national summit on waste to energy technology - companies...

Amit Rastogi Valmet Automation Hyderabad February 03, 2017

National Summit on Waste to Energy Technology - Companies & Equipment Providers

This is only 1-2% of the whole

power plant investment – but it has

big impact to the success of the

whole project.

Also, it plays the big role for the

whole lifecycle of the plant.

Control System/Automation System (DCS)

Contents

Valmet today

Offering

Automation for WtE Industry

1

2

4 Automation references, WtE & Biomass

3

Summary 5

Valmet Leading global developer and supplier of process technologies, automation and services for the pulp, paper and energy industries

Our mission

6

Converting renewable resources into sustainable results - defines our

core purpose

Recycled paper

Agro

Wood

Renewable

raw materials used

by our customers

Waste

Pulp

Paper

Board, tissue, paper

and new paper grades

Chemical pulp, mechanical

pulp, dissolving pulp

and biomaterials

Electricity, heat

and biofuels

End products

of our customers

Energy

Valmet Energy Solutions

7

Services • Reliability services

• Performance services

• Rebuild and upgrades

services

• Long-term service

agreements

Valmet`s energy solutions

Process Technologies

Services Automation

Customer

■ Efficient project delivery ■ Reliability ■ Performance

Process Technologies • Boiler plants

• Gasification plants

• Modular power plants

• Heat plants

• Air emission control

Automation • Distributed Control System

(DCS)

• Performance solutions

• Turbine automation

• Analyzers and

measurements

• Industrial internet solutions

Automation offering for Power Industry

Specialized expertise in energy industry

2016 © Valmet | Automation Business Line 10

COMBINED CYCLE

High availability,

emission minimizing,

flexibility

GASIFICATION

High cycle efficiency, high

availability

WASTE-TO-ENERGY

Maximizing waste disposal,

emission management,

environmentally efficiency

COAL FIRED

High availability, emission

minimization, combustion

optimization, flexible usage

COGENERATION

Flexibility, steam network

management, high

availability

HYDRO POWER

Efficiency, availability,

river optimization

Automation professionals in market areas 1,600 automation professionals

© Valmet | Automation Business Line 11

766 Nordics

69 South

America

222 North

America

108 Asia-Pacific

345 EMEA

112 China

Automation headcount - March 2015

Valmet DNA for WtE plants

- Wide range of products and solutions

- Highlights of our DCS system

- Special applications for WtE Plants -

(or other difficult fuels)

- Vibration monitoring system

Valmet Automation - your partner for WtE Plants We deliver automation for all kind of plant types!

13

We provide innovative system technology and services, e.g. advanced process

controls, advanced emission monitoring and authority reporting, support your

• Sustainable and safe energy production with lower emissions

• Improved energy and materials efficiency

• Improved operational efficiency

Bubbling Fluidized

Bed Boilers

Gasification Solutions

Grate Technology

Boilers

Valmet Automation The Right Solution, with Clean Technology

14

99,98% Availability

Reduced

Shutdowns

High

Performance

Waste Incineration

Expert Teams

Optimized

Combustion

Minimized

Emissions

87 Engineering

& Service Centers

close to you

24h Service

Engineering

Cost optimization

For your Success!

Advanced Process

Controls

Distributed Control

System

Information

Management Solution Condition and

Runnability Monitoring

Steam Turbine

Controller

MR Moisture Analyzer

for Biomass

Automation solution for thermal power plants

Boiler Corrosion

Manager

Valmet DNA

15

One system for all your needs!

Valmet

Corrored

Valmet

CorroStop /

Valmet Fuel

Diet

Valmet DNA Valmet DNA Valmet DNA Valmet DNA Valmet DNA

One system for all automation in power generation

Valmet DNA

© Valmet | 16

1979

Damatic

”Classic”

1988

Damatic XD Damatic XDi

1996

metsoDNA

2000

Metso DNA

CR

2006

Metso DNA

2011

Valmet DNA

2015

• Application compatibility since 1988

• Connectability

• Upgradeability

• Openness

• Same platform for all applications

• User friendly

• Flexible

• Reliable

• Long experience of developing control systems

Upgradeability with innovative evolution

© Valmet | 17

Valmet DNA redundancy

Redundant hard disks and

backup tape device

• Backup Power Supply for

- control node cabinets and rack I/O’s

• Optional power backup for

- control room devices and servers

Redundant

process

controller

Redundant

hard disk

• Redundant Field Bus

• Redundant I/O power

supply per rack

Redundant PLC

interface

Profibus DP

devices

PCS PCS GTW-LIS GTW-LIS PCS

Redundant control room bus and process bus

Information Server Operator Interface Engineering Server Alarm Processing

• Redundant power supplies

and Interface controller

•Redundant M120 I/O units

Availability up to

99,98%

Valmet DNA with SIL3 Boiler Protection System

2014 19

Ethernet network

• name based

communication

Redundant

controller with safeethernet

communication layer

-Communication using

HIMA tag names

-Time stamped data from

HIMax

Field devices 4-20 mA with HART

• HIMA (HIMax, HIMatrix or

M45) connected to Valmet

DNA Ethernet network with

safeethernet communication

Control room

• access to

HIMA data

in Valmet DNA

process controller

Windows Server

• engineering

database

• HIMA engineering

(SILworX) integrated

Windows WS

• engineering

tools

• Field Asset Management

Salient Feature of Valmet DNA System

Valmet DNA Feature

• Max. power plant functionalities in same system. DCS, Turbine Controller,

Vibration Monitoring System, Safety System etc in the same system.

Advantages:

- Seamless data integration, all functionality on the same platform;

- Inventory Management;

- Engineers trained on Valmet DNA can handle complete plant maintenance.

• Work Station based Architecture

• Industry standard workstation can be directly connected on communication

bus without any proprietary interface (Protocol conversion) card.

• Controller with 1024MB RAM and 1.86GHZ.

• Up to 256 Modules/Controller

• Fast control cycles, as low as 20 ms

50 ms to 1 sec

• As fast as 200 millisecond trends can be offered for some critical data

points

• Trend available in all stations

Salient Feature of Valmet DNA System

Valmet DNA Feature

• Operating Temp of l/O modules: 0 … +70°C

• Digital I/Os with max16 Ch/modules.

• DI/Os with status indication LED for each channel on the module.

• Latest M80 I/Os

• No mixing for Input/ output in a module

• Direct MODBUS (Rs485) and industry standard protocol connectivity with

Third Party Systems/ PLCs

• Communication speed between various I/O racks is identical.

• Integrated Sequence of Event Recording (SOE)

• SOE Viewing in all stations

• All Digital input modules with provision of 2 ms or faster time stamping in real

time on the card - alarms and causes can be analyzed accurately.

Valmet DNA - Operator Interface

Date Author Title 22

Description CSP FGT Common Sum

Process Graphic Displays 40 40 25 105 Monitor Windows 30 30 35 105

Sequences (5 steps) 10 5 5 20



Info Archive Licence Data Points 1000 1000 2000 4000

Shift, day, week, month report 2 1 2 5

Customized report page 2 1 2 5

Process Data Entry page 2 2 0 4

Difficult processes require easy operation

Valmet DNA Operate Operation tools for efficient problem solving

Efficient alarm analysis with 1 or 2

ms Sequence of Events (SOE) for

all the DI – segregation not

necessary

Replay history from any picture,

“time machine”

Drag and drop trend analysis

Dynamic function and interlocking

descriptions for machine and

process

Multilingual control room

23

Start History mode

Select displayed

moment and replay

History mode

indication

Feeling of

control

Valmet DNA Combustion Control System CCS


Navigator for Crane Driver

Not just basic automation – we implement our know-how!

Some APC solutions in Valmet DNA for power generation

25

Turbine

controls

Pulverized coal

fired combustion

optimization

Condition

monitoring

Sootblowing

optimization

DNA Training Simulator 100% match to real controls

• Virtual Valmet DNA can be executed on ordinary office PCs or laptops

• Process control configuration and user interface can easily be copied from

control system to DNA Training Simulator

26

• Exactly the same user interface both in DNA Training Simulator and on real

Valmet DNA system

Valmet DNA Machine Monitoring Prevent unplanned downtime by machine health monitoring

Vibration based condition monitoring for rotating

machinery in Valmet DNA automation system

Common user interface for process control and

condition monitoring

– Easier to use and share information between operation

and maintenance

Common history database for all process and machine

condition data

– Efficient analysis and reporting

One system and one engineering environment for

condition monitoring and process control

– Cost efficient to build and maintain

27 © Valmet |

Typical condition monitoring measurements

28

Steam turbine generator

• Relative shaft vibrations (x-y)

• x/y positions (GAP voltage)

• Absolute bearing vibrations (x-y-z)

• Axial positions (z)

• Differential expansions

• Absolute expansions

• Shaft eccentricity

• Tachometer

• Process parameters

Process specific auxiliary

equipment, e.g.

• Boiler HP feed pumps

• Circulation water pumps

• Exhaust air fans

• Fresh air fans

• Primary air fans

• Secondary air fans

• District heating pumps

• Booster pumps

© Valmet |

Plant Management applications

- For advanced reporting and calculations

- Analyzes of power plant performance

• Power plant management

• Production

• Operation

• Maintenance

• Environment

Dive into details of the plant performance

Valmet DNA Performance Monitoring for boilers and steam turbines

Enables following the real-time performance of main

equipment in real-time

The efficiency calculated based on real-time measurements

2016 © Valmet

Valmet DNA performance monitoring

• Key Performance Indicators (KPIs e.g.

heat rate, efficiency) solved for plant,

boilers, steam turbines, pumps and fans,

heat exchangers

• Calculations in accordance with accepted

standards (EN, ASME, ISO)

• To secure best performance and

availability of boiler, can be extended with

DNA Soot Blowing Manager or with the

DNA Fatigue and Creep Monitoring Improved efficiency,

maximized availability

Monitoring of operation point deviations Comparison to expected values

© Valmet | 31

Effect on efficiency Effect on costs

Report exported to Excel and PDF by one click

32 © Valmet |

Customer’s process

Today, customers are extensively utilizing our Industrial Internet capabilities

February 4, 2017 © Valmet 33

Online

connections with

customers

Performance

agreements with

remote

connections

Co-creation of

advanced

analytics with

customers

Information

management

system delivered

since 1985

480 Collaboration to

3rd party systems

80 Advanced

process control

installations

320 1000+ Ongoing

Valmet’s remote center

Valmet’s competence

network

100+

Plant Data Server

Plant Data Server

Plant Data Server

Performance Cloud System architecture Data management process


Performance Center

Service

Performance

Monitoring Platform DNA Historian

Power plant A Power plant B Power plant C

DNA Historian 3rd party DCS

Data Collection and Calculation Environment

DNA Historian

Reporting and Analyzing Environment

DNA Report

Valmet VPN for partners

Customer specified users

Valmet IT Network

Dashboards for users/roles

35

Maintenance dashboard

Summary Diary

Deeper alarm statistics

Site 1 Site 2

Site 1 summary Site 2 summary

HQ dashboard

Performance Limits

Design Target

Plant manager dashboard

© Valmet |

Available Report

widgets

Selected Project delivery references

- Waste-to-Energy Power Plants

Over 1,000 power plants worldwide utilize Valmet’s process automation


Power plant

installed base

Includes Valmet’s systems delivered by partners

EMEA 371

Biomass / multifuel 86

Coal fired power plant 78

Combined cycle power plant 61

Hydro power plant 11

Oil & gas fired power plant 65

Solar power plant 14

Waste-to-energy plant 56

APAC 476

Biomass 3



Hydro power plant 85


Waste-to-energy plant 2

NA 110

Biomass / multifuel 3




Sweden •Åmotfors Energi Ab

Estonia • Eesti Energi AS, Tallinn

UK • Ineos Runcorn, Manchester phase 1

• Ineos Runcorn, Manchester phase 2

• MES Environmental, Dudley

• MES Environmental, Wolverhampton

• Waste Recycling Group, Lincolnshire

• Veolia Environmental Services, Staffordshire

•Veolia Environmental Services, Shropshire

•Veolia Environmental Services, Leeds

•Viridor, Oxfordshire Ardley

•Viridor Cardiff

• Cory Environmental, Riverside London

• Veolia Environmental Services, Newhaven

• Sita, Cleveland 4&5

•SSE Ferrybridge Multifuel project

•Dundee Energy Recycling, Dundee

• RWE Markinch, Glenrothers

• London Waste, London

•WtE Peterborough

Austria • A.S.A., Zistersdorf

• AVE Wels II

• AVE Wels I

• AVE Lenzing

Italy •Trattamento Rifiuti Metropolitani, Turin

• Veolia, Piacenza

• Veolia, Energonut Hitachi Zosen Inova (former Von Roll Inova)

Keppel Seghers

CNIM

Valmet Power

Posco

Other technology or automation replacement

Norway • BIR Avallsenergi, Bergen

Waste-to-Energy references in Europe About 50% market share

© Valmet |

38

Finland • Westenergy Oy Ab, Vaasa

•Ekokem, Riihimäki

•Lahti Energia

Poland • LECH, Bialystok

• Krakow Waste, Krakow

WtE Plants references in Korea

Busan Environment Incinerator, 1996

Busan Haeundae Incinerator, 1997 / 2013

Jeounju Incinerator, 1996 / 2015

Icheon Incinerator, 2006

Geoje Incinerator, 2006

Chungwon Incinerator, 2008

Anyang WtE Plant, 2013

Daegu RDF Plant, 2015

Several others by our local partners

Valmet supplied first ones already 20 year ago

2007-2016:

12 Waste-to-

Energy plants

delivered

Example project: Riverside Resource Recovery Ltd,

London - England

Delivery Scope from Valmet:

The Valmet DNA automation

and information system monitors

and controls total plant operation

Integrated HIMA System

Results

• Electrical efficiency

of 27% expected to

exceed

• Increased energy

recovery

• Decreassed

emissions

Hitachi Zosen Inova W-to-E plants run with Valmet’s DCS

Hitachi Zosen Inova is a leading global

technology provider and contractor in

the field of Energy from Waste facilities

Plant sections and turn-key plants from

design to construction and operation &

maintenance & overhaul

Close to 500 W-to-E plants delivered –

mostly in Europe and Asia


Process Data of the Plant

Incinerator Units: 3

Waste Throughput: 29,8 t/h / Line

Average Heat Value: 9.600kJ/kg

Thermal Power: 81 MW / Line

Steam Production: 96 t/h / Line

Electr. Power of Turbine: 73MW

Valmet References WtE HZI.pptx






Start up: 2009

General Supplier:

Hitachi Zosen Inova AG

Owner:

A.S.A.

Plant Location:

Zistersdorf, Austria

Technology:

Grate 57,8 MWth; 405C; 42bar; 12,18MWel; 135.000t/a municipal waste

Delivery Scope of Valmet Automation:

•ValmetDNA Automation System (signals 2200HW, 800GW)

•Information Management Solution

ASA, Zistersdorf

Start up: 2010

General Supplier:

Von Roll Inova

Owner:

BIR

Plant Location:

Bergen - Norway

Technology:

Grate, 2x45 MWth, 2x110 000t/a municipal waste, 2 steam turbines


•ValmetDNA Automation System (4200 Signals)


BIR, Bergen

Start up: 2012

General Supplier:


Owner:

Riverside Resource Recovery Ltd.,

subsidiary of Cory Environmental

Plant Location:

Belvedere, London, UK

Technology:

Grate 3x81 MWth, 427C, 72bar, 65 MWel, 585.000t/a municipal waste


•ValmetDNA Automation System (signals 4000HW, 1000GW, 11000 profibus DP))


Cory, Riverside

44

Start – up: 2012

General Supplier:


Owner:

Veolia Environmental Services

Plant Location:

Newhaven - UK

Technology:

•Grate 2x36 MWth, 400°C, 50bar, 2x19,4 MWel, 2x105.000t/a waste

Delivery Scope Valmet Automation:

•ValmetDNA Control + BPS System (signals 2300HW, 350GW, 2850 Profibus DP)

•Information Activity Server

Veolia, Newhaven

45

Start – up: 2012

General Supplier:


Owner:

Westenery Oy Ab

Plant Location:

Mustasaari, Finland

Technology:

•Grate 61 MWth, 400°C, 40bar, 13 MWel, 150.000t/a waste


•ValmetDNA Control + BPS System (signals 2300HW, 250GW, 1400Profibus DP)


Westenergy, Vaasa

46

Start – up: 2013

General Supplier:


Owner:

SITA South Tyne and Wear Ltd.

(part of SUEZ group)

Plant Location:

Tees Valley, Billingham, UK

Technology:

•Grate 2x45,85 MWth; 410°C; 50bar; 24,2 MWel; 2x152.000t/a waste


•ValmetDNA Control + BPS System (signals 3000HW, 2500 via Profibus DP and GW)


SITA, Tees Valley unit 4 & 5

47

Start – up: 2013

General Supplier:


Owner:

Ferrybridge Multifuels Energy Ltd.

Plant Location:

Knottingley, West Yorkshire - UK

Technology:

•Grate 2x117,4 MWth; 430°C; 70bar; 76,5 MWel; 2x250.000t/a waste


•ValmetDNA Control + BPS System (signals 6000HW and Profibus DP, 2300GW)


SSE, Ferrybridge

48

Start – up: 2015

General Supplier:


Owner:

FCC Environment, Northampton

Location:

Calvert, Buckinghamshire – UK

(Greatmoor EfW Facility)

Technology:

•Grate 102 MWth; 402°C; 51,5 bara; 28,2 MWel; 300.000t/a

waste


•ValmetDNA Control System incl. Information Activity Server

•Integrated Boiler Protection System

FCC, Buckinghamshire

49

Start – up: 2016

General Supplier:


Owner:

Mercia Waste,

Location:

Hereford & Worchestershire – UK

Technology:

•Grate 68 MWth; 415°C; 58,5 bara; 20,4 MWel; 220.000t/a

waste


•ValmetDNA Control System incl. Information Activity Server

•Integrated Boiler Protection System

Mercia Waste

national summit on waste to energy technology - companies...

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