Yokogawa Vigilance at your service worldwide - representative projects
Mongolia
8 x 420 t/h
coal fired
revamping & simulat...
VigilantPlant: smart ideas for a sustainable future

Redefining VigilantPlant
For years, Yokogawa has used the word “Vigil...
Sustainable energy solutions for a promising future

Yokogawa has been providing
control solutions for generating
Carbon d...
Leading-edge technology for reduc ing CO2 emissions
The advanced technology, excellent product quality, and extensive
appl...
Yokogawa’s control strategy to reduce CO2 emissions
Protecting the environment has become a
pressing concern in many indus...
Benefit estimation of CO2 emissions
reduction and cost saving
Improvements

Example of typical benefit estimation

Superhe...
Benefit estimation of CO2
emissions reduction and cost saving

Example of boiler efficiency improvement
Know-how & technol...
Benefit estimation of CO2
emissions reduction and cost saving

Example of turbine and BOP efficiency improvement
Know-how ...
Benefit estimation of CO2
emissions reduction and cost saving

Example of plant output improvement
Know-how & technology
I...
Key services and products for
reducing CO2 emissions

Improving plant efficiency
Improving plant availability
Reducing CO2...
Key services and products for reducing CO2 emissions

Plant audits

Maximize your cost benefits and returns
Yokogawa deliv...
Key services and products for reducing CO2 emissions

Plant simulators

Reassure supreme accuracy
You no longer have to ig...
Key services and products for reducing CO2 emissions

Advanced management

Secure the predictability of your critical proc...
Key services and products for reducing CO2 emissions

Total power plant control

Coordinated control
Coordinated control

...
Key services and products for reducing CO2 emissions

Renewable energy control

Wind turbine view

Wind turbine details

S...
Key services and products for reducing CO2 emissions

Combustion gas analyzers
O2

CO

H2O

O2
H 2O

CO
H2O
O2

CH4
CO2

E...
Key services and products for reducing CO2 emissions

Intelligent field devices

Silicon resonant sensor

Take your plant ...
A case study of CO2 emissions
reduction

Retrofit of Mongolia’s largest thermal power plant

Plant name

Owner

:

Mongoli...
A case study of CO2 emissions reduction

The challenges
The existing combustion boilers employed an indirect firing system...
A case study of CO2 emissions reduction

Achievements
Coal consumption rate
for electricity generation
g/kWh

400

409

Co...
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Sustainable Energy Solutions for reducing CO2 emissions | VigilantPlant

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Yokogawa is committed to sustaining your business, the environment, and the society that we all are a part of.
We are doing this by developing more energy-efficient technology, helping operations produce a smaller
carbon footprint, and building rock solid products that protect our environment from contaminants.
Sustainability is not just a job for Yokogawa but for all industry.

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Sustainable Energy Solutions for reducing CO2 emissions | VigilantPlant

  1. 1. Yokogawa Vigilance at your service worldwide - representative projects Mongolia 8 x 420 t/h coal fired revamping & simulator Bulgaria 8 x 200 t/h flue gas desulfurization Italy 400 MW combined cycle UK 37 MW waste to energy Taiwan 2 x 550 MW coal fired Algeria 369 MW IWPP India 2 x 600 MW 2 x 500 MW coal fired Saudi Arabia 360 MW IWPP Kuwait 90,000 t/d desalination Canada 120 MW, cogeneration Trinidad and Tobago 720 MW combined cycle Vietnam 2 x 600 MW coal fired Brunei 110 MW combined cycle Indonesia 110 MW & 95 MW geothermal Australia 4 x 550 MW brown coal fired revamping simulator & training Australia solar (CSP) in the power industry Brazil 460 MW, combined cycle Australia 4 x 500 MW coal fired revamping Australia 4 x 720 MW coal fired revamping simulator & training turbine upgrading Sustainable energy solutions for reducing CO2 emissions Venezuela 460 MW combined cycle Vietnam 2 x 300 MW, coal fired simulator & training Thailand 2 x 110 MW combined cycle Singapore 2 x 600 MW oil fired simulator & training U.S 3 x 70 MW, gas & oil fired Japan 375 MW & 350 MW gas fired India 3 x 660 MW supercritical coal fired Egypt 750 MW 750 MW 750 MW combined cycle U.S 100 MW, combined cycle Japan 2 x 1,050 MW flue gas desulfurization China 6 x 300 MW coal fired China 450 MW wind power Nigeria 530 MW & 2 x 450 MW simple cycle U.S 480 MW, combined cycle Korea 800 MW supercritical training simulator Romania 4 x 330 MW flue gas desulphurization Turkey 130 MW combined cycle Spain 800 MW combined cycle w/ LNG terminal Korea 9 x 100 MW coal fired Brazil 2 x 75 MW, oil & gas fired Fossil fired power plants Gas turbine power plants Renewable energy power plants Plant services and/or plant simulators Yokogawa service offices YOKOGAWA ELECTRIC CORPORATION World Headquarters 9-32, Nakacho 2-chome, Musashino-shi, Tokyo 180-8750, Japan http://www.yokogawa.com/ Represented by: YOKOGAWA CORPORATION OF AMERICA 12530 West Airport Blvd, Sugar Land, Texas 77478, USA http://www.yokogawa.com/us/ YOKOGAWA EUROPE B.V. Euroweg 2, 3825 HD Amersfoort, The Netherlands http://www.yokogawa.com/eu/ YOKOGAWA ENGINEERING ASIA PTE. LTD. 5 Bedok South Road, Singapore 469270, Singapore http://www.yokogawa.com/sg/ YOKOGAWA CHINA CO., LTD. 3F Tower D Cartelo Crocodile Building No. 568 West Tianshan Road, Shanghai 200335, China http://www.yokogawa.com/cn/ YOKOGAWA MIDDLE EAST B.S.C.(c) P.O. Box 10070, Manama Building 577, Road 2516, Busaiteen 225, Muharraq, Bahrain http://www.yokogawa.com/bh/ Trademarks All brand or product names of Yokogawa Electric Corporation in this bulletin are trademarks or registered trademarks of Yokogawa Electric Corporation. All other company brand or product names in this bulletin are trademarks or registered trademarks of their respective holders. Bulletin 53T01A01-02E Subject to change without notice All Rights Reserved. Copyright © 2010, Yokogawa Electric Corporation [Ed:03/b] Printed in Japan, 105(KP)
  2. 2. VigilantPlant: smart ideas for a sustainable future Redefining VigilantPlant For years, Yokogawa has used the word “VigilantPlant” as our vision for operational excellence. What this meant was bringing out the best in your plant and people through visibility of information, predictability of process, and agility of business. We now believe VigilantPlant means much more than just what goes on in your plant. Yokogawa is committed to sustaining your business, the environment, and the society that we all are a part of. We are doing this by developing more energy-efficient technology, helping operations produce a smaller carbon footprint, and building rock solid products that protect our environment from contaminants. Sustainability is not just a job for Yokogawa but for all industry. Will you join in embracing a new VigilantPlant? 1 2
  3. 3. Sustainable energy solutions for a promising future Yokogawa has been providing control solutions for generating Carbon dioxide (CO2) is one of the major greenhouse power from solar, wind, hydro, biomass, geothermal, and other gases causing climate change renewable energy sources based and global warming. on its extensive experience in In the power industry, this field and technologies. Yokogawa has taken the lead For a brighter future, Yokogawa in providing solutions to improve offers sustainable energy solutions power efficiencies by reducing that minimize the impact of CO2 emissions. emissions and achieve the operational excellence that is the hallmark of the VigilantPlant. 3 4
  4. 4. Leading-edge technology for reduc ing CO2 emissions The advanced technology, excellent product quality, and extensive application know-how that go into Yokogawa’s optimum solutions help you reduce your power plant’s CO2 emissions. Efficiency improvement control solution Renewable energy control solution CENTUM VP is a core platform and a key component of our comprehensive control solutions that make it possible for power plants to operate more efficiently. Contr Field control station (FCS) ol LA N(V net/IP Solar power STARDOM with FAST/TOOLS provides an innovative web-based SCADA solution for renewable energy plants. Wind power Fossil power Hydro power ) Turbomachinery control & protection Boiler & BOP controls Combined cycle power Susta inable ene rgy solu tions Nuclear power Multi-sensing digital technology solution Combustion gas analysis solution The TruePeak TDLS200 analyzer utilizes powerful and highly sensitive lasers and can detect and analyze combustion gases under a wide variety of conditions. Biomass power Geothermal power DPharp series transmitters with multi-sensing digital technology offer unmatched performance and precision. Waste to energy DPharp ISA100.11a field wireless 5 DPharp Open access to field intelligence 6
  5. 5. Yokogawa’s control strategy to reduce CO2 emissions Protecting the environment has become a pressing concern in many industries, and the power industry is no exception. Many new regulations are forcing businesses to reduce their emissions of CO2 and other greenhouse gases to prevent global warming. E CO2 emissions reduction is crucial at coal-fired power plants, which discharge much greater amounts of this gas into the atmosphere than other types of fossil-fired power plants. By bringing to bear its technologies and expertise, Yokogawa is focused on improving environmental control over the entire plant lifecycle and ensuring clean air for generations to come. The 3Es of efficiency improvement, emissions reduction, and economic returns are a key part of Yokogawa’s control strategy for reducing CO2 emissions. Our unparalleled control schemes for coal-fired power plants help reduce CO2 emissions and create clean power. fficiency improvement E Optimal combustion and soot blowing inside the boiler enhance the heat rate, reduce outages, and reduce fuel consumption. missions reduction E Control strategies reduce emissions by optimizing combustion and improve emissions measurement. conomic returns 7 Improved performance reduces fuel and operating costs. 8
  6. 6. Benefit estimation of CO2 emissions reduction and cost saving Improvements Example of typical benefit estimation Superheated steam Annual returns from “3Es” for a 300 MW coal - fired unit G HP E DSH Condenser fficiency improvement E Approx. 0.3 - 1% CO 2 3 - 10 kilotons/year conomic returns Make up water RH HP heaters Feed water ECO Burner Pulverizer Boiler efficiency Demineralizer CP Coal bunker Approx. Raw water Reheated steam PSH FSH Drum missions reduction E LP IP BFP DeNOx LP heaters Deaerator Condensate polishers Turbine & BOP efficiency Flue gas Stack Fuel oil Hot air FOP Approx. Hot air 0.3 - 1.1 million US$/year PAF Coal yard Bottom ash AH FGD EP FDF IDF BUF Ambient air Plant output Waste water Fly ash Gypsum Ash pond Coal -fired power plant 9 10
  7. 7. Benefit estimation of CO2 emissions reduction and cost saving Example of boiler efficiency improvement Know-how & technology Improves heat rate Improves steam temperature control Implements coordinated control Minimizes opacity violations Overview Adapts to various fuel properties Enables optimal use of fuel-air mixing Optimizes closed-loop combustion Estimated 3Es Quickly analyzes hotspots inside boiler In a power generation unit, the Performs multivariable predictive control main conversion process takes place in E Enables smart automatic soot blowing the boiler, where superheated steam is generated fficiency improvement to drive the turbine. The thermodynamics inside the Approx. boiler are a complex, multivariable process, where 0.3 - 0.9% it is possible to both to improve the efficiency and reduce emissions. Hence, the boiler model is Superheated steam constantly updated based on the operating status, E missions reduction E Approx. CO 2 3 - 9 kilotons/year G and appropriate optimizing algorithms are used to HP improve the heat rate and minimize fuel consumption. DSH Approx. 0.3 - 0.9 million US$/year Condenser PSH FSH Drum The resultant fuel saving is converted to an equivalent emissions reduction. The economic conomic returns LP IP Reheated steam returns are calculated from both the optimal heat Make up water HP heaters Feed water rate and emission reduction initiatives. ECO Burner Pulverizer Demineralizer CP RH Coal bunker Raw water BFP DeNOx Deaerator LP heaters Condensate polishers Flue gas Stack Fuel oil Hot air FOP Hot air PAF Bottom ash Coal yard AH FDF FGD EP IDF BUF Ambient air Waste water Fly ash Gypsum Ash pond 11 Coal-fired power plant 12
  8. 8. Benefit estimation of CO2 emissions reduction and cost saving Example of turbine and BOP efficiency improvement Know-how & technology Minimizes condenser back pressure loss Minimizes feed heater loss Overview Minimizes high/low-steam pressure loss Minimizes low-steam temperature loss Minimizes auxiliary power consumption Estimated 3Es Optimizes feed pump operation Efficiency can also be greatly Reduces forced outages improved in the turbines and BOP. For the E turbines, the condenser back pressure loss, steam fficiency improvement Approx. pressure loss, and temperature loss can all be minimized. Up to 0.1% For BOP, which is vulnerable to variations in fuel Superheated steam feed, improvements can be attained by closely E missions reduction E Approx. CO 2 up to 1 kilotons/year G coordinating control strategies to optimize the HP operation of the feed pump and minimize auxiliary power consumption. DSH Condenser PSH FSH Drum Reheated steam conomic returns Make up water HP heaters Feed water Approx. ECO Burner Pulverizer Raw water Demineralizer CP RH Coal bunker Up to 0.1 million US$/year LP IP BFP DeNOx Deaerator LP heaters Condensate polishers Flue gas Stack Fuel oil Hot air FOP Hot air PAF Bottom ash Coal yard AH FDF FGD EP IDF BUF Ambient air Waste water Fly ash Gypsum Ash pond 13 Coal-fired power plant 14
  9. 9. Benefit estimation of CO2 emissions reduction and cost saving Example of plant output improvement Know-how & technology Improves plant availability Improves operating procedures Overview Improves maintenance procedures Improves ancillary plant performance Smoothens plant operations Recovers megawatts of power Plant output can be improved Reduces oil usage for start-ups by carrying out proper operating and Enables the creation of feasible maintenance schedules maintenance procedures, having advance warning of tube leaks, and optimizing soot blowing operations. The resulting benefits are calculable based on the Superheated steam recovered megawatt-hours from the reduction in G forced outages, improvement of plant availability, Highly reliable DCS & instruments for reduction in forced outages HP and reduction of start-up plant operation. LP IP DSH PSH FSH Drum E Condenser conomic returns Make up water HP heaters Feed water Approx. ECO Burner Pulverizer Demineralizer CP RH Coal bunker Up to 0.1 million US$/year Reheated steam Raw water BFP DeNOx Deaerator LP heaters Condensate polishers Flue gas Stack Fuel oil Hot air FOP Hot air PAF Bottom ash Coal yard AH FDF FGD EP IDF BUF Ambient air Waste water Fly ash Gypsum Ash pond 15 Coal-fired power plant 16
  10. 10. Key services and products for reducing CO2 emissions Improving plant efficiency Improving plant availability Reducing CO2 emissions Building a lasting future Envision a plant where people are watchful and attentive while your power generation business responds to changes quickly and efficiently. Now picture an operation that delivers non-stop power generation while confidently improving your plant efficiency and reducing CO2 emissions long into the future. Imagine no further. This is the reality attained by VigilantPlant, the clear path to operational excellence. 1 2 3 step Auditing your plant performance step Improving operation skills Improving asset management Reducing maintenance cost step With the VigilantPlant vision, Yokogawa delivers comprehensive solutions to ensure that environmentally friendly plants run continuously at maximum efficiency and optimal profitability throughout their lifecycle. Comprehensive solutions for your plant lifecycle Long-term partnership for your business From planning to project execution, operations, and maintenance, Yokogawa helps power plant users achieve operational excellence throughout their facility’s lifecycle with the following sophisticated solutions: During the relatively long life cycle of a power plant, there comes a time when the instrumentation and control systems must be renewed to maintain a competitive edge. Yokogawa supports power plants with expert services that maximize efficiency and minimize cost over the entire life cycle. From initial planning, design, engineering, construction, and operation to revamp and re-instrumentation, Yokogawa stands by your power plant. This long-term partnership ensures bottleneck-free performance and ongoing optimization that bring speed and flexibility to your business. Plant audits Plant simulators Advanced management Total power plant control Renewable energy control Combustion gas analyzers Intelligent field devices 17 18
  11. 11. Key services and products for reducing CO2 emissions Plant audits Maximize your cost benefits and returns Yokogawa delivers cost benefits through the refurbishment of power plant controls and instrumentation. This improves the performance of older plants and ensures that they can operate competitively in today’s open power markets, and also reduces their CO2 emissions. Audit your plant performance Yokogawa assists power plant owners and operators to identify areas of plant operations that will benefit from modern controls running on the latest digital control system platform, with modern field instrumentation. Our experts will visit your site to carry out field surveys and assess the status of your plant. We collect plant operating data and cost details, then prepare a plant survey report along with our recommendations on a control system and field instrumentation upgrade. Based on this data and these recommendations, a cost-benefit report is drawn up. This report, along with pricing information for a control and instrumentation upgrade project, is provided to the plant owner for consideration, discussion, and action. Plant availability, reliability, and efficiency Operating regime (daily and seasonal load profiles) Audit items Benchmarks against other facilities of similar age Review of organizational structure Review of maintenance management Review of costs, routine, and capital General plant condition and life expectancy 19 20
  12. 12. Key services and products for reducing CO2 emissions Plant simulators Reassure supreme accuracy You no longer have to ignore the complexity of real-life processes. No other simulators available today can match the accuracy of a Yokogawa power plant simulator. Flexible training scenarios can help your operators learn how to control the entire plant with complete confidence. Experience the reassurance that comes from having a Yokogawa power plant simulator. Simulation computer Features Flexible training and evaluation ・ Plant logics ・ Mathematical models ・ Executive process Turbine running up system ・ Training scenarios ・ Malfunctions ・ Trainee database • 99% accuracy (>99% steady state; >95% dynamic state) Freely devise any training scenario to improve and evaluate operator skills in the following areas: • Executing routine operational procedures • Responding to plant malfunctions • Performing unusual operations such as forced cooling and cold start-ups Etherne t Human interface station Benefits Faster commissioning Instructor system Power plant DCS • The DCS is fully tested before it is installed, drastically reducing the number of modifications to logic, set points, and tuning parameters during the commissioning phase. Performance-based operation 10 20000 18000 16000 7 6 5 4 Steam pressure Flue gas oxygen 9 8 14000 12000 10000 8000 3 0 500 400 Plant resource management 300 200 2000 0 • Before a DCS is installed at a power plant, it is fully tested using dynamic simulation. In this way, both operators and engineers become familiar with the DCS operation and controls. 4000 1 Smoother plant start-up 6000 2 600 MW,level,temperature High fidelity Full-replica power plant simulator 100 0 10 20 21 • By dynamically testing the safety interlocks prior to DCS installation, the simulator reduces the risk of major equipment damage occurring during the commissioning process. 40 50 60 Time ( Min. ) Turbine control Contr Boiler / BOP control Minimized risk of plant damage 30 ol LAN ( Vne t/IP ) Safety system 22
  13. 13. Key services and products for reducing CO2 emissions Advanced management Secure the predictability of your critical process Making plant information fully visible is vital in preventing disruptions to your critical plant processes. Our knowledge-based tools and advanced management solutions help you steadily improve efficiency and attain operational excellence. Performance-based operation Our key performance indicator (KPI) monitoring solution makes KPIs visible and enables you to efficiently operate the production. Plant information at your fingertips Exaquantum, a comprehensive plant information management package integrates and delivers operational information that helps enterprises meet complex business requirements. Increase operational efficiency Exapilot, an easy-to-use tool can be used to standardize operating methods by creating automatic sequences that incorporate the know-how of experienced operators. Benchmark your operational efficiency Exaplog is an easy-to-use suite of tools that analyze the historical logs of the DCS plant and the results on various graphs, allowing you to analyze and benchmark your operational and controllability performance. Predict availability Plant Resource Manager (PRM) provides easy-to-use tools for asset management and intelligent diagnostics for field instrumentation, actuators, and rotating equipment to increase plant availability. Performance-based operation with Exaquantum Exapilot Operation efficiency improvement package Exaplog Event analysis package PRM Plant Resource Manager 23 24
  14. 14. Key services and products for reducing CO2 emissions Total power plant control Coordinated control Coordinated control Turbomachinery control Steam turbine area Boiler control Balance of plant control Boiler control area Air and flue gas oveview Raise plant availability and performance With its state-of-the-art architecture, the highly reliable CENTUM VP platform is fully up to the challenge of monitoring and controlling an entire power plant’ s turbines, boilers, and balance of plant (BOP) facilities. Human interface station/ engineering station Performance-based operation 16000 7 6 5 14000 12000 10000 4 3 4000 1 0 500 400 300 2000 0 Field control station (FCS) 6000 2 Turbomachinery control & protection 8000 600 MW,level,temperature 18000 8 Steam pressure 20000 9 Flue gas oxygen 10 200 100 0 10 20 30 40 50 60 Time ( Min. ) Plant resource management The FCS provides powerful control functions with a highly reliable dual redundant configuration that incorporates Yokogawa’s own pair-and-spare technology. Boiler & BOP controls Steam turbine FGD EP Coal yard Plant safety system Safety control station (SCS) The ProSafe-RS SCS is a TÜV SIL3 certified safety system that incorporates Yokogawa’s pair-and-spare technology. Con trol LAN ( Vn et/I P) Fuel 25 26
  15. 15. Key services and products for reducing CO2 emissions Renewable energy control Wind turbine view Wind turbine details Shift to renewable energy STARDOM is a network-based control system that brings operational excellence to renewable energy plants that may be widely distributed. STARDOM autonomous controllers have remote management and stand-alone capability, and reduce running costs by making flexible use of e-mail, the web, and supervisory control and data acquisition (SCADA) technology. STARDOM is widely used in the renewable energy industry with the FAST/TOOLS distributed SCADA system. FAST/TOOLS is a scalable product to cover a wide range of very small up to large distributed applications. FAST/TOOLS supports remote web-based operations and maintenance. Remote devices Wireless LAN STARDOM engineering tool Plant information management system Plant resource manager GPS receiver, SNTP server Safety instrumented system R e n e w a b l e Optical fiber ring e n e r g y Modem Field control node Proce ss ne twork PSTN. xDSL. and more Wind power Modem Solar power Small hydro power Field control junction Geothermal power GSM/GPGR, Satellite, RF,and more Waste to energy 27 Remote terminal unit Biomass power 28
  16. 16. Key services and products for reducing CO2 emissions Combustion gas analyzers O2 CO H2O O2 H 2O CO H2O O2 CH4 CO2 Enhance combustion control The TruePeak TDLS200 is a pioneering combustion gas analyzer with a powerful tunable diode laser that is ideal for making direct measurements in harsh process environments. It can be used to optimize the combustion process in boiler plants to reduce both CO2 and NOx emissions, and is a highly cost-effective solution that makes no compromise in speed, accuracy, or reliability. Superheated steam Features Measures gases directly in the process (no sampling system required) Powerful laser overcomes the effects of high particulate loading (fly ash and dust) Measures gases continuously, accurately, sensitively, and selectively with no lag time DSH CO measurement for highest efficiency improvement FSH Continuous measurement of carbon monoxide (CO) and oxygen (O2) concentrations allows operators at fossil fuel power plants to fine tune the air-fuel ratio to boost combustion efficiency and reduce NOx emissions. The TruePeak TDLS200 utilizes powerful lasers that are highly sensitive and selective for CO. In boilers it can directly measure CO, eliminating lag time in detecting CO breakthrough and producing no false low readings. PSH Reheated steam Drum RH Coal bunker Feed water NH3 measurement for NOx reduction Ammonia (NH3) gas is injected to remove NOx and thus reduce the NOx concentration in the stack flue gas, as well as to increase the dust collection efficiency of the electrostatic precipitator (EP) and prevent corrosion. However, excess ammonia injection increases running costs and residual NH3, resulting in foul odors. Therefore, the NH3 concentration in the stack flue gas is measured, controlled, and monitored. NH3 injection ECO Burner Flue gas Pulverizer DeNOx With conventional ammonia analyzers that perform measurements indirectly, NH3 concentrations are obtained through a sampling system, causing problems with the maintenance and running costs of the sampling system, and time delays in measurement. The TruePeak TDLS200 solves all these problems. Fuel oil Hot air 29 PAF Bottom ash Hot air TruePeak TDLS200 30
  17. 17. Key services and products for reducing CO2 emissions Intelligent field devices Silicon resonant sensor Take your plant into the digital era DPharp digital pressure transmitters are the first to use a revolutionary silicon resonant sensor technology that provides superior stability and repeatability in the most demanding process applications. They are ideal for use in highly critical power plant processes. This intelligent field device a best-in-class and reliable digital solution that meets present and future needs in the power industry by being fully interoperable with an extensive range of open industrial protocols. DPharp DPharp ISA100.11a field wireless Open access to field intelligence For all ultra critical processes Boiler drum level measurement Main steam flow and pressure Very high static pressure Superheated steam Varying pressure affecting density PX FX Very small measurement span Best-in-class performance Precision and quick response time Feed water flow measurement FX Very high pressure surges (water hammer) Varying flow for varying load Field - proven reliability Spray flow No-error-prone A/D converter: Full end-to-end digital communications from process to control system DSH Drum level Drift free, long-term stability LX Unparalleled stability guarantee FSH PSH Reheated steam Drum RH Coal bunker Multi-sensing Measurement of differential pressure and static pressures (DP and SP) by a single transmitter minimizes your instrumentation cost. Feed water flow Feed water FX ECO Burner Multi-variable DP, SP, and inline temperature measurement in a single transmitter enables mass flow to be calculated by an on-board flow computer. Full interoperability Open industrial communications: Whether you choose BRAIN, HART, FOUNDATION™ fieldbus or Profibus, our transmitters will deliver their full benefits. Flue gas Pulverizer AH Air flow Fuel oil Hot air 31 DeNOx FX PAF Bottom ash Hot air FDF Ambient air 32
  18. 18. A case study of CO2 emissions reduction Retrofit of Mongolia’s largest thermal power plant Plant name Owner : Mongolian Ministry of Minerals and Power : 8 x 420 t/h (including steam for town heating) : 560 MW (4 x 100 MW and 2 x 80 MW) : Lignite coal : 1980 - 1990 Retrofit : 1997 - 2007 Output/fuel : Boilers - 8 x 420 t/h, lignite-fired Turbines - 2 x 80 MW, 4 x 100 MW with town heating Scope of replacement 33 Ulaanbaatar, Mongolia Construction TES4 is the largest coal-fired power plant in Mongolia and it generates 70% of the electricity for Mongolia’s central energy system and 65% of the heat energy used by Ulaanbaatar district heating system. : Fuel In Mongolia, temperatures fall as low as -40℃ in mid-winter. The heat and electricity generated by Thermal Power Plant No.4 (TES4) in the capital city of Ulaanbaatar is an important lifeline for the people living there. Location Electricity outputs (turbines) Project background Thermal Power Plant No. 4 Steam outputs (boilers) Plant information : : Retrofit of control and safety systems, and replacement of field instruments and actuators TES4 was built many years ago and has been severely affected by the scarcity of spare parts for its legacy systems. Plant shutdowns were a frequent occurrence due to equipment malfunctions and accidents, disrupting the supply of heat and power. In addition, the plant caused severe air pollution due to inefficient control of coal combustion. Efforts to correct these problems were also hampered by the loss of many of the plant’ s original blueprints and other design related documents. To solve these problems, the Mongolian government decided to execute a plant revamping project in two phases using an official development assistance (ODA) loan. Phase one for boilers one to four started in 1996 and was completed in 2000. Phase two for boilers five to eight started in 2002 and was completed in 2007. For this project, Yokogawa delivered control systems and field instrumentation for all eight boilers. 34
  19. 19. A case study of CO2 emissions reduction The challenges The existing combustion boilers employed an indirect firing system. This system stores pulverized coal in a silo and feeds it to the boilers as required. The indirect firing system caused frequent equipment troubles and there was a high risk of explosion. The boilers and mill burners were manually controlled by operators except for feed water control. The combustion air was always sent by fans fully opened, thus the combustion efficiency was extremely low. The control operation system was a board operation type equipped with analog and discrete control logics. Only a few very old Russian documents for the control logic scheme were available. Customer’s requirements Yokogawa’s solutions Full automation of boilers, burners, and balance of plant (BOP) facilities Design of fully automated control logic TES4 converted the existing indirect combustion system to the new direct combustion type. Yokogawa performed a detailed investigation of the original boiler combustion control system and the direct combustion control logic together with a new burner vendor and TES4’s engineers. Yokogawa succeeded in designing a fully automated burner management system that replaced the old manually A highly reliable and expandable distributed control system (DCS) operated system. Other major controls for the boilers and BOP facilities were also reviewed and designed based on the new control strategy and Yokogawa’s expertise. Replacement with state-of-art DCS The control systems for all eight boilers at TES4 were changed over to a state - of - the - art Yokogawa A power plant simulator for training DCS operators CENTUM CS 3000 DCS, which provides a highly reliable platform for the comprehensive control and operation of the entire power generation plant. As a result, operation efficiency and safety were dramatically improved. For interfacing with the existing I/O signals, a redundant remote fiber - optic network was installed that reduced the cabling cost and improved both safety and reliability. Supply of power plant simulator In line with the replacement of the DCS, a power plant simulator was supplied for operator training, allowing operators to get experience with plant operating procedures, gain familiarity with the DCS, and improve their skills. As the result, they achieved a smooth transition from the conventional analog control panels to an all-new graphical user interface. 35 TES4 plant control room before refit 36
  20. 20. A case study of CO2 emissions reduction Achievements Coal consumption rate for electricity generation g/kWh 400 409 Coal consumption rate for district-heating steam 22% reduction from 1997 to 2007 417 kg/Gcal 190 7% reduction from 1997 to 2007 188 186 393 389 388 186 389 184 365 184 184 365 182 350 181 180 349 180 177 337 E fficiency improvement E missions reduction E 174 317 The new control system for TES4’s eight boilers was changed over one boiler at a time, starting at the end of 1998 and finishing in 2007. Fuel consumption was dramatically reduced thanks to improved boiler efficiency. This has enabled the power plant to provide a stable supply of electricity and district-heating steam to the city of Ulaanbaatar. 170 300 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 1997 1998 2000 2001 2002 2003 2004 2005 2006 2007 Total CO2 emissions amount of electricity & district-heating steam kilo tons 3,000 Improved boiler efficiency and reduced coal and heavy oil consumption have made it possible for this power plant to generate more electricity from the same amount of fuel, and has significantly reduced CO2 emissions. 1999 2,957 2,930 2,846 17% reduction from 1997 to 2007 2,817 2,811 2,818 2,696 2,690 2,614 2,537 2,500 2,426 2,000 conomic returns 1997 Improved reliability and operation safety at TES4 have decreased the number of plant outages caused by boiler trips and accidents and reduced the amount of oil consumed for boiler start-ups. With the improved reliability of this plant, the Mongolian government no longer has to purchase as much electricity from other countries. 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Total heavy oil consumption tons 15,000 88% reduction from 1997 to 2007 13,897 10,300 10,000 7,280 4,793 5,000 4,757 4,755 4,012 3,852 2,808 1,897 1,682 0 1997 37 TES4 plant control room with CENTUM system 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Note : Coal consumption and CO2 emissions are estimated based on coal consumption rate at 7,000 kcal in 1997 with the following values. Calorific value: 29.3 GJ/ton Emission coefficient: 0.0247 tC/GJ CO2 conversion coefficient: 3.6667 38

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