metsoautomation for reliable and user-friendly energy...

Metso AutomationFor reliable and user-friendly

energy production

February 2014 Matti Miinalainen

Content

1. Metso Group overview

2. Metso Automation in short

3. Metso DNA for reliable energy production

4. Metso’s solution for Turbine Automation

5. Selected references – Power industry

Metso DNA –for reliable and user-friendly

energy productionPower production applications

Highlights of Metso DNA features

© Metso

COGENERATION Flexibility, steam network management, high availability

Specialized expertise in the power industry

HYDRO POWEREfficiency, availability, river optimization

PYROLYSISEnvironmentally efficiency, high availability,

WASTE-TO-ENERGYMaximizing waste disposal, emission management, environmentally efficiency

FLUIDIZED BED BOILERSFlexible multi fuel combustion, combustion optimization with corrosion management

COAL FIREDHigh availability, emission minimization, combustion optimization, flexible usage

SOLAR POWEREfficiency, availability, optimizing lifecycle maintenance costs

GASIFICATIONHigh cycle efficiency, high availability

COMBINED CYCLEHigh availability, emission minimizing, flexibility

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Product portfolioEnergy Demand ForecastingEnergy Trading and PurchasingProduction Optimization

Metso DNA Energy Management

Metso DNA Plant Operation Monitoring Metso DNA Boiler Performance MonitoringMetso DNA Steam Turbine Performance MonitoringMetso DNA Boiler Sootblowing ManagerMetso DNA Boiler Life MonitoringMetso DNA LCP Emission Monitoring

Plant Management Applications

Metso DNA Historian Calculation EnvironmentMetso DNA Report

Reporting & Analyzing Tools

Metso DNA HistorianMetso DNA Operate – Alarms & Events ServerApplication databases (SQL Server)

Information Services (Databases)

Metso DNA Fuel Power Compensator Metso DNA FBB Combustion Manager Metso DNA Steam Turbine ControllerMetso DNA Steam Network ManagerMetso DNA Training Simulator

Advanced Control Applications

User InteractionAutomated ProcessSecured Lifecycle

Metso DNA

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One system for all automation in power generationMetso DNA

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Metso DNA redundancyRedundant hard disks and backup tape device

• Backup Power Supply for- control node cabinets and rack I/O’s• Optional power backup for- control room devices and servers

Back-up(BU)

Redundant process controller

Redundant hard disk

• Redundant Field Bus• Redundant I/O power supply per rack

Redundant PLCinterface

Profibus DPdevices

PCSPCS GTW-LIS GTW-LISPCS

Redundant control room bus and process busRedundant control room bus and process bus

Information Server Operator InterfaceEngineering Server Alarm Processing

• Redundant power supplies and Interface controller

•Redundant M120 I/O units

Availability up to

99,98%03

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Servo outputs• 3 analog output channels

• Output range -100…+100 mA

• Settable range min and max

• Settable dither

- Frequency 50…500 Hz

- Amplitude 0…10 mA

• Field loop diagnostics

AIT4L Inputs• 4 LVDT input channels

• Input update interval 1 ms

• Settable measurement filter

• 16 bit A/D converter

ACN MR - powerful Metso DNA controller5ms control cycles now possible

Technology• Intel Atom processor

• Industry spec components

• 5 Ethernet ports

• installed in I/O-group

• Controller redundancy

Performance• Down to 5 ms control cycles

• 2 I/O-groups with < 20 ms

cycles

• More I/O-groups via Ethernet

DI for Valve shut down• 1 digital input channel

• Field voltage supply 24 VDC

• Current limit 40 mA

• Shut down function attachable

to each AO channel individually

• Reaction time 2 ms

• Power load unbalance runback

AIT4CInputs• 4 input channels 0/4-20 mA

• Input update interval 1 ms

• Settable measurement filter

• 16 bit A/D converter

Isolation• Field to system 1500 VAC

• Between channels 500 VAC

ACN MR Servo output unit AOI3S Valve position input

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Metso DNA OperateOperation tools for efficient problem solving

• Efficient alarm analysis with 1 ms Sequence of Events (SOE)

• Replay history from any picture, “time machine”

• Drag and drop trend analysis• Dynamic function and

interlocking descriptions for machine and process

• Integrated diary entries for trends and loops

Start History mode

Select displayed moment and replay

History mode indication

Feeling of control

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Multilingual Metso DNA Control Panel

• Used language can be selected per operator station • There can be several languages to choose from (these needs to be agreed

already on the sales phase)

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• Boiler HP feed pumps• Circulation water pumps• Exhaust air fans• Fresh air fans• Primary air fans• Secondary air fans• District heating pumps• Coal / peat mill feed air fans• Booster pumps

• Relative shaft vibrations (x-y)• x/y positions (GAP voltage)• Absolute bearing vibrations (x-y-z)• Axial positions (z)• Differential expansions• Absolute expansions• Shaft eccentricity• Tachometer• Process parameters

Typical condition monitoring measurementsBoiler and Turbine-Generator

Turbine generator(gas, steam or hydro)

Process specific auxiliary equipment, e.g.

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Fully integrated vibration monitoring

• ACN I/O solution- ACN M120 series I/O group with AIV8V

units for fast dynamic measurements- Max. 128 channels per I/O group- 8 measurements per I/O card => card

amount depends on monitoring points

• Vibration monitoring processing unit - ACN CS and ACN RT- A separate or shared with controls

• Application- Measurement, calculations, alarm limits- User Interface elements- History trending if TEA or IA databases are

part of the controls package

Vibration levels are on alarm or warning level

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Fuel Power Compensator (FPC)

• Compensates variations in:- fuel quality (dry/wet fuel, multiple fuels)- fuel amount (unmeasured variable)

• Improves combustion by supporting fuel flow controller and making corrections based on calculated fuel power

• Calculates fuel power in two different ways:- flue gas oxygen method (dynamic situations)- steam balance method (steady-state situations)

• Stabilizes:- boiler production- fuel consumption (minimizes usage)- combustion variables

• Recommended with Combustion Optimizer

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Proven benefits with Advanced Control Applications

Nox before

100 200 300 400 500 600 7000

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250

100 200 300 400 500 600 7000

200

400

600

800

1000CO before

100 200 300 400 500 600 7000

200

400

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800

1000

Optimization On

CO after

100 200 300 400 500 600 7000

2

4

6

8

10O2 before

100 200 300 400 500 600 7000

2

4

6

8

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Optimization On

O2 after

Nox after

100 200 300 400 500 600 7000

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100

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Optimization On

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Latest in Metso DNA to boost yourpower generation

Turbine controls

Pulverized coal fired combustion optimization

Condition monitoring

Sootblowing optimization

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Staying competitive in the electricity market

$12 million savings resulted in reduction of 7% limestone usage over the operating range

Metso played a significant role in helping Grant Town avoid considerable cost of installing a post combustion flue gas treatment system, and met our expectations of efficient, low cost operation.

Steve Friend Plant ManagerAmerican Bituminous

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Turbine AutomationCustomer specific approach

with deep knowledge of Steam Network controls

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Metso DNA Turbine Controller

• System- Common solution for the balance

of the plant, boiler and the turbine- Special fast io-cards for 5ms cycle

time

• Turbine controller- All required controls and

sequences- Better integration of boiler and the

turbine controls in demanding industrial applications

- Simulator for FAT and training

• Industrial customers- Advanced combustion controls- Model predictive steam network

control

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Metso DNA steam turbine automation

• Coordination of turbine and boiler island• Redundancy at all levels• Turbine Controller

- Speed control with automatic start-up- Auxiliary devices- Primary and secondary control- Simulator for FAT and training - Complex industrial pressure controls

• Turbine protection- Over speed protection - Hima / DNA modules - Machine protection

• Machine Monitoring- Performance monitoring calculations- Thermal stress calculations- Vibration diagnostics

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Steam Network knowhow in CHPsSteam Turbine essential part of the steam network

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Integrated machine monitoring

Metso DNA Machine Monitoring- ACN MR - server- M120 - cards

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• Extensive experience - Industrial turbines and large utility sized turbines- With overall control strategies for power boilers, steam

network management and frequency support applications

- Both retrofits of old installations as well as new turbine deliveries.

• Experienced with the following steam turbines: Doosan-Skoda, LMZ, HangZhou, Zamech, KWU, Lang (Alstom), Bergman-Borgman, ASEA Stahl, Siemens, ABB, Lang, BHEL, AEG, Triveni.

• OEM certification by LMZ (steam turbine)• OEM certification by Doosan-Skoda (steam turbine)

Metso DNA steam turbine automation Selected references

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Structure of the Turbine Control and Protection

Stop valve ControlValves

n > MAX

RotatingSpeed Measurement3 channel(Protech 203

Turbine protection(3-Channel)

Status data

SynchronizingDevice

Speed controller•Island operation•Disturbance reserve•Load shut-off •Manual output control

Turbine controller•Turbine run-up•Load control•Back-pressure control•Steam extraction controls•Limiting controls•Parameters for island operation

Turbine protection•Diagnostics•Testing

Logic•Control mode•Disturbance monitoring•Protection•Limits of generator switch•Island operation

4...20 mA

G

Monitoring•Speed•Position•Watch-dog

Island operation activiated

Generator’s breaker closed

I/O-LEVEL

Other measurements

Local Operator Interface

2 x 3 measurement

1 x 3

X 2

X 1 EH

4...20 mA

G-

X 2

Red.

Process Control StationBus Interface to Main System

X 2Test

Control hydraulics

EH

4...20 mA

G-

X 2

Red.

X 1 X 1 EH

4...20 mA

G-

X 2

Red.

X 1 EH

4...20 mA

G-

X 2

Red.

Valve coordinator

ESD

ESD

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Jaquet FT3000 overspeed SIL3 and Hima turbine protection SIL3 +24 VDC

2/3 - votedhydraulic trip block

K 4

K 5

K 6

Speed puls/mA(TCS)

K 1

K 2

K 3

Speed puls/mA (TCS)

Speed sensor AOverspeed test A 110%

Overspeed 110%

Sensor failure A(TPS)

Speed puls/mA (TCS)Speed sensor BOverspeed test B 110%

Overspeed 110%

Sensor failure B (TPS)Speed sensor COverspeed test C 110% Overspeed 110%

Sensor failure C (TPS)

Criteria ACriteria BCriteria CCriteria D

Criteria NN …

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20 © Metso

© Metso

Unified automation system provides many benefits

Kari EnwallAutomation-related electrical engineeringFortum NaantaliFinland

If the systems were from different suppliers, some of the features would definitely be lost at some point.”

Fluidized Bed BoilersOTSC PC Boilers

Combined Cycle Power PlantsTurbine Controllers

Waste-to-Energy Plants

Selected Power References

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Worldwide references

PowerCombined Heat & PowerWaste to EnergyFlue gas desulfurizationHydro

TransmissionRefinery & ProcessCombined CycleSolarWave Surge

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Automating the world’s largest FBB plants

Alholmens240MW –World’s largest multifuel boiler

Nacogdoches 100MW – Largest biomass boiler in US

Lagisza 460MW – World’s largest FBB – OT CFB

Sha Lang Tan 300MW –China’s largest FBB

Neyveli Lignite 250MW – India’s largest FBB

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Selected references in CFB Plants

0

200

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1200

0 5 10 15 20 25

Capacity MWth

Tornio

Kauttua

RovaniemiEC TychyToppila I

Rauma Pori

KokkolaToppila II

KaukasEesti Balti Alholmen

Ostroleka

Langerbrugge

Lagisza

Jing Hai x2

Keljonlahti

Bold = Foster Wheeler references

© Metso Date Author Title

• Worlds largest super-critical CFBC Boiler

• 460 MWe

• Foster Wheeler

• July 2009 start-up

• Total Plant Controls

• > 20,000 I/O’s

PKE Elektrownia Lagisza S.A. Poland

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Metso Power & Automation together

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Selected references in BFB plants

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Cap

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Units

Capacity MWth

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PowerCogenerationWaste-to-EnergyFlue gas desulfurization

Beijing,Liulihe Cement CogenBeijing, Sanhe

Jiangxi, GuixiJiangxi, Fengcheng I&IIJiangxi, Fengyi

Shanxi, Shentou INeimenggu, JinghaiNeimengtu, Dengkou

Hebei, ZhangjiakouHebei, Qinghuangdao

Guizhou, JinshaGuiZhou, QianbeiGuizhou, Yaxi

Sichuan, Yibin

Yunnan, QujingYunnan, Kunming 1&2Yunnan, Xiaolongtan 1&2Yunnan, Xuanwei V,VI, VIIYunnan, Xunjiansi

Jiangxi, Jiujiang Chemical

Henan,Xinxiang GuchengHenan, Xingxiang BaoshanHenan, Xingyang

Hubei, Xiangfan

Chongqing 1,2,3

Hunan, Lianyuan

Liaoning, Dalian Chemical

Shandong, Lunan Cement Cogen Zhangqiu

Jiangsu, Xutang I&IIJiangsu, Pengcheng I&IIJiangsu, Yizheng ChemicalMeishan Iron&SteelJiangsu, Xiaguan

Shanghai, WaigaoqiaoShanghai, Minhang

Zhejiang, Qianqing

Anhui, TianjiaanAnhui TonglingAnhui, AnqingAnhui, Ma’anshan

Guangzhou, Nansha CCPP

References - China

© Metso

Huadian Jurong Power Plant, China

• 2 x 1000 MWe Ultra-supercritical coal fired TPP

• Start-up: 2013

• Total BTG Controls

• 27,360 I/O’s

• Delivered by Metso SAC JV:- Main control system,- Furnace safety surpervision system- Data acquisition system - Steam turbine digital electro-hydarulic control system (DEH)- FGD plant control system and SCR controls

© Metso

Fengcheng Power Plant, China

• 2 X 700 MW OTSC

• Start-up: January 2007

• Shanghai Electric Co., China


• 23,300 I/O’s

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Maanshan Power Plant, China

• 2 X 660 MW OTSC

• Dec 2008 start-up

• Harbin Power Engineering, China


• 24,200 I/O’s

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NTPC RIHAND STGII 2x500 MWKOTA - 6 1x195 MWNTPC SIPAT 2x500 MWTAU DEVILAL PANIPAT 7 & 8 2x250 MWSGTPS BIRSINGHPUR 1x500 MWNTPC KAHALGAON 1x500 MWKPCL BELLARY 1x500 MWDVC MEJIA 1x210 MWNTPC VINDHYACHAL STGII 2x500 MWAPGENCO RAYALASEEMA 2x210 MWMS EB PARLI 1x250 MWCS EB KORBA EAST 2x250 MWKAHALGAON STGII 2x500 MWPARAS #1 1x250 MWMEJIA 5&6 2x250 MWCHANDRAPURA 2x250 MWSANTALDIH 1x250 MWJINDAL RAIGARH 4x250 MWAMARKANTAK V 1x210 MWBAKRESWAR 4&5 2x210 MWUKAI 1&2 2x120 MWTANDA (R&M) 3x110 MWTENUGHAT (R&M) 1x210 MW

MAHAGENCO BHUSAWAL 2X500 MWNTPC SIMHADRI II 2X500 MWOP JINDAL STPP 4X600 MW

NTPC UNCHAHAR 1x210 MWBALCO RENUSAGAR #9 1x67 MWGEB KUTCH LIGNITE 1x75 MWPARICHHA 1 & 2 2x210 MWNTPC RAMAGUNDAM 1x500 MWMAHAGENCO KHAPERKHEDA 1x500 MWANPARA 4 & 5 2x500 MWPIPAVAV TPP 2X600 MWPRAYAGRAJ STPP 3X660 MWGIRAL 1x125 MWLEHRA MOHABAT 2x250 MW

THERMAL POWER PLANTS

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KUTTALAM CCPP 101 MWDHUVARAN CCPP 107 MWGMR KAKINADA 230 MWGMR VASAVI CCPP 4X50 MWBHUSHAN CCPP 1x60 MWBHADRACHALAM1x21MWDHOLPUR CCPP 330 MWBHILAI STEEL 1x15 MWBHUSHAN 60 MWRAICHUR (R&M)

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ADITYA CEMENT 1x23 MWRIL, HAZIRA 40 MWTISCO JOJOBERA 1x120 MWHINDUSTAN ZINC LTD. 2x77 MWRAIGARH 55 MWHINDALCO 1x35 & 1x6 MWITC BHADRACHALAN 1x18.5 MWBHUSHAN LTD. 1x77 & 1x30.75 MWMONET ISPAT 1x80 MW NALCO ANGUL 2X120 MWGNFC 2x25 MWTISCO JAMSHEDPUR 1x30 MWSPB ERODE 21 MW

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National Thermal Power Corporation, Ramagundam Unit 7, India• First “Unified Automation Solution”

in India

• BHEL 1 x 500 MW

• Start-up: August 2004


• ~ 21,000 I/O’s

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Selected automation references: Hydro Power Plants

Location Country Capacity Start upYear

MWeDjerdap- 1 HPP Serbia 5 x 201MW 2013Irganayskaya HPP Russia 2 x 205 MW 2012Baksan HPP Russia 3 x 8,3MW 2012Ilarion HPP Greece 2x70MW, +5MW 2012Nho Que 3 Vietnam 2x55 MW 2012Anjalankoski Finland 14,5 MW 2012Anjalankoski Finland 3x4,5 MW 2012Peniche Portugal 300kW 2011Vuokskij kaskad Russia 8x27MW 2011Tuyen Quang Vietnam 3X114 2008Se San 3A Vietnam 2X55 2006Chukka HEP India 4x85 2006ROLEP 1 & 2 India 2x18.5 2005Koteshwar 1 to 4 India 4x100 2005Maneribhali 1 to 4 India 4x76 2004Turial 1 & 2 India 2x30 2004Almatti Units 1 to 6 India 5 X 55, 1 X 15 2004Madhikheda 1 & 2 India 2x20 2004Almatti Units 1 to 6 India 5 X 55 1 X 15 2004Bihai Taiwan 1x62.5 2003Parbati India 4x200 2003Can Don Vietnam 2 x 38.8 2003Kyröskoski Finland 15 1997Anjalankoski Finland 1994Kyröskoski Finland 5x 1992Tammerkoski Finland 2x 4,3 1992

36 © Metso

© Metso Title/Author

DATE

SIME LAEM CHABANG POWER CO. LTD,LAEM CHABANG, THAILAND2008

• Electrical output 60 MWe, process steam 45 t/h• Fuel: natural gas• Combined cycle

Selected automation references: Combined Cycle Power Plants

SEMBCORB UTILITIES,TEESSIDE, UNITED KINGDOM2008

• Electrical output 40 MWe• Fuel: natural gas• Gas turbine & HRSG

2010 ENERJI SABANDIRMA, TURKEY

• Electrical power 900 MWe • Fuel: natural gas• Combined cycle (2xGT+2xHRSG+1xST)

FORTUM POWER AND HEAT, SUOMENOJA, ESPOO, FINLAND2008

• Electrical output 234 MWe, District heat 214 MW • Fuel: natural gas• Combined cycle

KOJUHOVO HETAINH POWER PLANT, MOSCOW, RUSSIA2011

• Electrical output 170 MWe• Fuel: natural gas• Gas turbine & HRSG

OMV SAMSUN ELEKTRIK URETIM SAN. VE TIC. A.S, TURKEY2012

• Electrical output 880 MWe• Fuel: natural gas• Combined Cycle

AGE ENERJI,DENIZLI, TURKEY2013

• Electrical output 205 MWe• Fuel: natural gas• Combined Cycle

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© Metso

Experience with the technology providersGas turbine manufactures

• Gas turbine control system connected to Metso DNA through link- Monitoring and operation through Metso DNA operator interface- Start-up and shutdown sequences in Metso DNA- MW setpoints for the GT´s from the main load controller or AGC in Metso DNA in

pre-selected control mode- Typical link protocols: GE´s Mark II-VI GSM, Modbus TCP/IP, Profibus DP, OPC

• Gas turbine control system done with Metso DNA

GT manufactures

GT manufactures

GEABB AlstomAnsaldo

BHELEGTFiatHanjung

MitsubishiPGRolls-RoyceSiemens

ThomanssenTuma TurbomachWestinghouse

GEAEG

AlstomFiat

PR&GECSiemens

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ST manufactures

• Steam turbine control system connected to Metso DNA through link- Monitoring and operation through Metso DNA operator interface- Start-up and shutdown sequences in Metso DNA- Typical link protocols: Modbus TCP/IP, Profibus DP, OPC,Mauell PLC interface,

GE´s Mark II-VI GSM, Siemens S7 SAPI Ethernet TCP/IP

• Steam turbine control system done with Metso DNA

Experience with the technology providersSteam turbine manufactures

ST manufactures

Skoda LMZHangZhouZamech

KWULang (Alstom) Bergman-BorsigASEA Stahl

SiemensABBBHELAEG

LMZAlstomPrvni Brnenska StrojirnaSiemens

ABB GEAnsaldoFranco Tosi

BHEL Blohm+VossEkolFuji

KWU Lang MAN Mitsubishi

NEI ParsonSiemensSkodaSTT Thermodyn

Urals Turbine WorksZamech

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© Metso

Experience with the technology providersHeat recovery steam generator manufactures

• HRSG automated with Metso DNA

HRSG manufacturesAdatoSES TlmaceRafakoPodolsk

Ahlstrom Babcock&BorsigCMI BelgiumAlstom

Stork Energy KvaernerIdrotermiciStandard Fasel

Schelde BredaFoster Wheeler Senior thermalOschatz

Mech. de la Pena VogtZurnDeltak

SGPTampella PowerMetsoNooter/Eriksen

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41 © Metso

© Metso

ReferencesEurope

Finland• Westenergy Oy Ab, Vaasa

Sweden•Åmotfors Energi Ab

Estonia• Eesti Energi AS, TallinnUK

• Ineos Runcorn, Manchester phase 1• Ineos Runcorn, Manchester phase 2

• MES Environmental, Dudley• MES Environmental, Wolverhampton

• Waste Recycling Group, Lincolnshire • Veolia Environmental Services, Staffordshire

• Cory Environmental, Riverside London• Veolia Environmental Services, Newhaven

• Sita, Cleveland 4&5• Dundee Energy Recycling, Dundee

• RWE Markinch, Glenrothers• London Waste, London

Austria• A.S.A., Zistersdorf• AVE Wels II • AVE Wels I• AVE Lenzing

Italy•Trattamento Rifiuti Metropolitani, Turin• Veolia, Piacenza• Veolia, Energonut

Hitachi Zosen Inova (former Von Roll Inova)Keppel SeghersCNIM Metso PowerOther Technology or Automation Replacement

Projects in execution are mentioned in bold/italic

Norway• BIR Avallsenergi, Bergen

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