Vigilant Plant Success Stories

7/18/2019 Vigilant Plant Success Stories

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The clear path to operational excellence

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 t he future.

Imagine no further. This is the vision and promise behind VigilantPlant, the clear path to operational excellence.

Making critical plant information fully visible is just

the beginning of the vigilant cycle.

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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.

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.



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Plant InformationPlant name:Location:Project type:Plant type:Output:Order date:Completion:

System maintainabilityAnother important issue to be considered was system maintainability. From the late 1990’s (before the control system replacement), the

customer had progressively upgraded its analog eld instruments selecting Yokogawa DPharp EJA transmitters as well as other vendor’sdevices. A further requirement was to upgrade the original paper-based eld device management system to a Windows-based, user-friendly toolwhich integrates various data from multivender HART and analogue devices into a single database. The customer wanted system compatibilitywith the DCS and used the opportunity of the plant revamping to achieve tight integration of the eld device management system into the DCS.

Minimum plant outageAnother challenge was the tight commissioning schedule. The rst outage was planned 15 months after the initial order. To minimize the timetaken 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 realcontroller hardware. Yokogawa afliate TechComm Simulation developed the high-delity simulation system based on the detailed plantdocumentation supplied by the customer. Combining these capabilities, Yokogawa engineers were able to very extensively test the new controlsystem 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 theyhad not been familiar with the new system, ensuring a smooth plant commissioning process.

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, factoryacceptance, installation, commissioning & tuning

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 plantauxiliary systems. Yokogawa’s CENTUM CS 3000 R3 DCS supported this large application in a single architecture while ensuring reliable plantoperation with its”pair&spare” non-stop controller t echnology.

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 plantmanagers 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. Yokogawa’s high delity,full-replica simulator enabled custom-made operator training that fully replicated the characteristics of the Eraring Power Station. This allowedthe 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, securingoperator’s higher performance.

Eraring Energy

Australia

BackgroundEraring 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 ownerof 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 ensurethe competitiveness in the deregulated Australian power market. The re-instrumentation work started in early 2003 under the leadership ofYokogawa Australia, which teamed up with TechComm Simulation, a wholly owned Yokogawa subsidiary.

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, eld devicemanagement system, full-replica training simulator and eld instruments together with strong local support.

Highly Integrated Control and Monitoring SystemsSolution for Australia’s Largest Power Station

Yokogawa met these requirements for integrated device management across the HART protocol with a combination of its CENTUM CS 3000DCS and its Plant Resource Manager (PRM) software. The new system integrates all eld information into a single database on a PRM serverand allows real-time, remote maintenance of many hundreds of devices, including around 500 EJA transmitters, via the DCS networks andHART I/O modules. The open architecture of PRM will also allow the diagnostics of smart Fisher valve positioners via the Yokogawa DCS justby loading diagnostic plug-in software onto the PRM server. This integrated maintenance solution helped Eraring’s maintenance crew streamlineplant maintenance work.

The ResultsFaster commissioningThe four units at Eraring are being retrotted progressively, withthe rst changeover in August 2004 and the second unit beingcompleted at the beginning of 2005. The customer was verypleased that Yokogawa has completed return to service of the rstunit ahead of schedule, with the second unit approximately twoweeks early and similar results expected for the third and fourthunits.

Efcient operation ensuring high reliabilityThe renovated units give very stable, and at the same time more

exible operation than before. After the revamping, the customernow makes everyday load changes at a rate faster than with theprevious control system. This can provide nancial benets in thecompetitive Australian electricity market.

Efcient maintenanceIntegrated device management enables predictive maintenance, reducing routine maintenance work. Jeff Hogan, Power Station TechniciansSupervisor 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 associatedinstrument within a couple of minutes. A great diagnostic tool which enhances the Yokogawa CS3000 System.”

Plant InformationPlant name: Eraring Power StationLocation: New South Wales, AustraliaProject type: Plant revampingPlant type: Coal-fired power plantOutput: 4 x 660MWOrder date: 2003Completion: August 2004-2005



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System DetailsSystem: CENTUM CS 3000Total I/O: Approximately 1,400System congura tion: 9 x HIS, 1 x EWS, 1 x SIOS, 1 x GSGWOther: PRM (Plant Resource Manager), FF, Bailey INFI90 interfaceScope: System, project management, design, conguration engineering, commissioning services

Scope“We decided to handle all the new-system installation in-house,” said Stodden. “That way our personnel would be very familiar with everythinginvolved. We were delighted with how smoothly the entire procedure went, and we completed installation in only six weeks. We had virtually noproblems with the CS 3000 hardware or software. Our biggest obstacle was moving the electrical interlocks required to combine the two controlrooms 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. Aspart 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 Units1 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 foroperator interface. This control system, while dated, is still supported. Therefore, as a step toward uniformity among the units, we utilize theYokogawa Operator Console Platform to communicate with the older control system hardware already in place. The operators see the samestyle of operator screens as Units 1 and 2, without realizing that it is utilizing a completely different control system. Annunciators and selectedother functions work directly from the CS 3000 control; control loops are displayed on the CS 3000 screens but are processing existing controlloops 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 hethought the “…new system was the worst decision we had ever made.” But within two months after startup, the same operator asked ‘When arewe going to do the other three units?’ Sufce it to say that by now our operators are very comfortable and pleased.”

The CS 3000 system has provided the ability for automatic control sequences not previously practical. For example, shutting down a coal feederused to require many control manipulations to maintain safe operation of the boiler. The entire sequence is now automatic. “We just hit a keyand sit back to watch everything progress through the control sequence,” said Stodden with a satised smile.

Notes on James River Power PlantThe plant, which celebrated its 50th anniversary in 2007, consists of ve coalred boilers equipped with steam turbines and two natural-gas-redturbines. The plant initially was designed to utilize natural gas as its primary fuel, with coal as a winter backup fuel. This switched during the late1970’s 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 steamboilers.

Ultra low-NOX burners and overre air(OFA) were introducedlater to greatly reduce nitrogen oxide emissions inpreparation for EPA standards that went into effect in 2009.All units of the James River Power Station remain capableof burning either 100% coal or 100% natural gas in order toproduce electricity.

The plant currently supplies slightly more than half of the

electricity generated by City Utilities. Forced outages atthe plant have averaged slightly more than 1%, which isapproximately one-fth of the national average.

BackgroundIn 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 controlstations located throughout the facility.

“Through the years since,” explained Maintenance Manager Steve Stodden, “we had attempted to keep the existing systemfunctional, butmaintaining a 50-year-old system has proven difcult. Several years ago we started discussions with all plantpersonnel involved about upgradingthe old control system to improve the safety of the plant and to take advantage of modern digital technology. The result is that we now operateour ve generating units with varying stages of a new CS 3000 control system from Yokogawa.”

Evaluating the Choices“Our evaluation of competing vendors was based on consideration of a combination of factorswith the awareness that the new system will probably be in place for decades until the currentfacility is retired,” said Stodden. “We had to be condent of the vendor’s support during thisextended future time period.”

With the vendor selected, system details were then examined. The initial bid was based on 4-20mA protocol but replaced by FOUNDATION fieldbus (FF) as advantages of FF emerged. Theplant has ve generating units with a total capacity of 253 MW (two 22 MW, one 44 MW, one 60MW, and one 105 MW).

The City Utilities of Springfield

James River Power Plant Replaces LegacyControl System

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Plant InformationPlant name: James River Power PlantLocation: Springfield, MO, USAProject type: Control system revampingPlant type: Coal and gas fired power plantOutput: 253 MW (2 x 22 MW, 1 x 44 MW,

1 x 60 MW and 1 x 105 MW)Order date: March 2006Completion: April 2007

CENTUM CS 3000

System Conguration



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Plant DetailsType of boiler: Down-shot coal-redBoiler: 922 t/h, Mitsui Babcock Energy Ltd., UK (Doosan Babcock)Steam turbine: General Electric, USASteam temperature: 541°CSteam pressure: 17.0 MPaGross unit output: 600 MW (300 MW x 2 units)

Systems DeliveredDistributed control system for boiler control, burner management,balance-of-plant control, etc: CENTUM CS 3000Human-machine interfaces: 10 screens per unitField control stations: 15 controllers per unitTotal hardwired I/O: 16,400Field devices: Yokogawa transmitters

Customer SatisfactionNguyen Khac Son, PPC’s Chief Executive Ofcer, said, “We are very happy to be using the Yokogawa CENTUM CS 3000 process controlsystem. We are now operating nonstop without any major problems, using Yokogawa’s system and eld transmitters. We are operating nearcapacity almost every day and are sending this power to the national grid. Continuous operation is a very important point.” He continued, “TheCENTUM CS 3000 is the brain of this power station and the eld transmitters are important sensors for monitoring all power plant equipmentand processes. We have a good relationship with Yokogawa Vietnam and look to working with them in the future.”

The Challenges and the Solutions1. Steady power supply and safe operationPower demand from the national grid is high, and the Pha Lai 2 power station coversa signicant percentage of that. It needs to provide a very steady supply of power 24hours a day, 7 days a week, all through the year. Yokogawa’s highly reliable CENTUMCS 3000 DCS makes this possible.

In addition, Yokogawa transmitters installed in the power island area are contributing tothe high overall reliability of this power station.

The CENTUM CS 3000 provides integratedcontrol of the power station’s steam turbinecontrol system, water treatment PLC,wastewater treatment PLC, ash handlingPLC, burner management system, and coalhandling system, enabling the data fromthese systems to be monitored in real time ongraphic displays. This gives plant operatorsall the information they need to take quickand effective action whenever needed, thusensuring the safe operation of the plant andthe stable supply of power to the national gridat all times.

2. Environmentally optimized operationCoal-red power plants produce signicantly more greenhouse gasses thanplants that rely on natural gas and other fuels. Thanks to the ne-tuned boilercombustion control congured in the CENTUM CS 3000 system and the use of anoxygen monitoring system that can precisely track the oxigen concentration in theue gas, it has been possible to optimize the combustion process under varyingload conditions and keep CO2 emissions at this plant well within regulatoryguidelines. In addition, a Yokogawa solution has made it possible to monitor andstrictly control the CO, NOx, and SOx values in the ue gas and the pH valueof the water from the plant’s cooling towers. In these ways, the Pha Lai 2 powerstation is maintaining a sustainable operation.

3. High delity power plant training simulatorFor effective operation and engineering staff training, the training simulator uses

the test features of the CENTUM CS 3000 to simulate the power plant. Theoperator training interface accurately replicates the plant control console andgraphical interface.

Vietnam

Yokogawa CENTUM CS 3000 Ensures a StableSupply of Power to Vietnam’s National Grid Pha Lai 2 Thermal Power Joint Stock Company

Plant InformationPlant name: Pha Lai 2 Power StationLocation: Hai Duong, VietnamProject type: NewPlant type: Coal (anthracite) fired power plantOutput: 2x 300 MWOrder date: 1999Completion: 2002

Executive SummaryWith a power generating capacity of 600 MW, Pha Lai 2 is the largest coal-red plant in Vietnam. As part of a master plan by the VietnamMinistry of Industry to meet rapidly rising demand for power by doubling the country’s generating capacity, the power station was constructedat a cost of $540 million by Electric of Vietnam (EVN). Located approximately 65 km northeast of Hanoi, Pha Lai 2 and the adjacent Pha Lai1 power station (a Russian-built facility with eight 220 t/h coal-red boilers and four 110 MW turbines) are owned and operated by a whollyowned EVN subsidiary, Pha Lai Thermo Power Joint Stock Company. (PPC). It is estimated that the two power stations supply approximately80% of Hanoi’s power. In accordance with the Ministry of Industry’s master plan, no more than 20% of their power is allotted to private powercompanies, and the remainder goes to EVN.

In 2002, Yokogawa successfully designed, installed,and commissioned a CENTUM CS 3000 distributedcontrol system (DCS) for the Pha Lai 2 power station,and it has operated to date without any signicantproblems. Along with the Yokogawa DCS, a fullreplica plant simulator was installed to provide plant

operator training. The DCS and all related systems aremaintained by Yokogawa Vietnam under the terms ofan annual maintenance contract.

Central control room

Steam turbine unit 1

Unit 1 overview graphic display

Station staff training on the simulator

Unit 1 air and ue gas overview graphic display



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design in detail. As a result, no one completely understood the actual workings of the plant.

However, the Mongolian government had an urgent need to rehabilitate this large plant and thereby secure this major lifeline for its people. Thecustomer’s specic requirements were as follows:1. Full automation of the boilers, burners, and balance of plant facilities2. Change from an analog control system to a modern digital control system3. Use of a power plant simulator to train operators and achieve a smooth transition to screen-based operations.

The ChallengesThe original combustion system used indirect ring, with pulverized coal being transferred from a storage silo whenever the boiler was startedup. With the exception of feed water control, all the boilers and mill burners were manually controlled by operators. There were many equipmentproblems and a high risk of explosions, and combustion was extremely low.

In addition, there were just a few of the original blueprints dating back to when the plant was built in the 1980s, and none showed the boiler

Executive SummaryIn Mongolia, temperatures fall as low as -40℃ in mid-winter. The heat and electricity generated by Thermal Power Plant No. 4 (TES4) in thecapital city of Ulaanbaatar is an important lifeline for the people living there. This is the largest coal red power plant in Mongolia and it generates70% of the electricity for Mongolia’s central energy system and 65% of the heat energy used by the Ulaanbaatar district heating system.

TES4 was built many years ago and has been severely affected by the scarcity of spare parts for its legacy systems. Plant shutdowns were afrequent occurrence due to equipment malfunctions and accidents, disrupting the supply of heat and power. In addition, the plant caused severe

air pollution due to inefcient control of coal combustion. Efforts to correct these problems were also hampered by the loss of many of the plant’soriginal blueprints and other design related documents.

To solve these problems, the Mongolian government decided to execute a plant revamping project in two phases using an ofcial developmentassistance (ODA) loan. Phase one for boilers one to four started in 1998 and was completed in 2001. Phase two for boilers ve to eight startedin 2001 and was completed in 2007. For this project, Yokogawa delivered control systems and eld instrumentation for all eight boilers.

The SolutionsFirst of all, information had to be gathered that would provide a starting point for

the automation design. This was followed by conversion to a direct ring boilercombustion system in which pulverized coal is directly loaded into the boilers and thereplacement of the old mill burner control systems with a Yokogawa DCS.

Automation of boilers, burners, and balance of plant facilities and changeoverto a new boiler combustion systemTo meet the customer’s requirements for changing the old indirect combustionsystem to a direct combustion system, a Yokogawa project team of Russian, English,

Mongolian, and Japanese speakers conducted a detailed investigation of the originalboiler combustion control system and coordinated its activities with a new burnervendor. They had to crawl around every nook and cranny of this plant to create apiping & instrument diagram (P&ID) and a cabling drawing that accurately describedthe plant conguration. This was dirty and challenging work and it took many days tocomplete. Finally they succeeded in bringing together the documentation needed todesign the automation for the plant’s boilers, burners, and balance of plant facilitiesand change to a direct ring boiler combustion system.

Replacement of conventional analog control system with state-of-the-art digitalcontrol systemWith the completion of both phases of this project, the control of all eight boilers hasbeen integrated with a Yokogawa CENTUM CS 3000 DCS. The operator stationswere changed over from conventional analog panels to a modern graphical userinterface, and this has improved the efciency and safety of plant operations. Inaddition, a Yokogawa Exaquantum Plant Information Management System wasinstalled to enable remote monitoring of all boiler operations from the administrationbuilding, which contributes to correct and prompt plant operation management. As

for the system architecture, a redundant remote optical network was used for the I/Osystem to reduce the cabling cost and improve safety and reliability.

Power plant simulator improves skills and eases transition to screen-basedoperationsTogether with a state-of-art DCS, a power plant simulator was provided that operatorscan use to upgrade their skills. This made possible a smooth transition from theconventional analog control panels to an all-new graphical user interface.

The 4th Thermal Power Plant

Mongolia

Modernization of Large Thermal Power PlantMaintains a Key Lifeline for the People of Mongolia

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Plant InformationPlant name: Thermal Power Plant No. 4 (TES4)Location: Ulaanbaatar, MongoliaProject type: ModernizationPlant type: Coal-fired power plantOutput: 580 MW (1 x 80 MW and 5 x 100 MW) 8 x 420 t/hOrder date: 1996 (Phase one), 2002 (Phase two)Completion: 2001 (Phase one), 2007 (Phase two)

TES4 in winter TES4, lifeline for Mongolia New central control room

Old plant drawing

Original boiler control panel



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The 4th Thermal Power Plant

Mongolia9 10

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87% reduction

From 1997 to 2007

88% reduction

From 1997 to 2007

ResultsReduction of boiler trips and accidentsOne by one, the eight boilers were changed over to the new control system and resumed operation, starting at the end of 1998. Reliability andsafety have both been dramatically improved as a result of a steady decline in the number of boiler trips and accidents. With production up andoil consumption down, it has been possible to signicantly reduce energy imports from Russia.

Reduction of CO2 emissions through improved combustion efciencyWith the reduction of boiler trips and plant accidents, boiler combustion efciency has been dramatically improved. In addition to ensuring astable supply of heat and electricity to the city of Ulaanbaatar, this has made it possible to generate more electricity from the same amount ofcoal. The amount of oil consumed for plant restarts has also been decreased, further reducing CO2 emissions.

Technical transfer to TES4The Yokogawa project team worked together with TES4’s engineers from start to nish of this project, providing them the opportunity to improvetheir skills in such areas as engineering design and commissioning. A number of the boiler control systems were successfully replaced by theTES4 engineers. This transfer of power plant engineering expertise was one of the main aims of this ODA project, and this ensures that the skillsand know-how are in place to sustain operations at this plant.

Customer SatisfactionMore than a year after phase one was fully completed, one of the four boilerscaused a trip. Yokogawa dispatched engineers immediately and made everyeffort to solve the problem. The investigation found that the boiler trip was causedby a malfunction in one of the conventional components left over the old plant

control system. Even though a Yokogawa product was not at fault, the company’sengineers provided the TES4 engineers the support they needed to get the plantsafely operating again.

Mr. Tseveen, Executive Director of TES4, says, “Seeing is believing. Whatever

beautiful things sales people say, I will not believe until I see them at work. Whenwe experienced the plant trip, I learned what makes Yokogawa different fromothers. I admire their sincerity and devotion toward customers.”

Number of hot start Heavy oil consumption (Kilo ton)

Mr. TseveenExecutive Director of TES4

Fuel consumption per electricity generation (g/kWh)

g/kWh

Fuel consumption per heat generation (g/kWh)

kg/Gcal



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Plant InformationPlant name:Location:Project type:Plant type:Output:Order date:Completion:

Executive SummaryMacquarie Generation’s Liddell Power Station is located near Muswellbrook, NSW, approximately 200km north of Sydney in the Hunter Valley. Itcomprises four coal-red boiler steam turbine generator sets, each unit of 500MW capacity.

The project consisted of the replacement of all existing process controls and monitoring and protection systems on each unit as well as thecommon station plant equipment. In addition, a substantial part of the eld devices were replaced or new loops installed. Complete design andinstallation services were also included in the scope, and were provided by Yokogawa Australia in conjunction with alliance partner Downer-RML. An Exaquantum Process Information Management System was installed to handle the normal data history, comprising 20,000 tags perunit plus an additional 20,000 tags for the system common components, making a total of 100,000 tags for the complete system.

The rst unit controls were implemented in the new control system in 2002, followed by the common station plant controls. Thereafter, eachsubsequent unit will be installed progressively, culminating in nal completion in 2004.

The entire project is being conducted under an alliance contract, with the alliance partners comprising Macquarie Generation, YokogawaAustralia, and Downer-RML as the installation contractor. The alliance arrangement includes the concept of a target price which is the estimatedcost price for completing the work, and which is agreed to by all partners after the completion of the up-front engineering specication.Payment is made by Macquarie to the alliance partners on the basis of how close the nal cost is to the target price, and whether a set of KeyPerformance Indicators are met or exceeded.

The CENTUM CS 3000 distributed control system controls all aspects of the project, including all associated plant units. Yokogawa’s Sydneyand Melbourne ofces joined forces on the pursuit of the project with the engineering being performed by the Sydney ofce.

System DetailsSystem: CENTUM CS 3000Total I/O: approxima tely 30,000System Conguration: 12x HIS, 20x Screens, 2x EWSOther: Exaquantum Information Management systemScope: System, project management, design, conguration engineering, installation, commissioning services

Macquarie Generation

Australia

Liddell Power Station revampedsuccessfully Macquarie Generation

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Plant InformationPlant name: Liddell Power StationLocation: New South Wales, AustraliaProject type: Plant revampingPlant type: Coal-fired power plantOutput: 4 x 500MWOrder date: 2000Completion: 2004



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System DetailsOutput: 2 x 1,050 MWControl system for environmental control facilities: CENTUM CS

Executive SummaryOne of Japan’s largest coal-red power plants, with advanced environmental protection measures

- Supplies electricity to a wide area in western Japan (Kansai, Chugoku, Shikoku, and Kyushu)- Has the largest coal-red generation units in Japan, each with an output of 1,050 MW- Protects environment by removing NOx/SOx emissions and ash dust, and recycling y ash- Integrated control and monitoring of the environmental facilities, supported by Yokogawa’s highly-reliable CENTUM system and state-of-art

large displays

BackgroundThe Tachibanawan Thermal Power Station is owned by Electric Power Development Co., Ltd. and is located in Anan City, Tokushima Prefecture.With two 1,050 MW generating units, it is one of the largest coal-red power plants in Japan.The station entered commercial operation in 2000 and supplies electricity to a wide area in western Japan through four power utilities that servethe Kansai, Chugoku, Shikoku, and Kyushu regions.

The plant is well known not only for its stable electricity supply but also its environmental protection measures. The plant layout was optimizedto keep the site size to a minimum, and colors were selected that matched the scenic surroundings of the Seto Inland Sea area. Part of the

y ash from the combustion process is recycled to make cement. To prevent air pollution, state-of-art environmental control facilities such asFlue Gas Desulfurization (FGD) systems were installed, removing NOx, SOx and ash dust. In 2004 this plant received ISO14001 certication,demonstrating that its environmental protection measures meet international standards.

The Challenges and the SolutionsIntegrated operation of large environmental control facilitiesThe environmental control facilities at this plant consist of FGD, electric precipitator, coal handling, ash handling, and waste water treatmentsystems. This large application with more than 30,000 data items is monitored and controlled by Yokogawa’s CENTUM CS integrated controlsystem. With a remote I/O architecture that minimizes cabling, highly reliable dual-redundant ber-optic cables, and communication links withplant auxiliary sub-systems, the CENTUM system achieves highly-reliable, single-architecture monitoring of all facilities.

Mouse operation and large displaysFor safety and efciency, plant operators can perform input with a mouse and monitor operations on two 100-inch displays. Yokogawa hasoptimized the operation of these large displays through the development of individual screens, frames, and alarm functions. For example,in an emergency, a guidance message pops up on a screen and easy-to-understand video/audio prompts enable operators to quickly verifyassociated systems and instruments. This customized operator interface helps to ensure that the plant operates smoothly and safely.

Calculation system for environmental management systemFor the effective management of the FGD and waste water treatment facilities, a calculation system was embedded in the CENTUM controlsystem. The system also includes an operation management function that reduces operating costs and extends equipment life, a forecastcalculation function, and a reporting function. This supports highly-reliable and efcient management of the environmental control facilities.

Since entering commercial operation in 2000, the environmental control facilities at the Tachibanawan Thermal Power Station have beenmanaged effectively by the CENTUM control system, achieving a stable electricity supply with minimal impact on the environment.

Control Solutions for Environmental ControlFacilities Tachibanawan Thermal Power Station, Japan Tachibanawan Thermal Power Station

Japan

Plant InformationPlant name: Tachibanawan Thermal Power StationLocation: Tokushima, JapanProject type: NewPlant type: Flue gas desulfurizationOutput: 2 x 1,050 MWOrder date: 1997Completion: 2000



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Itoigawa Power Plant

System DetailsSystem: CENTUM CSTotal I/O: Aprox. 1,500System conguration: 4 x HIS, 1 x EWS, 4 x FCDScope: System, project management, design, conguration engineering, commissioning services

Japan

Flexible Control Solution for IPP GenerationFacility with CFB Boiler

Executive SummaryFlexible operation of circulating uidized bed (CFB) facility by independent power producer (IPP)- 149 MW coal-red power plant operated by IPP- First use of circulating uidized bed (CFB) boiler by IPP in Japan- Fly ash recycled at adjacent cement plant- Daily operation in swing mode and shutdown/startup responding to shifts in electricity demand- Controlled by Yokogawa’s CENTUM system

The Challenges and the ResultsFlexible response to shifts in electricity demandTo adjust to shifts in electricity demand, the customer runsthe Itoigawa Power Plant in swing mode. During the daytimehours of high electricity demand, the plant is run at up to

100% of its capacity, with output being adjusted exiblyin response to commands from a central load dispatching

center. At night the plant is operated at just 40% of itscapacity.

Automatic shutdown/startup capabilityYokogawa fully implemented the operation logic for its highly-reliable CENTUM CS control system to match frequentload changes and provide a high degree of exibility in thesystem’s operation.

The CENTUM control system also supports automaticshutdown/startup to keep to a minimum the manual checksperformed by operators. They are only required to checkthe master control sequence for stopping and starting theplant facilities, which ensures a safe, smooth shutdown andstartup.

Since commencing commercial operation in July 2001,the Itoigawa power plant has been operating reliably andefciently under its Yokogawa CENTUM control system whileemploying CFB technology to generate environmentally friendly electricity.

BackgroundThe Itoigawa Power Plant was constructed adjacent to a cement plant in Itoigawa City, Niigata Prefecture, and is operated by an IPP thatsupplies electricity to Tohoku Electric Power, one of Japan’s major power companies. The use of a 149 MW coal-red CFB boiler in this powerplant is a rst for an IPP in Japan, and this effectively reduces NOx emissions. This power plant also recycles at an adjacent cement plant the yash that is the byproduct of coal combustion.

Plant InformationPlant name: Itoigawa Power PlantLocation: Niigata, JapanProject type: NewPlant type: Circulating fluidized bed boilerOutput: 149 MWOrder date: 1999Completion: 2000

Daily operation example in swing mode

Plant automatic sequence monitoring

Control room



7 Power 18

System DetailsSystem: CENTUM CSTotal I/O: 43,410 (DIO: 37,300, AIO: 5,840)System conguration: 51 x FCS, 3 x EWS, 29 x operation monitors, 4 x alarm monitors, 2 x CCTV, 3 x sequence-of-events manager/visual

annunciator systems, 2 x on-line performance monitoring systems, 3 x historian systems

Executive SummaryThe Tuas Power Station and its associated facilities are located on reclaimed land along the western shore of Singapore. The station occupiesan area of approximately 75 hectares and is being built in two stages.

Stage I of Tuas Power Station is comprised of two 600 MW oil-red steam-generating sets. The power station entered commercial operation inMarch 1999 when the rst of these units was fully commissioned.

As part of its work in stage I of this project, Yokogawa supplied the CENTUM CS integrated production control system (DCS) for the plant’svery large power generation units. Yokogawa Electric Asia Pte. Ltd., Singapore produced the control system in Singapore and carried out allengineering work.

In addition to supplying Instrumentation & Control (I&C) equipment, Yokogawa handled system design/engineering, conguration, projectmanagement, commissioning services and maintenance.

The Tuas Power Station successfully entered commercial operation on schedule and the plant owner has attributed this in part to Yokogawa’sgood performance in delivering both products and services.

The development of Stage II comprised of four-block combined cycle power plants was completed in September 2005, which brought the Station

to its licensed capacity of 2,670 MW.

Singapore

Tuas Power Station

Safe and Efficient Power Plant Operation

Plant InformationPlant name: Tuas Power StationLocation: Tuas, SingaporeProject type: NewPlant type: Gas and oil fired power plantOutput: 1,200 MW (2 x 600 MW)Order date: July 1995Completion: March 1999

A full-scope, high-delity training simulator supplied by Yokogawa enabled a simulator training in all aspects of operating complex plant systemsand has made a signicant contribution in raising the skill levels of the highly motivated Tuas Power Station workforce.

Yokogawa also designed the Tuas Power Station’s central control room (CCR), which has won praise from users for its good operatingenvironment. Our CCR design methodology emphasizes the importance of sound ergonomic design in reducing operator errors and facilitatingthe smooth running and control of processes.

Central control room designed by Yokogawa

Replica simulator showcase



Power 20

Korea South East Power Co., Ltd.

Plant DetailsOwner: Korea South East Power Co., Ltd. (KOSEP)Output: 2 x 800 MWPlant efciency: 43.5%Operation mode: Base load & cycle operation Fuel: Bituminous coalBoiler type: Supercritical pressure, once through, single reheatTurbine: Tandem compound, HP, IP, and LP turbine , single stage reheat, condensin g typeGenerator: Cylindrical rotor, hydrogen and water cooled, three-phase synchronous generatorSimulator system: Yokogawa full-replica plant simulator (main computer + instructor system + DCS)

Executive SummaryFaster, smoother plant commissioningThe customer has successfully brought online a greeneld 800 MW supercritical power plant using a Yokogawa full-replica plant simulator toensure a fast and smooth plant commissioning process.

The full-replica plant simulator was used for:- Control system validation prior to DCS commissioning- Operator training

Thorough Off-line Control ValidationThe simulator was delivered on-schedule to the site in September 2002, twelve months before the boiler was to be red up for the rst time. Incollaboration with the DCS manufacturer and Yokogawa, the customer proceeded to test and validate the DCS conguration on the simulator,conducting an I/O checkout, drive checks, sequence checks, control module checks/tuning, alarm/trip setting, and DCS r esponse checks as wellas tests in which malfunctions and other abnormal situations were simulated. This enabled thorough validation of the control conguration priorto DCS installation at the site, thereby minimizing the nal tuning work. A signicant number of potential plant trips and incidents where there waspotential for damage to the plant were identied and resolved before the initial plant startup, ensuring a safe and smooth plant commissioningprocess.

The Challenges and the ResultsTo ensure that the commissioning process for its new plant went smoothly, KOSEP turned to Yokogawa and its TechCommSimulation subsidiary for a full-replica training simulator solution.

The purpose of this full-replica training simulator was twofold:- To conduct a thorough, off-line test and validation of the DCS conguration prior to the control system’s actual loading and commissioning at

the plant.

- To aid in the initial/refresher training of plant operators, which was conducted in parallel with the plant commissioning.

To achieve these objectives, the simulator was required to fully stimulate DCS functions and emulate turbine, generator, and electrical control

functions. Yokogawa’s full-replica simulator met the customer’s requirements with high accuracy (> 99% steady state; >95% dynamic state),calculation of models at less than 250msec per cycle, and the ability to perform performance tests and a wide variety of simulations includingstartups, shutdowns, and load changes under normal, abnormal, and emergency operating conditions.

BackgroundIn Korea, steadily growing demand for electricity together with limited indigenous energy resources and a heightened environmental awarenesshave required additional power generation facilities with improved efciency and environmental performance. Korea South East Power Co., Ltd.(KOSEP), a wholly owned subsidiary of the government-owned Korean Electric Power Company, constructed two new 800 MW supercriticalcoal-red units in Yonghung, Korea to generate highly efcient, environmentally friendly electricity.

800 MW Supercritical Coal-fired Power Plant Achieves Smooth and

Rapid Plant Commissioning Using a Full-replica Plant Simulator

Korea9

Custom-made Operator trainingThe thorough control system validation on the simulator also provided asuitable training environment for plant operators. The simulator aided inthe initial training for plant operators and refresher training for experiencedoperators under a wide variety of normal, abnormal, and emergencyoperating conditions. In parallel with DCS commissioning, KOSEP plantoperators were well trained under the new control environment, reproducingcustom-made exible operating scenarios on the simulator. This avoidedmistakes that could have occurred if the operator had not been familiar withthe new system, thereby ensuring safe and smooth plant operation.The simulator also has the exibility and expandability to accommodatefuture improvements in plant performance. The simulator continues to bean effective tool for the customer to optimize operational procedures and theplant logic/system.

Plant InformationPlant name: Yonghung Thermal Power Plant

(Units 1 & 2)Location: Yonghung, KoreaProject type: NewPlant type: Coal-fired power plantOutput: 2 x 800 MW (supercriti cal)Order date: 2001Completion: 2004


Power plant simulator



21 Power 22

System DetailsSystem: CENTUM CS 3000/UOI (BBE) CENTUM CS 3000 (BBG)

System conguration: 4 x operator stations(BBE) 1 x engineering workstation 2 x UOI (Cimplicity) servers 4 x eld control stations 2,600 inputs/outputs 1,800 communication Signals

System conguration: 1 x engineering stations (BBG) 6 x operator stations 4 x control stations 1,500 inputs/outputs 2,500 communication signals 1 x OPC Server

Spain

Bahia de Bizkaia Electricidad

Bahia de Bizkaia Gas

Combined Cycle Power Plant with Regasification Facility

Realizes Stable Power Supply

The Challenges and Results1. High availability (BBE and BBG)Both facilities aim to have high availability. The eld-proven CENTUM CS 3000 distributed control system (DCS) ensures this by enabling thecontrol and monitoring of the entire BBE power station. The BBG regasication facility is designed to operate 24 hours a day, 365 days a yearwithout having to be shut down for maintenance. Yokogawa’s highly reliable CENTUM CS 3000 DCS offers a high degree of redundancy thatcontributes to the entire plant’s high availability.

2. Unied operation of multivender control systems (BBE)At the BBE power station, General Electric Company gas and steam turbines have been installed and are controlled by the company’s ownturbine control system. The electrical equipment of the power station is controlled by another vender’s system. With its Unied Operator Interface

(UOI), Yokogawa’s CENTUM CS 3000 enables the seamless operation of each of these control systems. With the UOI solution, all of the actionsrequired for the operation, management, and maintenance of turbines, the heat recovery steam generator (HRSG), and the balance of plantand electrical controls can be carried out from a single operator interface. The UOI also eliminates the requirement for operators to master theoperation of multiple systems.

3. Flexible operation and reduced start-up time (BBE)The BBE power station is capable of working both at base load and at partial loads, which provides exibility in the plant operation. In addition,to reduce the start-up time, 100-percent-ow by-passes were designed to start the gas turbine and the HRSG individually without starting upthe steam turbine. The Yokogawa DCS for which the Spanish engineering company Siemsa Notre S.A. (SIEMSA) fully implemented the aboveoperation logic has steadfastly supported the safe plant operation and smooth startup.

Background of the ProjectIn Spain, the demand for electricity and imported natural gas has been rapidly increasing, a trend that is anticipated to continue for years tocome. To augment the country’s energy supply, several new LNG regascation plants as well as combined cycle gas turbine plants have beenconstructed in Spain.

Customer SatisfactionThe SIEMSA engineer commented, “We appreciate CENTUM CS 3000’s operationality and system reliability. With the UOI solution, the DCScontrols use the same HMI system as the turbine and electrical control system, and there is no need for a dedicated communication gatewayand separate screens. This signicantly reduces the engineering time and costs.”

About the Bahia de Bizkaia Plant - BBE and BBGTo achieve a stable supply of gas and electricity for the country, the Spanish government decided to build the Bahia de Bizkaia Plant. Located inBilbao, this plant consists of Bahia de Bizkaia Electricidad (BBE), an 800 MW gas red combined cycle power station, and Bahia de Bizkaia Gas(BBG), a regasication facility with regasicators having a total capacity of 2.7 billion cubic meters.

The Bahia de Bizkaia Plant was one of the most signicant power projects to be carried out in this region. The project was led and nanced byEnte Vasco de la Energia, Repsol-YPF, British Petroleum, and Iberdrole S.A., with the total investment of approximately 600 million euros.

Plant InformationPlant name: BBE & BBG PlantsLocation: Bilbao, SpainProject type: NewPlant type: Combined cycle power plantOutput: 800 MWOrder date: 2001Completion: 2003



Power

About the ProjectThe Bucurresti Vest Combined Cycle Heat and Power Plant (CCHP) is located in the Romanian capital of Bucharest and supplies both electricityand heat to this city. Sited next to two existing 125 MW plants, it was built to meet Romania’s rising demand for electric power.

The owner of the plant is SC Electrocentrale București SA (ELCEN), a major energy supplier in Romania that accounts for approximately 20% ofthe nation’s power generation capacity. ELCEN’s thermal power plants generate over 2 gigawatts (GW) of electricity, of which 1 GW is supplieddirectly to the city of Bucharest.

The Bucuresti Vest CCHP consists of a GE 9E gas turbine that generates up to 135 MW, a heat recovery steam generator (HRSG)manufactured by Austrian Energy and Environment, and a SKODA steam turbine that generates up to 60 MW.

The main contractor for this plant construction project was the Combined Cycle Division of VA Tech Hydro AG (integrated into the Andritz Groupin 2006). VA Tech Hydro’s scope of supply included the complete electrical systems and instrumentation and control, all auxiliary plant units suchas gas supply, and all structural engineering. Yokogawa provided the CENTUM CS 3000/UOI distributed control system (DCS), ProSafe-RSSafety Instrumented System, and the Exaquantum Plant Information Management System, as well as engineering, installation, commissioning,and operator training services.

The project was executed in a professional manner. The construction period was kept short – less than 30 months net – to facilitate a rapid

return on investment.

Yokogawa’s state-of-the–art plant control system contributes signicantly to high degree of plant automation and plant reliability.

CENTUM CS 3000 R3/UOI Improves Reliability and Efficiencyby Integrating Systems Controls at Bucuresti Vest Power Plant

Customer SatisfactionVA Tech Hydro chose Yokogawa’s automation system for this project because of the demonstrated capabilities of the CENTUM CS 3000control system in power plant applications and its compliance with the relevant VGB guidelines. An additional factor leading to this decision wasthis system’s use of redundant Probus cards in keeping with the Probus decentralized periphery (DP) concept and its support of IEC60870communication proles.

The design and structure of the CENTUM CS 3000 DCS for this new power plant met this customer’s high expectations in terms of availabilityand operational reliability.

At the operator desk in front of the HMI operator station, the merits of Yokogawa’s UOI solution become obvious:

- It's easy to navigate through the power plant control and turbine control processes as both are represented in a similar manner and run on the

same visualization platform. The process graphics that were prepared for this project are excellent overall, with well structured and detailedprocess overview and operator displays.

- The Consolidated Alarm List software helps operators quickly identify cause and effect relationships in power plant and turbine control.

Romania

SC Electrocentrale Bucuresti SA

System DetailsControl systems: CENTUM CS 3000/UOI, ProSafe-RSNumber of I/O points: 6,900 (1,300 hard wired, 3,600 via Probus, 2,000 via other bus protocols)System conguration: 4 UOI viewers, 2 engineering stations, 2 UOI servers, 1 Exaquantum server, 1 SOE server,

1 IEC server, 4 50” plasma screens, 8 FCS, 1 safety control station (SCS)

23 24

The Solutions1. Single Operator InterfaceThe CENTUM CS 3000/UOI provides a single operator interface for theoperation, management, and maintenance of the plant’s turbines, HRSG,balance of plant (BOP) facilities, and electrical systems.Yokogawa’s uniedoperator interface (UOI) makes this possible. It was developed by Yokogawa toprovide a common control platform for the CENTUM DCS and the GE Mark VIgas turbine control system. All data from the GE Mark VI turbine control system,Siemens Simatic steam turbine control system, and other plant systems can beaccessed from the CENTUM CS 3000/UOI. No gateway is r equired.

The București Vest CCHP is operated and monitored from four operator stationsthat are located in the central control room and provide access to more than 90process graphics. Each of these stations has four monitors that can display fourseparate graphics. In addition, there are four 50” operator displays.

The turbine graphics and other system graphics are shown right. With thesegraphics at the CENTUM CS 3000/UOI stations, operators can monitor andcontrol all the plant’s different systems with the same look and feel.

2. Automatic Plant Start-up and ShutdownFor the new CCHP, Yokogawa congured block sequences for automatic plantstart-up and shutdown. The heating plant units that supply up to 190 MW ofthermal energy to Bucharest’s district heating network were also automated toensure a high degree of exibility in responding to uctuations in demand.

The power plant can be operated in an accentuated electrical mode or in anaccentuated thermal mode that requires the calculation of complex mathematicalequations. This computation can be handled by the DCS eld control station(FCS) and does not need to be outsourced via OPC or other means.

3. Advanced Alarm ManagementAlarm management at this power plant is done with Yokogawa’s ConsolidatedAlarm List software. This manages both DCS and turbine controller alarmsas well as alarms from subsidiary controllers and safety systems, using the

sequence of events (SOE) signals to timestamp these events with millisecondaccuracy.

ata Highway for Mark VI Control Bus (Vnet IP)

CENTUM CS3000FCS(s)(for HRSG)

CENTUM CS3000FCS(s)(for BOP)

UOIServer(s)(CIMPLICITY Server)

CENTUM CS3000Builder PC

Siemens S7(for Steam Turbine)

Mark VI(for Gas Turbine)

ConfigurationPC

Unified Operator Interface (UOI)Unified Operator Interface (UOI)

UOI UOIUOIUOI UOI

Ethernet

Data/MessagefromHRSG/BOP Project

Data/MessagefromTurbine Project

CIMPLICITYServers

Turbine Control byGeneral Electric Company


HRSG/BOP and Safety Controlby Yokogawa


UOIviewers(CIMPLICITY)

ProSafeRSSCS(s)(forsafety)

a a g w ay fo r a

iemens(or te am r b ine )

arGa su b i ne)

tion C LC Y v s

Unit Data Highway for Mark VI Control Bus (Vnet IP)

CENTUM CS3000FCS(s)(for HRSG)

CENTUM CS3000FCS(s)(for BOP)

UOIServer(s)(CIMPLICITY Server)

CENTUM CS3000Builder PC

Siemens S7(for Steam Turbine)

Mark VI(for Gas Turbine)

ConfigurationPC

Unified Operator Interface (UOI)if d Ope a or e f c e( O )Unified Operator Interface (UOI)

UOIUOI UOIUOIUOIUOIUOIUOI UOIUOI

Ethernet





CIMPLICITYServers


T r n C bne a l e ct i c C m a ny

u e oon rroo y yee l ee t cc oo



/B and f C n lb Y

/ a aa ee y oo rr l y y oo oggaa aa


UOIviewers(CIMPLICITY)

ProSafeRSSCS(s)(forsafety)

Plant InformationPlant name: Bucuresti Vest Combined Cycle Heat

and Power Plant (CCHP)Location: Bucharest, RomaniaProject type: ModernizationPlant type: Coal-firedOutput: 186 MW (electrical), 197 MW (thermal)Order date: May 2005Completion : March 2009

(Electrical plant overview) (Condensate system)

(Gas turbine startup) (Steam turbine by-pass control)



25 Power 26

Monthly electricity demand

Customer SatisfactionAccording to the Plant Manager, “The system allows operators to clearly see theplant’s status and know what is going on. With this information, our operatorscan take quick action whenever there is a problem with a gas or steam turbineor with an HRSG. When there is a problem with the transmission lines or someother part of the national grid, the plant is immediately put into island mode andprovides electricity only to its local customers. We are very pleased with theperformance of Yokogawa’s CENTUM CS 3000 at our power plant.”

Plant DetailsGas turbine: 2 x 40 MW, GEHRSG: 2, AlstomSteam turbine: 60 MW, Alstom

System DetailsDistributed control system: CENTUM CS 3000Total I/O: 1,500Field devices: Yokogawa pH meters, conductivity meters

The Challenges and the Solutions1. Highly efcient operationThe national grid operated by EGAT needs a steady supply of electricity atall times, and the same is true for the Rayong Industrial Park. The CENTUMCS 3000 plays a core role by controlling and enabling the monitoring of allprocesses at the EGCO Cogen plant.The gas and steam turbine control systems as well as the PLCs controllingthe water treatment and chemical injection facilities are all integrated withthe CS 3000 system through a Modbus interface. The CS 3000 system hasaccess to both horizontally and vertically integrated data from throughout the

plant, allowing EGCO Cogen to calculate the efciency of each gas and steamturbine as well as each of the HRSGs in real time.Operators have constant access to plant performance data and a dailyreport showing the hourly base performance gures can be printed out. Theperformance data is utilized to plan maintenance and improve control strategy.Currently, the plant’s overall efciency is about 60%.

2. Steady and safe operationBased on monthly requests from EGAT, EGCO Cogen supplies a steady owof electricity to the national grid. EGCO Cogen also supplies load of 40 MWto the Rayong Industrial Park. To meet these requirements under a variety ofcircumstances, the CS 3000 system has the following control functions:2-1) Automatic start-up and shutdown sequences2-2) Automatic load sharing and plant optimization2-3) Load shedding control2-4) Voltage and power factor control2-5) Island operation when disconnected from the national grid2-6) Plant performance monitoring

Each operator workstation has function keys that allow quick access to a target process from the plant overview graphic display. With certainsequences, clear and easy-to-understand operation procedures are displayed. Operators thus have all the information needed to take quick andtimely action whenever needed, making this a very safe plant.

Executive SummaryThe Electricity Generating Public Company Limited (EGCO) was the rst independent power producer (IPP) to be established in Thailand asthe result of an initiative by that country’s government to allow broader private sector investment in the power sector. EGCO was incorporatedon May 12, 1992 by the Electricity Generating Authority of Thailand (EGAT), and over the next three years it became a public company andwas listed on the Stock Exchange of Thailand (SET). Operating as a holding company, it invests in power generation and supply and providescomprehensive operation, maintenance, engineering, and construction services to the power industry and other industries in Thailand as well asother countries. Furthermore, the company searches for good growth opportunities that are related to its core energy business.

EGCO Cogeneration Co., Ltd, an EGCO Group company,operates a combined cycle power generation plant at

the Rayong Industrial Park. The plant uses natural gasfrom PTT to power gas turbines that generate electricity.Heat recovery steam generators (HRSG) use waste heatfrom the turbines to produce steam for a steam turbine

that generates additional electricity. Sixty percent of thegenerated electricity goes to the national grid (EGAT)and the remaining 40% is utilized by companies at theRayong Industrial Park.

To control these processes at the EGCO Cogen powerplant, Yokogawa Thailand installed a CENTUM CS 3000process control system in 2002. This facility has operatedwithout any major system failures since then.

Thailand

Fully Automated Power Plant Supplies SteadyFlow of Electricity to Thai National Grid EGCO Cogeneration Co., Ltd.

Plant InformationPlant name: Cogeneration plantLocation: Rayong, ThailandProject type: NewPlant type: Combined cycle cogenerationOutput: 140 MW (2x 40 MW electrical and 1 x 60 MW electrical)Order date: 2000Completion: 2002


HRSG graphic display

Plant performance screen

EGCO Cogen operators

Main process overview



27 Power 28

The Challenges and the Solutions1. Steady power supplyWith 90% of this plant’s generated power going to the Thai NationalGrid, which is owned and operated by the Electricity GeneratingAuthority of Thailand (EGAT), it is vital for the production controlsystem to be highly reliable. EGAT sends a power demand patternevery month (see the right gure) to the power station and it mustgenerate electricity accordingly. With an availability that exceeds99.99999%, Yokogawa’s CENTUM CS 3000 system has been key tomeeting this requirement.

2. Operational data visualization for safe operationThe Yokogawa CENTUM CS 3000 controls and monitors the plant’sHRSG units and its balance of plant (BOP) facilities. Other vendors’systems such as the gas turbine and steam turbine control systemsare all integrated through Modbus interfaces with the CENTUM CS3000 system, so almost all plant data can be viewed at the CENTUMCS 3000 human machine interface (HMI) stations. Operators canclearly see in real time the status of the compressors and all otherequipment throughout the plant, and thus have the information theyneed to take quick and effective action when necessary. This datais also used to facilitate equipment diagnosis so that engineers canschedule maintenance at the most appropriate time and ensure safeoperation.

3. Sustainable power generationThe replacement of this plant’s legacy control system has enhancedperformance in a number of ways. This includes steady improvement

in the heat rate (BTU/kWh), as the graph in the lower left shows.

Signals from a variety of analyzers are also monitored by theCENTUM system to control emissions. The continuous measurementof CO and O2 concentrations allows operators at this power plant tone tune the air-fuel ratio and thereby boost combustion efciencyand reduce NOx emissions.

Executive SummaryA 126 MW gas red cogeneration power plant built by Thailand’s Samutprakarn Cogeneration Co., Ltd. began generating electricity on August23, 1999. Ninety MW of its output is supplied to the Thai National Grid, with the remainder going to local companies. The plant operates 24hours a day, seven days a week, and is shut down for 35 days once a year for maintenance. A major overhaul is done every six years. Forimproved efciency, this power plant was designed to have more than one thermodynamic cycle, and uses both gas and steam turbines. TwoGE gas turbines burn fuel to produce heat energy and generate electricity, and the waste heat is used to produce steam that passes through anAlstom steam turbine to generate additional electricity.

The gas fuel for this plant comes from a PTT gas separation plant,which receives gas via an undersea pipeline from wells in the Gulf ofThailand. The plant’s boilers utilize heat recovery steam generators(HRSG) with a capacity of 80 t/h (max.120 t/h) and a maximumallowable steam pressure of 65 bar. The steam temperature is 500degrees Celsius.

The decision by Samutprakarn Cogeneration to upgrade this plant’slegacy distributed control system was made because it was proving

difcult to procure spare parts from the system vendor. Yokogawa

Thailand successfully installed the CENTUM CS 3000 system onschedule and on budget.

Thailand

Replacement of Legacy System with CENTUM CS 3000

Ensures Steady Supply of Electricity to Thai National Grid Samutprakarn Cogeneration Co., Ltd.

Customer SatisfactionKitpoat Srasomsub, Maintenance Manager, had the following to say about the plant’s newcontrol system: “We have been very happy with Yokogawa’s CENTUM CS 3000 sinceintroducing it in 2007. The system is very reliable and there have been no major problems withit. We have the important mission of providing a steady supply of electricity to both the EGATnational grid and local companies 24 hours a day, seven days a week, throughout the year. Weare always striving to improve efciency and reduce emissions through the visualization of allplant data.”

Plant InformationPlant name: Samutprakarn Cogeneration PlantLocation: Samutprakarn, ThailandProject type: Control system revampingPlant type: Gas fired cogeneration power plantOutput: 126 MWOrder date: 2005Completion: 2007


Mr. Srasomsub

Power generation overview



Power 3029

Australian Gas Light Company

System DetailsSystem: CENTUM CS 3000/UOI

Scope: (Hallett) Interface to GE SPEEDTRONIC Mark V turbine controllers Balance of plant (BOP) control Interface to ALSTOM SCADA Interface to electricity market network for load dispatch

Scope: (Somerton) Interface to Triconex turbine controllers Balance of plant (BOP) control Interface to electricity market network for load (NEMMCO) dispatch

The SolutionIn these projects for AGL, Yokogawa Australia cooperated closely with the Group’s Singapore factory to develop and deliver a fully engineeredcontrol system on specication and on schedule.

For its Hallett and Somerton plants, AGL selected Yokogawa’s CENTUM CS 3000 together with its Unied Operator Interface (UOI). The systemplatform in the UOI is the GE Fanuc CIMPLICITY Human Machine Interface (HMI) system, which fully integrates the controllers for the turbineand balance of plant (BOP) auxiliaries and uses the same screens/formats in both the turbine and BOP HMI displays. The CIMPLICITY HMIused in the UOI is a SCADA based design that fully supports AGL’s requirement for remote operation capability.

For the Hallett plant, AGL also introduced an automatic turbine optimizer. This embedded system automatically schedules and selects turbinesto exibly meet peaking market demands.

Australia

Unified Operator Interface Enables Remote OperationAGL Hallett & Somerton Power Stations, Australia

Executive SummaryThe Australian Gas Light Company (AGL) was established by private interests in New South Wales in 1837 to light the streets of Sydney withcoal gas. Today, AGL is Australia’s leading energy provider. AGL’s wholesale and retail marketing businesses sell natural gas, electricity, andassociated products and services.

Electricity consumption is growing rapidly in southern Australia. In response to growing summer demand in South Australia, AGL built a powerstation in 2001 in Hallett, South Australia, and completed construction of another power station the following year in Somerton, Victoria. Both arepeak power plants that help reduce the likelihood of power blackouts and keep electricity prices stable during periods of peak demand.

The ChallengeTo respond to these pressing needs, AGL required the following:

• Remote control and operation

The 12 gas turbines in the Hallett plant and the 4 gas turbines in the Somerton plant needed to be remotely controlled from an existing controlcenter in Melbourne.

• Fast-track construction

Each plant construction project was placed on a fast-track three-month completion schedule so that they could be operational by the summerof 2002. All system equipment had to be delivered and installed within this timeframe.

• Flexible operation

The turbine control system had to have the capability to exibly meet the intermittent power needs of a peaking power station.

Plant InformationPlant name: AGL Hallett and Somerton Power StationsLocation: South Australia (Hallett) and Victoria

(Somerton), AustraliaProject type: NewPlant type: Gas turbineOutput: 200 MW (Hallett) 150 MW (4 x 37 MW) (Somerton)Order date: 2001

Completion: 2002

Remote control and operation

CENTUM CS 3000/UOI



31 Power 32

System DetailsDCS: CENTUM CS 3000Total I/O: Approximately 2000System conguration: Dual LCD operator stations, engineering work stations with virtual test function, eld controllers, I/O with HART,

sequence of events I/OScope: Distributed control system including control system software, factory acceptance, commissioning assistance

Predicted reliability being achievedThe Honourable Donna Camseld, Minister of Energy, at the Cogen Plant opening on Dec.2, 2005, said in part, “Today’s plant openingis another step in Ontario’s cogenerational potential and another example of the Greater Toronto Airport Authority’s signicant record ofenvironmental leadership.” She cited benets of cogeneration to include:• Adds more capacity added to the power grid• Produces high combined fuel efciency• Helps control industry costs• mitigates electricity cost increases• Improves transmission and system reliability• Helps replace coal thus creating a cleaner environment• Increases the number of facilities that recover quickly or even continue to operate in the event of power interruption.

Comments by those associated with the plant and echoed by other industry and government groups visiting the Toronto facility – about two suchtours per month since installation – attest to the central focus of system reliability. The GTAA facility and its Yokogawa control system qualify onall counts.

BackgroundCanada’s Toronto Pearson International Airport, along with millions of people in Eastern Canada and eight US states, suffered a severe electricalpower outage in 2003. This catastrophic failure made it painfully apparent that the airport neededa reliable, independent source of electricity.Round-the-clock reliability was simply an absolute must, but the economics of such a system had also to be carefully considered.

These two factors – reliability and costs – have now been met by a cogeneration power plant design using twin GELM6000PD aero-derivativegas turbines, each capable of producing 42 MW. Exhaust from the turbines passes through steam generators which run a third steam-drivengenerator capable of 33 MW output. Remaining plant heat can be used to heat/cool the airport buildings. Economics were addressed in thisgenerous design to allow sale of excess power generated to the Ontario power grid. A Yokogawa CENTUM CS 3000 control system, selectedafter careful evaluation of system reliability for various vendors, completes the plant.

“Those involved with the Cogen plant have been very pleased with reliability of the Yokogawa control system,” states Henry Oberhauser, SeniorManager, Utilities for Greater Toronto Airports Authority (GTAA). “The only substantial system outage occurred due to sub-standard processwater supplied by a sub-contractor. We feel Yokogawa’s claim of ‘seven 9’s’ reliability – which translates to less than one minute of downtime in40 years – is well on its way to reality.”

1GTAA operates Pearson Airport, an international gateway with 65 airlines via 82 gates in three terminal buildings. A fourth terminal is currently beingdesigned. The airport generates $14-billionin annual revenues, $2.8-billion tax revenues and provides 135.000 jobs. It has 16,000 parking spaces.

2SNC-Lavalin, one of the leading groups of engineering and construction companies in the world, has ofce across Canada and in thirty other countries. It is at work in over 100 countries.

The PlantThe airport is owned by the GTAA1, which hired outside rms to help design, build, and operate the plant. The airport, by meeting the twinrequirements of a coincident demand for electricity and thermal power along with access to fuel (natural gas), was an ideal candidate for a

Cogeneration system. In early 2001, GTAA had constructed a Central Utility Plant for the airport; it replaced a legacy plant torn down as variousairport facilities were being added. The plant supplied steam for heating and chilled water for cooling the airport terminals.This new plant can

supply steam needs but also allows the optional operation of the plant’s steam boilers in standby mode while using steam from the Cogensystem. The plant was constructed in 2003. A year later the Yokogawa control system was commissioned.

An interesting facet of the design is the use of two “once-through steam generators” (OTSGs) supplied by Innovative SteamTechnologies (IST)of Cambridge, Ontario. These units offer several advantages over conventional designs. They are efcient,exible and capable of full operation

from cold starts within less than 30 minutes. They start, run and nish dry. Conventional-pass stacks, diverter valve systems and stack silencersare not needed.An OTSG is basically a heat exchanger composed of a series of tubes whose boiler water is simultaneously heated, evaporatedand superheated. Heat recovered in the OTSG supplies the steam turbine at its required temperature and pressure.

Yokogawa CENTUM CS 3000 control systemEncompassed by the Yokogawa monitoring and control system is the entire Cogen plant including the two OTSGs. Startup, operation andshutdown of the OTSGs is fully automatic. The complex logic involved was developed by close cooperation of Yokogawa, IST and SNC-Lavalin2

engineers.

Not shown but also in the control room is an engineering station. It allows access to technical drawings and related information such asapplicable codes and standards and other engineering information. It includes a system simulator used in operator training and to examine andtest changes in the CS-3000 logic. This logic can be modied through this station. A HART plug-in allows diagnostics for HART I/O. Naturally,access to the station is fully protected and limited to only the plant’s certied engineers.

A monthly printout – both tabular and graphical – by a companion J.D. Edwards software package, using selected inputs from the Yokogawales, provides maintenance guidance. Since installation of the Yokogawa system, no major maintenance has been required.

Steve Sadecki in the Cogen Plant control room with multiple at-screendisplays. Control is provided for plant balance and unit operations.Monitors provide rapid and complete displays of all system assets. SaysSadecki, “The display formats are very well thought out and extremelyoperator friendly. It took me, and fellow operators, less than a week oftraining to be completely familiar and comfortable with the system– eventhough none of us had previous experience withYokogawa equipment.”Steam fed to the OTSGs must be of ultra-high quality. Steam monitoringand water purication control is included in the CENTUM system.

Canada

Greater Toronto Airports Authority

Toronto Airport Cogen Plant Focuses onReliability

Plant InformationPlant name: Cogeneration plant at Pearson

International AirportLocation: Toronto, ON, CanadaProject type: Control system revampingPlant type: Gas fired cogeneration plantOutput: 117 MW (2 x 42 MW electrical,

1 x 33 MW thermal)Order date: 2004

Completion: 2005



33 Power 34

Customer SatisfactionSeree La-Ongutai, acting general manager, said, “We are producing electricity and steam for the whole airport terminal, adjacent hotel andThai Airways facilities. It is very hot in Thailand all through the year, so the airport always needs a stable utility. We very much appreciate thereliability of Yokogawa’s CENTUM CS 3000, which is the cooling of all our airport facilities here. So far the plant has operated with great stability,availability and safety, and I believe this is due in good part to the integration of the system’s sequence logic functions and the dynamic graphic

displays on the human machine interface (HMI). We are striving to save energy in the whole facility, so we would like to work together withYokogawa for continuous improvement.”

Plant Details- Gas turbines: 2 x 41MW, IHI- HRSG: CMI- Steam turbines: 12 MW, Shin Nippon- Steam absorption chillers: 21,000 refrigerant tons- Electric chillers: 12,480 refrigerant tons- Steam generation: 126 t/h- Steam temperature: 430 deg C- Steam pressure: 60 bar

Systems Delivered- Distributed control system: CENTUM CS 3000- Total I/O: 1841- Field devices: Yokogawa magnetic owmeters

The Challenges and the Solutions1. Steady and safe supply of power and steamDCAP’s mission is to ensure a steady supply of electricity and steam to the airport terminal, a hotel nearby, and a Thai Airways catering facility.The steam is supplied to steam absorption chillers at east and west of the airport terminals that drive the cooling systems at the airport complexand the airline catering facilities. The airport receives power over a main line from the DCAP power plant and a line from the MetropolitanElectricity Authority (MEA).There are four operation modes to meet any cases for power requirement and steam requirement situations.

• Full operation including steam chillers• Half operation including steam chillers• Half block + steam chiller operation

• Aux. boiler + steam chiller operation

The operation procedures carefully congured in the CENTUM CS 3000 ensure smooth transfers between these modes. Regarding gas andsteam turbine control, the turbine suppliers installed the respective controllers; however, they receive major settings from the CENTUM CS 3000via a Modbus interface as master setpoints and all process data in the turbine systems can also be monitored by the CENTUM CS 3000. Safeand steady supply of electricity to, and air conditioning at, the entire airport complex is thus assured all year round.

2. Environmentally optimized operationsNatural gas supplied by PTT Public Co., Ltd. powers DCAP’s main gas turbines and auxiliaryboilers. Even though natural gas is low in emissions, the CENTUM CS 3000 system tracks anddisplays the relevant process data. The data are linked to a continuous emissions monitoring system(CEMS) through a plant network that is connected to the government’s systems. Data on NOx, SO2,

CO, O2, and opacity are sent twice a day. The water used in this plant is also carefully monitored

and controlled to keep it within recommended limits.

Executive SummaryDistrict Cooling System and Power Plant Co., Ltd. (DCAP)operates a power plant near Bangkok’s SuvarnabhumiInternational Airport that supplies electricity and steam to the

Bangkok International airport main terminal, a hotel nearby anda Thai Airways catering facility. The DCAP plant has two 41MW gas turbines, two heat recovery steam generators (HRSG,63 t/h each), and one 12 MW steam turbine. In average, 50MW electricity is transferred to the Airport of Thailand (AOT),30 MW is selling to the national grid (EGAT)and total left MWis utilized in this DCAP power plant. The steam is sent to 10steam absorption chillers located at the airport’s main terminal,

east and west, about 2 km away from DCAP facility .

To be a steady supply of electricity and steam to SuvarnabhumiInternational Airport, which operates 24 hours a day / 365 daysaround a year, is most important issue for DCAP. Yokoga waThailand successfully installed a CENTUM CS 3000 distributed

control system, eld transmitters and magnetic owmeters. Thefacility is in operation without any problem since 2004.

Thailand

CENTUM CS 3000 Ensures Stable Supply of Electricityand Steam to Bangkok’s Suvarnabhumi Airport District Cooling System and Power Plant Co., Ltd.

Plant InformationPlant name: District cooling system and power

plant at Bangkok's Surarnabhumi airport Location: Samutprakarn, ThailandProject type: NewPlant type: Combined cycle cogenerationOutput: 94 MW (2 x 41 MW electrical,

1 x 12 MW thermal)Order date: 2002

Completion: 2004


Plant overview

Chiller overview

Process overview

Continuous emissions monitoring system



35 Power 36

Kraftszer Kft

Hungary

About the ProjectThe plant is located at Füredi út in Budapest. The main contractor is Kraftszer Kft., a Hungarian engineering company that has built a number ofCHP plants, and the plant will be operated by Zugló-Therm Energiaszolgáltató Kft.

The Füredi power plant consists of three (3) Wärstilä 18V34SG gas engines rated for an electrical output of 18 MWe, three (3) heat exchangersfor each engine that supply the hot water for the district heating system, and auxiliary systems for such functions as fuel and air supply. Naturalgas is the main fuel for the power plant.

The hot water is distributed by Fötáv Rt., the main district heating utility in Budapest.

Although the emphasis is on the supply of hot water for district heating, the generated electricity is also supplied to approximately 20,000households on the public power grid. In Hungary this kind of CHP plant is required to have a minimum total efciency of 65% per month and75% per year.

Customized STARDOM & FAST/TOOLS Plant ManagementSolution Helps Füredi CHP, Hungary Operate Optimally

System DetailsControl system: STARDOM FCN and FAST/TOOLS SCADA systemNumber of I/O points: 2,500Field instruments: EJA530A x 9, EJA110A x 13, EJA120 x 2, YTA70 x 2,

non-Yokogawa products x 116, manometers x 100Installation: March 15, 2005Start-up: April 4, 2005Commissioning: April 20, 2005Training: May 15-16, 2006

Executive SummaryThe Füredi Power Plant project is a showcase for the use of SCADA and STARDOM in a power sector application, and it posed certain uniqueoperation and control requirements. A FAST/TOOLS SCADA system was seamlessly integrated with a STARDOM automation system, providingthe information needed by power plant managers, operators, and maintenance personnel to efciently monitor the plant’s operation and analyzeits performance. A history database integrated into FAST/TOOLS collects and stores the measured and calculated parameters.

The system covers approximately 16,000 items, collects data, creates shift/daily/weekly reports, and makes monthly calculations. The collectedand calculated data is kept for the lifetime of the plant. Through this project, Zugló-Therm Energy Supply Ltd. has achieved the following:

• Easy set point denition for all plant power generation operations The heat produced by the entire plant and the electrical set points for the engines can be dened in an Excel le every 24 hours, with 15

minute resolution, and this data can be easily exported into the FAST/TOOLS system.

• Stable electric power generation The superior control system can respond exibly to changing heat demand, focusing on the operational conditions of the gas engines.

• Power plant optimization The control system supports on-line calculation of both plant and gas engine efciency, enabling adjustments for optimal operation.

• Control of electric power generation based on net performanceThe control application in STARDOM can automatically calculate the in-house power consumption of the power plant. With this function, theplant can more accurately control the required amount of power to be supplied to the national grid operator.

The Challenges and the Solutions1. Easy set point denition for all plant power generation operations

The district heating set points are dened in Excel and sent to the district heating company.As shown below, the Excel data can be imported into FAST/TOOLS with just one mouse click.Plant operators can see the actual daily plant set points on screen.

This system is used for the electrical set points as well. In this case the plant manager has todene the set points for each of the three gas engines. Please refer to the Excel sheet below.

2. Stable electric power generation

The automation system realized in STARDOM can also recalculate the set points for each gasengine in the event of a malfunction such as a trip of a gas engine. If one of the gas enginesshuts down, the other two gas engines will increase power output to compensate.

3. Power plant optimization

STARDOM calculates the efciency factors for each gas engine and for the entire powerplant, and provides data that operators can use to make the plant operate economically andefciently.

Scope/Special Features of the Control SystemThree fully redundant STARDOM eld control node (FCN) stations controldifferent parts of the plant, including the electrical system, district heating system(including the gas engines connected to the PLCs), and air system.

Redundancy is realized at different levels in the FCN controllers such as thepower supply, CPU, communications between the nodes, and I/Os. One of themost important criteria is the 10 msec time stamping of electrical signals.

The STARDOM controllers manage the plant’s measuring and supervisory controlactivities, governing approximately 550 hardwired I/Os. Via serial communicationlines (MODBUS, IEC-103), they collect an additional 500 signals; 1,500 signalsare connected through redundant OPC interfaces.

Plant InformationPlant name: Furedi Power PlantLocation: Budapest, HungaryProject type: NewPlant type: Gas fired combined heat and

power plantOutput: 34.5 MW (3 x 6 MW electrical,

and 1 x 16.5 MWt)Order date: 2004

Completion: 2005Setpointsof No. 1

gasengine

Setpointsof No. 2gasengine

Setpo i ntso fNo . 3gasengine

Sumo f the setpoints

One clickexportinto FAST/TOOLS



37 Power 38

PetroChina Company Limited

Customer SatisfactionLiu Jian Ming, Director of the Utility Control and Instrumentation Department said, “Every day we are trying to improve operations at our plantand to reduce both coal consumption and CO2 emissions, because one of our targets is to achieve sustainable manufacturing. We very muchappreciate that Yokogawa supplies very reliable products and systems, and has been working together with us to provide support. Of the manyvendors that are supplying products and services for this PetroChina utility plant, Yokogawa is one of the best.”

The Challenges and the Solutions1. Safe and steady operationThe utility plant operates non-stop throughout the year, ensuring an uninterrupted supply of steam, water, and electricity to the main process

facilities. In response to boiler master signals that are issued in real time by the production scheduling center, the four boilers must adjust theiroutput to match shifts in demand for steam by the processes and the turbines that generate electricity for the complex. With its highly reliabledual redundant CPUs and seven 9s availability, Yokogawa’s CENTUM CS 3000 production control system maintains steady control of the boilersand ensures that operations can continue nonstop without any major system problems.

Standard process graphics, process overview, trend, operator guidance, and alarm summary displays are all designed with safe operation inmind, and can be accessed quickly and smoothly by operators, giving them a comprehensive overview of operations.

2. Total integration of informationThrough an OPC interface, the PetroChina Dushanzi renery and petrochemical complex uses a supervisory information system (SIS) as itsplant information management system (PIMS). All process data from throughout the complex are gathered by the CENTUM CS 3000 systemand the GE PLCs used in the water and ash treatment processes. Based on this process data, boiler efciency, coal consumption, rate ofelectricity generation, and many other kinds of useful data from the boilers can be accessed by the engineers at their desks, without havingto visit the central control room. The CENTUM CS 3000 system is a very steady platform and provides a very convenient process monitoringenvironment.

The integration of information allows PetroChina Dushanzi to reduce its consumption of water, coal, and other resources. In many differentperformance statistics, it is ranked number one in the PetroChina Group.

Executive SummaryAt a cost of 30 billion yuan ($4.4 billion), PetroChina, China's largest oil producer,constructed a large renery and petrochemical complex on a 455 hectare parcel of landin Dushanzi, a city in China’s Xinjiang Uyghur Autonomous Region. Using mainly highsulfur crude oil from the Kazakhstan-China pipeline, the complex processes 10 milliontons of crude oil and produces 1 million tons of ethylene per year. As such it plays an

important role in the China-Kazakhstan energy cooperation strategy.

The utility plant that provides steam, electricity, and water to this complex include ve440 t/h circulating uidized bed (CFB) boilers, three 100 MW turbines/ generators, andchemical and water treatment systems.

The complex’s CFB boilers use brown coal as a fuel and are designed to keep CO2

emissions to a minimum. Normally, four of the complex’s ve boilers are in use and theremaining boiler is kept on standby and undergoes maintenance.

For the utility plant at this important industrial complex, Yokogawa China successfullyinstalled a CENTUM CS 3000 integrated production control system and the Plant

Resource Manager (PRM) package.

China

Yokogawa’s CENTUM CS 3000 and PRM Assure UtilitySupply for Dushanzi Refinery & Petrochemical Complex

Plant InformationPlant name: Utility plant for refinery and petrochemical plantsLocation: Dushanzi, Xinjian Urghur Autonomous Region, ChinaProject type: NewPlant type: Circulating fluidized bed boilerOutput: 5 x 440 t/h, 2 x 220 t/hOrder date: June 2006Completion: January 2010

Renery Petrochemical plant

SIS boiler operation display

The PetroChina Dushanzi head ofce

Total system conguration

SIS

Boiler(CENTUM CS 3000)

Water treatment(GE-PLC)

Ash treatment(GE-PLC)

Production scheduling center



39 Power 40

Customer SatisfactionEBAC believes that the engineering complexity and innovation involved in installing 21st century control systems technology in an old plantwas quite remarkable. Not only did the project increase the reliability of electricity supply, it reduced plant stress and decreased its maintenancecosts. This was accomplished by optimizing the use of raw fuels. The successful outcome of this control system modernization project will allowthe Morwell power generation and briquetting facility to operate well into the future while meeting anticipated economic and emissions standards.

Peter Morrow, General Manager of EBAC (left) and Philip Nicholson, Principal Engineerof Yokogawa Australia (center) accepted the PACE Zenith Award from Jeremy Needhamof Mitsubishi Electric, the sponsor of the Transport, Power and Infrastructure category.

Energy Brix Australia Corporation

Australia

Yokogawa Australia Undertakes Extensive Replacement and

Upgrade of Power Plant Control and Monitoring Systems

Executive SummaryEnergy Brix Australia Corporation (EBAC) commissioned Yokogawa Australia Pty. Ltd. to modernize the Morwell Power Station and Brown CoalBriquetting Plant by replacing their control and monitoring systems with a modern Yokogawa CENTUM CS 3000 distributed control system (DCS)and a range of eld instruments.

EBAC is a long established electric utility in Morwell, which is in the coal rich Latrobe Valley region approximately 150 kilometers east ofMelbourne, Victoria. The Morwell Power Station has an installed generating capacity of 180 MW and was built in the 1950s by the StateElectricity Commission of Victoria to generate power for the national power grid. The Morwell Station also provides process steam to theadjacent brown coal briquette factory.

This extensive modernization of the Morwell Station’s control systems by EBAC and Yokogawa Australia was completed in 2008.

EBAC’s goals for undertaking this extensive DCS upgrade were to:

• Reduce station operating and maintenance costs• Generate additional power for export• Improve plant operating exibility• Provide modern conditions for plant operators

• Reduce plant emissions

Following the successful completion of this complex and challenging project, Yokogawa Australia and EBAC were jointly awarded the prestigious2009 PACE Zenith Australia Industry Award for their leadership in the application of technological excellence and innovation.

The PACE Zenith Awards were established in 2004 and are presented to Australian industry annually for outstanding achievements intechnological excellence and innovation. Yokogawa Australia’s projects have previously won awards in 2005, 2007, and 2008.

The Challenges and the SolutionsThe application of modern DCS technology at the Morwell Power Station was highly successful in achieving EBAC’s objectives. This projectaccomplished the following:

• Optimized the use of labor by enabling a preventive maintenance approach

• Optimized the plant’s operating conguration by allocating turbine loads, allowing the station to operate at continuous maximumcapability

• Coordinated station control (range and pressure and process steam pressure), which in turn allows maximum plant exibility by optimizingboiler and turbine loading to take account of fuel quality variation, plant condition, and briquette factory process steam demand

• Optimized the consumption of brown coal fuel and minimized ue gas discharge by fully automating combustion control on all boilers

• Minimized the consumption of fuel oil, improved furnace stability, and reduced plant stress and operating costs as a result of theautomation of brown coal combustion

• Reduced thermal stress on the plant as a result of automating the boiler nal steam temperature control• Signicantly improved plant safety by automating drum level control and furnace temperature control

• Increased operational exibility and improved station response t o load demand variations by tting modern digital governors to allve turbine generators

• Increased consistency of plant operations and reduced rate of load variation• Reduced maintenance costs through tighter control and more consistent/less stressful operation by reducing the number of signicant

excursions outside plant design parameters• Signicantly increased continuous MW load output from the available capacity while minimizing steam wastage and improving

operating efciency by automating steam consumption across all turbines and condensers• Introduced a new screen-based operator interface that allows operators to monitor plant operations while relying on automation systems

to maintain the plant in a stable and controlled condition throughout all steady state, load change, and plant upset conditions

CENTUM CS 3000

control system cabinet

Low pressure condensing turbine generator

CENTUM CS 3000

station operator consoles

Plant InformationPlant name: Morwell Power StationLocation: Victoria, AustraliaProject type: Control system revampingPlant type: Coal-firedOutput: 180 MWOrder date: 2005Completion: 2008



41 Power 42

PNOC-EDC

Philippines

System DetailsControl system: CENTUM CS 3000 & PRMNumber of I/O points: 112 points (14 segments)Products: EJX430A (52 units), EJX110A (52 units) and CA71 (1 unit)System conguration: • FF for advanced eld instrumentation • Standard-conguration transmitters for the geothermal application: EJX430A-FAS3G-917DN/A/X2/D4/M11 EJX110A-FAS3G-917DN/A/X2/D4/M11 • PRM for optimal plant asset management • WAN for remote data monitoring

Customer SatisfactionPNOC-EDC was very satised with Yokogawa’s performance in the NNGP. The Companyearned the customer’s trust with its project management expertise and local engineering capabilities.This project is part of the government’s efforts to reduce dependency on oil through the use of renewalenergy sources. The NNGP was inaugurated by no less than the President of The Philippines,Ms. Gloria Arroyo, who was accompanied by key ofcials in the power sector.

Executive SummaryThe Northern Negros Geothermal Project (NNGP) was a breakthrough forYokogawa. After a long selection process, PNOC-EDC awarded the contract fora Fluid Collection Re-injection System (FCRS) control system to Yokogawa. Thisattested to the Company’s capabilities as a major automation vendor.

There were several key factors for this success, including:

1. Yokogawa had a strong track record in the region of executing projects involvingFOUNDATION fieldbus (FF) technology, which had been selected for the control

system. This was critical in gaining the trust and condence of the PNOC-EDC.The coordination and cooperation between Yokogawa Engineering Asia Pte. Ltd.and other Yokogawa companies showed PNOC-EDC that Yokogawa was the bestpartner for automation of the FCRS control system. Another advantage was thatYokogawa’s infrastructure in the Philippines ensured long-term support.

2. The contract included not only CS 3000 Vnet/IP, eld instrumentation fromYokogawa and other suppliers, PRM, and engineering, but also construction.

Yokogawa’s project management expertise was another important success factor.

Through this project, PNOC-EDC obtained:• State-of-the-art FF technology

• Plant Resource Manager (PRM) eld device management system • Remote data monitoring capability via wide area network (WAN)

The Challenges and the Solutions

State-of-the-art FF technologyPNOC-EDC had adopted FF and was aware that there were many vendors of this technology. They needed to select the best partner for thelong haul, and they did this through interviews and plant visits. After speaking with other end users of Yokogawa fieldbus products in the region,PNOC-EDC saw that Yokogawa was best positioned for a long-term relationship.

Plant Resource Manager (PRM) eld device management systemPNOC-EDC recognized the importance of optimizing its operational costs and realized that asset management would be a critical success factorfor attaining this objective. Yokogawa’s versatile PRM platform and fieldbus devices met the operational and technical requirements. With PRM,PNOC-EDC anticipates lower operational costs, effective maintenance programs, and high system availability.

Remote data monitoring via WANCritical to the overall operation of the plant was the availability of plant information to PNOC control centers in Negros and in Manila. As part ofthe project, the FCRS control system was connected to a WAN by another vendor.

Yokogawa's Reliable Control System is Runningat Geothermal Power Plant in the Philippines

Plant InformationPlant name: Northern Negros Geothermal

Power PlantLocation: Negros Occidental, the PhilippinesProject type: NewPlant type: Geothermal power plantOutput: 49 MWOrder date: December 2005Completion: February 2007

President Arroyo (Left of console)

PRM windows

System Layout



43 Power 44

Customer SatisfactionDr. Lovegrove explained, “As a clean energy source, solar energy is a natural complement to wind andbased on our climate is more available and provides most of the energy when you need it.“As an example, in a large system with an array of dishes all feeding steam to a single efcient large steamturbine, each dish of this size would contribute the production of more than 100 kW when operating at fullefciency in full sunlight. Roughly speaking, up to 100 advanced energy-efcient homes could be powered byevery dish. A solar eld with the size of the Australian capital Territory (ACT) could power the entire country.

“The medium-term goal for the concentrating solar technologies is to make electricity for about the samecost as wind, which is currently around 10-12 cents a kilowatt/hour. While that’s around double the cost ofconventional coal-red power stations, it may prove to be cheaper than adding carbon capture and storageto existing coal-red power stations.“Of course, the ultimate energy economics will be inuenced by ruling government policy, with any movesto tax carbon impacting on fossil fuel power stations and tipping the economics more in favor of alternateenergy sources in the future.

“We are very happy with the high reliability of Yokogawa’s system. This is very important to keep our solarplant running 24/365. Also, our engineers can easily congure the system at any-time. FAST/TOOLSbenets us in many ways and allows us to clearly see the entire process, giving us the information we needto take immediate action.”

Power generation ow with solar collecting dish

The Challenges and the SolutionsThe latest dish, SG4, was completed in June 2009, and since then a great deal of effort and research by Mr. Burgess and others has gone intone-tuning the solar tracking, sourcing computer, and communication components, testing optical performance, and installing and testing therst steam generating receiver. Yokogawa has worked closely with these researchers to optimize the performance of this system by providinga PLC SCADA system that computes the precise position of the sun to ensure millimeter perfect tracking of the sun. The system also includessafety features that, for example, will put the dish into a “parked” position at night and before storms to prevent damage from high winds.

As new units are constructed at this ANU facility, the plan is to employ Yokogawa’s new HXS10 controller as a cost-effective means toautomatically track the sun and ensure maximum efciency of the solar reecting dish.

Executive SummaryLed by Associate Professor Dr. Keith Lovegrove, the Australian National University’s (ANU) Solar Thermal Group has constructed the world’slargest solar collecting dish on the ANU campus in Canberra. This reecting parabolic dish is 25 m wide and has 500 m2 of highly efcientpurpose-built mirrors that reect the sun’s rays onto a collector coil. This converts water to steam, which drives a steam turbine that generateselectricity. Yokogawa’s FAST/TOOLS software ne-tunes the dish’s ability to automatically track the sun and maximize the energy collected.

This project had its genesis in the early 1970s, when a team lead by Stephen Kaneff and Peter Carden paved the way for the construction of theWhite Cliffs solar power station, with 14 comparatively small 20 m 2 dishes. Convinced the idea had merit, the team at ANU proceeded to scale-up the solar generator, with the rst ”Big Dish” built in 1994 using commercially available space-frame technology. According to lead researcherGreg Burgess, the aim of the solar project has been to demonstrate that solar generated electricity is viable on a commercial scale. Theirthinking is that building fewer large dishes, which can be easily replicated in the eld, is more economic than building lots of smaller ones.

Planning is underway for the construction of a pilot solar generating plant that will prove out the concept already demonstrated by the existingsolar generator dish. Mr. Burgess also sees other potential applications for super-heated steam produced by reected solar energy. Such is theintensity of energy generated by the dish’s efcient design that when concentrated it can melt through solid aluminum, stainless steel plate, andeven the hardest ceramic known.

Yokogawa Australia is involved in this exciting solar energy project, which may provide the key to future solar energy projects in Australia.

Australia

Yokogawa PLC and FAST/TOOLS SCADA ControllAustralian National University’s “Big Dish” Australian National University

Plant InformationPlant name: ANU's Solar Thermal GroupLocation: Canberra, AustraliaProject type: NewPlant type: Solar thermal plantOutput: 100 kW/dishOrder date: 2009Completion: 2010

Left to right: Mark Biggin, Yokogawa Australia;

Mr. Burgess, ANU: Dr. Lovegrove, ANU

Steamgeneration

Steamturbine

FAST/TOOLS

Field operation center

Solar collecting dish



45 Power 46

Customer SatisfactionNEP Solar’s Chief Executive Ofcer, Johan Dreyer, an engineer with experience as a project manager for one ofAustralian’s largest commercial and industrial construction companies, said, “It is very important to control costs andensure reliability for solar energy to achieve its potential in Australia. The critical part of the solar system is the ability

to accurately track the sun. We need to focus exactly on one point (the solar tube), and the tracking needs to be veryaccurate. Yokogawa’s HXS10 solar tracking controller makes this possible.” Mr. Dreyer went on to say, “The efciencyof the mirrors is such that the system can capture enough solar energy to cool even on a partly cloudy day. In full sun,direct normal insolation using this type of system can be as high as 1000 watts per square meter.”

Flowmeters and temperature sensors such as those produced by Yokogawa can determine how much energy is beingconverted into thermal energy to monitor the efciency of the entire system.

NEP Solar will next use the Yokogawa HXS10 and the related FAST/TOOLS on a desalination project in Spain and ata dairy processing plant in Switzerland.

The Challenges and the SolutionsAccurate sun tracking and visualization of all process dataThe critical part of the efciency of the concentrated solar system is the ability to very accurately track the sun and adjust the angle of thereectors on two axes to capture the maximum incident solar rays. When NEP Solar became aware of the advantages of Yokogawa’s newHXS10 solar tracking controller and the FAST/TOOLS SCADA system, it could see the advantages of using the solar tracking controller toreplace common PLCs in future projects. The HXS10 is capable of accurately positioning the troughs in line with the sun, and the FAST/TOOLSsoftware provides detailed performance and status information on the solar eld to maximize output. FAST/TOOLS can even tell an operator thatthere is too much dust on the troughs (important as dust diminishes output). NEP Solar’s solar collector utilizes a specially coated aluminum mirror, which is mechanically polished to an extremely reective nish – as high

as 92% – rivaling the highest quality heat-sag glass mirrors. The lightweight, composite sandwich construction mirror panels and tracking systemare robust to maintain tracking and focus for optimum conversion efciency. They are also strong and can withstand winds up to 108 km/h in the“parked” position.

Executive SummaryYokogawa Australia has supplied its breakthrough HXS10 solar tracking controller to NEP Solar – one of the pioneers of solar energy in Australia

– for use in a solar cooling project.

NEP Solar of Warriewood on Sydney NSW grew out of companies that were involved in wind farm development, but later became a pioneerof novel solar applications such as the rst solar cooling project in Australia in 2004. NEP Solar’s local projects to date include a solar coolingdemonstration project under the Renewable Energy Development Initiative(REDI) at the Commonwealth Scientic and Industrial Research Organization(CSIRO) Energy Centre in Newcastle, and a solar cooling demonstration projectfunded under New South Wales Government's Sustainable Energy. ResearchDevelopment Fund (SERDF) in Padstow, partly funded under the New SouthWales government’s SERDF.

One of NEP Solar’s latest projects is a commercial installation of a solar eld todrive a chiller for part of the GPT Charleston Square shopping complex in theregional city of Newcastle north of Sydney. The 345 m 2 “PolyTrough 1200” solareld is mounted on a rooftop above a cinema complex. The chiller uses the heatfrom the solar eld and a concentrated salt solution in which water gets absorbed

and re-absorbed, exchanging heat in the process. The chilled water from theabsorption chiller feeds into the shopping center’s return cooling loop to reduce

the amount of energy expended to further cool the water for the center’s airconditioning system.

Australia

Yokogawa’s HXS10 Solar Tracking Controller OptimizesConversion Efficiency at Australian Solar Cooling Plant NEP SOLAR Pty Ltd.

Plant InformationPlant name: Solar cooling PlantLocation: Charlestown, AustraliaProject type: NewPeak Thermal Power: 200 kWOrder date: 2010Completion: 2011

FAST/TOOLS main overview screen with wind compass

Mr. DreyerEmployees of Yokogawa AustraliaJoint exhibit with NEP Solar at All-Energy Australia

exhibition in October 2011

Overview of solar cooling process



47 Power 48

Customer SatisfactionChanapai Sahudsa, A.T. Biopower’s Engineering Manager, had the following to say about Yokogawa’s solutions: “Thisis the rst plant to be approved by the Thai government under the Clean Development Mechanism (CDM) denedin the Kyoto Protocol. We are very happy to be using Yokogawa’s system and products at this rice-husk-fuelledboiler plant, the world’s largest of its type. We are always looking for ways to improve its operation and make thecombustion process more efcient. We always appreciate the solutions provided by Yokogawa Thailand.”

Plant detailsPlant type: Thermal powerGenerating capacity: 22.5 MW (internal 2.5 MW)Fuel: Rice husksDaily fuel requirement: 500 - 600 tons at maximum capacityBoiler: 91 t/h, 65 bar, MacburneySteam turbine: Shin NipponDaily water requirement: Approximately 2,200 m3

Precipitator system: Electrostatic precipitator capable of detecting 99.5% of particulates

The Challenges and the Solutions1. Stable combustion controlThe burning of the ground rice husks in the boiler’s furnace chamber is a complex process that must be carefully controlled. Fuel oil-red burners heat thecombustion chamber. Once this chamber reaches 700-800 degree C, ground rice husks are fed from a service silo to a fuel-air mixing system, where thismixture is compressed by air from a primary service fan and blown through the burners into the center of the combustion chamber. Adjustable vanes onthe burners circulate the fuel-air mixture to maintain optimum combustion at 800-900 degree C. At the same time, compressed outside air that has beendrawn in by a forced draft fan and heated in an economizer is directed into the lower part of the combustion chamber in order to keep the ground rice husksin a suspended state and ensure complete combustion. Once the ground rice husks are burning steadily, the supply of fuel oil to the burners is graduallyreduced and then stopped completely. With the pressure inside the combustion chamber in balance with the outowing ue gases, the heat from the uegas generates 480 degree C steam that drives the steam turbine. The ue gases are then released through the economizer to recover the remaining heat.

Steam from that has passed through the turbine is cooled down by a condenser as a condensate. This condensate is transported as drops of water back tothe boiler to be recycled as steam. Meanwhile, the heated cooling water that was used to condense the steam is cooled down in a cooling tower for reuse.This system is thus a closed-circuit type cooling system.

Yokogawa’s CENTUM CS 3000 system handles all of these sequences as well as the control of feed water, steam temperature and pressure, and drumlevel, and uses sensory inputs from a Yokogawa zirconia oxygen analyzer to optimize combustion of the fuel in the furnace, thereby assuring the stable year-round supply of electricity to the national grid. And when the power plant switches to island mode, the system adjusts the boiler ring rate to decrease thesupply of steam to the plant’s steam turbine, thereby decreasing power production to a level that meets the plant’s own requirements. All of these sequencesare also congured in the CENTUM CS 3000 system. Graphic displays at the control stations give operators a clear view of what is going on throughout thissystem at any given time, ensuring that they have all the information needed to take quick and decisive action whenever intervention is required.

2. Emissions monitoringAfter combustion in the furnace, the heavier particles fall down to the inclined

bottom of the furnace and are swept out through an ash port by a screwconveyer for removal. Lighter particles mixed with ue gases are carried out ofthe combustion chamber through a ue port. An induced draft fan draws theseue gases into groups of electrostatic precipitator (ESP) that trap the lightery ash particles before the ue gases pass up the stack for discharge into theatmosphere. This ue gas is monitored by the Yokogawa CEMS, which measuresCO, CO2, O2, NOx, and SOx concentrations for reporting to the government on aweekly and monthly basis. All water used in the plant is analyzed by a pH meterand conductivity meter so that it can be kept within an allowable range.

Thailand

Thai SPP Uses CENTUM CS 3000 to ImproveEfficiency of Biomass Power Plant A. T. Biopower Co., Ltd.

Plant InformationPlant name: A. T. Biopower Co., Ltd.Location: Pichit Province, ThailandProject type: NewPlant type: Biomass Power PlantOutput: 22.5 MWOrder date: 2004Completion: 2005

Burner management displayCentral control room

Executive SummaryIn 2005, A.T. Biopower Co., Ltd. built a biomass power plant in Pichit, Thailand. Using ground rice husks as its fuel, this plant generates 22.5MW of electricity, of which 20 MW is sold to the Electricity Generating Authority of Thailand (EGAT). The plant was built with the support of theThai government’s Ministry of Energy, which is promoting the construction of power plants by small power producers (SPP) that utilize hydro,biomass, or thermal cogeneration technology. In addition to promoting the use of renewable energy sources, this policy aims to reduce thecountry’s dependence on imported fuel. At present,

about 90% of the electricity generated in Thailandcomes from power plants that rely on non-renewablefossil fuels, namely, oil, coal, and natural gas. If no

effort is made to nd and develop new energy sources,it is estimated that the country’s coal and natural gas

reserves will be completely exhausted in the next 30years. The use of modern technology to generate

power from rice husks and other kinds of agriculturalwaste will not only contribute to the country’s energyindependence, but will also help reduce environmentalpollution and provide employment opportunities for thelocal community.

For A.T. Biopower’s biomass cogeneration power plant,Yokogawa Thailand successfully installed the CENTUMCS 3000 production control system, eld instruments,and a continuous emission monitoring system (CEMS).

Continuous emission monitoring system

Mr. Sahudsa



49 Power 50

Customer SatisfactionThe integrated control system allows JWD to manage the operation of each of its windmills and provide a steady supply of power to the nationalpower grid. JWD plans to begin constructing wind farms outside Japan, and to this end is working together with Yokogawa and Tokyo Densanto develop the necessary high-speed systems and equipment. Through this development of renewable energy facilities, JWD hopes to make alasting and signicant contribution to the building of a more sustainable society.

Plant detailsWindmills: 34 x 1,500 kWBattery: NaS type, 2 MW x 17 sets with 17 sets of AC/DC convertersTransmission capacity: 51 MWTransformer: Primary - 154 kV/60 MVA, secondary - 22 kV/60 MVA

The Challenges and the SolutionsSteady power supply by reliable control systemTo ensure a stable supply of power to the national grid even when power production dips as the result of low wind speed, the Rokkasho windfarm utilizes large-capacity NaS batteries.

The STARDOM network-based control system and FA-M3 range-free controllers play an important role in smoothing out the supply of this powerto the grid. A power monitoring and control system and a battery control system are both congured in the dual redundant STARDOM controllers.FA-M3 range-free controllers are utilized to monitor and control each windmill. Controllers from other vendors are integrated with this system viaan OPC interface. Factoring in the uctuations in power production as a result of varying wind conditions, a power generation scheduling systemcalculates operation plan parameters and a power output pattern, based on which instructions are issued to each FA-M3 controller. The actual

power output can be monitored on a trend graph. The operating status of each of the 34 windmills and the charge status for each of the 17battery units can also be monitored together with various other types of operation data.

This power monitoring and control system carries out the following main functions:

1. Operation planning and monitoringUsing the power generation scheduling system, operators can access the weekly operation plan data, based on which they can draw up anoperation plan for the next day. At their stations, operators can view graphic displays showing the power sales target, power generation plan,and battery charge-discharge plan.2. Associated power monitoringOperators can view data on total power output for the entire facility, battery charge status, and transformer operation status.3. Windmill monitoringFor each windmill, data on power output, wind direction and speed, and operating status is displayed.4. Battery monitoringFor each battery, the charge-discharge rate, charge status, and operation status are displayed.5. Remote monitoring and controlOperations can also be monitored and controlled wherever network access is available.

Executive SummaryAmidst growing concerns about the depletion of fossil fuels and the effects of climate changes caused by rising CO2 emissions and otherfactors, there is a growing push to generate power from wind, solar, biomass, and other renewable energy sources and thereby create a moresustainable society.

Japan Wind Development Co., Ltd. (JWD) is a specialist in wind power generation technology with vast knowledge and expertise in this eld.JWD is building and providing all necessary support services for a nationwide wind power generation network.

In May 2008, JWD completed construction of a wind farm near Rokkasho village in Aomori Prefecture, in northern Honshu. This smart grid windfarm is the rst facility of its type to use sodium sulfur (NaS) batteries to store electricity for supply to the national power grid. These batteriesare charged at night, when the demand for power is lower, and the stored electricity can be supplied to the grid together with the electricitygenerated by the wind turbine during the daylight hours. This ensures a steady supply of power to the grid even during those periods whenpower production falls as the result of low wind speed.

To control the transmission of power from the Rokkasho wind farm to the national power grid, Tokyo Densan, a Yokogawa representative andsystems integrator, successfully installed STARDOM network-based controllers and FA-M3 range-free controllers.

Japan

STARDOM and FA-M3 Ensure Smooth Supply of Power to Grid

by Wind Farm Equipped with Large-Capacity NaS Batteries Japan Wind Development Co., Ltd.

Plant InformationPlant name: Japan Wind Development Co., Ltd.Location: Rokkasho, Aomori, JapanProject type: NewPlant type: Wind power generationOutput: 34 x 1500 kWCompletion: May 2008

Total system conguration


Battery

Charging

Power

Charging

Time

Smoothedpower to

national grid

0 7 12 18 23

Power generation by windmills



51 Power 52

Customer SatisfactionIn his comments to Yokogawa, Danny Coulston, General Manager of the Lakeside EFW facility, touchedon the following points:･Everyone at Lakeside EFW is pleased with the high reliability of the Yokogawa systems and their

ease of operation and engineering.

･The new plant was designed to meet the requirements of the European Waste IncinerationDirective, which mandates tight controls on the atmospheric release of dioxins, heavy metals, acidgases, nitrogen oxides, particulates, and other products of the combustion process. This reducesenvironmental impact and protects human health, and the facility’s emissions of dioxins and otherhealth related pollutants are low compared to common air pollution sources such as outdoor

burning and vehicle exhaust.･Lakeside EFW well recognizes the importance of water conservation and has designed the facility

so that all process water and water from maintenance activities is collected in a tank to be reusedas "gray" water for non-critical purposes.

･The company has built an education center that extends out over a nearby lake. This is used toeducate the public on the efforts that Lakeside EFW is making toward a sustainable future.

Waste to Energy overview ow

The Challenges and the SolutionsLakeside EFW is continually looking for ways to operate this incineration facility more efciently. Waste is trucked to the facility, with the vehiclesbeing weighed on entry into the site and again on exit to calculate the amount of delivered waste. Grab cranes mix the waste in a 7,500 toncapacity bunker to obtain a more controllable caloric value, then load the waste into a hopper from where it is pushed into the incinerator byhydraulic rams. The initial ring of the boiler is achieved using an approved low sulfur diesel. Once the waste is burning inside the incinerator,the diesel burners are switched off and the waste becomes the fuel.

Superheated, dry steam created from the boiler process is used to drive a steam turbine, which in turn drives a generator set. The generatorproduces enough electricity to power the Lakeside facility and export 34 MW onto the National Grid. Spent steam from the turbine is condensedand pumped back to the boiler, making a closed-loop steam/water circuit. The facility has also been designed so that off-site district heating

(combined heat & power - CHP) can be provided to local consumers in the future.

The bottom ash from the waste incineration process is transported by moving belts to dedicated bunkers. Ferrous metals are r emoved fromthe bottom ash for recycling. The ash is removed from the site and processed into an approved aggregate material for road building andconstruction.

The hot gases from the incineration process that were used to heat the water contain various compounds and chemicals that need to be treated.These gases and chemicals are cleaned in a ue gas treatment process. This uses slaked lime to absorb sulfur gases and HCl, activatedcarbon to absorb dioxins and heavy metals, and ammonia to reduce NOx gases. The air is subsequently passed through a bag lter before itis released from the stacks. The emissions are monitored in r eal time using state-of-the-art, independently calibrated measuring instruments toensure compliance with permitted emissions limits.

With the integration of the Yokogawa CENTUM CS 3000 and ProSafe-RS systems, operators in the central control room enjoy ready accessto operations throughout the plant. Ergonomically designed CS 3000 human interface stations (HIS) provide a window into all of this facility’sprocesses, giving operators real-time access to all the information they need to make quick and timely decisions.

Executive SummaryAs existing fossil fuel reserves have become unviable or unreliable, the challenge of providing a secure energy supply for power generationwithin the UK has increased signicantly in terms of both nancial and environmental cost. At the same time, landlls lack the capacity to handlethe increasing amount of household and municipal waste. While efforts to reduce, re-use, or recycle waste have made some headway, otheroptions have had to be explored. One such effort underway that is making a valuable contribution toward providing a balanced and secureenergy portfolio for the UK involves the extraction of energy from residual (non-recyclable) waste.

Lakeside EFW Ltd. operates an energy-from-waste (EFW) facility near London that is staffed by experts in energy recovery technologies whoare working hard to ensure the plant remains efcient, technologically up to date, and above all, safe. The plant has the capacity to consume410,000 tons of household and municipal waste per year and exports at least 34 MW per hour to the country’s National Grid. This processdiverts the majority (over 97%) of waste from landll.

Lakeside EFW uses a mass-burn process to generate high temperatures that are then used to produce high pressure steam. The steam in turndrives a turbine to produce electricity. Residues and ue gases are carefully treated to minimize the release of environmental pollutants. Thefacility operates under strict environmental controls, within the guidelines of the waste incineration directive (WID) and an environmental permitadministered by the environment agency.

For Lakeside EFW, Yokogawa UK installed a CENTUM CS 3000 distributed control system and a ProSafe-RS safety instrumented system to

automate control of the facility’s boilers, burners, and balance of plant facilities. The facility has operated safely with no major system failuressince coming online in 2008.

UK

Modern Waste to Energy Facility in UKUses CENTUM CS 3000 and ProSafe-RS Lakeside EFW

Plant InformationPlant name: Lakeside EFWLocation: Lakeside, UKProject type: NewPlant type: Stoker boilerOutput: 34 MWOrder date: January 2007Completion: April 2008


Incoming waste Incineration Generation of electricity

Lakeside Education Center



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