Complexul Energetic Oltenia S.A., Turceni, Romania
The Turceni thermal power plant (TPP), located in southwest Romania's Gorj county, is this country's largest coal-fired power plant, belonging to the Romanian state-owned coal energy producer Complexul Energetic Oltenia S.A. With a total installed capacity of 3,900 MW (9 units x 330MW,2 units x 315MW, 2 units x 150 MW spread across 4 power plants), it generates approx. 30% of the country's electricity.
As Romania joined the EU in 2007, it was required to bring its power plants' sulfur dioxide (SO2) and dust emissions into compliance with the EU environmental standards by 2011. Thus the power plants had a very tight deadline for achieving this reduction, and would not be allowed to continue the operation if they failed to comply. Given this situation, the Turceni TPP pollution abatement project chosed to make use of a yen-denominated official development assistance (ODA) loan from the Japan Bank for International Cooperation (JBIC) to finance the installation of flue gas desulfurization (FGD) systems for units 3, 4, 5, and 6 at the Turceni power plant.
The FGD systems are designed to remove 96.4% of the SO2 and up to 80% of the fly ash from the boiler flue gas. Each boiler of units 3 through 6 is equipped with an absorber unit, and there is a total of two limestone slurry preparation lines for the four boilers. The flue gas SO2 absorption process produces a gypsum slurry that is pumped out to a subsequent dehydration process. 15,000 tons/year of commercial grade gypsum are produced. This technology is the one of the former Austrian Energy & Environment (AE&E), actually Andritz Energy & Environment.
The FGD control room
For the Turceni TPP, Yokogawa provided its CENTUM VP integrated production control system (PCS); field devices such as DPharp EJX pressure/differential pressure transmitters, pH analyzers, and temperature transmitters; the Plant Resource Manager (PRM) integrated device management tool; the Exaquantum plant information management system (PIMS); the eLogBook tool for shift operator logging; and paperless recorders for environmental emissions tracking and the monitoring of large motors. Following the delivery of all of these products and systems between 2009 and 2012, the FGD systems for all four units have been operating to the customer's complete satisfaction.
The Challenges and the Solutions
1. Integration with subsystems
The Turceni TPP has to run 24/7/365 for a steady supply of electricity to the national grid while meeting the strict requirements of the new EU environmental standard, which provides that the SO2 content in the flue gas must never exceed 200 mg/Nm³. To promptly make the necessary adjustments, the operators in the FGD control room need to see in real time what is happening in each of the FGD processes. Yokogawa made this possible by achieving complete integration between its CENTUM VP PCS with FGD subsystems such as the gas monitoring and recording system (GMRS), vibration monitoring and recording system (VMRS), asset management package (PRM), and the closed circuit television system (CCTV).
From their human machine interface (HMI) stations in the FGD control room, operators can view live feeds from CCTV cameras installed in various plant locations, and are able to zoom in/out and pan left/right. Also, at the HMI stations, operators have access to a PRM screen that gives the status information for all field devices and a VMRS screen that displays a continuous stream of data as well as data logged by paperless recorders that can be used to identify when preventive maintenance is required for any of the large motors in the FGD facility, thereby minimizing the possibility that a failure can lead to an unscheduled plant shutdown.
Thus, operators can stay on top of what is happening in the process at all four units and they are provided with the right information at the right time to ensure that they can promptly take the right action to ensure safe and efficient operations.
2. Optimum FGD absorber control
The FGD absorber has three main processes that must be precisely controlled to meet the government's environmental standard and to ensure the efficient production of a high quality gypsum by-product:
- Limestone: the storage of limestone and preparation of limestone slurry
- Absorption: the supply of limestone slurry and air to remove SO2 and produce a gypsum slurry
- Gypsum: the recovery of commercial-grade gypsum from the gypsum slurry
The flue gas enters the absorption unit after passing through an electrostatic precipitator that removes fly ash. Based on the type of coal used and the data on the flue gas flow rate, the CENTUM VP system automatically controls how much slurry is sprayed inside the absorber unit by controlling pumps on or off, thereby ensuring the optimum desulfurization rate required to meet EU environmental standards. The reaction between the SO2 and limestone slurry produces calcium sulfite, which undergoes a further conversion to gypsum through the introduction of oxidation air. After the pH level is adjusted to 7.0 through the addition of CaCO3, the gypsum slurry is transferred to a gypsum separator. Here, through some processes, such as filtration and dehydration that necessitate the operation of numerous motors and pumps, a saleable gypsum by-product is produced and it is over 95% pure.
All strategies for the automated control of the above processes are configured in the CENTUM VP system, using a combination of sequential and feedback control functions. By means of graphic displays and guidance messages at the HMI stations, operators at the Turceni TPP are able to interact with CENTUM VP and stay on top of what is happening in these processes.
Flue gas desulfurization processes
3. Reporting and information transferring
The Turceni TPP must regularly submit reports showing that it is in compliance with the new EU environmental standard. The Exaquantum plant information management package collects all the necessary operational data for these reports, which are automatically generated on a daily, weekly, and monthly basis by the CENTUM VP system. The amounts of water, electricity, limestone, and steam used in the processes are also calculated so that the overall efficiency can be determined. This information can be used to further improve the operation.
The eLogBook tool allows the operators on each eight hour shift to record and transfer information on any significant activities, operation changes, problems, and so on to the operators working the next shift, ensuring greater safety and efficiency in plant operations.
Marian Motocu, the former general manager of Complexul Energetic Turceni S.A. (at this moment, being the manager of Craiova II TPP): "Yokogawa's fully integrated control solution and competence came with a great contribution to the success of this pollution abatement project, opening a new phase in the Romanian energy power sector."
Laviniu Danciu, complex project manager, Turceni TPP, said, "Yokogawa's systems and products, including the CENTUM VP PCS, Exaquantum PIMS, PRM plant asset management package, instrumentation, the eLogBook tool, sequence event recording (SER), and integrated 3rd party subsystems such as a vibration monitoring system, emissions monitoring system, and CCTV system have all demonstrated their strong capabilities over a one year period at all four units. Yokogawa is one of our best partners."
1970년대 중반, Yokogawa는 EBS 전기 제어 시스템 (EBS Electric Control System)의 출시와 함께 전력 사업에 진출했습니다. 그 이후로 Yokogawa는 전 세계 고객에게 최상의 서비스와 솔루션을 제공하기 위한 기술과 역량의 개발을 꾸준히 지속해 왔습니다.
Yokogawa는 역동적인 글로벌 전력 시장에서 더욱 적극적인 역할을 수행하기 위해 글로벌 전력 솔루션 네트워크를 운영했습니다. 이로 인해 Yokogawa 내에서 보다 긴밀한 팀워크가 가능해져서 글로벌 리소스와 업계 노하우를 하나로 모았습니다. Yokogawa의 전력 산업 전문가들은 각 고객에게 정교한 요구 사항에 가장 적합한 솔루션을 제공하기 위해 협력합니다.
석탄, 석유 또는 가스를 연료로 사용하는 화력발전은 전 세계적으로 대부분의 전력을 생산하고 있습니다.
Exaquantum은 공정의 모든 측면에서 데이터를 수집하고 해당 데이터를 쉽게 사용할 수 있고 가치 높은 정보로 바꾸어 제공합니다.
Plant Resource Manager (PRM)는 플랜트 운영 및 유지 보수의 환경을 개선하고 높은 예측 기능을 통해 플랜트 자산의 신뢰성 및 가용성을 극대화하는 것을 목표로하는 Yokogawa의 독창적인 자산 관리 핵심 플랫폼입니다.
The YTA110/310/320 series is Yokogawa's base traditional temperature transmitter in the field-mount transmitter line.
YTA50은 측정된 온도에 상응하는 단순한 4 ~ 20 mA 출력을 출력하는 2 선식 아날로그 온도 전송기입니다.
YTA50과 마찬가지로 YTA70은 측정 된 온도에 상응하는 단순한 4 ~ 20 mA 출력을 출력하는 2 선식 아날로그 온도 전송기입니다. 그러나 HART 5 (코드 -E) 또는 선택 가능한 HART 5 또는 HART 7 (코드 -J) 디지털 통신을 추가 할 수 있습니다.
Yokogawa는 프로세스 자동화를 위해서 중요한 운영 인프라를 제공합니다. 분산제어시스템(DCS)은 플랜트 또는 산업 공정의 자동화 된 제어 및 운영을 위한 플랫폼입니다. 10,000개 이상의 플랜트에서 고객의 생산 목표 달성하기 위해서 Yokogawa DCS가 적용되었습니다.
Yokogawa는 head-mount형, panel-mount형 또는 field-mount형 온도 전송기 제품 군을 제공합니다.