Reference report Energy

Transcription

1 Around 100,000 tones of combustible wastes and effluent sludge are thermally utilized environmentally and legally compliantly at the new incineration plant at Thun annually. The thermal energy thereby gained in the incineration process is either converted into electricity or directed into the district heating system. The waste incineration plant has been operating since February Plant owner and operator is the AVAG KVA AG, a subsidiary of the AVAG. The AVAG has many years of experience in waste utilization and treatment and is a competent service provider fully aware of their responsibility for a region with over 300,000 inhabitants, dealing with the waste from around 150 municipalities. The process technology for KVA was supplied by VonRoll Inova (furnace/boiler, RGR, ABA), the Caliqua AG (thermal system), and the BKW FMB (energy supply). The alliance partners LeitTec AG and AEK Elektro AG were assigned with supply of the electrical and control systems for the new Thun incineration plant. The project including planning, delivery, assembly, and commissioning of the control system, instrumentation, low-voltage supply and industrial cabling, realization of control systems was performed by the LeitTec AG.

2 Simatic WinCC Open Architecture (WinCC OA) was deployed as process control system, This system standing out through object orientation, flexibility, high availability and open system, allowing the LeitTec AG control standards to be easily implemented into the system for use in this project. This standard for incineration plants, thermal systems and power stations is implemented using various SPS systems and is easily expanded with specific functions for future applications. Deployment of this standard allows complex systems with the highest demands on availability and process operation to be realized quickly and effectively. End user AVAG, KVA AG System integrator LeitTec AG Open control system The WinCC OA and Step7 development environments form the central core of electrical and control system engineering at Thun, these configuration tools being complemented by the LeTo MSR database and Eplan electrical package, allowing powerful and efficient engineering tuned to the needs of power generation customers and operators. The LeTo MSR database plays a central role in data management, as the MSR data for SPS, control level, and communication are administered in this database and the individual components provided to the system. Inputs from the process suppliers such as MSR information, device or consumer lists are prepared by us using the LeTo MSR database so they can are subsequently available as export files for the WinCC OA Step7 control system, OPC configuration, and electrical package. Using LeTo new revisions of our inputs from the process suppliers can be compared with already processed data, with an automatically generated deviation report which plays a central role in quality assurance and possible queries. The new and altered inputs are entered into the project database, ensuring that work is always on the latest update of the project. LeTo has interfaces to all common SPS systems and software packages, making it easily possible to couple further components (such as autonomous systems) with the visualization over a bus (e.g. Profibus) and so integrate them into the operating station.

3 Open control system data flow Using this concept we can guarantee that the standards determined during basic engineering are maintained and comprehensive, relational and consistent documentation is produced, also providing a very high standard within the entire control system and documentation. Control level The control level of the new Thun incineration plant primarily consists of two redundant WinCC OA servers (hot standby), a data server for backing up archive data and applications, five operator stations each with dual monitors, a RAS server, back-projection system and the network combining these components. WinCC Open Architecture is deployed as the visualization system, which allows a client / server architecture on the control level. The core of the process operation is formed by the two redundant (Hot standby) WinCC OA servers, providing the required high availability. The individual dual screen operating stations are clients which exchange the required data with the WinCC OA servers. The fast Ethernet TCP/IP control level network also provides high availability through the selected hardware layout. The architecture allows the broad possibilities of remote diagnostics to be used. The two networks for the control system and plant administration are independent but connected through a firewall

4 for data exchange. A RAS server with specific security functions is integrated into the control level network, protecting the control system for process monitoring from defined office workstations or over the internet. Important help functions are available on the visualization to support management functions, such as information from the documentation system, display of the circuit diagrams or simplified shift book. Additional management support is provided by a Barco DLP back projection system in the command room. The modular OverView-mDG system with a projection area of 1.5m high by 3m wide is used as a WinCC OA workstation, and the images of the video monitoring system are also displayed on this system. Central engineering station is provided for system maintenance and application adjustment, the separation of engineering and operations guaranteeing optimal availability of the control system. From this engineering station the complete control system is centrally configured from process station input and output modules up to the control level. Archiving of process data is on both redundant WinCC OA servers, which means that even the archive is kept redundantly, should one server possibly fail the respective archive database is updated with the correct values from the second server. To achieve greatest possible data security the archive is cyclically dumped to the data server where another backup is held.

5 Flow chart of the flue gas scrubber Functions Visualization / operation of the entire plant (process and building services) Operator aids such as dynamic criteria and hint texts Alarm handling and management Trending with individual compression levels Communication with the automation level Data archiving on all servers Swapping of process data to the data server Interface to system maintenance Interface to central operating data acquisition and processing Simplified shift book

6 Calculation and representation of optimal operating points (firing diagram navigator) Process level The process level consists of the Siemens SPS System 7. The redundant process stations are built from S7-400H components and the decentral remote I/O units from ET200 components. To provide optimal availability of the entire system four independent redundant (Hot Standby) process stations are provided for the individual process sections firing/boiler, flue gas scrubbing/waste water processing, thermal system and energy supply. A further, non-redundant process station is provided for the internal building systems. Decentral ET2000 I/O modules are installed in local cabinets as field interface. Communication between the redundant process stations and the I/O interface connection of the local cabinets consists of a redundant fiber optic Profibus DP. Process The following process sections are integrated into the LeitTec PLS/SPS system: Firing, consisting of hopper, plunger/grate control and push floor Firing output regulation with integrated firing diagram navigator Dashing with plunger purging, pneumatics, conveyors, rapper, ash removal etc. Air-flue gas path consisting of primary air, secondary air, NOX separation and induced draught Water/steam circuit consisting of feed water system, make-up water system, drum, overheating, with injection regulation, start-up valve, condenser system etc. Entire thermal system HP and LP steam distributors Flue gas scrubber Denox-system FLUWA (flue ash washing apparatus) Waste water treatment MV switchgear control and energy supply Building systems Auxiliary systems such as compressed air supply, chemical filling, hydraulic station, aquaroll cooling, adsorption dosing etc.

7 Configuration/Value conservation Projections using the LeTo MSR database enable consistent forward planning, as is usual for conventional process control systems. Value conservation of the engineering is guaranteed thanks to the open structure of LeTo, system independently providing the current MSR data of all control system-related components at the Thun incineration plant. Incinerator