interests
in over 45 power stations and some
closely linked businesses around
Rugeley power station, part of
International Power’s portfolio, is
coal fired and can produce
approximately 1,000MW of electricity
fed into the National Grid system
at a high voltage of 400,000 volts.
The output is enough to meet the
needs of roughly 1/2 million homes.
Capula Limited Orion House, Stone, Staffordshire ST15 OLT
t: +44 (0)1785 827000 e: firstname.lastname@example.org
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