Emerson Process Management will maximize customer profitability by enhancing manufacturing productivity, reducing downtime, and increasing yields at the same time it reduces ownership costs of automation. Specific customer deliverables include: in-plant consulting and audits, investment scoping and justification, packaged application software, design and implementation services, startup commissioning and testing services, remote performance and equipment health monitoring, and ongoing site maintenance and repair.

Power Process Control Capabilities

• Control and Information
  • Automatic Turbine Startup
  • Boiler Feed Pump Turbine Control
  • Boiler Combustion Control
  • Burner Management Systems
  • Balance of Plant (Logic, Binary)
  • Combined Cycle BOP Control
  • Coordinated Combustion System (Load Demand Computer)
  • Combined Cycle with Turbine Control
  • Continuous Emissions Monitoring Systems
  • Data Acquisition Systems
  • Energy Management Systems
  • Fluidized Bed Control
  • Gas (Combustion) Turbine Control
  • Performance Optimization
  • Scrubber Control
  • Simulators
  • Steam Turbine Control (DEH)
• Advanced Control
  • Boiler Efficiency Optimization
  • Low NOx Optimization
  • Opacity Optimization
  • Steam Temperature Optimization
  • Sootblower Optimization
  • Sootblower Cleanliness Advisors
  • Economic Dispatch Optimization
  • Global Performance Advisors
• Consultation Services
• Project Management
• Field Engineering Services
• Support Services (SureService)
• Training
• Hardware & Software
  • Power-specific I/O cards and modules (Turbine Control Cards and Interfaces)
  • Integrated AMS (Asset Management Solutions)
  • Engineering Tools
  • Open systems
  • Enterprise-wide Archival and Reporting Tools
    

Utility Boilers - Startup & Operation

• Startup and problem analysis for utility boilers ranging in size from 100 MW to 600 MW.
• Firing systems included pulverized coal, cyclone furnaces, natural gas, and fuel oil.
• Utilities served included:
  • American Electric Power
  • Cincinnati Gas & Electric
  • East Kentucky Rural Electric
  • Union Electric
  • Southern Electric Generating
  • Tennessee Valley Authority
  • Southern Indiana Gas & Electric
  • City of Gainesville, Florida
  • Pacific Power & Light
  • Aurora Energy

Coal Handling

• Control algorithms to optimize coal train unloading.
• Provide the electrical design required for converting all coal handling areas to Class II, Division 1.
• Provide equipment interlocking and sequencing via new PLC networks, including fire detection, sampling, and dust suppression.
• Multi-GUI stations including equipment control screens, maintenance and utility screens, alarming and trending.

Predictive Emissions Monitoring System

• Oil and gas fuel flow meters.
• Zirconium oxide insitu oxygen analyzers.
• Engineering and design.
• Hazardous area classification for coal dust areas and verification that facilities comply with latest NEC and OSHA regulations for hazardous coal dust areas.

Burner Management

• Redesign of the burner management system to comply with NFPA guidelines.
• Develop control systems and algorithms for steam and/or air atomizing of fuel oil in multi-burner boilers.

Gas Data Acquisition System (SCADA)

• Provide hardware and software configuration to remotely monitor system gas flow volumes and gas pressures at metering stations.
• Perform AGA Calculations.
• Communicate both calculated gas flow volumes and raw data to the central site for display, logging, data base management and control.
• Utilized Fisher ROC Units and FactoryLink OS/2.
• Hazardous area classification at gas metering facilities.

Power Studies

• Perform a wide variety of power system studies of interest to the utility industry.
• Experience includes projects for several utility main generating stations, multiple cogeneration and standby generating installations, electrically isolated power systems, industrial and municipal substations, tuned and untuned reactive power compensation installations and a variety of industrial / commercial power distribution systems.
• Topics of interest to utility main generating stations include:
  • Load measurement and assessment studies
  • Load flow and short circuit analysis studies
  • Motor starting and acceleration studies
  • Protective device coordination studies
  • Plant operating procedure studies

Coal Pulverizers

• Startup, calibration and operation of coal pulverizers.

Fans

• Forced draft, induced draft, primary air, and gas recirculation fans.

Air Heaters

• Large tubular and regenerative units
• Leakage Tests
• Flow Induced Vibration Diagnosis

Waste Heat Boilers

• Basic oxygen furnace hoods
• Gas turbine heat recovery
• Refinery cat cracker units
• Copper reverbatory furnace

Fuels

• Experience firing of many different fuels in a wide variety of furnaces including pulverized coals, stokes coal, natural gas, fuel oils, sawdust, hydrogen, waste, carbon monoxide, blast furnace gas, hydrogen cyanide, and other gaseous and liquid chemical waste streams.

Emission Testing

• Conduct tests for S02, NO, CO, 02 and particulate on gas, oil and coal fired boilers.

Energy Efficient Motor Program

• Meet with utility company's customer to analyze motors and motor drive systems at the customer's facilities.
• Provide recommendations for reducing demand and/or energy-use associated with motor systems.
• Make field measurements and prepared formal report outlining findings and recommendations.

Coal Mill - Steam Inerting

• Provide instrument/electrical assistance in the check out, start up and commissioning of the coal mill steam inerting system.

Soot Blowers - Long Lances

• Conversion of long lances from air to steam.
• Automated sequencing of long lances and soot blowers using a PLC.
• Installation of operator interface consoles running Factory Link software.

Low NOx Burners - Electric Relocation

• Relocate tray to facilitate ductwork installation
• Provide wiring design for all instrumentation supplied with Low NOx burners, registers, and dampers which were to interface with the plant DCS system.
• Provide checkout and startup assistance.

Instrument Calibration System - Hydro Plants

• Assist installation of automation projects at hydroelectric power Generation facilities.
• Field check all temperature, pressure and flow instruments.
• Train plant personnel on theory and practice of instruments and maintenance procedures.
• Wrote manual for plant use in trouble shooting and repair of control systems.

Instrument Calibration - Oil Fired Plant

• Calibration, checkout and combustion control tuning of oil fired plant boilers.

Magnetic Separators

• Engineering & design of the electrical system
• PLC programming and interface on the coal handling system
• System Startup

Fiber Optic Upgrade

• Upgrade fiber optic systems for coal handling
• Start up of the system for the fiber optic cable we installed.