US-based Emerson Process Management, a wing of Emerson business, has implemented the comprehensive automation and control solution that contribute to the operational improvements at the Porcheville thermal power plant.
The comprehensive Emerson solution incorporates the company’s PlantWeb digital plant architecture with the Scenario simulation, Ovation expert control system, AMS Suite predictive maintenance software and Smart Wireless technology, as well as its SureService customer support program.
Its measurable improvements that includes a 50% improvement in the plant’s ability to ramp up and down on demand, helps to maintain grid stability in France and provides economic benefits for the plant’s owner, EDF Group.
The Porcheville plant is located in the Yvelines region along the Seine, approximately 30 miles west of Paris. It commenced its operations in 1968 as a four-unit, 2,400MW (4 x 600) oil-fired peaking plant. Units 1 and 2 at the plant were closed by EDF Group, a top electricity producer in Europe, due to the high cost of fuel and surplus capacity in France’s electricity market.
The automation and control portion of the project called for Emerson to replace obsolete Control Data analog controls with its Ovation control system for all four units. Ovation system at each unit comprises a controller to manage individual operations of the Alstom steam turbine and three controllers for monitoring critical data associated with the boiler and balance-of-plant processes. The Ovation system would also receive additional tank level measurements from Emerson’s Smart Wireless network, soon to be installed. Smart Wireless extends PlantWeb predictive intelligence into areas that were previously out of physical or economic reach, opening the door for new possibilities in process improvement.
Emerson, despite the project’s requirements, including modernizing two units that had been mothballed, could install, test and start up the control systems within separate 18-day windows that had been allotted for each unit.
Prior to the upgrade, EDF was able to ramp the Porcheville units by +/- 60MW when requested by the grid. Since commissioning, Ovation has boosted Porcheville’s maneuverability to +/- 90MW – a 50% improvement. Emerson’s automation solution enabled EDF to put the Porcheville units back online.
The company’s AMS Suite at the Porcheville plant, Intelligent Device Manager, works with the Ovation system to manage smart field devices, resulting in improved production reliability. Maintenance personnel can access predictive diagnostics on all HART instruments, including Emerson’s Micro Motion mass flowmeters and Rosemount OXYMITTER 4000 transmitters, as well as Fisher DVC 6000 digital valve controllers installed throughout the plant.
EDF, as part of the comprehensive project, is also taking advantage of Emerson’s Scenario simulation solution. The simulation would be used to train new and existing operators, strengthening their skills and ability to respond to varying situations, which would enhance plant performance. EDF is also utilizing Emerson’s SureService customer support program, which offers access to comprehensive technical support and Ovation software upgrades for five years.
Bob Yeager, president of the Power & Water Solutions division of Emerson, said: “A project of this scope and complexity demonstrates how Emerson is uniquely positioned to provide power generators with a comprehensive plant automation and control solution that incorporates not only the control system itself, but also simulation, field instrumentation, wireless technologies – and more. It’s this ability that sets Emerson apart from other vendors who lack the technology, expertise or resources to successfully complete such a complex project within an aggressive timeframe.”