Expert controls replace legacies, 3% boost

Tighter system integration and new controls at the 10th largest U.S. power plant improved load ramp rates by 3% and better regulated temperature. Emerson Process Management said that its Power & Water Solutions group is replacing legacy controls in all four units of Progress Energy Inc.


Tighter system integration and new controls at the 10thlargest U.S. power plant improved load ramp rates by 3% and better regulated temperature. Emerson Process Management said that its Power & Water Solutions group is replacing legacy controls in all four units of Progress Energy Inc.'s (PE) 2,462 MW steam-plant in Roxboro, NC, with Emerson's Ovation expert-control system. The multi-year project began in early 2005, with installation of Unit 2 controls, continuing as controls are installed in the plant's remaining three units. It's part of PE's move to a centralized, integrated control strategy for Roxboro.

Although in place only a few months, coordinated controls reportedly have helped Unit-2's load ramp-rates improve from 91% in 2004 to 94% through November 2005. Additionally, tighter control strategies have helped to improve Unit 2's superheat temperature regulation byoF during load ramps.

Old unit-control systems were at maximum capacity, precluding addition of new controls for selective-catalytic reduction (SCR) and scrubber systems. Now Unit 2 has started-up a recently added SCR system along with the plant controls. Moreover, a flue-gas desulphurization system, using FOUNDATION fieldbus, will also link to the new controls.

The new, integrated control system replaces distributed control systems (DCS) that were data-linked to numerous PLC-based plant systems. DCSs and PLCs used Genius I/O blocks encompassing over 20,000 remote I/O points. Due to a tight outage schedule and added costs, it was not feasible to replace existing Genius I/O with new modules.

Migrating controls for the four-unit plant posed a number of challenges, including:

  • Supplying reliable and affordable redundant interfaces to the station's 2,700 Genius I/O blocks;

  • Furnishing operators with a centralized coordinated system to enhance plant operation;

  • System installation within a 30-day outage schedule; and

  • Providing flexibility for adding new plant controls.

No comments
The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
The System Integrator Giants program lists the top 100 system integrators among companies listed in CFE Media's Global System Integrator Database.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
This eGuide illustrates solutions, applications and benefits of machine vision systems.
Learn how to increase device reliability in harsh environments and decrease unplanned system downtime.
This eGuide contains a series of articles and videos that considers theoretical and practical; immediate needs and a look into the future.
Intelligent, efficient PLC programming: Cost-saving programming languages are available now; Automation system upgrades; Help from the cloud; Improving flow control; System integration tips
Smarter machines require smarter systems; Fixing PID, part 3; Process safety; Hardware and software integration; Legalities: Integrated lean project delivery
Choosing controllers: PLCs, PACs, IPCs, DCS? What's best for your application?; Wireless trends; Design, integration; Manufacturing Day; Product Exclusive
PLCs, robots, and the quest for a single controller; how OEE is key to automation solutions.
This article collection contains several articles on improving the use of PID.
Learn how Industry 4.0 adds supply chain efficiency, optimizes pricing, improves quality, and more.

Find and connect with the most suitable service provider for your unique application. Start searching the Global System Integrator Database Now!

Special report: U.S. natural gas; LNG transport technologies evolve to meet market demand; Understanding new methane regulations; Predictive maintenance for gas pipeline compressors
Cyber security cost-efficient for industrial control systems; Extracting full value from operational data; Managing cyber security risks
Drilling for Big Data: Managing the flow of information; Big data drilldown series: Challenge and opportunity; OT to IT: Creating a circle of improvement; Industry loses best workers, again