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Yokogawa’s VigilantPlant delivers visibility, predictability and agility for power generation – throughout the plant life cycle.
Yokogawa in thePower Industry
Bulletin 53T01A01-01E
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ACT WITH AGILITY Fewer surprises KNOW IN ADVANCE
Minimize reactive measures, unexpected downtime, quality variations
Reduce delays, lost opportunities, knowledge silos
Free of bottlenecks
SEE CLEARLY
Avoid guesswork, instability, sub-optimization
Less blind spots
The clear path to operational excellenceEnvision a plant where people are watchful and attentive while your businessresponds to change quickly and efficiently. Now picture an operation that delivers non-stop power generation while confidently expanding your capabilities into the future. Imagine no further. This is the vision and promise behind VigilantPlant, the clearpath to operational excellence.
Making critical plant information fully visible is just the beginning of the vigilant cycle.
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.
The plant’s alert approach to operations, maintenance, and information is obvious. Operators are calm and in control. Managers are well informed, but never overwhelmed with data. All facilities are under control, ready to unleash their full potential for occasional peak load. At the same time, potential problems are anticipated before they happen. All this in the life of a vigilant operation.
You know a well run plantthe moment you walk in
A New PlantComes On-streamThe control room is quiet, with arrays of computer
screens displaying trends and messages on the walls
and operating desks. Gone are the chart recorders,
printers, meters and push buttons of yesterday. Operat-
ing staff remain calm, monitoring operations, preparing
the plant for routine testing and maintenance.
Other operating staff take time out from the control room
for refresher training on the plant’s full replica training
simulator. Here, the atmosphere is not quite as calm as
operating staff get put through their paces responding to
emergency conditions, and undergo training for less
common tasks such as plant start-up.
Being trained for a wide variety of emergencies, the
operators are ready to handle unexpected events with
confidence. Unscheduled shut-downs are minimized
and rapid recoveries from unforeseen incidents are
assured.
To a casual observer, this calm & efficient setting may seem rather boring. But this is the way a plant should run –allowing you to See Clearly, Know in Advance, andAct with Agility. It should run like a VigilantPlant.
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Daily Operations & MaintenanceDuring the night, while most of the community sleeps,
the power plant remains in operation, ticking over at
minimum output, meeting society’s needs for an uninter-
rupted electricity supply. The plant is prepared for the
surge in electricity demand as the community awakes
and commercial activities resume.
The CENTUM VP system coordinates operations
throughout the plant, ensuring that boilers, steam
turbines, and balance of plant (BOP) facilities function
stress-free and at optimum efficiency while staying within
safe operating limits.
The advanced alarm and monitoring system monitors all
control system traffic, alerting operating staff to
problems, while blocking out unnecessary messages.
Most alarm messages relate to routine issues, such as
the failure of an aging field instrument or a problem with
the operation of a valve or damper.
As morning approaches, operating staff check the
plant’s daily schedule and begin placing additional coal
grinding mills into operation to increase the plant’s output
and meet the morning demand.
During the day, the control system continually adjusts the
plant output up and down to meet shifts in power
demand. A sudden cold weather snap a hundred km
away – or a failure in a plant elsewhere – may call for
more power. In the competitive electricity market, a plant
must be agile to quickly respond to market needs and
capitalize on opportunities to increase profitability.
Recent heavy rain may result in deliveries of wet coal
from the local mines. Operating staff respond by placing
an extra milling plant in reserve, and then relax knowing
that the Yokogawa control equipment includes fuel control
strategies to cope with changes in fuel conditions.
Meanwhile, in the maintenance workshop, plant techni-
cians responsible for 24/7 maintenance of all plant
instruments and control systems use the PRM asset
management software to monitor the performance of
field devices such as transmitters, analysers and
actuators.
The control system provides high-level operational and
maintenance diagnostics, enabling immediate identifica-
tion of plant faults, greatly accelerating response to
problems.
Plant managers keep an eye on plant performance via
secure remote access. Plant experts check and evaluate
plant performance from the comfort of their office
environment.
Plant Revamp & ExpansionWith today's power plants remaining in operation for sev-
eral decades, there comes a time when instrumentation
and control systems must be renewed to maintain a
competitive edge.
At the start of a replacement project, Yokogawa's experi-
enced engineering team carries out a plant and control
system audit. The sustainable and flexible architecture of
Yokogawa’s control system means that only the obsolete
control units need to be changed over, allowing existing
equipment to be retained to the maximum extent. Strate-
gies for increasing plant safety, avoiding project cost over-
runs, and increasing plant availability are put into place.
While the design and fabrication proceed, other process
application specialists review the plant control strategies
and incorporate new control concepts. This is thoroughly
tested by simulation, almost always with a full replica
simulator. Testing proceeds separately from the manu-
facture of control equipment, providing low risk engineer-
ing processes for projects with short outage times.
Once the plant outage begins, existing control equipment
is quickly removed, without disturbing existing cabinets
and cables. The new factory-assembled and tested control
equipment is installed, and connections made to existing
terminals and cables. Commissioning and testing of the
new control equipment commences almost immediately.
As the outage concludes, operating staff "run up" the
plant with the confidence that comes from having under-
gone extensive training on the plant simulator.
With the new control system, the power plant is set for many
more years of safe, reliable and competitive operation.
SEECLEARLY
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The effectiveness and efficiency of power plant operations depend on the availability of key performance information about the plant and the process. Yokogawa delivers a single-architecture monitoring and control system that integrates information from all facets of a power plant and keeps the plant personnel well informed. The industry-leading availability, reliability, and long-term stability of the Yokogawa automation platforms ensure an operating environment where your people can have 20:20 vision of your entire operation.
Improving visibility of all plant informationwith a single unified architecture Key Enablers:
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CENTUM VP total power plant control system for turbine, boiler and balance of plant (BOP) controls
TÜV SIL3 certified ProSafe-RS integrated safety controller for the burner management system (BMS) and
protection system
FOUNDATION™ fieldbus and HART interface for field instruments, analyzers, and valve positioners
PROFIBUS interface for electrical equipment and motor valves
IEC 60870-5 interface for substation equipment
Single architecture covering the entire plant
-
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Field-proven controller with seven 9s (99.99999%) availability in unique pair-and-spare redundant
architecture
Pair & spare fail-safe architecture is also available for the ProSafe-RS safety controller
High availability
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±0.04% accuracy of the DPharp EJX digital transmitter even in the most critical applications (drum level, etc)
±0.1% of upper range limit (URL) for 10 years with EJA/EJX transmitters
Long term stability
Digital sensing & control
Error (%@max.span)
0.10
0.05
0.00
-0.05
-0.101 2 3 4 5 6 7 8
Year
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Optimizing operation & maintenance forunprecedented plant management efficiency
KNOWIN ADVANCE
Advanced plant management
Key Enablers:
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Intelligent alarm management automatically displays alarms requiring operator attention, informing
operators whether alarm points are improving while suppressing irrelevant alarm messages.
Exaplog event analysis package analyzes the frequency of alarms and operator actions, visualizing
statistical data and helping to find the root causes of alarm occurrence and areas for improvement.
Event sequence analysis with built-in Sequence of Events Manager (SEM) allows 1msec time resolution
and 1msec accurate time synchronization system across all controllers.
Alarm Management
- Integrated asset management with PRM Plant Resource Manager enables effective maintenance of plant
assets in a single unified database system across different protocols and multiple suppliers.
Plant Asset Management
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Full-replica simulator performs highly accurate modeling of actual plant behavior under any scenario for
optimized operation and control.
Performance calculation is fully integrated with the Yokogawa DCS and uses predefined formulae to monitor
and optimize performance.
Plant Modeling & Simulation
- Long-term data archiving and data transformation with Exaquantum ensures enhanced, seamless
information flow within and between plant systems and business applications.
Plant Information ManagementOnce into commercial operation, competitive power plants pursue operational excellence by continually improving efficiency and preventing/minimizing abnormal situations. Yokogawa enables optimization solutions that empower plant personnel under both normal and abnormal conditions. Knowledge-based tools and consulting services enable continual productivity improvement, advanced alarm management, and integrated plant asset management. No longer just reacting to problems, your people and your assets are focused on meeting tomorrow’s challenges.
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During the relatively long life cycle of a power plant, there comes a time when the instrumentation and control systems must be renewed to maintain a competitive edge. Yokogawa supports power plants with expert services that maximize efficiency and minimize cost over the entire life cycle. From initial design, construction, and daily operation to revamp and reinstrumentation, Yokogawa stands by your power plant. This long-term partnership ensures bottleneck-free performance and ongoing optimization that bring speed and flexibility to your business.
Enabling agility of business with plantservices throughout the plant life cycle
- Our philosophy of continuous evolution, demonstrated over a 30 year period with CENTUM, ensures a
smooth migration path and keeps your investment for I&C refurbishment to a minimum.
Sustainable control system architecture
- Certified professional trainers deliver competency-based training using a plant simulator to create training
scenarios that flexibly replicate normal, abnormal, and emergency operating conditions.
Custom-made operator training
- 24/7/365 remote monitoring combined with real-time diagnostic tools and services ensures system
maintenance can be condition-based, not time-based, reducing maintenance spending.
Condition-based system maintenance
- Plant-wide audits examine human resources, fuel, asset management, environment, production, plant
operation, and information systems, identifying opportunities for improvement and cost reduction.
Plant auditing and consulting
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Automated operation procedures created with Exapilot enable the know-how of experienced operators to
be shared with less experienced staff.
Documentation of standard procedures for operation, maintenance, training, commissioning, audit, and
reporting.
Standard knowledge base
- Offline commissioning on a high-fidelity simulator allows thorough validation of the DCS configuration
before the software is loaded at the actual plant, keeping to a minimum the final tuning that must be done
during plant commissioning.
Efficient plant commissioning with plant simulator
ACTWITH AGILITY
Plant life cycle services
Key Enablers:
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- Pressure, temperature, flow, and level measurement
- Valve positioners and converters
- TÜV SIL3 certified integrated safety systems for burner management and
emergency shutdown
- Analog/digital meters, clamp-on power meters, power monitors,
insulation testers, handy calibrators
- Performance analysis, operational efficiency improvement, and alarm management
- Asset management
Field Instruments
Safety Management Systems
- Liquid analysis (pH/ORP, conductivity, dissolved oxygen)
- Gas analysis (NOx, SO2, CO, CO2, O2, hydrogen purity)
Analytical Instruments Meters and Test Instruments
Plant Optimization Software
- Commissioning, operator training, operation, maintenance,
and simulation services
Power Plant Services- Distributed control systems
- SCADA and network-based control systems
Unit Control Systems
Yokogawa in the power industry
- Paperless videographic recorders
- PC-based and stand-alone data acquisition equipment
- Single loop and highly scalable programmable logic controllers
Data Acquisition and Control
SEE CLEARLY KNOW IN ADVANCE ACT WITH AGILITY
- Geothermal
- Biomass
- Waste to energy
Renewablepower plants
- Flue gas desulphurization (FGD)
- Circulating fluidized bed (CFB) boilers
Environmentprotection
Wide application experience in the power industry
- Coal/oil/gas fired
- Combined cycle
- Simple cycle
- Co-generation
- Industrial boilers
- Independent water and power
producers (IWPPs)
Fossil fuel firedpower plants
Coal fired power plant
Industrial boiler plant/co-generation plant
Combined cycle power plant
Waste to energy plant
CFB boiler plant
FGD plant
Geothermal power plant
Yokogawa supports a wide range of applications, from conventionalpower to renewable energy.
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Boiler & BOPControls
Plant SafetySystem
Plant informationmanagement
Plant resource management integrates and manages maintenance information from field instruments and monitors online conditions.
Plant resourcemanagement
Human interface station/engineering station
The ProSafe-RS SCS is a TÜV SIL3 certified safety system that incorporates Yokogawa’s own pair-and-spare technology.
Safety Control Station (SCS)
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Coal yard
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Ash pond
Boiler
EP
FGD
Waste water
TurbomachineryControl & Protection
Typical coal fired power plant
Turbomachinery
Water treatment
Steam turbine
The FCS provides powerful control functions with a highly reliable dual redundant configuration that incorporates Yokogawa’s own pair-and-spare technology.
Field Control Station (FCS)
- Boiler control- Burner management- Turbomachinery control
Typical control scope ofa coal fired power plant
- Balance of plant (BOP) Coal handling Water treatment Ash handling Flue gas desulphurization (FGD), etc.
All types of plant information including process data, alarms, events and sequence of events (SOE) are handled by plant information management, enabling the analysis of plant operational performance.
The human interface station (HIS) provides a unified and intuitive operating environment. Screens are ergonomically designed and arranged toreduce operator fatigue and discomfort. The engineering station provides powerful configuration tools and a virtual test function.
Total power plant control system
CENTUM VP provides an excellent platform for the comprehensiveand coordinated control of power plants.
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In this revamping project, one important
issue to be considered was the improve-
ment of system maintainability. The
customer wished to centrally manage
through the DCS architecture many
hundred HART-enabled and analogue
devices from multiple venders.
Yokogawa’s PRM Plant Resource
Manager integrates all field device
information and device diagnostic
information into a single database,
allowing real-time, remote maintenance
via DCS networks. When a plant
problem occurs, associated instruments
can be remotely checked and verified in
just a few minutes, which minimizes
routine maintenance work.
Efficient field asset management
The highly accurate simulation
environment (>99% steady state; >95%
dynamic state) enabled thorough
validation of the control configuration on
the simulator prior to the control system’s
actual commissioning at the plant. A
significant number of potential plant trips
and incidents were identified and
resolved before the initial plant startup.
The simulator also aided in the
initial/refresher operator training. In
parallel with the plant commissioning,
the plant operators were well trained
under a wide variety of normal,
abnormal, and emergency operating
conditions.
This ensures a safe and smooth plant
commissioning process.
Faster commissioning with plant simulator
Unified operation of turbine, process, and electrical controls
Real stories in the power industry
SEE CLEARLY800 MW combined-cyclewith LNG terminal
KNOW IN ADVANCE4 x 660 MW coal-firedrevamping
Eraring Power Station, Australia’s largest power station, maximized plant availability for a further 20 years, supported by Yokogawa’s highly integrated control and monitoring systems solutions.
This coal-fired plant has been operated reliably since 1981 and has a generating capacity of 2,640 MW. To ensure market competitiveness for the next few decades and to improve plant operation and efficiency while maintaining reliability, the customer decided to replace the original hard-wired control equipment.
Yokogawa provided an integrated control
solution comprised of a DCS, plant
ACT WITH AGILITY2 x 800 MW supercriticalfull-replica training simulator
Korea South East Power Co., Ltd. (KOSEP) has built and successfully brought online a greenfield supercritical power plant in Yonghung. With its two 800 MW coal-fired units, this plant will help meet the Korean market’s need for clean and efficient power.
To ensure that the commissioning process for its new plant went smoothly, KOSEP turned to Yokogawa and its TechComm Simulation subsidiary for a full-replica simulator solution.
The simulator was used for thorough off-line control system validation prior to DCS commissioning and for operator training in parallel with the plant commissioning.
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Spain's BBE combined cycle power plant and BBG LNG regasification plant are using Yokogawa's field-proven control solutions to provide a stable energy supply.
The construction of these two plants has been a significant undertaking and has been necessitated by the country’s increased demand for electricity and imported natural gas.
Both facilities aim to have high availability. The Yokogawa CENTUM CS 3000 DCS supports reliable plant operation with its field-provenpair-and-spare non-stop controller technology.
At the BBE power plant, the CS 3000 with Unified Operator Interface (UOI) enables the seamless operation of multi-vendor control systems for turbine, Heat Recovery Steam Generator (HRSG), Balance of Plant (BOP), and electrical equipment through a single operator interface.
At the BBE power plant, turbine,
HRSG/BOP process, and electrical are
controlled by different vendors’ systems.
The CENTUM CS 3000/UOI enables
unified operation of multi-vendor control
systems from a single operator
interface, eliminating the need for the
duplication of human machine interfaces
(HMIs) and requiring no engineering for
cross-system communications.
The turbine, process, and electrical
control systems embrace the same HMI
environment as the turbine system HMI.
This enables unified operation of the
entire plant with a common look & feel,
integrated data displays, and integrated
alarm with original time stamp.
information management system, plant asset management system, full-replica training simulator, and field instruments together with strong local support.
The units have been returned to service ahead of schedule and have been operating very stably and efficiently.
Asset OptimizationLife Cycle Solutions
Operation & Maintenance ServicesStandard Knowledge Base
The 4th Thermal Power Plant (Phase One)4 x 420 t/hr, coal fired, plant revamping
A more stable and robust power supplyThe re-instrumented boilers realized both higher stability and
increased throughput, assuring a stable energy supply.
Reduction of malfunctions and accidentsSince the renovation, equipment malfunctions have dropped
dramatically, eliminating costly plant downtimes.
“Seeing is believing. Whatever beautiful things sales people say, I will not believe until
I see them at work. When we experienced the plant trip, I learned what makes
Yokogawa different from others. I admire their sincerity and devotion toward
customers.”
Complex revamp/expansion projects test the alertness, care, and skill of both
the user and the supplier of automation. Yokogawa delivers practical
engineering solutions with professional care, modernizing and expanding your
plant with minimum disturbance to your business.
Ongoing adaptation and optimization requires continued collaboration.
Yokogawa keeps in close touch with your plant through 24/7 operation support
and expert consultation services.
Good coordination between multiple suppliers and engineering teams is the
key success factor in commissioning. Yokogawa ensures both human
collaboration and technical integration throughout the project life cycle.
Early involvement and collaborative project execution lowers the overall risk of the
project. Yokogawa strives to understand the goals of each project upfront and to
secure a firm ground for ongoing teamwork. Throughout execution, Yokogawa
secures strict quality gates based on proven procedures.
Design & Engineering
Installation & Commissioning
Operation & Optimization
Revamp and Expansion
“Seeing is believing”Front-End Engineering & Design (FEED)Main Instrumentation Vendor (MIV) Services
Site EngineeringIntegration Testing
Turn-Key ServicesCommissioning Services
Optimization Consulting24/7 Operation Support
Online Diagnosis SupportOperator Training
Services for a lifetime of plant efficiency
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Ts. Bayarbaatar, Head of the 4th Thermal Power Plant, Mongolia
Be it diagnosis, root cause analysis, or predictive maintenance, practical
solutions are in short supply. Yokogawa brings you the tools and services that
help you take concrete actions to improve the effectiveness of your plant assets.
Maintenance and Upgrade
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After the 1998 revamping,power output showed adefinite increase
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An industry leader on a clear pathIn 2002, Eraring Energy began a revamp process to replace the original 1970s design hard-wired electronic control equipment and computer equipment at its Eraring Power Station, one of Australia’s largest. Inviting and evaluating proposals for the latest equipment from the major control systems suppliers, Eraring Energy chose Yokogawa.
“The ability to operate flexibly gives us a competitive advantage”
“Yokogawa took advantage of the flexibility of its equipment to suit the existing installation. Where possible, the new equipment slot-ted into existing cabinets, reusing existing field cables, termina-tions, cabinets, and connectors. New equipment was wired and tested in the factory. This avoided disturbing most existing cabling and greatly sped up installation and commissioning times.”
“The new control equipment makes fault finding a breeze, while the new graphic displays show us all the details we need.”
“The asset management system allows us to directly monitor and manage all smart field devices from our workshop.”
“The renovated units are now more flexible and responsive than before, giving the station additional advantages in a highly com-petitive electricity market. The refitted control room is state-of-the art and provides a quiet and stress free operating environment for our staff.”
Jeff Hogan, Instrument and Control Team Manager of Eraring Energy
New control room ( CAD drawing )
Test result of control performance(Load change 66 MW/minute, fixed pressure)
“Expectations exceeded, our plant was backin operation ahead of schedule”
Choose Yokogawa as your partner for operational excellence.Let us be vigilant about your business!
“Yokogawa has exceeded our expectations, bringing each revamped unit back into reliable service ahead of schedule. Utilizing a full replica simulator, our engineering team and Yok-ogawa fully tested the new logic and control configurations before they were loaded on the actual plant. This significantly reduced the time needed for site commissioning, and avoided plant trips during commissioning. Being thoroughly trained on the new screen-based control system training simulator, our operators were well prepared for the new control scheme in time for plant commissioning. This assisted in ensuring an uneventful, smooth return to service.”
Power plant simulator
Eraring Power Station, Australia ( 4 x 660 MW, coal fired )
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Michael Mortiss, Project Manager of Eraring Energy
“For flexibility, experience and commitment, we selected Yokogawa”
“Our decision to carry out the revamping project was based on the need to maintain a competitive advantage in the Australian deregulated electricity market. Maximizing plant availability for at least another 20 years, timely returns to service of each unit, and efficiency gains were also significant project drivers.”
“While there are several very capable control systems vendors, Yokogawa provided the most completely integrated solution of plant control system, training simulator, plant asset manage-ment system, and plant information and management systems.
Yokogawa’s flexible approach to design and implementation of large power plant revamp projects, team of experienced power plant engineers, and commitment to meeting all-important project outage schedules were further reasons for selecting Yokogawa.”
“We had already purchased other Yokogawa equipment such as transmitters and paperless chart recorders for our plant, and had received excellent service and on-going support.”
Michael Mortiss, Project Manager of Eraring Energy“Supported by the high-level operational and maintenance diag-nostics, together with strong local support from Yokogawa, we are sure that Eraring Power Station will secure high plant availability for a further 20 years.”
Faster load change, whilesecuring stable operation!
O2 Control(%O2)
Drum Level(mm)
Super Heater Temp.(degC)
Hot ReheatAverage Temp.(degC)
Main Steam Pressure(kPa)
Unit Demand(MW)
Output(MW)
[Ed:05/b] Printed in Japan,010(KP)
Subject to change without noticeAll Rights Reserved. Copyright © 2005, Yokogawa Electric Corporation
Fossil fired power plants
Gas turbine power plants
Renewable energy power plants
Plant services and/or plant simulators
Yokogawa service offices
Italy 400 MWcombined cycle
Romania180 MWcombined cycle
Turkey130 MWcombined cycle
China2 x 300 MWcoal fired
China 6 x 300 MW coal fired
India 2 x 600 MW 2 x 500 MW coal fired
India3 x 660 MWsupercriticalcoal fired
Algeria369 MWIWPP
Nigeria 530 MW & 2 x 450 MW simple cycle
Taiwan2 x 550 MWcoal fired
Korea9 x 100 MWcoal fired
Brazil 2 x 75 MW, oil & gas fired
Peru 650 MWcombined cycle
Venezuela 460 MW combined cycle
Bulgaria8 x 200 t/hflue gas desulphurization
Korea800 MW supercriticaltraining simulator
Japan2 x 1,050 MWflue gas desulfurization
U.S480 MW, combined cycle
U.S100 MW, combined cycle
Canada120 MW, cogeneration
U.S3 x 70 MW, gas & oil fired
Brazil 460 MW, combined cycle
Vietnam2 x 300 MW, coal firedsimulator & training
Japan 375 MW & 350 MW gas fired
Brunei110 MWcombined cycleThailand
2 x 110 MWcombined cycleSaudi Arabia
360 MWIWPP Australia
4 x 500 MWcoal fired revamping
Indonesia110 MW & 95 MWgeo-thermal
Singapore2 x 600 MWoil firedsimulator & training
Australia4 x 660 MWcoal fired revampingsimulator & training
Australia 4 x 550 MW brown coal fired revamping simulator & training
Mongolia8 x 420 t/hcoal firedrevamping & simulator
Spain800 MWcombined cyclew/ LNG terminal
UK37 MWWaste to energy
TrademarksCENTUM, Vnet/IP, vigilance and vigilantplant are either trademarks or registered trademarks of Yokogawa Electric Corporation.All other company brand or product names in this bulletin are trademarks or registered trademarks of their respective holders.
Represented by:
URL:www.yokogawa.com/pwr
Yokogawa Vigilance at your service worldwide - representative projects
