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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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Subject to change without noticeAll Rights Reserved. Copyright © 2010, Yokogawa Electric Corporation
Represented by: YOKOGAWA ELECTRIC CORPORATIONWorld Headquarters9-32, Nakacho 2-chome, Musashino-shi, Tokyo 180-8750, Japanhttp://www.yokogawa.com/
YOKOGAWA CORPORATION OF AMERICA12530 West Airport Blvd, Sugar Land, Texas 77478, USAhttp://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, Singaporehttp://www.yokogawa.com/sg/
YOKOGAWA CHINA CO., LTD. 3F Tower D Cartelo Crocodile BuildingNo. 568 West Tianshan Road, Shanghai 200335, Chinahttp://www.yokogawa.com/cn/
YOKOGAWA MIDDLE EAST B.S.C.(c)P.O. Box 10070, ManamaBuilding 577, Road 2516, Busaiteen 225, Muharraq, Bahrainhttp://www.yokogawa.com/bh/
TrademarksAll brand or product names of Yokogawa Electric Corporation in this bulletin are trademarks or registered trademarks of Yokogawa ElectricCorporation. All other company brand or product names in this bulletin are trademarks or registered trademarks of their respective holders.
[Ed:03/b] Printed in Japan, 105(KP)
Fossil �red power plants
Gas turbine power plants
Renewable energy power plants
Plant services and/or plant simulators
Yokogawa service o�ces
Italy 400 MWcombined cycle
Romania4 x 330 MW�ue gas desulphurization
Turkey130 MWcombined cycle
China450 MWwind power
China 6 x 300 MW coal �red
India 2 x 600 MW 2 x 500 MW coal �red
India3 x 660 MWsupercriticalcoal �red
Algeria369 MWIWPP
Nigeria 530 MW & 2 x 450 MW simple cycle
Taiwan2 x 550 MWcoal �red
Korea9 x 100 MWcoal �red
Brazil 2 x 75 MW, oil & gas �red
Trinidad and Tobago720 MWcombined cycle
Bulgaria8 x 200 t/h�ue gas desulfurization
Korea800 MW supercriticaltraining simulator
Japan2 x 1,050 MWflue gas desulfurization
U.S480 MW, combined cycle
U.S100 MW, combined cycle
Canada120 MW, cogeneration
U.S3 x 70 MW, gas & oil �red
Brazil 460 MW, combined cycle
Vietnam2 x 300 MW, coal �redsimulator & training
Japan 375 MW & 350 MW gas �red
Brunei110 MWcombined cycleThailand
2 x 110 MWcombined cycle
Saudi Arabia360 MWIWPP
Australia4 x 500 MWcoal �red revamping
Indonesia110 MW & 95 MWgeothermalSingapore
2 x 600 MWoil �redsimulator & training
Australia4 x 720 MWcoal �red revampingsimulator & trainingturbine upgrading
Australia 4 x 550 MW brown coal �red revamping simulator & training
Mongolia8 x 420 t/hcoal �redrevamping & simulator
Spain800 MWcombined cyclew/ LNG terminal
Venezuela 460 MW combined cycle
UK37 MWwaste to energy
Kuwait90,000 t/ddesalination
Egypt750 MW750 MW750 MWcombined cycle
Australiasolar (CSP)
Vietnam2 x 600 MWcoal �red
Yokogawa Vigilance at your service worldwide - representative projects
Bulletin 53T01A01-02E
Sustainable energy solutions for reducing CO2 emissionsin the power industry
21
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?
Sustainable energy solutions for a promising future
Carbon dioxide (CO2)
is one of the major greenhouse
gases causing climate change
and global warming.
In the power industry,
Yokogawa has taken the lead
in providing solutions to improve
power efficiencies by reducing
emissions.
Yokogawa has been providing
control solutions for generating
power from solar, wind, hydro,
biomass, geothermal, and other
renewable energy sources based�
on its extensive experience in
this field and technologies.
For a brighter future, Yokogawa
offers sustainable energy solutions�
that minimize the impact of CO2
emissions and achieve the
operational excellence that is the
hallmark of the VigilantPlant.
3 4
Control LAN ( Vnet/IP )
Boiler & BOPcontrols
Turbomachinerycontrol & protection
Field control station (FCS)
Geothermalpower
Biomasspower
Windpower
Solarpower
Hydropower
Fossilpower
Nuclearpower
Combinedcycle
power
Waste to energy
Renewable energy control solutionSTARDOM with FAST/TOOLS provides an innovative
web-based SCADA solution for renewable energy plants.
Efficiency improvement control solutionCENTUM 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.
Multi-sensing digitaltechnology solution
DPharp series transmitters with multi-sensing digital technology offer unmatched performance and precision.
Combustion gas analysis solutionThe TruePeak TDLS200 analyzer utilizes powerful and highly sensitive lasers and can detect and analyze combustion gases under a wide variety of conditions.
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.
Leading-edge technology for reduc ing CO2 emissions
Susta inable energy solutions
DPharpISA100.11a
field wireless
DPharpOpen access
to field intelligence
5 6
fficiency improvement
missions reduction
conomic returns
E
E
E
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.
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.
Optimal combustion and soot blowing inside the boiler enhance the heat rate, reduce outages, and reduce fuel consumption.
Control strategies reduce emissions by optimizing combustion and improve emissions measurement.
Improved performance reduces fuel and operating costs.
Yokogawa’s control strategy to reduce CO2 emissions
7 8
Approx.
Approx.
Approx.
0.3 - 1%
CO 2 3 - 10kilotons/year
0.3 - 1.1million US$/year
fficiency improvement
missions reduction
conomic returns
E
E
E
Turbine & BOP efficiency
Plantoutput
Boilerefficiency
Improvements
Benefit estimation of CO2 emissions reduction and cost saving
Example of typical benefit estimation Annual returns from “3Es” for a 300 MW coal - fired unit
Coal-fired power plant
Coal yard
Coal bunker
PulverizerBurner
DrumFSH
Bottomash
Ash pond
Ambient air
FDF
AHHot air
PAFHot air
Waste water
RH
Reheated steamCondenser
Raw water
CP Demineralizer
LPheatersBFP
HPheaters
ECO
Feedwater
DeNOxFlue gas
EP IDF
FGD
BUF
Stack
Fly ash Gypsum
Superheated steam
Make up water
FOP
Fuel oil
PSH
LPHP IP
Condensatepolishers
DSH
Deaerator
9 10
G
Approx.
Approx.
Approx.
0.3 - 0.9%
CO 2 3 - 9kilotons/year
0.3 - 0.9million US$/year
fficiency improvement
missions reduction
conomic returns
E
E
E
Example of boiler efficiency improvement
Benefit estimation of CO2 emissions reduction and cost saving
Know-how & technology
Improves heat rate
Improves steam temperature control
Implements coordinated control
Minimizes opacity violations
Adapts to various fuel properties
Enables optimal use of fuel-air mixing
Optimizes closed-loop combustion
Quickly analyzes hotspots inside boiler
Performs multivariable predictive control
Enables smart automatic soot blowing
In a power generation unit, the
main conversion process takes place in
the boiler, where superheated steam is generated
to drive the turbine. The thermodynamics inside the
boiler are a complex, multivariable process, where
it is possible to both to improve the efficiency and
reduce emissions. Hence, the boiler model is
constantly updated based on the operating status,
and appropriate optimizing algorithms are used to
improve the heat rate and minimize fuel
consumption.
The resultant fuel saving is converted to an
equivalent emissions reduction. The economic
returns are calculated from both the optimal heat
rate and emission reduction initiatives.
Estimated 3Es
Overview
Coal-fired power plant
Coal yard
Coal bunker
PulverizerBurner
DrumFSH
Bottomash
Ash pond
Ambient airFDF
AHHot air
PAFHot air
RH
Reheated steam
Condenser Raw water
CP Demineralizer
LPheatersBFP
HPheaters
ECO
Feedwater
DeNOxFlue gas
EP IDF
FGD
BUF
Stack
Fly ash Gypsum
Superheated steam
Make up water
FOP
Fuel oil
PSH
LPHP IP
Condensatepolishers
DSH
Deaerator
Waste water
11 12
G
Approx.
Approx.
Approx.
Up to 0.1%
CO 2 up to 1kilotons/year
Up to 0.1million US$/year
fficiency improvement
missions reduction
conomic returns
E
E
E
Estimated 3Es
Example of turbine and BOP efficiency improvement
Benefit estimation of CO2 emissions reduction and cost saving
Efficiency can also be greatly
improved in the turbines and BOP. For the
turbines, the condenser back pressure loss, steam
pressure loss, and temperature loss can all be
minimized.
For BOP, which is vulnerable to variations in fuel
feed, improvements can be attained by closely
coordinating control strategies to optimize the
operation of the feed pump and minimize auxiliary
power consumption.
Know-how & technology
Minimizes condenser back pressure loss
Minimizes feed heater loss
Minimizes high/low-steam pressure loss
Minimizes low-steam temperature loss
Minimizes auxiliary power consumption
Optimizes feed pump operation
Reduces forced outages
Overview
Coal-fired power plant
Coal yard
Coal bunker
PulverizerBurner
DrumFSH
Bottomash
Ash pond
Ambient airFDF
AHHot air
PAFHot air
RH
Reheated steam
Condenser Raw water
CP Demineralizer
LPheatersBFP
HPheaters
ECO
Feedwater
DeNOxFlue gas
EP IDF
FGD
BUF
Stack
Fly ash Gypsum
Superheated steam
Make up water
FOP
Fuel oil
PSH
LPHP IP
Condensatepolishers
DSH
Deaerator
Waste water
G
13 14
Approx.
conomic returnsE
Example of plant output improvement
Benefit estimation of CO2 emissions reduction and cost saving
Highly reliable DCS & instruments for reduction in forced outages
Plant output can be improved
by carrying out proper operating and
maintenance procedures, having advance warning
of tube leaks, and optimizing soot blowing
operations.
The resulting benefits are calculable based on the
recovered megawatt-hours from the reduction in
forced outages, improvement of plant availability,
and reduction of start-up plant operation.
Know-how & technology
Improves plant availability
Improves operating procedures
Improves maintenance procedures
Improves ancillary plant performance
Smoothens plant operations
Recovers megawatts of power
Reduces oil usage for start-ups
Enables the creation of feasible maintenance schedules
Overview
Up to 0.1 million US$/year
15 16Coal-fired power plant
Coal yard
Coal bunker
PulverizerBurner
DrumFSH
Bottomash
Ash pond
Ambient airFDF
AHHot air
PAFHot air
RH
Reheated steam
Condenser Raw water
CP Demineralizer
LPheatersBFP
HPheaters
ECO
Feedwater
DeNOxFlue gas
EP IDF
FGD
BUF
Stack
Fly ash Gypsum
Superheated steam
Make up water
FOP
Fuel oil
PSH
LPHP IP
Condensatepolishers
DSH
Deaerator
Waste water
G
1
32
step
step
step
Auditing your plant performance
Improving plant efficiencyImproving plant availabilityReducing CO2 emissions
Improving operation skillsImproving asset managementReducing maintenance cost
Comprehensive solutions for your plant lifecycleFrom 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:
Long-term partnership for your businessDuring 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.
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.
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.
Key services and products forreducing CO2 emissions
Plant audits
Plant simulators
Advanced management
Total power plant control
Renewable energy control
Combustion gas analyzers
Intelligent field devices
Building a lasting future
17 18
Audit your plant performance
Plant audits
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.
Maximize your cost benefits and returns
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.
Key services and products for reducing CO2 emissions
Audit items
Plant availability, reliability, and efficiency
Operating regime (daily and seasonal load profiles)
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
Full-replica power plant simulator Instructor systemSimulation computer Turbine running up system
Ethernet
Control LAN ( Vnet/IP )
20000 600
500
400
300
200
100
010 20 30 40 50 60
Time ( Min. )
18000
16000
14000
12000
10000
8000
6000
4000
2000
0
10
9
8
7
6
5
4
3
2
1
0
MW
,leve
l,tem
pera
ture
Stea
m p
ress
ure
Flue
gas
oxy
gen
Boiler / BOP control
Safety system
Turbine control
Human interface station
Performance-based operation
Plant resource management
Power plant DCS
Training scenariosMalfunctionsTrainee database
・・・
Plant logicsMathematical modelsExecutive process
・・・
Features
Benefits
Plant simulatorsKey services and products for reducing CO2 emissions
High fidelity
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
Flexible trainingand evaluation
• 99% accuracy (>99% steady state; >95% dynamic state)
Faster commissioning
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.
Smoother plant start-up
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.
Minimized risk of plant damage
By dynamically testing the safety interlocks prior to DCS installation, the simulator reduces the risk of major equipment damage occurring during the commissioning process.
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.
Reassure supreme accuracy
•
•
•
21 22
Exapilot
Performance-based operation with Exaquantum
Operation efficiency improvement package
Exaplog Event analysis package
PRMPlant Resource Manager
Plant information at your fingertips
Our key performance indicator (KPI) monitoring solution makes KPIs visible and enables you to efficiently operate the production.
Performance-based operation
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.
Advanced management
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.
Secure the predictability of your critical process
Key services and products for reducing CO2 emissions
23 24
The ProSafe-RS SCS is a TÜV SIL3 certified safety system that incorporates Yokogawa’ s pair-and-spare technology.
Safety control station (SCS)
The FCS provides powerful control functions with a highly reliable dual redundantconfiguration that incorporates Yokogawa’s own pair-and-spare technology.
Field control station (FCS)
Performance-based operation
Coordinated control
Turbomachinery control
Boiler controlBalance of plant control
Coordinated control
Steam turbine area
Boiler control area
Plant resource management
20000 600
500
400
300
200
100
010
20 30 40 50 60Time ( Min. )
18000
16000
14000
12000
10000
8000
6000
4000
2000
0
10
9
8
7
6
5
4
3
2
1
0
MW
,leve
l,tem
pera
ture
Stea
m p
ress
ure
Flue
gas
oxy
gen
Human interface station/engineering station
Boiler & BOPcontrols
Plant safetysystem
Turbomachinerycontrol & protection
Steam turbine
Control LAN ( Vnet/IP )
Air and flue gas oveview
Coal yard
EP
FGD
Fuel
Total power plant control
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.
Raise plant availability and performance
Key services and products for reducing CO2 emissions
25 26
Wind turbine view
Wind turbine details
Remotedevices
Wireless LANSTARDOM
engineering tool
Plant informationmanagement system
Plant resource manager
Modem
Modem
GSM/GPGR,Satellite,
RF,and more
GPS receiver,SNTP server
Process network
Safety instrumented system
PSTN. xDSL.and more
Field control node
Field control junction
Remote terminal unit
Optical fiber ring
Wind power
Solar power
Small hydro power
Geothermal power
Waste to energy
Biomass power
Renewable energy control
Shift to renewable energy
Key services and products for reducing CO2 emissions
R e n e w a b l e e n e r g y
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.
27 28
O2
O2
CO2
H2O
H2O
CH4
CO
CO
O2
H2O
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
Combustion gas analyzersKey services and products for reducing CO2 emissions
Coal bunker
Pulverizer
Burner
FSH
Bottomash
Hot air
PAFHot air
RH
ECO
Feedwater
DeNOx
Flue gas
Fuel oil
PSH
Reheated steam
TruePeakTDLS200
Superheated steam
DSH
Drum
Features
CO measurement for highest efficiency improvement
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.
Enhance combustion control
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.
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.
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.
NH3injection
29 30
Feed water flow
Ambient air
FDF
AH
DeNOx
Flue gas
Silicon resonant sensor
Intelligent field devicesKey services and products for reducing CO2 emissions
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.
Take your plant into the digital era
Best-in-class performance
Precision and quick response time
Field - proven reliability
No-error-prone A/D converter: Full end-to-end digital communications from process to control system
Drift free, long-term stability Unparalleled stability guarantee
Full interoperabilityOpen industrial communications: Whether you choose BRAIN, HART, FOUNDATION™ fieldbus or Profibus, our transmitters will deliver their full benefits.
Multi-sensing Measurement of differential pressure and static pressures (DP and SP) by a single transmitter minimizes your instrumentation cost.
Multi-variable DP, SP, and inline temperature measurement in a single transmitter enables mass flow to be calculated by an on-board flow computer.
Coal bunker
Pulverizer
Burner
FSH
Bottomash
Hot air
PAFHot air
RH
ECO
Feedwater
Fuel oil
PSH
Reheated steam
Superheated steam
DSH
Drum
Drum level
PXFX
FX
FX
LX
Main steam flow and pressure
Spray flow
Air flow
FX
For all ultra critical processesBoiler drum level measurement
Very high static pressure
Varying pressure affecting density
Very small measurement span
Feed water flow measurement
Very high pressure surges (water hammer)
Varying flow for varying load
DPharpISA100.11a
field wireless
DPharpOpen access
to field intelligence
31 32
Plant information
Thermal Power Plant No. 4
Ulaanbaatar, Mongolia
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
1997 - 2007
Boilers - 8 x 420 t/h, lignite-firedTurbines - 2 x 80 MW, 4 x 100 MW with town heating
Retrofit of control and safety systems, and replacement of field instruments and actuators
Plant name :
Location :
Owner :
Steam outputs (boilers) :
Electricity outputs (turbines) :
Fuel :
Construction :
Retrofit :
Output/fuel :
Scope of replacement :
Project background
A case study of CO2 emissions reduction
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.
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.
Retrofit of Mongolia’s largest thermal power plant
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.
33 34
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
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.
Full automation of boilers, burners, and balance of plant (BOP) facilities
A highly reliable and expandable distributed control system (DCS)
Replacement with state-of-art DCSThe control systems for all eight boilers at TES4 were changed over to a state-of-the-art Yokogawa
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.
A power plant simulator for training DCS operators
Supply of power plant simulatorIn 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.
The challengesThe 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.
TES4 plant control room before refit
Yokogawa’s solutionsCustomer’s requirements
A case study of CO2 emissions reduction
35 36
TES4 plant control room with CENTUM system
1998 1999 2000 2001 2002 2003 2004 2006
10,000
5,000
0
15,000
1997 2005 2007
tons
13,897
10,300
7,280
4,7934,757 4,755 4,012 3,852
2,8081,897 1,682
Total heavy oil consumption
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.
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.
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 2006
400
350
300
1997 2005 2007
g/kWh
409417
393
389 388 389
365 365
349
337
317
Coal consumption ratefor electricity generation
1998 1999 2000 2001 2002 2003 2004 2006
190
180
170
1997 2005 2007
kg/Gcal
188
186 186
184 184 184
182181
180
177
174
Coal consumption ratefor district-heating steam
1998 1999 2000 2001 2002 2003 2004 2006
3,000
2,500
2,000
1997 2005 2007
kilo tons
2,9302,957
2,8462,817 2,811 2,818
2,696 2,6902,614
2,537
2,426
Total CO2 emissions amountof electricity & district-heating steam
fficiency improvement
missions reduction
conomic returns
E
E
E
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
22% reductionfrom 1997 to 2007
7% reductionfrom 1997 to 2007
17% reductionfrom 1997 to 2007
88% reductionfrom 1997 to 2007
A case study of CO2 emissions reduction
Achievements
37 38
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