Emerson Process Management: Power Industry Solutions: Success Stories
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Our commitment to our customers is evident in everything we do, from our industry-leading products and services to our customer-focused project management strategies. Our philosophy involves performing all engineering and systems integration work under the supervision of a Europe-based Engineering Director, as well as assigning a dedicated Project Manager to serve as the single point of contact. The Project Manager ensures that technical and commercial terms are executed to meet customer requirements. We also maintain a staff of engineers who have extensive experience in project management, installation, and commissioning of DCS systems. To better serve our customers, a network of regional centers are designated to support our entire line of control system products. By listening to our customers and watching industry trends, we continually improve our strategies and technologies to keep our customers on the cutting edge.

Iberdrola Energia Solar De Puertollano SA Solar Plant

The Puertollano plant uses Emerson’s Ovation expert controls to monitor and control the solar plant with 2000 devices. Emerson’s project scope includes one Ovation control system with AMS Device Manager (2000 tags) and Hart analog I/O. Ovation is expected to provide the customer with maximum control of the steam and electricity production via real time command and monitoring of the 352 parabolic cylindrical mirrors in the solar field.

This is the third plant of its kind in the world, preceded by the Nevada Unit 1 64MW U.S. plant and the Andasol 2x50MW plant in Spain. The plants use large 70-100 meter horizontal parabolic semi-cylindrical mirrors mounted on steel structures that are laid in the terrain from north to south to follow the sun's path. The sun rays collected by these mirrors heat the thermal oil that flows through a pipe located in the mirror focus. The oil then flows through a heat exchanger producing the steam that drives the conventional steam turbine generator.

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Elektrownia Belchatow S.A. Units 3 and 4

At Belchatow, Emerson’s Ovation system will monitor and control each unit’s Sulzer-type boiler and balance of plant processes and equipment, as well as the 6kV and 0.4kV electrical switchgears and unit power output. In addition, the Ovation system will interface to each unit’s BBC-type turbine controls. For optimum productivity, plant operators will monitor both units from a central, integrated control room. In total, Emerson’s sophisticated control solution will monitor and control roughly 20,000 I/O points (10,000 per unit) via 24 Ovation controllers (12 per unit) and 18 workstations (nine per unit).

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Pietrafitta

Pietrafitta has been designed with an interesting combination of one gas turbine and two steam turbines. Using fieldbus technology, the configuration of the plant allows it to operate when one of the two steam turbines is not operating. Due to the many benefits that fieldbus technology provides, ENEL Production chose to apply this technology to all of its new combined cycle plants. Since all of ENEL's new plants would use fieldbus, it made sense to update the Instrumentation & Control (I&C) of all their existing plants. ENEL employed Emerson Process Management to install a DeltaV control system. Along with Ovation® and WDPF®, DeltaV® is the third distributed control system sold within Emerson’s Process Management family of companies. Using DeltaV allowed Emerson to provide ENELPOWER, the EPC contractor, a "turn-key" supply consisting in: DCS, ESD system (interfaced via OPC), Site activities (supervision to installation, commissioning, and start up), Control room, Foundation Fieldbus field instruments (170 Pressure transmitters and 40 DVC controllers).

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AES Tisza

AES Tisza goes beyond mere process control with our revolutionary PlantWeb digital plant architecture and the AMS™ Suite Intelligent Device Manager. Using HART field devices, the AMS Device Manager allows plant operators to diagnose and correct issues for the more than 600 control valves and field instrumentation before costly problems can occur. Emerson also installed SmartProcess® plant optimization software. AES Tisza chose Smart Process' Global Performance Advisor, which allows operators to identify controllable losses, track equipment performance against design specifications, and quickly identify problematic process areas to reduce operating costs.

Results

  • Reduced panel space, terminations, I/O cards, and wiring
  • Reduced total commissioning time
  • Reduced configuration time
  • Reduced costs due to preventive maintenance
  • Increased configuration and calibration savings
  • Increased productivity

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Termoelectrica Rovinari Power Plant Unit 3

By implementing PlantWeb, Termoelectrica has the ability to constantly monitor actual equipment condition and use the information to predict when a problem is likely to occur. This is made possible through the integration of intelligent HART and Foundation™ fieldbus instruments – including transmitters, analyzers and digital valve controllers – that use on-board microprocessors and diagnostic software to monitor equipment health and performance, as well as process performance, and indicate when a problem is going to occur or maintenance is needed.

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Zespół Elektrociepłowni w Łodzi S.A Lodz Unit 2

The Lodz II Regeneration Control Project marked the second installation of Ovation® expert control system in Poland, but the first for Elektrocieplownie Lodzkie S.A. Based on its state-of-the-art technology and proven potential to minimize overall operating costs, the Ovation system by Emerson Process Management was chosen as the control system for Lodz.

All applications use Ovation R-Line I/O combined with Ovation controllers and Emerson-designed control logics. Approximately 15 graphics were developed to visually depict the process on the operator workstations. Best of all, Ovation’s open architecture opened the door for future communications between sites, with the potential for future expansion at other plant units owned by Elektrocieplownie Lodzkie S.A. By combining various plant networks, system troubleshooting can be easier than ever before.



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IBERINCO Energy Works Project

Emerson Process Management was selected by General Electric to supply an Ovation® expert control system to the Energy Works Polycarbonate Plant in Cartagena, Spain. The project consisted of a distributed control system upgrade for the 95- megawatt combined cycle, co-generation facility, which provides power to the GE’s Cartagena plastics plant.

The Ovation system enables the Energy Works Facility to operate continually, and avoid costly plant downtime. Additionally, the redundancy and modularity of Ovation delivers reliability and allows plant staff to conduct necessary plant repairs and maintenance while the system remains online. With Ovation, IBERINCO realizes the ability to maintain optimal, uninterrupted processes.

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RAO UES Volzhskaya Hydro Power Plant

Emerson will act as the general contractor for design, delivery, installation and startup of the Ovation system, as well as field instruments, cabling, local control panels, electrical protection systems and a vibration monitoring system by Bently Nevada. Conclusion of the Unit 8 modernization is only the beginning of the Emerson relationship with Volzhskiy Cascade Management Company and RAO UES Russia. Upon completion of the trial project on Unit 8, RAO UES Russia will standardize on Emerson solutions and Ovation expert technology not only for the remaining 21 Volzhaskaya HPP units, but for eight other hydroelectric plants throughout along the Volga River as well.

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Lietuvos ENERGIJA Elektrenai Power Plant Unit 6

Ovation’s coordinated control application was installed to optimize the entire power generation process by selecting an operating mode that most effectively meets current power demands. Coordinated control is a cost-effective means to maximize plant efficiency by unifying the boiler and turbine operation control. Elektrenai’s use of coordinated control will align boiler and turbine operations to meet load demands at the highest possible level of efficiency, permitting local (plant control room) or remote (dispatch center) operation.

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