PlantWeb™ digital plant architecture with Ovation™ control system to help maximize capacity of coal-fired plant that produces 13 percent of power for Kazakhstan
PITTSBURGH (June 8, 2010) — Emerson Process Management has received two contracts to modernize controls at the Ekibastuz GRES-1 thermal power plant with its PlantWebTM digital plant architecture and OvationTM expert control system. The largest power plant in Kazakhstan, the 4,000 MW facility produces 13 percent of the country’s power. It is located in Ekibastuz, the industrial center of a bituminous coal-mining basin that has coal reserves estimated at 8 billion tons. This modernization project will help ensure the plant is operating efficiently so that it is better able to meet the growing electricity needs of the country.
Under the first contract, Emerson will modernize the controls for the steam turbine and turbine drives for feedwater pumps at six 500-MW units (Units 3-8). Emerson's Ovation technology will monitor and control the Turboatom turbines at two of the units and LMZ turbines at the other four; as well as two KTZ turbine drives for feedwater pumps at each unit. The contract also includes retrofitting the turbine protection system and turbine DEH (digital electro hydraulic) system. The controls upgrade for two of the units will be completed in 2010, and the other four will be finished in 2011-2012.
Utilizing a single Ovation platform to control equipment supplied by different turbine manufacturers will help Ekibastuz GRES-1 streamline operations and improve overall efficiency by reducing the need for training and spare parts. Operators at the plant are also already familiar with the Ovation system because Emerson has previously upgraded other controls at Units 3-7.
Under the second contract, Emerson will digitally automate all major equipment and processes, including unit coordinator and startup and shutdown sequencing at Unit 8. Coordinated control not only enhances unit-wide compatibility, but also contributes to improved unit stability, responsiveness and thermal efficiencies; tighter overall control of plant operations; and a more streamlined view of key plant and turbine parameters. In all, Ovation will monitor and control 5,000 I/O points at this unit, which is scheduled to return to service in 2012.
Over the next five years, Ekibastuz GRES-1 also plans to extend the scope of Ovation’s control at Units 3-7 to provide unit coordinated control and opportunities for additional process optimization.
One of the key reasons that Emerson was selected for these two projects was their successful performance of control upgrades at Units 3-7 over the last six years. The efficient and reliable operation of Ekibastuz GRES-1 plant has important implications for this region and, as such, plant management wanted to utilize proven, state-of-the-art control technology. They look forward to additional operational efficiencies that will become possible due to control system modernization program at Ekibastuz GRES-1.
“By leveraging our extensive expertise in power plant automation, as well as turbine control and mechanical solutions, Emerson is providing Ekibastuz GRES-1 with modernization and controls enhancements that will help ensure the safe, reliable and more efficient operation of these units,” said Bob Yeager, president of the Power & Water Solutions division of Emerson. “We are pleased to expand our relationship with Ekibastuz GRES-1; it speaks volumes about our state-of-the-art plant and turbine controls, as well as the top-notch service and support we provide in this region.”