Central and remote operationThe plant is operated from the main control room, where two operator workstations are used to control and operate the whole plant. Operators are given a complete view of the plant statuses via the Plant Visualization Station (PVS), while a system operation station shows a complete overview of the main process, events and alarms of the plant. System of systemsFor the Xina Solar One project, more than just a single control system was deployed. To meet the needs of the plant and requirements based on the engineering performed by Abengoa, Yokogawa developed a complete control system solution that integrates the subsystem controls and enables the operators to control the entire plant via the same user interface while providing plant statuses in real time. Electrical monitoringAnother challenge for the control system is to enable proper real-time monitoring of all the electrical signals. Yokogawa Unified Gateway Station (UGS), which is deployed wherever necessary, unifies the subsystem controllers on the redundant control network of the CENTUM VP. These UGSs gather all the electrical signals via diverse communication protocols, realizing a full monitoring application required by the power plant control system, such as for process alarms, annunciations and system alarms. Steam turbine monitoring via Matrikon® OPC serverFor complete integration, the CENTUM VP in this project allows steam turbine monitoring via a UGS and Matrikon turbine controller OPC server. All turbine control data is thus gathered, allowing the operators to monitor both the turbine and BOP operation on the same user interface. Business layer (PI System) integrationXina Solar One is part of the extensive renewable power plant portfolio in South Africa as it is connected to the grid, helping to strengthen the balance of the electricity demand of the country. Due to the high integration level of the plant, the control system needs to deliver sufficient data to the business layer to ensure proper operation of the plant in compliance with the power demand of the grid. For this business layer integration, the CENTUM VP uses the OPC protocol, which is widely used for integration with PI Systems (OSIsoft).The CENTUM VP at Xina Solar One not only controls the core equipment - the steam generator, steam turbine, aero condenser, and molten salt storage system - and utilities such as the water treatment plant, but also integrates the solar field control and monitoring system to enable the user to control the entire plant at a single place.One of the challenges for the CENTUM VP system was to implement all the control system blocks for all units and pieces of equipment and the integrated subsystems such as packaged units. Integration of all processes into the CENTUM VP system has greatly benefited the operators thanks to full visibility of all the components of the plant with a real distributed control schema. The unsurpassed reliability of the CENTUM VP distributed control system, which has been proven in many industry sectors and cannot be attained by PLCs, gives operators greater flexibility in plant operation.The UGSs provide electrical data to field control stations (FCSs) in each location. In critical locations, a model with dual-redundant CPUs is used to reinforce the availability. The capacity of 100,000 tags and 1,000,000 data items per UGS makes it ideal for supervising electrical devices and subsystems when integrating electrical devices in the CENTUM VP. The OPC station delivers structured data necessary to update the databases of the PI System. The data gathered and delivered is taken directly from the control network and CENTUM VP FCSs, so the PI System obtains reliable data in real time, thus enabling digital transformation with high-quality and reliable operations data. This integration facilitates the analyst’s work and potential for correct market control and delivery.The operation is supported by Plant Resource Manager (PRM), which is crucial for ensuring proper, timely maintenance of the plant. The PRM helps to improve equipment maintenance plans and optimize equipment maintenance costs.For the purposes of monitoring and management, the control room is connected to a remote operator workstation located in the meeting room, which provides full control of the plant via a remote connection under a secure engineered connection.CENTUM VP:• Field control stations, including integration of two local HMIs for field control and supervision• Turbomachinery modules• Operator stations (with four monitors)• Remote DCS station• Supervisor station• UGS stations (single- and redundant-CPU models)• PRM server• Third-party subsystem integration (via Modbus, IEC 60870 or IEC 61850):- Steam turbine- Solar steam generator (SSG)- Heat transfer fluid (HTF) system- Steam boiler- Thermal energy storage (TES) system- Chemical dosing- Solar tracking system- Siemens VF/SS- Siemens SICAM-TM- Siemens D20- Siemens SICAM-PAS• OPC communication with PI System10Customer SatisfactionThe solution delivered by Yokogawa to Xina Solar One is characterized by robustness, reliability and resilience. The control system, one of the key parts for the operation of the plant, meets the requirements and exhibited the high performance for which the CENTUM VP is renowned.System DetailsGeneral:• CENTUM VP DCS for all BOP control and integration of the Solar Field SCADA• Integration of subsystems and remote access• Connection with PI System for asset management• Optimized subsystem integration to eliminate many points of failureXina Solar One / South Africa
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