Power Plant Names Main Automation Contractor

Replacing existing controls with Ovation™ technology expected to eliminate frequent plant trips, boost reliability at 695-MW supercritical unit

Emerson Process Management has been named main automation contractor for a comprehensive, fast-track controls replacement project to improve reliability at the Longview Power plant in Maidsville, W.Va. Under the contract, Emerson will remove the existing plant controls and I/O, and engineer and install its Ovation™ control technology.

Commissioned in 2011, the 695-MW, coal-fired supercritical unit serves Morgantown and surrounding communities.

“This is our first collaboration with Emerson,” said Stephen Nelson, Senior Vice President – Plant Rehabilitation, Longview Power. “We based our decision on their experience managing large, complex projects; successful track record automating supercritical units; and ability to be an open and responsive partner.” Another critical consideration, according to Nelson, was Emerson’s ability to complete the project in an accelerated 13-month timeframe, with commissioning slated for June 2015. Projects of similar scope and complexity typically take 18 to 24 months to complete.

Since it was commissioned three years ago, the unit has suffered frequent, costly plant trips that have weakened plant reliability. Under the contract, Emerson will replace the Siemens T3000 system currently controlling the Foster-Wheeler boiler, Siemens turbine, air quality control system, burner management system and other balance-of-plant equipment and processes.

Providing a more integrated control strategy for the boiler and turbine on a single, unified platform is expected to stabilise the unit and greatly enhance reliability. In doing so, Longview Power will gain the ability to bid into the regional grid operator’s ancillary services market for such functions as automatic generation control and synchronised reserve, making it possible to capture additional revenue.

Emerson will also provide HART® smart instrumentation, including its Fisher® FIELDVUE™ Digital Valve Controllers, Rosemount Guided Wave transmitters and a number of wireless devices — all of which are inherently compatible with Ovation I/O. Using AMS Suite predictive maintenance software, the plant’s limited staff will be able to easily diagnose, maintain and troubleshoot plant equipment and processes.

Although more challenging to control because of the high temperatures and pressures involved, supercritical technologies can boost the efficiency of coal-based electricity generation by approximately 40 percent while reducing carbon and other emissions. Emerson’s Ovation technology has been selected for nearly 100 of these complex units worldwide, according to Bob Yeager, president of Emerson Process Management’s Power & Water Solutions.

“The tighter control provided by Ovation technology can help customers like Longview Power run their plants reliably and efficiently, and capitalise on the economic and environmental advantages these units offer,” Yeager explained. “We look forward to working alongside them as they fulfil their objective of enhancing the electricity infrastructure in the region.”

Amy Schlemmer,
Emerson Process Management, Power & Water Solutions
1 (412) 963-4912,
Amy.Schlemmer@Emerson.com