The Large Combustion Plant Directive (LCPD) (2001/80/EC) aims to reduce acidification, ground level ozone and particles throughout Europe by controlling emissions of sulphur dioxide (SO2), oxides of nitrogen (NOx) and dust (particulate matter (PM)) from large combustion plants.

In compliance with these regulations International Power (IPR) have

installed Flue Gas Desulphurisation (FGD) plant at their coal-fired

power station in Rugeley, Staffordshire. A turn-key EPC contract was

awarded to Lentjes UK in 2006, who were responsible for the design,

construction and commissioning of the FGD plant and its integration

into the existing power station.

Lentjes appointed Capula in 2007 as the control systems supplier

for this project, with the scope of work including:

> PLC and SCADA based control systems

> Safety and protection systems

> Field Instrumentation supply and installation

> Installation of field cabling

> Local man-machine interface equipment

> Cable marshalling equipment

> Integration of the new control systems into existing generating unit

control systems

The contract was awarded in 2007, and commissioning of the plant

was successfully achieved with flue gas scrubbing operational in mid-

2009, removing approximately 96%of the SO2.

Business challenges The new FGD plant receives flue gases from the existing boiler

plant. Therefore, the FGD control systems had to integrate with the

generating unit control systems at the power station to safely control

the flue gas path through the entire plant.

Furthermore, IPR required that the operator control facilities were

fully integrated into the existing power plant control room to enable

the safe, efficient control of the boiler and FGD plant. Capula was

challenged with creating an innovative solution and system designs

which would allow this seamless integration, both during installation

and commissioning and following project completion.

International Power plcRugeley Power Station Flue Gas Desulphurisation

Business benefits delivered

> Skilled assistance to Lentjes on applying Rugeley and UK engineering standards> Local integrator able to provide good support> Experienced system integrator able to handle major project implementation on a large scale> Experienced FGD control systems integrator> Dedicated and able to meet the tight timescales

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A large number of field instruments (approximately 350) were supplied for the measurement of the

process parameters (ie. flows, pressure, temperature, levels, chemical composition etc).

The FGD control system relies on precise measurement and control of the process, and Capula was

responsible for the specification, supply, installation, fitting and commissioning of each instrument.

The timescales of the project were also a significant challenge. It involved major plant design and

construction whilst minimising the disruption on the power station.

Major outage tie-ins were provided, but much of the installation and commissioning had to be

carried out whilst the power plant was operational. This exerted significant pressure on the design

and site commissioning teams, but careful planning and co-ordination on the part of Lentjes and

all sub-suppliers, including Capula, allowed the project to be successfully completed.

Why CapulaCapula was chosen because of the company’s extensive experience on the boiler control systems

at Rugeley, which is based on APACS and APMS, and there are only a limited number of companies

who can provide this level of support for these systems.

The ability to work closely with the main contractor on this project, together with their

responsiveness and delivery ethos, all contributed to the success.

International Power plc

International Power plc (IPR) is

a growing independent power

generation company with interests

in over 45 power stations and some

closely linked businesses around

the world.

Rugeley power station, part of

International Power’s portfolio, is

coal fired and can produce

approximately 1,000MW of electricity

fed into the National Grid system

at a high voltage of 400,000 volts.

The output is enough to meet the

needs of roughly 1/2 million homes.

Capula Limited Orion House, Stone, Staffordshire ST15 OLT

t: +44 (0)1785 827000 e: sales@capula.co.uk

www.capula.co.uk

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