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...
Each year, a panel of Control Engineering editors and industry expert judges select the System Integrator of the Year Award winners.
Control Engineering Leaders Under 40 identifies and gives recognition to young engineers who...
Learn more about methods used to ensure that the integration between the safety system and the process control...
Adding industrial toughness and reliability to Ethernet eGuide
Technological advances like multiple-in-multiple-out (MIMO) transmitting and receiving
Virtualization advice: 4 ways splitting servers can help manufacturing; Efficient motion controls; Fill the brain drain; Learn from the HART Plant of the Year
Two sides to process safety: Combining human and technical factors in your program; Preparing HMI graphics for migrations; Mechatronics and safety; Engineers' Choice Awards
Detecting security breaches: Forensic invenstigations depend on knowing your networks inside and out; Wireless workers; Opening robotic control; Product exclusive: Robust encoders
The Ask Control Engineering blog covers all aspects of automation, including motors, drives, sensors, motion control, machine control, and embedded systems.
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
News and comments from Control Engineering process industries editor, Peter Welander.
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
This is a blog from the trenches – written by engineers who are implementing and upgrading control systems every day across every industry.
Anthony Baker is a fictitious aggregation of experts from Callisto Integration, providing manufacturing consulting and systems integration.
Integrator Guide

Integrator Guide

Search the online Automation Integrator Guide

Create New Listing

Visit the System Integrators page to view past winners of Control Engineering's System Integrator of the Year Award and learn how to enter the competition. You will also find more information on system integrators and Control System Integrators Association.

Case Study Database

Case Study Database

Get more exposure for your case study by uploading it to the Control Engineering case study database, where end-users can identify relevant solutions and explore what the experts are doing to effectively implement a variety of technology and productivity related projects.

These case studies provide examples of how knowledgeable solution providers have used technology, processes and people to create effective and successful implementations in real-world situations. Case studies can be completed by filling out a simple online form where you can outline the project title, abstract, and full story in 1500 words or less; upload photos, videos and a logo.

Click here to visit the Case Study Database and upload your case study.