process control systems

Power Distribution Control Systems

Power Station Control Systems

Control Room Technology

Automation Equipment

Reference List

Process Control Systems forPower Plants

Contents Page

General Information 4

Generating Unit Control Systems 7

Fail-Safe Burner Control 9

Turbine Control Systems 10

Flue Gas Desulfurization Plants 13

Hydropower Stations 14

Coal Feeder Plants 18

Water Treatment Plants 19

DeNOx Plants 20

Ammonia (NH3) Tank Farms 20

Waste Incineration Plants 22

Expert Systems 23

Soot Reinjection Plants 26

Block-Type Thermal Power Stations 27

Building Services Control 28

Gas and Steam Power Plant 30

Power Plant Simulators 31

3

4Demands on Modern Automation Today, in all fields of engineer-ing, industrial production which is economical and at the same time goes easy on resources and environment is not possible without a high degree of automa-tion. Process control systems used for the automation of power stations must meet particularly high requirements for increased availability, large functional range and decentralized architecture.

Our ME 4012 process control sys-tem meets these high demands. Not only does it provide all the facilities necessary for the acquisi-tion, preparation and processing of plant data; it is also equipped with sufficient intelligence for sequence and closed-loop control tasks and for the monitoring and optimization of plants and plant components.

Observation, monitoring and operator control of the plant as a whole are done in a central control room equipped with monitors. The architecture of the ME 4012 process control system is based on the decentralized, redundant SUB-NET process bus, the AE4012 programmable controllers and the ME-VIEW operator control and process monitoring system.

ME 4012 structures the entire process in a hierarchy of horizontal control levels thus fulfilling the different tasks of the plant:

Interfacing to plant and processes

Sequence, logic and closed-loop control of individual drives

Individually automated function groups providing a high degree of plant automation

In addition, the plant is sectioned vertically into a number of functional units. This division is governed by criteria such as:

Process correlations

Standby requirements

Minimization of signal exchange

ME 4012 ensures complete standby facilities in the areas of data communication and operator control.

Economical Solutions The hardware of the ME 4012 pro-cess control system is of modular design. Therefore, with ME 4012 you will be able to find a made-to-measure solution for your specific problem whatever the automation task is.

Economical solutions for small ap-plications may comprise just one AE 4012 programmable control-ler. These can be expanded as required, responding to increasing demands in the areas of:

Plant and process control

Geographical expansion

Standby and redundant configurations

Plant automation

Auxiliary machinery can easily be integrated using the programmable controller which is compatible with the process bus and can be configured and programmed by the machine manufacturer.

Field-proven Solutions and Technological Know-how

For many years now, our applica-tion experts have proven their experience and know-how in the design of automation and process control schemes for technological processes in the fields of:

Block-type thermal power sta-tions (lignite or coal boilers)

Fail-safe burner control (oil, gas or coal)

Steam turbine control

Gas turbine control

Flue gas desulfurization

DeNOx plants / Ammonia (NH3) tank farms

Coaling plants, supply and disposal installations

Waste incineration

Water treatment

Water power stations

Training schemes for power station control

General Information

5Field instruments and installation For all applications mentioned in this Reference List we supplied the control system (inner plant control). In almost all cases, we also pro-vided, installed and commissioned the complete instrumentation, measuring and control equipment for the process peripherals. This includes in particular the transduc-ers for measured quantities such as temperature, pressure, flow, level, water and flue gas analysis, revolutions per minute, position etc.

Equipment and systems are usu-ally installed by our own personnel. Our responsibilities also cover the installation of hook-ups according to our own design, and all pipe-work in connection with stepping lines, which is mostly welded and always carried out using standard and quality-approved conduit material. The frames required for the installation of transducers and the cable subdistributors are manufactured by ourselves to the highest quality standards and adapted to the specific application.

Inline components such as control valves, fittings, covers, nozzles etc. were purchased and provided by us according to the specification of the plant supplier or planning engineers, ready for being installed by the plant supplier.

After completion of all mount-ing and installation work by our personnel, we commissioned the systems and finally provided a complete set of system documents

according to the high technical VGB Standards, R 170 C (VGB = German Association of the Power Station Industries).

Hydraulic Mechanical Systems The scope of our services comprises:

Planning and layout of hydraulic components and systems

Design and delivery of hydraulic mechanical components

Optimization tests of all hydraulic components in our own testing bays before they are shipped

Modernization of hydraulic systems (units, pipelines, control modules) and adaptation on existing machines

Commissioning of hydraulic systems and plants

Delivery and installation of all systems required for turbine strain, vibration, speed, etc. measurement

Maintenance services after project completion

Training of customer personnel for direct plant maintenance/monitoring

Our project engineers prepare hydraulic diagrams, define the component specifications and develop concepts for the con-structing engineers. The configu-ration and design documentation is created with 3D (Solid Works Software (SW)) and 2D (Auto CAD Software) systems.

6Coal power station

Computer Animation Power Plant

Computer Animation Power Plant

Brown coal-fired power plant Boxberg Unit RBase load operation Availability: > 91 % Controllability: 50 % to 103 %High level of automationTransmission Code complianceNet efficiency> 43.7 % Live steam: T = 600 C; p = 285 bar IS steam: T = 610 C; p = 52 barCoal consumption: 4.5 million t/aSpecific CO2 emissions: 924 g/kWh

Hard coal-fired power plant Moorburg Unit ACombustion heat output: 3700 MW max.

Combustion heat output: 3354 MW under design cond.

Gross electrical output: 1654 MW under design cond.

District heating output: 650 MW max.

Live steam: T = 600 C, p = 276 bar

IS steam: 610 C, p = 52 bar

Controllability at load operation: 35 to 103%

Hard coal consumption: 480 t/h; 4.21 million t/a approx.

Ashes produced: 63 t/h; 0.56 million t/a approx.

Hard plaster produced: 18 t/h; 0.16 million t/a approx.

Flue gas desulfurization

Induced draft Electric filter Steam generator Power houseCooling tower with flue gas passes

7Generating Unit Control SystemsExcerpt

Customer Location Block Output Power Mechanical Engineering

E.ON Kraftwerke Ingolstadt 3+4 420 MW each EVT

GDF Suez-Gruppe Zolling 5 450 MW VKW-Babcock

E.ON Kraftwerke Irsching 3 300 MW EVT

STEAG-RWE Voerde A 750 MW Auxiliary plant

STEAG-RWE Voerde B 750 MW Auxiliary plant

STEAG-VEW Bergkamen 750 MW Auxiliary plant

swb Bremen-Hafen 6 320 MW EVT

E.ON Kraftwerke Shamrock 1 130 t / h Babcock

E.ON Kraftwerke Shamrock 2 130 t / h Steinmller

E.ON Kraftwerke Shamrock 3 130 t / h EVT

E.ON Kraftwerke Shamrock 4 130 t / h Drr

E.ON Kraftwerke Scholven FWK-Buer District heating Steinmller

Stadtwerke Duisburg HKW III District heating Standardkessel

Daimler Benz HKW I District heating EVT

Eletrosul, Brasilien Jorde Lacerda lll 5 125 MW Skoda

Eletrosul, Brasilien Jorde Lacerda lll 6 125 MW Skoda

Kasseler Fernwrme Kassel 2 Fluidization 180 t / h Lurgi / Lentjes

AllessaChemie Frankfurt 1 Process heat Steinmller



swb-Erzeugung Mittelsbren 4 240 MW EVT

Freundenberg Service Weinheim 5 45 t / h Standardkessel

Vattenfall Europe Boxberg R 700 MW Hitachi Europe

Vattenfall Europe Moorburg A 820 MW Hitachi Europe

Vattenfall Europe Moorburg B 820 MW Hitachi Europe

8Computer Animation Power Plant Boxberg

Waste Incineration Plant

9Fail-Safe Burner Control Excerpt

Customer Location Block Output Power Mechanical EngineeringE.ON Kraftwerke Ingolstadt 4 420 MW EVT E.ON Kraftwerke Ingolstadt 3 420 MW EVT GDF Suez-Gruppe Zolling 5 450 MW VKW-BabcockE.ON Kraftwerke Irsching 3 300 MW Balcke Drrswb HKW Hafen 6 320 MW EVTswb HKW Hastedt 1 100 t / h MACCIswb HKW Hastedt 2 100 t / h MACCIswb Mittelsbren 4 240 MW BabcockE.ON Kraftwerke Scholven F 750 MW EVTE.ON Kraftwerke Scholven FWK-Buer District heating SteinmllerE.ON Energy f. Waste Stapelfeld 1 165 000 t / a SteinmllerE.ON Energy f. Waste Stapelfeld 2 165 000 t / a SteinmllerKasseler Fernwrme Kassel 2 Fluidization 180 t / h Lurgi / LentjesFreudenberg Service Weinheim 3 Process heat EVTFreudenberg Service Weinheim 4 Process heat EVTEletrosul, Brasilien Jorde Lacerda lll 5 125 MW SkodaEletrosul, Brasilien Jorde Lacerda lll 6 125 MW SkodaRWE Wesseling 1 Process heat Balcke DrrRWE Wesseling 2 Process heat Balcke DrrRWE Wesseling 6 Process heat Balcke DrrTechnische Werke Stuttgart 23 35 MW BabcockGemeinschaftkraft-werke

Veltheim 1 100 MW Balcke Drr

Gemeinschaftkraft-werke



Veltheim 3 300 MW Babcock




Veltheim HK 35 t / h Eisenw. Baumgarte

AllessaChemie Frankfurt 2 Process heat SteinmllerCasella AG Frankfurt 3 Process heat SteinmllerStadtwerke Frankfurt HKW Messe District heating StandardkesselAWG Wuppertal Wuppertal 12 Waste incineration LentjesAWG Wuppertal Wuppertal 14 Waste incineration LentjesAWG Wuppertal Wuppertal 15 Waste incineration LentjesAWG Wuppertal Wuppertal 16 Waste incineration LentjesStadtwerke Duisburg Duisburg I Heating and power station StandardkesselHoltzmann Karlsruhe-Maxau Process heat StandardkesselVattenfall Europe Boxberg R 700 MW Hitachi Power EuropeVattenfall Europe Moorburg A 820 MW Hitachi Power EuropeVattenfall Europe Moorburg B 820 MW Hitachi Power Europe

10

Turbine Control Systems Excerpt

Customer Location Block Turbine * Output Power Function *swb-Erzeugung Hafen 6 ME 320 MW TCSE.ON Kraftwerke Buschhaus 1 ME 350 MW TCSRWE Power AG Frimmersdorf Q AEG 350MW TCSRWE Power AG Huckingen A ME 300 MW TCSRWE Power AG Huckingen B ME 300 MW TCSESKOM Engineering Group, Sdafrika Lethabo 1 ME 620 MW TCSESKOM Engineering Group, Sudafrika Lethabo 2 ME 620 MW TCSESKOM Engineering Group, Sdafrika Lethabo 3 ME 620 MW TCSESKOM Engineering Group, Sdafrika Lethabo 4 ME 620 MW TCSESKOM Engineering Group, Sdafrika Lethabo 5 ME 620 MW TCSESKOM Engineering Group, Sdafrika Lethabo 6 ME 620 MW TCSESKOM Engineering Group, Sdafrika Matimba 1 ME 665 MW TCSESKOM Engineering Group, Sdafrika Matimba 2 ME 665 MW TCSESKOM Engineering Group, Sdafrika Matimba 3 ME 665 MW TCSESKOM Engineering Group, Sudafrika Matimba 4 ME 665 MW TCSESKOM Engineering Group, Sdafrika Matimba 5 ME 665 MW TCSESKOM Engineering Group, Sdafrika Matimba 6 ME 665 MW TCSIEC Israel Electric Corporation Limited Rutenberg 1 ME 550 MW TCSIEC Israel Electric Corporation Limited Rutenberg 2 ME 550 MW TCSIEC Israel Electric Corporation Limited MD-B, Hadera 5 ME 550 MW TCSIEC Israel Electric Corporation Limited MD-B, Hadera 6 ME 550 MW TCSRheinbraun AG Wachtberg 1 ME 90 MW TCSVattenfall Europe Tiefstack-Ersatz ME 160 MW TCSEPON, Niederlande Bergum 1 ME 300 MW TCSEPON, Niederlande Bergum 2 ME 300 MW TCSENSO Gutzeit OY, Finnland Imatra TU 7 ME 92 MW TCSVSE Ensdorf 1 AEG 110 MW TCSRWE Energie AG / VSE Ensdorf 3 ME 315 MW TCSHaindl Papier Augsburg VII ME 25 MW TCSVoest AG, sterreich Linz IV ME 85 MW TCSVattenfall Europe Jnschwalde A LMZ 500 MW TCSVattenfall Europe Jnschwalde B LMZ 500 MW TCSVattenfall Europe Jnschwalde C LMZ 500 MW TCSVattenfall Europe Jnschwalde D LMZ 500 MW TCSVattenfall Europe Jnschwalde E LMZ 500 MW TCSVattenfall Europe Jnschwalde F LMZ 500 MW TCSESKOM Engineering Group, Sdafrika Matla 1 ME 600 MW TCSESKOM Engineering Group, Sdafrika Matla 2 ME 600 MW TCSESKOM Engineering Group, Sdafrika Matla 3 ME 600 MW TCSESKOM Engineering Group, Sdafrika Matla 4 ME 600 MW TCS

11

Customer Location Block Turbine * Output Power Function *ESKOM Engineering Group, Sdafrika Matla 5 ME 600 MW TCSESKOM Engineering Group, Sdafrika Matla 6 ME 600 MW TCSE.ON Kraftwerke G. Knepper C AEG 350 MW TCSSTEAG Lnen 7 AEG 350 MW TCSMVA Kiel Kiel L1 + L2 B&V 9 MW TCSTha Toom Thailand 1 GAE 160 MW TCSTha Toom Thailand 2 GAE 160 MW TCSVALA Finnland 1 GAE 230 MW TCSPCK Schwedt Schwedt 1 GAE 90 MW TCSPCK Schwedt Schwedt 2 GAE 90 MW TCSNOK Thei, Austria Thei - GAE 250 MW TCSE.ON Kraftwerke, KW Heyden Petershagen 4 Siemens 920 MW TCSESKOM Engineering Group, Sdafrika Grootvlei 1-6 ME 6 x 200 MW TCSElectrabel MV NP, Belgium Doel 4 Alstom 1100 MW TCS / THSElectrabel MV NP, Belgium Tihange, Huy 3 Alstom 1100 MW TCS / THSElectrabel MV NP, Belgium 2 x SPAT/TFP 3 Ratau 3000 t/h TCS / THS

* Turbine / turbine ME = MAN-ENERGIE, Nrnberg

AEG = AEG-AG, Berlin

LMZ = Leningrader Metallwerke Sankt Petersburg

GAE = GEC-Alsthom Energie, Nrnberg

B&V = Blohm & Vo, Hamburg

** Turbine Control System Functions:

TCS = Turbine control system retrofit

THS = Turbine hydraulic system retrofit

Turbine

Matimba, South Africa Installation Power Plant Doel, Belgium

12

Coal power station (Flue gas desulfurization)

Lignite-fired power plant

13

Flue Gas Desulfurization Plants Excerpt

Customer Location Block Output Power Mechanical EngineeringE.ON Kraftwerke Ingolstadt 3+4 420 MW KRC-Umwelttechnik

STEAG-VEW Bergkamen A 750 MW Steinmller

STEAG-RWE Voerde A 750 MW Steinmller

STEAG-RWE Voerde B 750 MW Steinmller

VEBA KW Ruhr AG Shamrock 1+2 District heating 2x130 t / h Thyssen

VEBA KW Ruhr AG Shamrock 3+4 District heating 2x130 t / h Thyssen

swb Hafen 5 300 MW Babcock

swb Hafen 6 420 MW Babcock

VSE / RWE Ensdorf 3 315 MW NIRO / KRC

VSE / RWE Ensdorf 1 150 MW NIRO / KRC

E.ON Kraftwerke Scholven B 300 MW Thyssen

E.ON Kraftwerke Scholven C 300 MW Thyssen

E.ON Kraftwerke Scholven D 300 MW Thyssen

E.ON Kraftwerke Scholven E 300 MW Thyssen

E.ON Kraftwerke Scholven FWK-Buer District heating Thyssen

VEAG Berlin Jnschwalde A 540 MW KRC-Umwelttechnik

VEAG Berlin Jnschwalde B 540 MW KRC-Umwelttechnik

VEAG Berlin Jnschwalde C 540 MW KRC-Umwelttechnik

VEAG Berlin Jnschwalde D 540 MW KRC-Umwelttechnik

VEAG Berlin Jnschwalde E 540 MW KRC-Umwelttechnik

VEAG Berlin Jnschwalde F 540 MW KRC-Umwelttechnik

VEAG Berlin Boxberg N 540 MW L. & C. Steinmller

VEAG Berlin Boxberg P 540 MW L. & C. Steinmller

Vattenfall Europe Boxberg R 700 MW Babcock Noell

Vattenfall Europe Moorburg A 820 MW Babcock Noell

Vattenfall Europe Moorburg B 820 MW Babcock Noell


Casella AG Frankfurt 3 Process heat Steinmller

Stadtwerke Frankfurt HKW Messe District heating Standardkessel

AWG Wuppertal Wuppertal 12 Waste incineration Lentjes




Stadtwerke Duisburg Duisburg I Heating and power station Standardkessel

Holtzmann Karlsruhe-Maxau Process heat Standardkessel

Vattenfall Europe Boxberg R 700 MW Hitachi Power Europe

Vattenfall Europe Moorburg A 820 MW Hitachi Power Europe

Vattenfall Europe Moorburg B 820 MW Hitachi Power Europe

14

Hydropower Plants Excerpt

Customer Location Type of PlantOutput Power

Mechanical Engineering

E.ON Wasserkraft

Eitting Run-of-river power station Turbosets

Scope of delivery: Start and stop automatics, ME 4002

4 x 10 MW

VOITH

E.ON Wasserkraft

Aufkirchen Run-of-river power station Turbosets


4 x 10 MW

VOITH

E.ON Wasserkraft

Finsing Run-of-river power station Turbosets Turboset


3 x 4 MW 0,25 MW

VOITH

E.ON Wasserkraft

Niedernach Walchensee

Run-of-river power station Turbosets


3 MW

Escher-Wyss

E.ON Wasserkraft

Haag Oberzolling

Run-of-river power station Turboset 3 Weir control systems

Scope of delivery: Start and stop control, level control, ME 4012 Remote control of the weirs at Oberzolling, ME8018 Remote data transmission to the central control station at Zolling, ME 8008 Remote control of the plant, ME-VIEW Centralized alarm and event monitoring , ME2015

4 MW

Escher-Wyss NOELL

15



RWE Energie AG Herdecke / Ruhr

Pumped storage power station

Scope of delivery: Signal conditioning and drive control, ME 4012 Automatic synchronization, Distributed visual/acoustic alarm handling ME 3008 / ME 7002 Event and alarm recording system , ME 2015M Mechanical protection , ME 4002 Equipment for central control room: control desks, mosaic boards and panels as well as complete indoor installation and furnishing ,sup-ply of the machine control panel

150 MW / 200 MVA

VOITH / SEW

E.ON Wasserkraft

Ettling Run-of-river power station Turbosets 4 Weir control systems

Scope of delivery: Start /stop automatic with automatic synchroni-zation of the turbosets, ME 4002 Control system for 4 weirs Complete equipment for central control room and machine control panel

3 x 4 MW

Escher-Wyss NOELL

BKW Bernische Kraftwerke AG

Unterwerk Schwarzen-burg (CH)

ME 400 Signalling and monitoring system


Wasserkraft-werk Brgg(CH)



Unterwerk Schwarzen-burg (CH)



Unterwerk Amsoldingen (CH)



Unterwerk Heimiswil (CH)


16

Hydropower Plants Excerpt



Weiachtal-Kraftwerks eG

Oberstaufen Werk III

Run-of-river power station Turboset Run-of-river power station Pump turboset

Scope of delivery: Automatic machine control with automatic synchronization, ME 4012, Level control, Refer-ence control

0,5 MW 0,15 MW

VOITH VOITH

EnBW Kraftwerke

Rudolf Fettweis Werk

Pumped storage power station

Scope of delivery: Automation of the pump turbine, machine 6, ME4012, Supply of machine control panel Remote central control room with integrated process bus for the communication with 16substations for remote level measurement in the water collecting area , and for a connection to the load distribution plant at Daxlanden Report generator (ME-AIS) for status and accounts reports on the inlets and outlets Operator control and process monitoring system, ME-VIEW Configuration and diagnostics station, ME-PC

25 MW Escher-Wyss

Nordost Sch-weizerische Kraftwerke AG

Beznau, CH Run-of-river power station Turbosets Scope of delivery: ME 4012 for the control and monitoring of the machine groups and of the 8kV switchgear stations, Sequence and closed-loop control in various auxiliary plant, Plant operator control and VDU operator control system ME-VIEW in redundant configuration, Central configuration and diagnostics station ME-PC

11 x 2,5 MW

Bell / Escher-Wyss

E.ON Wasserkraft

Pfrombach Run-of-river power station 7 Turbosets

Scope of delivery: Start and stop automatics with ME 4002

20 MW total

VOITH

17



E.ON Wasserkraft

Pielweichs Run-of-river power station Turbosets 4 weir control systems

Scope of delivery: Start and stop automatics with automatic synchronization, Level control with respect to the power stations at Oberlieg, Surge control, ME4012, (Complete instrumentation and measurement equipment), Remote control of the weirs , ME 8008, Complete equipment for central control room and machine control panel

3 x 4 MW

Escher-Wyss NOELL

Weiachtalkraft-werke AG

Oberstaufen Werk I

Run-of-river power station 3 Turbosets Peak power output Diesel generator

Scope of delivery: Automatic machine control with automatic synchronization, ME 4012, Level control, refer-ence control, master control system for diesel generators, Machine control panel

1100 kW 450 kW 100 kW 1100 kW 2 x 880 kW

VOITH

Nordost Schweizerische Kraftwerke AG

Wildegg-Brugg, CH

Run-of-river power station Turbosets

Scope of delivery: Control of machine groups and auxiliary plant, ME 4012, Analysis of water resources , control of proportioning machines and 110kV switchgear Control of station service equipment, ME-VIEW VDU system in redundant configuration for op-erator control, Plant information system ME-AIS Central configuration and diagnostics station ME-PC

2 x 23 MW

Bell / Escher-Wyss

18

Coaling PlantExcerpt

Customer Location Block Control and Monitoring of

swb-Erzeugung KW Hafen 5, 6 Coal loading bridge

STEAG Voerde A, B Bunker coaling, Up and down coal stacker, Ash removal and loading Shipper with surge guard, Coal sampler

STEAG Voerde West 1, 2 Bunker coaling, Up and down coal stacker, Ash removal and loading Shipper with surge guard, Coal sampler

GDF Suez-Gruppe

Zolling 5 Bunker coaling, Coal up and down stacker, Ash removal and loading

Kasseler Fernwrme

Kassel 2 Coaling plant, Ash removal and loading

Vattenfall Europe

Moorburg, Hamburg

A / B Bunker coaling; Ash removal and loading, Shipper with surge guard coaling plant; coal bunker, belt conveyor; grinding mill, coal pulveriser, circular coal storage, reclaimer system, weighing scale; from-bin transfer; block distribution

19

Water Treatment Plants Excerpt

Customer Location Block Control and MonitoringE.ON Wasserkraft Ingolstadt 4 Waste water treatment, Company: Hager & Elssser

GDF Suez-Gruppe Zolling 5 5 District heating 5

Desalinization plant, Company: WABAG Condensate treatment, Company: WABAG Component current cleaning Heating water, Company: WABAG Waste water treatment, Company: Philipp Mller

STEAG-RWE Voerde A, B Waste water treatment, Company: Philipp Mller Cooling tower make-up water treatment, Philipp Mller Desalinization plant, Company: WABAG Condensate treatment

STEAG-VEW Bergkamen A Desalinization plant, Company: Steinmller

swb, HKW Hastedt 1 2 Desalinization plants, Company: Babcock

swb, HKW Hafen 5, 6 Waste water treatment, Company: Philipp Mller

RWE Mhlheim-Krlich

Cooling tower make-up water treatment, Philipp Mller

Gemeinschafts-KW Weser

Veltheim Desalinization plant, Company: Polysius

ARA Buholz Emmenbrcke (CH)

Alarm and event indication system for the entire waste treat-ment plant with interface to the ME 4012 SUB-NET process control system of the sludge incineration plant 6 off ME300 event data acquisition systems connected to the SUB-NET bus

Stadtwerke Mnchen HKW Mnchen-Sd

ME 4012 screen control in central control room

Vattenfall Europe Moorburg / Hamburg

A, B ME-REG with printer in central control room Desalinization plant, Company: WABAG Condensate treatment, Company: WABAG Desalinization plant, Company: WABAG Condensate treatment, Company: WABAG Chemicals supply: HCC, NaOH, FeCl3, Antiscalant, Biocid, NaHSO3Component current cleaning Heating water, Company: WABAG Waste water treatment, Company: Philipp Mller Cooling tower make-up water treatment, Philipp Mller Process water treatment, Fa. ELGA, Berkefeld (VWS Deutschland)

20

De-NOx PlantsExcerpt


E.ON Kraftwerke Ingolstadt 4 De-NOx, Fa. EVT

GDF Suez-Gruppe Zolling 5 De-NOx, Fa. Uhde

swb-Erzeugung Hafen 5, 6 De-NOx, Fa. EVT

E.ON Kraftwerke Shamrock 1+2, 3+4 De-NOx, Fa. Thyssen

E.ON Kraftwerke Scholven FWK Buer De-NOx, Fa. Thyssen

Vattenfall Europe Boxberg R Hitachi Power Europe

Vattenfall Europe Moorburg, Hamburg A, B Hitachi Power Europe


STEAG Bergkamen De-NOx, Fa. EVT

Gemeinschaftskraftwerk Veltheim Veltheim De-NOx, Fa. Uhde

swb-Erzeugung Hafen De-NOx, Fa. EVT

GDF Suez-Gruppe Zolling De-NOx, Fa. Thyssen

Vattenfall Europe Boxberg De-NOx, Fa. Thyssen

Vattenfall Europe Moorburg, Hamburg Hitachi Power Europe

Vattenfall Europe Moorburg, Hamburg A, B Hitachi Power Europe

Ammonia (NH3) Tank FarmsExcerpt

21

Coal power station (Flue gas desulfurization)

DeNOx Plant for Nitrogen Oxide Reduction Coal contains small amounts of nitrogen that is partly formed into nitrogen oxide during the combus-tion process. In the DeNOx plant, the nitrogen oxide is removed from the flue gases of the coal combus-tion process. This is done by injecting ammonia into the flue gas and then conveying the mixture across catalyzers. A catalyzer stimulates chemical reactions but is chemically unchanged at the end of the reaction (selective catalytic reaction, SCR). In the power station catalyzers, ammonia and nitrogen oxide react with each other and produce nitrogen and steam, which are natural compo-nents of our breathing air.

Ammonia tank farm

Ammonia Tank Farm Ammonia (NH3 ) is a chemical compound derived from the reaction of nitrogen and hydrogen. Ammonia is pungent smelling, colorless, water-soluble and toxic gas and must be safely stored and transported in compliance with the regulations of the Hazardous Incident Ordinance. The neces-sary process control measures are thus very complex, especially with respect to the protection against risk from fire and explosion.

22

Customer Location Boiler No. Output Power Mechanical Engineering

MVA Stapelfeld Hamburg Linie 1,2 je 165.000 t / a Steinmller, H. Petersen, v. Roll

Scope of delivery: Automation of the incineration lines no. 1 and 2 and all auxiliary plant, such as flue gas washery, DeNOx plants, flue gas secondary treatment, cyclone combustion chamber, water treatment, evaporation plant, district heating output and electrical station service equipment.

AWG Wuppertal Wuppertal Kessel 11 bis 16 Lentjes-Umwelttechnik

Scope of delivery: Automation of boilers, general plant, flue gas treatment using open-hearth furnace coke filter and SCR nitrogen removal of lines 1 to 3 Modernization of central control room

KVA Bern Bern (CH) Linie 23, 24 von Roll

Scope of delivery: Automation of combustion, boiler, DeNox, washery and fly-ash treatment of lines 23 and 24, and of radiant type boiler, hot water boiler, threepass boiler, district heating supply and steam turbine, flue gas treatment

MVA Oftringen Oftringen (CH) Scope of delivery: Control of station services and local control

MVA Zricher Oberland

Hinwil (CH) Scope of delivery: Control of station services and local control

Papierfabrik Ziegler

Grellingen (CH) Scope of delivery: Control of station services and local control

SVA Buholz Emmenbrcke (CH)

Slurry incineration Thyssen

Scope of delivery: Automation of the slurry incineration and general plant Modernization of the central control room

Waste Incineration Plants Excerpt

23

Expert SystemsExcerpt

Definition of Process Quality There is not yet a generally ac-cepted definition of the term Process quality in conjunction

with power plant processes. We use the definition illustrated in Figure 1 on the basis of the follow-ing explanations.

Index "IST" represents the actual unit efficiency factor under the present operating conditions. Index "SOLL" represents the maximum unit efficiency factor theoretically possible under the same operating conditions, or the specific heat consumption deter-mined for that unit.

The term Process quality can therefore be understood as a complex status description of the overall system according to the above definition. Determination of the process quality by continuous comparing actual and required values allows efficient monitoring of the entire power plant process.

Fig. 1

Process quality monitoring of the water-steam cycle

Customer Location Application

Vattenfall Europe Boxberg Power/path diagnosis pipeline Main steam line service life calculation Unit allowance computer Energetic calculation for the process quality PIGM interface balances and reports

Vattenfall Europe Moorburg, Hamburg Power/path diagnosis pipeline Main steam line service life calculation Unit allowance computer Energetic calculation for the process quality PIGM interface balances and reports PI system OSI-Soft balances and reports

swb HKW Hafen, Block 6, Bremen

Process quality monitoring for sustained plant management and efficiency enhancement in cogeneration plant Hafen, unit 6, 320MW

Process Quality

24

Plant Management System Monitoring the remaining service life of components subjected to high stress is an important task in the responsible operation of a power plant, which becomes even more pressing the longer these components stay in operation. In order to assess the effects of the operating conditions on the life span of the steam generator components, appropriate meas-urements and calculations must be carried out. The analysis of these results in compliance with the specifications of the technical rules and standards acc. to DIN EN 12952 provides information about any reduction of the components initial life expectancy that may become necessary.

Service Life Management of Mechanical Components (components subjected to high stress and pressure; failure is not permitted)

Time-oriented MaintenanceMaintenance cycles are specified on the basis of experience observ-ing high safety margins. (Periodic inner test 3 years max.).

The service life reserve of a component can be continu-ously monitored with diagnostic methods. When optimally imple-mented, this condition-oriented maintenance represents the most efficient way.

Failure-oriented maintenance is the most efficient if safety and availability of the overall system is not a relevant factor.

Pipeline monitoringLoad condition:

Operation

Weight

Thermal expansion

Display:

Shift

unscheduled

Time-oriented Maintenance

Preventive Maintenance

Condition-oriented MaintenanceFailure-oriented Maintenance

Cond

ition of the co

mpone

nt

Time

25

Application example: Process quality monitoring in power plant Hafen Unit 6, 320MW for sus-tained system management and efficiency enhancement The process quality monitoring system (PG) was modeled, and thus on the basis of the valid data, the closed water-steam cycle as well as the air-flue gas system including the fuel model.

The successful implementation in the utility company swb genera-tion, Hafen power plant Bremen, coal unit 320MW, is used as a reference example.

To enable online usage of this important tool for plant efficiency enhancement, the results of the process quality monitoring (PG) are entered in the ME-VIEW user interface. Deviations from the optimum capacity are displayed in color and recorded by the

signalling system. The data is transmitted over a bidirectional line in the form of 5-minute values via a database interface.

Some excerpts from the ME-VIEW user interface are shown below:

Process quality monitoring fluegas-air path

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Steam blower Water blower


STEAG RWE Voerde A 108 ED, 4 Luvo und 46 LS

STEAG RWE Voerde B 108 ED, 4 Luvo und 46 LS

STEAG RWE De-NOx, Block A 30LS

STEAG RWE De-NOx, Block B 40LS

STEAG KW-West I 25 ED, 2 Luvo und 26 LS

STEAG KW-West II 25 ED, 2 Luvo und 26 LS

RWE-Ensdorf 1 2 Luvo und 14 LS

RWE-Ensdorf 2 2 Luvo und 14 LS

Vattenfall Europe Moorburg A 73 DB, 8 WB

Vattenfall Europe Moorburg B 73 DB, 8 WB

Vattenfall Europe Boxberg R 118 DB, 56 WB

swb Heizkraftwerk Hafen, Block 6 25 ED, 2 Luvo und 26 LS

ED = Single jet blower Luvo = Preheater blower LS = Long or lance screw-motion blower WB = Water blower DB = Steam blower

Soot Reinjection Plants Excerpt

27

Block-Type Thermal Power Stations Excerpt

Combined Heat and Power Plant (CHP)

Customer Block Plant Application

E.ON Ebersberg 1 Gas motor 822 kWth / 471 kWel1 Gas boiler 2,4 MW 1 Electric boiler 1,2 MW 1 Storage heater 13 m3

Automation and ON/OFF logics of the heat exchangers, consider-ing the heat requirements and applied fuel materials. Heat loop control supplied by BoB. Remote control, local control panel in mosaic design.

E.ON Unterhaching 1 Gas motor 520 kWth / 348 kWel1 Gas boiler 1,8 MW 1 Electric boiler 1,2 MW 2 Storage heaters 10 m3

E.ON Puchheim 4 Gas motors 798 kWth / 542 kWel1 Gas boiler 2,3 MW 1 Gas boiler 7 MW 3 Electric boilers 1,2 MW 1 Storage heater 21 m3

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Building Services Control Excerpt


Coutts & Co. AG Zrich (CH) Spillway bridge

Building monitoring and gate reception, ME 4012 control system ME 8018 remote control system, mosaic-type control room

Telekurs AG Zrich (CH) Computer Centre

Power distribution control, resource management and gate recep-tion, ME 4012 system, ME-VIEW / ME 2015, mosaic-type control room, ME-PC

Schweizerischer Bankverein

Altstetten (CH) Computer Centre

Power distribution control, energy control ME 4012 system


Altstetten (CH) Office building

Power distribution control, energy control ME 4012 system

Schweizerische Bankgesellschaft

Zrich (CH) Building control for heating, cooling, air-conditioning and ventila-tion, ME 4012 system

Bank Leu Stettbach (CH) Computer Centre

Power distribution control, energy control ME 4012, ME 2015 systems

Schweizerische Nationalbank

Zrich (CH) Telekurs remote monitoring system ME 8018 systems for SNB, mosaic-type control room

Swiss Stock Exchange Zrich (CH) Control system for security centre AE 4012 systems, mosaic-type control room

Swiss Stock Exchange Zrich (CH) Computer Centre

Energy control and energy management system AE 4012 systems, ME-PC, ME-VIEW

Schweizerische Nationalbank

Zrich (CH) Remote monitoring system Seefeld SNB stock exchange, ME 8018 remote control system, mosaic-type control panel ME 2025 event indication


Opfikon (CH) Power distribution control, energy control ME 4012, ME 2015 systems, mosaic-type control room, H1 bus coupler, ME-PC

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Credit Suisse Horgen (CH) Computer Centre

Power distribution control, energy control ME 4012-SUB-NET system, mosaic-type control room, ME-VIEW


Opfikon (CH) UPS monitoring system, Energy control with LAN coupler ME 4012-SUB-NET system, ME-VIEW

Zrich Insurance Schlieren (CH) Computer Centre

Power distribution control, energy control with LAN coupler, ME 4012-SUB-NET system, ME-VIEW

Schweizer Rck Zrich (CH) Power distribution control for main low-voltage distribution for securing the energy supply in the event of mains failure or inter-ruption 3 programmable controllers with SUB-NET 1 operator control and process monitoring system 1 active mimic diagram

St. Galler Kantonalbank

Headquarters St. Gallen (CH)

Power distribution control for main low-voltage distribution for securing the energy supply in the event of mains failure or inter-ruption 6 programmable controllers with SUB-NET 1 operator control and process monitoring system ME-VIEW 1 active mimic diagram

University Hospital Zrich

Zrich (CH) Power distribution control for main medium and low voltage distribution for securing the energy supply in the event of mains failure and interruption 12 programmable controllers with SUB-NET 2 operator control and process monitoring systems ME-VIEW 1 active mimic diagram

30

Gas and Steam Power Plant Excerpt

Power plant AltbachControl room

Customer Manufacturer turbine ST / GT Function / Gas turbine (GT)

HKW Halle / Trotha Siemens / Siemens V 64.360 MW / 25 MW

Serial integration of the gas turbine and steam turbine control into the main control system ME 4012

Public services Munich CHP Munich South Gas and steam power plant 1

Siemens / Siemens V 94.1105 MW / 2 x 100 MW

Overall plant control technology, ME4012 for control technology and protection

Public services Munich CHP Munich South Gas and steam power plant 2

ALSTOM Power / General Electric Frame9E

140 MW / 2 x 140 MW

Overall plant control technology, ME4012 for control technology and protection process bus integration of the Mark 5 gas turbine control

EnBW KW Altbach / Deizisau, GT-A

Siemens V93.0 50 MWOverall plant control technology, ME4012 for control technology and protection

Industrial power plant Freudenberg Service, Weinheim, GT1

Ruston Tornado 6,3 MWlink up to the block control of boiler 4 by parallel coupling

Industrial power plant Freudenberg Service, Weinheim, GT2

Turbomach Caterpillar, Taurus T60

5,5 MWlink up to the block control of boiler 5 by parallel coupling

31

Power Plant Simulators Excerpt

Customer Power Station

Trainingsinstitut Faisalabad WAPDA, Pakistan

KWS-Essen Stadtwerke Bremen, KW Hafen

Sultan Salahuddin Abdul Aziz Kraftwerk Abdul Aziz, Malaysia

Krnkraftskerhet och Utbildning AB - Studsvik Vattenfall AB, Ringhals Block 1, Schweden

STN-Atlas Elektronik, Bremen Escom, Matimba Block 1-6, Sdafrika

STN-Atlas Elektronik, Bremen Escom, Kendal Block 1-6, Sdafrika

Leibstadt KKW Leibstadt, Schweiz

Thomson, Frankreich Pacific Power, KW Mount Piper, Australien

KSG-Essen Kernkraftwerk Emsland (nuclear power plant)

KSG-Essen Kernkraftwerk Biblis

KSG-Essen Kernkraftwerk Philippsburg 2

KSG-Essen Kernkraftwerk Brokdorf

KSG-Essen Kernkraftwerk Philippsburg 1

KSG-Essen Kernkraftwerk Isar 1

KSG-Essen Kernkraftwerk Isar 2

Krnkraftskerhet och Utbildning AB-Studsvik Vattenfall AB, Ringhals Block 2, Schweden

KSG-Essen Kernkraftwerk Unterweser

KSG-Essen Kernkraftwerk Neckarwestheim

KSG-Essen Kernkraftwerk Obrigheim

KSG-Essen Kernkraftwerk Borssele

Tenagu Nasional Berhadad Kernkraftwerk Connaught Bridge, Malaysia

Kernkraftwerk Gsgen KKW Gsgen, Schweiz

Kernkraftwerk Mhleberg KKW Mhleberg, Schweiz

Siemens, Erlangen KKW Tianwan, China

Krnkraftskerhet och Utbildning AB-Studsvik KKW Oskarshamn Block 2, Schweden

Krnkraftskerhet och Utbildning AB-Studsvik KKW Oskarshamn Block 3, Schweden

CAE Electronics, Canada KKW Beznau, Schweiz

Westingshouse, Pittsburgh Ringhals, Schweden

CAE Electronics, Canada Hartlepool, England

British Energy Heysham, England

Siemens, Erlangen Olkiluoto 3, Finnland

Southern California Edison San Onofre Nuclear Genarating Station, USA

Soluziona Ing. / Tecnatom Trillo, Spanien

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Subject to change.01.0000.04E12

process control systems

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