The Power Industry Specialists

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1 The Power Industry Specialists

2 The Leader in Power Generation Control With more than 40 years of leadership in Instrumentation and Control technology for the power generation industry, Emerson Process Management is uniquely qualified to provide the products, services and expertise necessary to help you achieve success.

3 total I&C solutions While instrumentation and control (I&C) systems comprise a very small fraction of a plant s total costs, the impact on overall operations and asset management can be significant. Reaching and maintaining higher levels of plant availability, reliability and performance are today s business drivers, and Emerson Process Management has the experience, technology and commitment to help you succeed in meeting those objectives. The Power & Water Solutions division of Emerson Process Management leads the company s business endeavors in the power generation sector by delivering the widest array of advanced instrumentation, control, and automation technologies available from any supplier. Our leadership in the power generation industry gives us the insight and vision to understand the changing dynamics of that industry and to apply our wide portfolio of solutions to help you achieve your business objectives. All of our products and services are backed by our unequaled expertise in all aspects of power generation, allowing us to work with you to develop custom solutions designed to meet your unique requirements. From expert consultant services to world-class technologies to comprehensive project management, field service and technical support, Emerson Process Management can provide total I&C solutions for a single unit, or your entire generating fleet. The Power of PlantWeb Emerson s revolutionary PlantWeb digital architecture takes process automation one-step further by delivering the information and performance you want, when and where you need it. PlantWeb is an architecture that delivers asset management, process control, and management execution through intelligent field devices, industry standard platforms, and integrated modular software. These networked components are linked by open communication standards that include HART and FOUNDATION fieldbus at the field level, Ethernet at the plant level, and OPC at the supervisory level. In the PlantWeb solution, all components act as nodes on the network collecting, distributing, and using information to create a powerful architecture to significantly improve process performance, reliability and profitability. Measurement and Analytical Rosemount Rosemount Analytical Brooks Micro Motion Saab Rosemount Daniel Final Control Devices Fisher Bowman Bettis El-O-Matic Shafer Dantorque Hytork Systems and Software Ovation DeltaV AMS Suite SmartProcess 3

4 Total Capabilities Our control technologies have been employed in over 3000 systems at power generation facilities around the world. As part of Emerson Process Management, we offer the widest range of I&C capability in the industry for both retrofitting and modernization of existing units to complete I&C responsibility for greenfield plants. Our capabilities include Engineering, Procurement, and Construction (EPC) services from consulting to systems design, to installation, start-up and post-operation services. Our engineering staff averages more than 15 years of experience and combined has thousands of man-years of hands-on knowhow in designing and implementing effective systems to minimize both the total installed cost and total cost of operation. We apply proven process control and monitoring logic on our world class Ovation expert control system to provide a powerful yet user-friendly operations center while coordinating various systems in a comprehensive plant-wide architecture. Sophisticated Alarm Management software quickly directs operators to the source of problems by recognizing and prioritizing alarms, allowing personnel to focus on the most meaningful data in a transient situation. Our systems provide automated start-up and shut-down sequencing as well as automated runback and rundown reduce controls for rapid event management. Clear, concise high-resolution graphics provide intuitive navigation and include on-line help screens and detailed system documentation. 4

5 With our Global Performance Advisor software the control system tracks key equipment and process parameters alerting and guiding plant personnel in how to improve plant performance and to avoid costly unplanned outages. With our PlantWeb architecture, field device configuration, calibration, diagnostics and documentation can be coordinated from a single point using powerful AMS Suite Software to save commissioning and maintenance man-hours, avoid failures and improve process performance. operating costs 5 Our Remote Diagnostic capabilities allow your system experts to remotely view operations to diagnose problems and make recommendations for improvement.

6 Project Management In either new plant construction or modifications to existing units, it is estimated that up to 30% of the risk associated with timely and efficient plant startup is related to I&C systems. Poorly designed or integrated systems can delay plant start-up, cause expensive re-work, and when left uncorrected, hamper operations and decrease plant availability, capacity and efficiency. We are committed to aggressively managing that risk. With over four decades of experience, we have provided project management for thousands of power applications, from simple modifications to full-scope EPC projects including management of craft labor. your schedules. We conduct comprehensive factory acceptance testing programs designed to resolve problems before they get to the field. Projects are overseen from start to finish by engineers experienced in the needs and nuances of the power generation industry. That experience includes familiarity not just with our products, but with providing seamless interfaces to virtually any device or sub-system found in the power plant operations. Dedicated and certified installation and commissioning teams are fully integrated with our design processes to maximize efficiency in the field and assure timely project completion. Our project management approach focuses on working closely with your personnel on managing detailed systems design and risk implementation plans to meet 6

7 No supplier has more experience in power generation projects. 7

8 Unmatched Applications Expertise We have provided our technologies for virtually every type of power generation facility from traditional coal-fired boilers to the latest combined cycle and renewable energy applications. From basic control and monitoring to multi-plant Economic Dispatch and Load Management systems, Our reputation for quality and reliability is second to none. In conventional furnace operations, our systems control hundreds of thousands of MW worth of drum, once-through and fluidized bed boilers from virtually every manufacturer. Your plant performance benefits from our expertise in developing highly efficient control strategies for combustion control, burner management, feedwater control, our patented Load Demand Computer for coordinated boiler/ turbine control, full BOP control and sub-system controls such We have supplied more than 1000 Steam and Gas Turbine control systems around the world including complete retrofits to General Electric, ABB, Westinghouse and Siemens machines. Our turbine control replacements include speed and load control, rotor stress and automatic turbine start-up as well as complete mechanical/ hydraulic packages. They provide increased reliability, improved diagnostics and more precise control. Hundreds of combined cycle, cogeneration and district heating plants have selected our control technology for turbine, boiler, HRSG and BOP control systems to provide user friendly, reliable and cost-effective control and monitoring. With our system flexibility, we have provided hydroelectric plants in North America and Europe with control and fleet management including remote monitoring, dispatching and as SCRs, scrubbers, ash handling water resource management systems, water treatment systems, capabilities. and cooling towers. system flexibility 8

9 Our SmartProcess optimization software consists of powerful statistical, fuzzy logic and neural net technologies designed for on-line optimization for critical operating objectives. SmartProcess Packages are standalone applications that can be applied on any distributed control system architecture. They include: Combustion Optimizer Steam Temperature Optimizer Sootblower Optimizer Fleet Economic Optimizer Fleet Emissions Optimizer Global Performance Advisor For Ovation systems, additional embedded advanced control software is available for automated, adaptive tuning as well as our APC (Advanced Process Control) Toolkit for direct integration of intelligent algorithms into control schemes. 500 MW Coal -Fired Unit Project Steam Temperature Optimizer Results Steam temperature variation decreases from ±40 F to ±5 F No boiler tube leaks during peak generating season 760 MW Gas-Fired Unit Project Combustion Optimization Results 13% average annual NOx reduction $650k/year savings from heat rate improvement 200 MW Cyclone Boiler Project Combustion Optimization Results 25% average annual NOx reduction $1M/year NOx credit benefit 9

10 Complete Service and Support Comprehensive services for the life of the system. Independent surveys have rated our service and support the best in the industry and we pride ourselves on that confirmation of our quality and responsiveness. That support begins with our customer training programs. Conducted by experienced engineers at your facility or ours, our training programs provide your operators, engineers and technicians with the knowledge and skills they need to effectively operate and maintain our systems. Our training programs can be tailored for your needs and can include custom-designed plant simulators that employ the same software and graphics used on the actual system. We also understand the pressures to minimize plant staff while maximizing plant performance. With that understanding, we have structured our service and support programs to provide the flexibility and responsiveness necessary to meet your needs. Our SureService program allows you to customize a service and support program to meet you specific needs. SureService includes 24 hour telephone support, remote systems diagnostics, scheduled on-site visits, emergency service calls, and coverage for critical components. Packages can also include training programs as refresher courses for experienced personnel or introductory courses for new personnel. As an additional service, our secure Internet-based SureNet service provides off-site archiving of system software, regular updates to the latest software revision level, on-line tutoring programs, remote system diagnostics, and custom application enhancements to increase the efficiency of your control software. Our unique Ovation Evergreen program is designed to provide hardware and software upgrades to keep your Ovation system current with rapidly advancing technology. 10

11 customized service 11

12 Achieving the Full Potential of Your Generating Facilities While instrumentation and control systems represent less than 3% of the typical plant s capital investment, they impact all other aspects in a big way. Construction Other Equipment Engineering Automation & Controls Major Equipment Automation and control equipment is a small percent of initial total plant costs... but has a large impact on plant design, construction, start-up, and operations and maintenance. No business has experienced a more dramatic change in dynamics than the power generation industry. As a company committed to the power industry, Emerson understand those realities and is prepared to help you achieve your goals. In new plant development, we work with developers in designing and implementing a standardized, repeatable plant I&C design that reduces costs, risk and schedule for subsequent units. We incorporate a balanced focus on both the total installed cost and the subsequent total cost of operations to ensure that the most beneficial solutions are applied. For existing plants, we offer our Premier Services Program, a systematic, results-oriented approach to help you reach the full potential of your generating assets. Working with your personnel, our experts in power plant operations assess the operational performance of your plant. We benchmark your plant against similar units and established industry best practices. A detailed report is then developed including recommendations for improvement prioritized for the highest return on investment. When implemented, we measure and document the performance of those changes and their impact on plant profitability. Consultation Performance Studies/Audits Results and Sustained Performance Benchmarking vs. Industry Best Practices Execute Plans Improvement Recommendations and Planning Our value-focused methodology guarantees the fastest return on your investment. performance impro 12

13 Plant Performance Improvements Estimated Improvements Estimated Savings Summary of Savings Per Unit Per Year Per Unit Per Year Expected ($) Improved Heat Rate +1.25% 273,750 Improved Availability -2 Forced Outages 436,800 Improved +1% of MCR Per Minute 302,400 Maneuverability Ramping Reduced Maintenance -30% Labor Hours 43,785 Reduced Start-Up -10% Fuel Used 5,400 Fuel Cost Total 1,062,135 vement 13

14 Emerson Solutions for Power Fleet/Enterprise Management & Optimization Fleet financial performance optimizer Fleet emissions optimizer Fleet performance monitoring and visualization Fleet historian and report generator Enterprise-wide systems integration Fleet-wide asset management and reliability programs Plant Optimization Software Plant financial performance optimizer Boiler efficiency optimizer Emissions optimizer Steam temperature optimizer Sootblower optimizer Fleet Performance Monitoring Center Unit Controls & Monitoring Systems Distributed control systems (HMIs, controllers, I/O, network, etc.) for: Burner management Boiler Turbine Fuel handling Balance of plant Emissions (SCR, SNCR, precipitators and scrubbers) Unit historian and report generator Electronic documentation Integration with other systems and intranet/internet Fieldbus solutions (HART, Foundation Fieldbus, PROFIBUS, DeviceNet, ASI bus, etc.) Boiler Simulator High-fidelity simulators Plant Performance & Emissions Monitoring Real-time on-line performance monitoring Plant heat rate & unit efficiencies performance calculations Controllable losses Equipment performance deviations from design Combustion emissions monitoring systems (CEMS) Web-based remote equipment performance monitoring of: Boilers, turbines, heat exchangers, condensers, desuperheaters, pumps, etc. Equipment Condition Monitoring Online/portable vibration monitoring Motor diagnostics Infrared thermography Laser alignment/balancing Oil analysis Fuel Handling Plant Engineering Offices & Maintenance Lab Corporate Offices Fleet Performance Monitoring Center Plant Engineering Offices & Maintenance Lab Control Room Fuel Handling Boiler Turbine Balance of Plant Emissions Switchyard 14

15 Corporate Offices Intelligent Device Management Management software for HART & Foundation Fieldbus-based devices for: Health Monitoring Calibration Configuration Audit Trails Emissions Intelligent and Analog Field Devices Transmitters Pressure, temperature, flow and level Liquid/Gas analyzers CO, O2, NOx, SO2, ph, conductivity, dissolved oxygen Valves and valve actuators General service, severe service, and specialty Balance of Plant Turbine Electrical and Auxiliaries UPS, power conditioning and distribution Precision cooling Motors Couplings Gear reduction drives Backup power generators Services Installation, commissioning, and start-up services Support, reliability & maintenance services Mechanical equipment Electrical equipment Process equipment Control systems Instruments and valves Optimization programs Operations Automation and information systems Reliability-centered maintenance Educational Services Asset optimization, reliability and safety Process control and automation Engineering, operation, maintenance and management of field devices, control systems, electrical equipment, etc. Switchyard Control Room

16 The contents of this publication are presented for informational purposes only, and while every effort is made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by our software licensing agreement, and terms and conditions, which are available on request. We reserve the right to modify or improve the designs or specifications of our product at any time without notice Emerson Process Management Power & Water Solutions, Inc. All rights reserved The Emerson logo is a trademark and service mark of Emerson Electric Co. Ovation, PlantWeb, SureService, and SmartProcess are marks of Emerson Process Management. All other marks are property of their respective owners. Emerson Process Management Power & Water Solutions 200 Beta Drive Pittsburgh, PA Phone: Fax: CP-BRO-XX-110 5K 11/03