Vigilant Plant Success Stories

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Vigilant Plant Success Stories part 1


<ul><li><p>2010</p><p>30204</p><p>VigilantPlantSuccess StoryCollection</p><p>00A01A53-01E</p><p>TrademarksAll 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. </p></li><li><p>This is a showcase of success stories from our customers worldwide.</p><p>Many leading companies are using Yokogawa products to manage their </p><p>plants and processes.</p><p>VigilantPlant Success Stories</p></li><li><p>The clear path to operational excellence</p><p>Envision a plant where people are watchful and attentive while your business responds to change quickly and efficiently. Now picture an operation that delivers non-stop production while confidently expanding your capabilities into the future. </p><p>Imagine no further. This is the vision and promise behind VigilantPlant, the clear path to operational excellence.</p><p>Making critical plant information fully visible is just the beginning of the vigilant cycle.</p><p>Power</p><p>Contents VigilantPlant Success Stories</p><p>23 SC Electrocentrale Bucuresti SA2325 EGCO Cogeneration Co., Ltd.2527 Samutprakarn Cogeneration Co., Ltd.27</p><p>29 Australian Gas Light Company2931 Greater Toronto Airports Authority 3133 District Cooling System and Power Plant Co., Ltd.3335 Kraftszer Kft3537 PetroChina Company Limited3739 Energy Brix Australia Corporation 3941 PNOC-EDC41</p><p>01 Eraring Energy0103 The City Utilities of Springeld0305 Pha Lai 2 Thermal Power Joint Stock Company0507 The 4th Thermal Power Plant0711 Macquarie Generation1113 Tachibanawan Thermal Power Station1315 Itoigawa Power Plant1517 Tuas Power Station1719 Korea South East Power Co., Ltd.1921 Bahia de Bizkaia Electricidad, Bahia de Bizkaia Gas21</p><p>49 Japan Wind Development Co., Ltd.4951 Lakeside EFW51</p><p>43 Australian National University4345 NEP SOLAR Pty Ltd.4547 A.T. Biopower Co., Ltd.47</p><p>Seeing clearly gives you the knowledge necessary to anticipate the changes required in your process. Knowing in advance brings you the speed and flexibility to optimize your plant in real time. </p><p>And by acting with agility, you are able to adapt to the ups and downs of your business environment. </p><p>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.</p></li><li><p>1 Power 2</p><p>Plant InformationPlant name: Location: Project type: Plant type: Output: Order date: Completion: </p><p>System maintainabilityAnother important issue to be considered was system maintainability. From the late 1990s (before the control system replacement), the customer had progressively upgraded its analog field instruments selecting Yokogawa DPharp EJA transmitters as well as other vendors devices. A further requirement was to upgrade the original paper-based field 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 field device management system into the DCS.</p><p>Minimum plant outageAnother challenge was the tight commissioning schedule. The first 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.</p><p>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 affiliate TechComm Simulation developed the high-fidelity 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 final tuning work once the unit returned to service. </p><p>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.</p><p>System DetailsDistributed control system, Burner management system: CENTUM CS3000 R3 Plant information management system: Exaquantum Integrated plant resource management system: Plant Resource Manager (PRM) Simulator: TechComm full-replica training simulator Field devices: EJA series electronic pressure transmitters, GD series gas density meters Project includes: Full functional requirements design, control system software development, factory acceptance, installation, commissioning &amp; tuning</p><p>Operational improvements ensuring plant reliabilityThe 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.</p><p>To satisfy the need for further operational improvement, a Yokogawa Exaquantum plant information management system was used for long-term 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. </p><p>The customer also desired to improve plant operation in the aspects of human resources and operating environment. Yokogawas high fidelity, 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.</p><p>Eraring Energy</p><p>Australia</p><p>BackgroundEraring Power Station, located just north of Sydney, is one of the largest power stations in Australia, comprising four 660MW coal-fired 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). Significant 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.</p><p>The Challenges and the SolutionsThe 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, field device management system, full-replica training simulator and field instruments together with strong local support.</p><p>Highly Integrated Control and Monitoring Systems Solution for Australias Largest Power Station</p><p>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 field 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. </p><p>The ResultsFaster commissioningThe four units at Eraring are being retrofitted progressively, with the first 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 first unit ahead of schedule, with the second unit approximately two weeks early and similar results expected for the third and fourth units.</p><p>Efficient operation ensuring high reliabilityThe renovated units give very stable, and at the same time more flexible 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 financial benefits in the competitive Australian electricity market.</p><p>Efficient maintenanceIntegrated device management enables predictive maintenance, reducing routine maintenance work. Jeff Hogan, Power Station Technicians Supervisor of Eraring Energy said, The upgrading of field 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 configuration settings of the associated instrument within a couple of minutes. A great diagnostic tool which enhances the Yokogawa CS3000 System.</p><p>Plant InformationPlant name: Eraring Power StationLocation: New South Wales, AustraliaProject type: Plant revampingPlant type: Coal-fired power plantOutput: 4 x 660MW Order date: 2003Completion: August 2004-2005</p></li><li><p>Power 4USA</p><p>System DetailsSystem: CENTUM CS 3000 Total I/O: Approximately 1,400System configuration: 9 x HIS, 1 x EWS, 1 x SIOS, 1 x GSGWOther: PRM (Plant Resource Manager), FF, Bailey INFI90 interfaceScope: System, project management, design, configuration engineering, commissioning services</p><p>ScopeWe 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. </p><p>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.</p><p>Units 3, 4 and 5 use a hybrid configuration. 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.</p><p>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? Suffice it to say that by now our operators are very comfortable and pleased.</p><p>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 satisfied smile.</p><p>Notes on James River Power PlantThe plant, which celebrated its 50th anniversary in 2007, consists of five coalfired boilers equipped with steam turbines and two natural-gas-fired 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.</p><p>Ultra low-NOX burners and overfire 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.</p><p>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-fifth of the national average.</p><p>BackgroundIn 1957, the City Utilities of Springfield, 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. </p><p>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 difficult. 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 five generating units with varying stages of a new CS 3000 control system from Yokogawa.</p><p>Evaluating the ChoicesOur 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 confident of the vendors support during this extended future time period.</p><p>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 five generating units with a total capacity...</p></li></ul>