Emerson to automate new coal-fired power plant | Automation.com

Emerson to automate new coal-fired power plant

Emerson to automate new coal-fired power plant
Adoption of Emerson's PlantWeb® digital plant architecture with Ovation® control system expected to reduce installation and startup costs at new 660-MW Nebraska City Unit 2 plant

PITTSBURGH (June 22, 2006) - Emerson Process Management has won a contract to install its PlantWeb digital plant architecture with the Ovation expert control system at Nebraska City Station Unit No. 2, a new sub-critical pulverized coal plant to be operated by Omaha Public Power District (OPPD). The 660-MW generating unit will be built adjacent to OPPD's existing Nebraska City Station Unit No. 1 facility located along the Missouri River near Nebraska City.

Nebraska City Unit 2, expected to begin commercial production by May 2009, will approximately double the generating capacity of the station. OPPD will use half of the output from the new unit to meet its customers' electricity needs, while the remaining half will be used by seven other public power entities participating in the project.

Nebraska City Power Partners (NCPP), comprised of Zachry Construction, Overland Contracting (subsidiary of Black & Veatch), and Gilbert Industrial, serves as the EPC contractor for the project. For Nebraska City Unit 2, Nebraska City Power Partners selected Emerson's PlantWeb automation solution. PlantWeb utilizes high-speed communications networks, intelligent field devices and bus I/O technologies to help power producers reduce installation and startup costs, control critical plant processes, increase plant efficiencies and megawatt production, and realize long-term operations and maintenance savings.

"We set out to design and build a state-of-the-art plant that not only employs current technologies, but also offers economic advantages for our customer as well," said Rod Unruh, NCPP Project Executive. "Because of the installation, startup and ongoing operational savings that are possible with digital bus technologies, we see the value in adopting this solution."

Emerson's successful track record implementing digital automation projects was a key consideration for this project, according to the NCPP engineering team. "Emerson's advanced control technologies, combined with its technical and industry experience, makes Emerson a good fit for this project," explained Tim Suellentrop, NCPP Lead I&C Engineer.

At the new coal-fired plant, Emerson's Ovation system will manage more than 8,500 I/O points. Specifically, the Ovation system will monitor and control the IHI Heavy Industries boiler (the first installation of this boiler in the United States), the burner management system, and balance of plant processes. The system will also perform data acquisition and interface to the plant's Toshiba turbine.

An Emerson high-fidelity simulator will help pave the way for the smooth, efficient startup and operation of the new plant. Emerson will provide the high-fidelity models, as well as the hardware and software, on their virtual controller platform, resulting in a state-of-the-art simulation solution. In the virtual architecture, actual controllers are replaced with Ovation virtual controllers that reside on a Microsoft Windows-based personal computer, known as the virtual host. The virtual controllers, which utilize standard Ovation engineering tools and operator interfaces, provide one-on-one functionality that mirrors the actual Ovation controllers that comprise the plant control system, but with a significantly reduced footprint.

The high-fidelity simulator will be used as a training tool, enabling operators to fine-tune their skills and familiarize themselves with the new controls and plant equipment before startup. By training staff to operate the plant more efficiently, the Ovation simulator can result in the reduction of costly, unplanned trips. Furthermore, after the plant is up and running, the simulator will be used as an engineering tool to test changes in control logic.

In the boiler area, Emerson's digital automation solution calls for Foundation fieldbus and Profibus technologies to communicate with a number of the company's intelligent field devices, including Fisher valves equipped with Fisher FIELDVUE digital valve controllers featuring advanced performance diagnostics, and Rosemount pressure and DP transmitters for boiler, steam turbine, and other plant services. Emerson has also been selected to negotiate the supply of additional balance of plant instrumentation.

Emerson's comprehensive digital automation solution for Nebraska City Unit 2 also includes the AMS Suite: Intelligent Device Manager. For new plant construction, AMS Device Manager streamlines device configuration and commissioning, thereby contributing to more efficient plant startup. AMS Device Manager also provides online access to instrument and valve process information, diagnostic status information, and automatic documentation of all field device maintenance information - all contributing to ongoing efficiency of plant operations and maintenance activities. This important capability will be further enhanced through incorporation of Emerson's AMS ValveLink SNAP-ON, which delivers additional valve diagnostic information.

Emerson's PlantWeb digital plant architecture has an extensive track record across a number of industries of lowering installation costs, ensuring a fast startup and improving ongoing plant operations and maintenance. Furthermore, the PlantWeb approach advocated by Emerson has been validated by a recent study by JDI Contracts Inc. that reinforces how integrating digital bus technology into initial plant design can reduce new coal plant construction costs by millions of dollars. Based on this proven combination of startup, operational and bottom-line benefits, the power industry is increasingly exploring digital bus-based technologies.

"With more than 2,000 installations operating around the globe, the PlantWeb approach has already been proven across a number of process industries," said Bob Yeager, president of the Power & Water Solutions division at Emerson. "As this project demonstrates, our power industry customers, such as OPPD and NCPP, also understand the value, and are anxious to capitalize on the operational results and competitive advantages that are possible through a digital automation solution."

About Emerson Process Management
Emerson Process Management, an Emerson business, is a leader in helping businesses automate their production, processing and distribution in the power, water and wastewater treatment, chemical, oil and gas, refining, pulp and paper, food and beverage, pharmaceutical, and other industries.

Emerson's Power & Water Solutions division is a global supplier of advanced distributed process control and information systems. The Pittsburgh-based company is a recognized leader in developing plant-wide process control solutions for the power generation, water treatment and wastewater treatment industries. Power & Water Solutions plays a key role in the Emerson mission of combining superior products and technology with industry-specific engineering, consulting, project management and maintenance services. Emerson brands include: PlantWeb; Ovation; SmartProcess; Fisher; MicroMotion; Rosemount; Mobrey; Daniel; Bristol; DeltaV; and AMS Suite.

About Emerson
Emerson (NYSE: EMR), based in St. Louis, is a global leader in bringing technology and engineering together to provide innovative solutions to customers through its network power, process management, industrial automation, climate technologies, and appliance and tools businesses. Sales in fiscal 2005 were $17.3 billion.
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