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Rockwell Automation Air Pollution Control Solutions


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Rockwell Automation has a rich heritage in Power Generation application with a large installed base of equipment. Rockwell Automation offers broad portfolio from devices to control architecture and integrated solutions that help ensure safe, reliable and available power production

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Rockwell Automation Air Pollution Control Solutions

  1. 1. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900DPower GenerationAir Pollution Control Solutions
  2. 2. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Power Generation Trends World Energy Demand continues to rise Environmental Regulations are forcingchanges Retrofits of Coal Plants Retiring Coal Plants New Natural Gas Plants – Shale Gas Aging Plants and Infrastructure Retrofits Migrations Renewables Increasing Renewable Portfolio Standards Tax Subsidies & Incentives Integration of Distributed Generation Energy Independence & Security2
  3. 3. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Environmental Regulations:USA - EPA Legislation & Impacts U.S. Environmental Protection Agency’s (EPA) finalMercury and Air Toxics Standards (MATS) rulepublished on December 21, 2011 Plants must meet new standards by 2015 Retire plant Retrofit with new air pollution controltechnology Cross-State Air Pollution Rule (CSAPR) finalized onJuly 6, 2011 Requires states to significantly improve airquality by reducing power plant emissions thatcontribute to ozone and/or fine particle pollutionin other states. Requires reduction of SO2 and NOX emissionsfrom power plants in the eastern half of theUnited States. Source: U.S. Energy Information Administration AnnualEnergy Outlook 2012 Early Release Overview3
  4. 4. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Environmental Regulations:European Union - Directives NEC – National Emissions Ceiling Directive Covers emissions in the territory of the Member States and their exclusiveeconomic zones from four pollutants which arise as a result of human activities: emissions of sulphur dioxide (SO2), emissions of nitrogen oxides (NOx), emissions of volatile organic compounds (VOC), and emissions of ammonia (NH3). IED – Industrial Emissions Directive Successor of the IPPC Directive and in essence, it is about minimizing pollutionfrom various industrial sources throughout the European Union. IPPC Directive - integrated pollution prevention and control (until 2013) LCP - Large Combustion Plant Directive Control of emissions from large combustion plants - those whose rated thermalinput is equal to or greater than 50 MW Sets ceilings and reduction targets for reducing emissions of acidifying pollutants,particles, and ozone precursors.4
  5. 5. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Environmental Regulations Regulations will require air pollution controls to bedeployed and/or updated at coal fired plants andindustrial and campus sites with coal fired boilers. Flue Gas Desulfurization (FGD): SO2 removal Selective Catalytic Reduction (SCR): NOx removal Activated Carbon Injection: Mercury removal Coal plants without scrubbers account for amajority of U.S. SO2 emissionsAbout 40% of coal-burning units don’t use add-on controls such as scrubbers.5
  6. 6. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Power Producer Challenges World Energy Demand requires Power Producers to: Maximize uptime Optimize generation from existing plants Drive innovation in new production capabilities Government Regulations require Power Producers to: Reduce emissions Enhance security Increase the % of renewables in their portfolio Controlling capital and operational costs to generate and deliver alwaysavailable power safely and reliably Sustainable power production6
  7. 7. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Air Pollution Control Challenges Adherence to global codes and standards Build once & deliver anywhere in the world Desire to leverage latest technology & tools Utilities do not use state of the art technology in many cases High availability and equipment reliability Improve operating efficiency Application designed for Data Access More diagnostics and reporting Log data required for environmental reporting Sustainable Production Reduce emissions & energy consumption Optimize use of raw materials used in the process (ammonia) Increase life of catalysts Safe Operation Modular Solutions – including application code and equipment sub-assemblies Communication Protocols and Interlocking Easily integrate equipment with DCS and other BOP equipment Support for various utility protocols7
  8. 8. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rockwell Solution Capabilities:Process Equipment to Power Plant Control PlantPAx Solution Process Object Libraries speeds application development – AOIs+Faceplates Advanced Process Control capabilities with Pavilion – processoptimization + regulatory compliance Integrated world-class Historian – OSIsoft Reporting – Views & Analytics based on user roles Alarms time stamped with high accuracy – Sequence of EventReporting with IEEE 1588 Endress + Hauser Partnership Instrumentation Integration HART, Foundation Fieldbus, Profibus networks Asset Management – Instrument configuration & calibration Integrated Architecture – a Single Platform Multi-disciplined Control for safety and process control in a singleplatform Scalable Platform – OEM Skids to Power Plant Control Safety Shutdown Systems using GuardLogix Modular Code templates makes deploying application quicker8
  9. 9. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation Value PlantPAx solutions quickly & easily integrate into the PowerPlant Control Integrated Architecture System - Premier Integration of power,control, safety and networks Product life cycle longevity of OTS components Networking capabilities meet your application demandsincluding: Time Synchronization (Sequence Of Events) Remote Diagnostics, monitoring and programming via EtherNet/IP Stratix EtherNet/IP Switch capability NERC-CIP / Cybersecurity Solutions from our PartnerNetwork specialists Instrumentation – Endress & Hauser Solution Providers – EPC Firms and Systems Integrators Encompass Partners – Products/Components that enhance the platform Global Support/Network of Technical ConsultantsRockwell Automation can help provide the total solution from standalone equipment toa completely integrated Power Plant Control system9
  10. 10. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Proven Solutions and TechnicalConsultants Modular Programming methodologies that follow industry standards Leveraging PlantPAx libraries – process and power generation applications Templates for quick code development while allowing creativity for equipment uniqueness Technical Consultants can support in applying the correct solution10Technical Consultants• Senior engineers withextensive field experience• Focus: technical supportand cost reduction• Machine innovation• Best practice sharing• Training, examples, side byside engineering,experience, knowledge
  11. 11. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Proven Solutions using Process andPower Generation Libraries PlantPAx Library Benefits Tested instructions which model realdevices Including simulation of devices foroperator training, strategy testing Consistent modes of operation Avoid operator confusion Assist maintenance without having toopen logic Consistent interfaces between objects Modular design eases construction ofcomplex control strategies Consistent user interface Standards-based HMI emphasizesabnormal conditions Color palette tool to align HMI objectswith your color standards Reduced development andmaintenance time11
  12. 12. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Power Generation Facilities Worldwide DeployNol-Tec’s Dry Sorbent Injection Systems12Challenge• Meet tougher government regulations for SOx emissionsin coal fired power plants• Use the minimal amount of sorbent necessary to meetthe emission limits• Ensure chemical reaction occurs with the correctamount of sorbent being injected• Develop scalable, standardized system with flexibility forpotential future modificationsResults• Diagnostics are readily available for fastertroubleshooting and preventative maintenance with thedeployment of networked drives and MCCs• Rockwell platforms provide flexibility to communicatedirectly with customer’s existing control system, for real-time data and control of sorbent injection loops• “Plug and play” modules allow for system scalability withminimum system reworkRockwell Automation’s Integrated Architecture allowsfor seamless integration of Nol-Tec’s DSI systemswith power generation processing equipment,resulting in lower development costs and fasterdeployment.Coal fired power generation facility improvesemission mitigation of SO2 and SO3 bydeploying a DSI system.
  13. 13. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Korea Electric Power Corporation -FGD System13Challenge• High maintenance costs due to outdated,degraded system• Rapid installation to enable uninterrupted power• Environmentally systems part of the operationsthat generate and deliver power• Utilize existing I/O system and fieldinstrumentationResults• Uptime rate of 90%• Saved 30% in costs over implementing DCSsystem• Met environmental goals• Reduced maintenanceEnvironmentally Friendly Power Solution Increases UtilityUptime by more than 20%Flue Gas Desulfurization Solution utilizingRockwell Automation’s Integrated Architecturesimplifies maintenance and improves operations.
  14. 14. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.European Power Stations usingAlstom Power Solutions – FGD System14Challenge• Use of COTS hardware and software to allow furtherexpansion using the same platform and modularityand to ensure a future migration path• Produce standardized control system componentsfor use across multiple Power Stations• Meet power station requirements for control systemstandards• Integration of new equipment with existing plantcontrols and operator interfaceResults• Met environmental goals• Reduced maintenance• Easily transferable design allowed staff to movefrom site to site for fast commissioning• Simulation model to test application sequences andmodes sped site commissioning• Modular code was deployed and reused acrossmultiple sitesWet flue gas desulfurization equipment reduces sulfurdioxide emissions by ~ 94%.European coal fired plants are meeting the LargeCombustion Plant Directive with Flue GasDesulfurization equipment controlled withRockwell Automation’s Integrated Architecture.
  15. 15. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.USA Utility’s Fleet of Power Plants deployActivated Carbon Injection Systems15Challenge• Fast track projects to comply with EPA regulations andstate sponsored mandates• Project schedule required precise timing to avoid penalties• Produce standardized control system components for useacross multiple power generation sites• Integration of new equipment with existing plant controlsand operator interface (DCS) – align DCS templates withstand-alone control functionsResults• Modular code was developed, deployed and reused acrossmultiple sites• Easy integration between BOP and Plant DCS by utilizingEthernet and a common data exchange format• Control system standardization results in improvedavailability, spare parts, and operational training• Improved maintenance – Plant DCS operation as well aslocal operator interface at the equipment provided thediagnostics required for faster troubleshootingRockwell Automation’s Integrated Architecturedeployed on the ACI subsystem provides fullstandalone process control in addition to integratinginto the existing DCS infrastructure.As part of the utility’s environmental improvementprogram for their fleet of 800 MW and highergeneration plants, the utility added activatedcarbon injection systems.
  16. 16. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Arkansas Electric CooperativeCorporation (AECC) – Software CEM®16Challenge• Must meet stringent regulatory standards forenvironmental quality• Hardware emission monitor equipment obsoleteand needed to be replaced• Reduce maintenance labor, eliminateconsumables, reduce cost of operationResults• Cost Savings: One year ROI over a CEMShardware replacement investment• Reduced need for skilled maintenancelabor• Reduced consumable costs associated withcalibration gases• Reduced energy consumption• System Certified Through a Relative AccuracyTest Audit (RATA)• Certified at < 7.5% for less then 10ppm NOxSoftware CEM® is helping AECC save more than$50,000 per year in costs relative to operating ahardware-based CEM system.AECC Benefits from Sustainable EmissionsMonitoring, Reduced Operating Costs andGreater Accuracy through Software CEM® fromRockwell Automation.
  17. 17. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Typical Architectures & Solutions Coal Fired Power Plant Pollution Control Equipment Including SCR Optimization Model Gas Fired Power Plant Pollution Control Equipment Including Software CEM® & SCR Optimization Models Medium Voltage Drives for ID & FD Fans Condition Based Monitoring Systems Software CEM® - Continuous Emission Monitoring System (CEMS)17
  18. 18. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Coal Fired PlantPollution Control Equipment18
  19. 19. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Gas Fired PlantPollution Control Equipment19
  20. 20. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Sample Architecture –an Advanced Technology Approach20
  21. 21. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rockwell Solution Capabilities:Medium Voltage ID / FD Fan Applications PowerFlex 7000 Direct to Drive Technology Eliminates the Isolation Transformer - increases the efficiency of the wholestring Allows any motor brand to be selected by the pump manufacturer Integrates easily with PlantPAx or 3rd Party DCS solutions Networking Options -Profibus DP, Modbus TCP, EtherNet/IP, etc. Robust and Safe Design More than 16 years MTBF for the whole Drive Symmetrical Gate Commutated Thyristor (SGCT) - Non-rupture, non-arcfailure mode Lower Mean Time To Repair (MTTR) reduces lost production costs Simple, reliable power structure with low component count Fewer devices / simpler design minimizes maintenance requirements Easy to maintain – SGCT can be changed quickly without special tools Standards Meets IEEE 519-1992 Harmonic Guidelines Certified equipment for 50ºC operation (all the elements including DC PowerSupply, Control system, etc.)21
  22. 22. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Typical Fan/Pump Monitoring & ProtectionSystem Architecture22
  23. 23. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rockwell Solution Capabilities:Condition Based Monitoring Systems BOP Fans & Pump Skids - Condition Based MonitoringSolution Scalable options – walk around to fully integratedsolutions Integrates easily to PlantPAx or 3rd party DCS solutions Real-time Protection Protection from catastrophic failures - Alarms can belinked to equipment relays to shutdown equipment ondangerous levels of vibration Predictive Maintenance Predictive maintenance package is needed to flagpending pump problems before they occur Better scheduling of Preventative Maintenance Diagnostics Knowledge of the root cause of the equipment failures(unbalance, looseness, misalignment, or bad bearings) Reduced downtime, spare parts and emergency repair costsPrevent this fromhappening23
  24. 24. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Software CEM® Solution An Emission Model is developed andthen run in real-time. The modelreflects the relationship betweenprocess operations and ambientconditions to emissions. A Patented Sensor Validation isutilized to ensure the accuracy of thepredicted emissions data.24
  25. 25. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rockwell Solution CapabilitiesSoftware CEM® Cost Effective Monitoring & Compliance A proven, model-based, software solution that leverages existing processinstrumentation and data Does not require additional capital equipment or real estate Up to 50% less cost to install and maintain than hardware CEMS No specially trained technicians/dangerous environments/hazardous materials No consumable products, thus no increase in material operating costs Highly Accurate & Reliable Emissions Monitoring & Reporting Continuous, real time sensor validation & emission performance Detects & alerts operator to sensor failures Meets strict continuous emissions monitoring data availability requirements of95% or more Accurate emissions modeling with robust prediction capabilities 100% data validation lowers the risk of inaccurate reporting Environmental and Industry Experience & Expertise Proven solutions that meet unique, local regulatory requirements Meets all US EPA requirements for PEMS 40 CFR Part75; Subpart E for “Alternative Monitoring Systems” 40 CFR Part 60; Appendix A, Performance Specification 16 (PS-16) 100% Certification Record with 300+ PEMS installations25
  26. 26. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.www.rockwellautomation.comFollow ROKAutomation on Facebook & Twitter.Connect with us on LinkedIn.Rev 5058-CO900DThank You!