Emerson Process Management: Power Industry Solutions: Success Stories
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Combining best-in-class service with the most respected technologies in the industry, our solution offers preeminent designing, manufacturing, installing, and servicing of advanced, process automation architectures for a variety of industries. With more than 3,500 systems worldwide, our versatile, high-performance distributed control and information systems are recognized industry leaders.

China Huadian Zouxian Units 7 and 8

Use of the cleanest, most efficient, and most advanced plant equipment required an equally exceptional automation solution in order to maximize the units’ operation. Because this is one of the first ultra-supercritical projects implemented in China, the new Zouxian units needed a proven, state-of-the-art control solution backed by superior technical expertise. A solution based on Foundation™ fieldbus technology, another first installation in China, was imperative to the project’s success.

Emerson’s PlantWeb® digital plant architecture utilizes high-speed communications networks, intelligent field devices, asset management software, and bus I/O technologies to help power producers control critical plant processes, increase plant efficiencies and megawatt production, and realize long-term operations and maintenance savings. PlantWeb offers additional advantages to power generators such as China Huadian: by lowering wiring costs, and streamlining device installation, communications verification and troubleshooting, this digital bus-based approach translates into faster startup, and reduced startup and commissioning costs.

Results

  • Contributed to 22.6-month construction period of 1000-MW ultra-supercritical unit
  • Achieved record-setting 23-day commissioning time due to smooth startup and performance of the Ovation expert control system
  • Completed aggressive project schedule 9 months ahead of planned conclusion

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Huaneng Power International Yuhuan, China's First 100 MW Ultrasupercritical Unit

The Yuhuan Ovation system encompasses over 9,000 I/O points per unit with an additional 4,000 common I/O for a total of 42,000 I/O points for the entire plant. The system uses a Fast Ethernet Ovation Network that connects to over 120 Ovation Controllers and 50 workstations for plant operation, engineering, and historical functions. Advanced Ovation algorithms were implemented to help maintain constant steam temperatures within a narrow set point bandwidth during routine dynamic load changes.

Emerson Process Management successfully provided Huaneng Power International with a proven automation strategy for Yuhuan, China’s first plant to use ultra-supercritical technology. Emerson’s solution consisted of an Ovation® expert system for control and monitoring of all major plant equipment, including boiler, flue gas desulphurization, generator, and balance of plant processes. Specifically, the following applications were implemented for the Yuhuan units:

  • Data Acquisition and Monitoring
  • Sequential and Modulating Control
  • Automatic Startup and Shutdown Sequencing
  • Furnace Safeguard Supervisory System
  • Electrical Control

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Mirant Corporation Pagbilao Power Station Units 1 & 2, Quezon, Philippines

Mirant had two options for upgrading the Pagbilao plant. They could replace both existing systems with an entirely new control system, or they could migrate their existing WDPF system to Emerson’s latest technology, the Ovation® expert control system, and replace the existing burner management controls with the new Ovation technology.

Mirant chose a WDPF-to-Ovation migration because of the successful history and reliability with the existing WDPF system, and because Emerson maintains a long-term system lifecycle plan. Mirant was particularly satisfied with Emerson’s commitment of long-term support for the Q-Line I/O, which continues to be classified as a current product. By migrating to Ovation, the total cost impact of the project was reduced. Also, much of the existing inventory of spare parts stocked at the plant could continue to be used with the Ovation system.

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LANCO Amarkantak Units 1 and 2

With coal being an abundant and low-cost energy source in India, LANCO is focused on making the Amarkantak Project its pioneering entry into coal-based power generation. The Project is being developed in phases to ultimately become a 1200 MW Power Project. In terms of its size, choice of fuel, strategic captive mining and project design, the Amarkantak Project is set to emerge as a trend-setter in the Indian IPP sector.

Emerson Process Management received the contract to digitally automate the new Amarkantak Power Plant by installing its PlantWeb® digital plant architecture with the Ovation® expert control system. China-based Dongfang Electric Corp., the project’s EPC contractor, awarded the contract to Emerson. Unit 1 is scheduled to begin commercial operation in June 2008, Unit 2 is expected to go into service July 2009.

Emerson's Power & Water Solutions industry center is coordinating and supervising the project. Emerson’s comprehensive PlantWeb solution includes deployment of the Ovation control system for data acquisition, as well as for monitoring and control of the modulating control system, sequence control system, furnace safeguard supervisory system and electrical control system for all major plant components, including the boiler, turbine and balance of plant processes.

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Korea South-East Power Company (KOSEP), Yonghung Units 1 & 2

South Korea consumes about 15 gigawatts of energy each year, half of which goes to the country's largest and most densely populated city, Seoul. With annual energy consumption growing at eight percent, Korean power generators must take steps to maintain high levels of availability and reliability to maintain cost-effective production. The Yonghung power plant is part of KOSEP's strategy to maintain low-cost, high-quality electricity for Seoul's metropolitan area. Newly constructed and online in 2004, Yonghung Units 1 & 2 were built to be the ultimate example of the next generation of clean-burning, highly efficient power plant operations. The plant is required to exhibit above-average heat rate; short hot and cold startup times; environmental protection; operational and fuel savings; and state-of-the-art technology. Emerson Process Management provided a total plant solution based upon the PlantWeb digital plant architecture. The plant's Integrated Control and Monitoring System (ICMS) consists of an Ovation® expert control system that manages all plant systems including boiler control, burner management, data acquisition, motor control and balance-of-plant processes. In addition, to the control system, the ICMS also incorporates an advanced, high-fidelity Ovation® simulator, SmartProcess® plant optimization technology, and AMS™ Suite: Intelligent Device Manager.

Results

  • Completion of plant testing and startup approximately 3 months ahead of schedule
  • Lowest SOx, NOx and dust emissions of all the thermal power plants in Korea
  • Minimization of cabling and maintenance costs due to simplified circuitry

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Handan Iron and Steel Group Iron Making Plant

Targeting on "high speed, high efficiency, high quality and high returns," HISG selected Emerson’s Ovation expert technology to control the blast furnace operations at their Iron Making plant. The plant’s Ovation system will provide automatic control of the blast furnace process, thus optimizing plant operations and increasing reliability. Blast furnace control is a multifaceted and dangerous activity that needs to operate non-stop for 24 hours per day, seven days per week. Any interruption can mean financial losses as high as thousands of dollars per day. That is why HISG selected Emerson’s expert controls with inherent redundant features to ensure the operations would never fail.

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China Huadian Wangting Combined Cycle Plant

The China Huadian Group chose Emerson Process Management’s proven PlantWeb® solution for the Wangting plant. The Ovation® expert control system powers the new system, and as part of the PlantWeb architecture, includes the AMS Suite for asset management and FOUNDATION™ fieldbus for communication and predictive intelligence. At Wangting, Emerson installed a redundant Fast Ethernet network, eight redundant controllers (four per unit), 10 Ovation workstations (five per unit), Hart intelligent field devices, Rosemount Foundation fieldbus temperature devices, and AMS Suite: Intelligent Device Manager. Ovation controls applications throughout the plant, including data acquisition system, sequence control, electrical control, and the main control system.

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Harbin Water Supply and Drain Company, Water Treatment Plant and Reservoir

At Harbin, PlantWeb with the Ovation expert control system, Foundation™ fieldbus intelligent field devices, and SCADA (Supervisory Control and Data Acquisition) system with integrated AMS™ Suite: Intelligent Device Manager, will provide continuous monitoring and control of the new plant and reservoir complex, as well as monitoring and control of 14 existing remote wastewater plants and pump stations that are part of the wastewater collection system. In total, Emerson’s Ovation system will monitor and control roughly 20,000 I/O points. Emerson will install two redundant networks, five redundant controllers, one redundant SCADA server, 48 laptop PCs, 24 operator stations, two remote terminal units and 142 Foundation fieldbus intelligent devices including Rosemount® transmitters and Rosemount Analytical instruments.

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