Post on 17-Jun-2021
Amit Rastogi Valmet Automation Hyderabad February 03, 2017
National Summit on Waste to Energy Technology - Companies & Equipment Providers
This is only 1-2% of the whole
power plant investment – but it has
big impact to the success of the
whole project.
Also, it plays the big role for the
whole lifecycle of the plant.
Control System/Automation System (DCS)
Contents
Valmet today
Offering
Automation for WtE Industry
1
2
4 Automation references, WtE & Biomass
3
Summary 5
Valmet Leading global developer and supplier of process technologies, automation and services for the pulp, paper and energy industries
Our mission
6
Converting renewable resources into sustainable results - defines our
core purpose
Recycled paper
Agro
Wood
Renewable
raw materials used
by our customers
Waste
Pulp
Paper
Board, tissue, paper
and new paper grades
Chemical pulp, mechanical
pulp, dissolving pulp
and biomaterials
Electricity, heat
and biofuels
End products
of our customers
Energy
Valmet Energy Solutions
7
Services • Reliability services
• Performance services
• Rebuild and upgrades
services
• Long-term service
agreements
Valmet`s energy solutions
Process Technologies
Services Automation
Customer
■ Efficient project delivery ■ Reliability ■ Performance
Process Technologies • Boiler plants
• Gasification plants
• Modular power plants
• Heat plants
• Air emission control
Automation • Distributed Control System
(DCS)
• Performance solutions
• Turbine automation
• Analyzers and
measurements
• Industrial internet solutions
Automation offering for Power Industry
Specialized expertise in energy industry
2016 © Valmet | Automation Business Line 10
COMBINED CYCLE
High availability,
emission minimizing,
flexibility
GASIFICATION
High cycle efficiency, high
availability
WASTE-TO-ENERGY
Maximizing waste disposal,
emission management,
environmentally efficiency
COAL FIRED
High availability, emission
minimization, combustion
optimization, flexible usage
COGENERATION
Flexibility, steam network
management, high
availability
HYDRO POWER
Efficiency, availability,
river optimization
Automation professionals in market areas 1,600 automation professionals
© Valmet | Automation Business Line 11
766 Nordics
69 South
America
222 North
America
108 Asia-Pacific
345 EMEA
112 China
Automation headcount - March 2015
Valmet DNA for WtE plants
- Wide range of products and solutions
- Highlights of our DCS system
- Special applications for WtE Plants -
(or other difficult fuels)
- Vibration monitoring system
Valmet Automation - your partner for WtE Plants We deliver automation for all kind of plant types!
13
We provide innovative system technology and services, e.g. advanced process
controls, advanced emission monitoring and authority reporting, support your
• Sustainable and safe energy production with lower emissions
• Improved energy and materials efficiency
• Improved operational efficiency
Bubbling Fluidized
Bed Boilers
Gasification Solutions
Grate Technology
Boilers
Valmet Automation The Right Solution, with Clean Technology
14
99,98% Availability
Reduced
Shutdowns
High
Performance
Waste Incineration
Expert Teams
Optimized
Combustion
Minimized
Emissions
87 Engineering
& Service Centers
close to you
24h Service
Engineering
Cost optimization
For your Success!
Advanced Process
Controls
Distributed Control
System
Information
Management Solution Condition and
Runnability Monitoring
Steam Turbine
Controller
MR Moisture Analyzer
for Biomass
Automation solution for thermal power plants
Boiler Corrosion
Manager
Valmet DNA
15
One system for all your needs!
Valmet
Corrored
Valmet
CorroStop /
Valmet Fuel
Diet
Valmet DNA Valmet DNA Valmet DNA Valmet DNA Valmet DNA
One system for all automation in power generation
Valmet DNA
© Valmet | 16
1979
Damatic
”Classic”
1988
Damatic XD Damatic XDi
1996
metsoDNA
2000
Metso DNA
CR
2006
Metso DNA
2011
Valmet DNA
2015
• Application compatibility since 1988
• Connectability
• Upgradeability
• Openness
• Same platform for all applications
• User friendly
• Flexible
• Reliable
• Long experience of developing control systems
Upgradeability with innovative evolution
© Valmet | 17
Valmet DNA redundancy
Redundant hard disks and
backup tape device
• Backup Power Supply for
- control node cabinets and rack I/O’s
• Optional power backup for
- control room devices and servers
Redundant
process
controller
Redundant
hard disk
• Redundant Field Bus
• Redundant I/O power
supply per rack
Redundant PLC
interface
Profibus DP
devices
PCS PCS GTW-LIS GTW-LIS PCS
Redundant control room bus and process bus
Information Server Operator Interface Engineering Server Alarm Processing
• Redundant power supplies
and Interface controller
•Redundant M120 I/O units
Availability up to
99,98%
Valmet DNA with SIL3 Boiler Protection System
2014 19
Ethernet network
• name based
communication
Redundant
controller with safeethernet
communication layer
-Communication using
HIMA tag names
-Time stamped data from
HIMax
Field devices 4-20 mA with HART
• HIMA (HIMax, HIMatrix or
M45) connected to Valmet
DNA Ethernet network with
safeethernet communication
Control room
• access to
HIMA data
in Valmet DNA
process controller
Windows Server
• engineering
database
• HIMA engineering
(SILworX) integrated
Windows WS
• engineering
tools
• Field Asset Management
Salient Feature of Valmet DNA System
Valmet DNA Feature
• Max. power plant functionalities in same system. DCS, Turbine Controller,
Vibration Monitoring System, Safety System etc in the same system.
Advantages:
- Seamless data integration, all functionality on the same platform;
- Inventory Management;
- Engineers trained on Valmet DNA can handle complete plant maintenance.
• Work Station based Architecture
• Industry standard workstation can be directly connected on communication
bus without any proprietary interface (Protocol conversion) card.
• Controller with 1024MB RAM and 1.86GHZ.
• Up to 256 Modules/Controller
• Fast control cycles, as low as 20 ms
50 ms to 1 sec
• As fast as 200 millisecond trends can be offered for some critical data
points
• Trend available in all stations
Salient Feature of Valmet DNA System
Valmet DNA Feature
• Operating Temp of l/O modules: 0 … +70°C
• Digital I/Os with max16 Ch/modules.
• DI/Os with status indication LED for each channel on the module.
• Latest M80 I/Os
• No mixing for Input/ output in a module
• Direct MODBUS (Rs485) and industry standard protocol connectivity with
Third Party Systems/ PLCs
• Communication speed between various I/O racks is identical.
• Integrated Sequence of Event Recording (SOE)
• SOE Viewing in all stations
• All Digital input modules with provision of 2 ms or faster time stamping in real
time on the card - alarms and causes can be analyzed accurately.
Valmet DNA - Operator Interface
Date Author Title 22
Description CSP FGT Common Sum
Process Graphic Displays 40 40 25 105 Monitor Windows 30 30 35 105
Sequences (5 steps) 10 5 5 20
Sequences (10 steps) 10 15 10 35
Sequences (20 steps) 0 5 5 5
Info Archive Licence Data Points 1000 1000 2000 4000
Shift, day, week, month report 2 1 2 5
Customized report page 2 1 2 5
Process Data Entry page 2 2 0 4
Difficult processes require easy operation
Valmet DNA Operate Operation tools for efficient problem solving
Efficient alarm analysis with 1 or 2
ms Sequence of Events (SOE) for
all the DI – segregation not
necessary
Replay history from any picture,
“time machine”
Drag and drop trend analysis
Dynamic function and interlocking
descriptions for machine and
process
Multilingual control room
23
Start History mode
Select displayed
moment and replay
History mode
indication
Feeling of
control
Valmet DNA Combustion Control System CCS
Date Author Title 24
Navigator for Crane Driver
Not just basic automation – we implement our know-how!
Some APC solutions in Valmet DNA for power generation
25
Turbine
controls
Pulverized coal
fired combustion
optimization
Condition
monitoring
Sootblowing
optimization
DNA Training Simulator 100% match to real controls
• Virtual Valmet DNA can be executed on ordinary office PCs or laptops
• Process control configuration and user interface can easily be copied from
control system to DNA Training Simulator
26
• Exactly the same user interface both in DNA Training Simulator and on real
Valmet DNA system
Valmet DNA Machine Monitoring Prevent unplanned downtime by machine health monitoring
Vibration based condition monitoring for rotating
machinery in Valmet DNA automation system
Common user interface for process control and
condition monitoring
– Easier to use and share information between operation
and maintenance
Common history database for all process and machine
condition data
– Efficient analysis and reporting
One system and one engineering environment for
condition monitoring and process control
– Cost efficient to build and maintain
27 © Valmet |
Typical condition monitoring measurements
28
Steam turbine generator
• Relative shaft vibrations (x-y)
• x/y positions (GAP voltage)
• Absolute bearing vibrations (x-y-z)
• Axial positions (z)
• Differential expansions
• Absolute expansions
• Shaft eccentricity
• Tachometer
• Process parameters
Process specific auxiliary
equipment, e.g.
• Boiler HP feed pumps
• Circulation water pumps
• Exhaust air fans
• Fresh air fans
• Primary air fans
• Secondary air fans
• District heating pumps
• Booster pumps
© Valmet |
Plant Management applications
- For advanced reporting and calculations
- Analyzes of power plant performance
• Power plant management
• Production
• Operation
• Maintenance
• Environment
Dive into details of the plant performance
Valmet DNA Performance Monitoring for boilers and steam turbines
Enables following the real-time performance of main
equipment in real-time
The efficiency calculated based on real-time measurements
2016 © Valmet
Valmet DNA performance monitoring
• Key Performance Indicators (KPIs e.g.
heat rate, efficiency) solved for plant,
boilers, steam turbines, pumps and fans,
heat exchangers
• Calculations in accordance with accepted
standards (EN, ASME, ISO)
• To secure best performance and
availability of boiler, can be extended with
DNA Soot Blowing Manager or with the
DNA Fatigue and Creep Monitoring Improved efficiency,
maximized availability
Monitoring of operation point deviations Comparison to expected values
© Valmet | 31
Effect on efficiency Effect on costs
Report exported to Excel and PDF by one click
32 © Valmet |
Customer’s process
Today, customers are extensively utilizing our Industrial Internet capabilities
February 4, 2017 © Valmet 33
Online
connections with
customers
Performance
agreements with
remote
connections
Co-creation of
advanced
analytics with
customers
Information
management
system delivered
since 1985
480 Collaboration to
3rd party systems
80 Advanced
process control
installations
320 1000+ Ongoing
Valmet’s remote center
Valmet’s competence
network
100+
Plant Data Server
Plant Data Server
Plant Data Server
Performance Cloud System architecture Data management process
Date Author Title 34
Performance Center
Service
Performance
Monitoring Platform DNA Historian
Power plant A Power plant B Power plant C
DNA Historian 3rd party DCS
Data Collection and Calculation Environment
DNA Historian
Reporting and Analyzing Environment
DNA Report
Valmet VPN for partners
Customer specified users
Valmet IT Network
Dashboards for users/roles
35
Maintenance dashboard
Summary Diary
Deeper alarm statistics
Site 1 Site 2
Site 1 summary Site 2 summary
HQ dashboard
Performance Limits
Design Target
Plant manager dashboard
© Valmet |
Available Report
widgets
Selected Project delivery references
- Waste-to-Energy Power Plants
Over 1,000 power plants worldwide utilize Valmet’s process automation
2016 © Valmet | Automation Business Line 37
Power plant
installed base
Includes Valmet’s systems delivered by partners
EMEA 371
Biomass / multifuel 86
Coal fired power plant 78
Combined cycle power plant 61
Hydro power plant 11
Oil & gas fired power plant 65
Solar power plant 14
Waste-to-energy plant 56
APAC 476
Biomass 3
Coal fired power plant 228
Combined cycle power plant 102
Hydro power plant 85
Oil & gas fired power plant 56
Waste-to-energy plant 2
NA 110
Biomass / multifuel 3
Coal fired power plant 47
Combined cycle power plant 19
Oil & gas fired power plant 41
Sweden •Åmotfors Energi Ab
Estonia • Eesti Energi AS, Tallinn
UK • Ineos Runcorn, Manchester phase 1
• Ineos Runcorn, Manchester phase 2
• MES Environmental, Dudley
• MES Environmental, Wolverhampton
• Waste Recycling Group, Lincolnshire
• Veolia Environmental Services, Staffordshire
•Veolia Environmental Services, Shropshire
•Veolia Environmental Services, Leeds
•Viridor, Oxfordshire Ardley
•Viridor Cardiff
• Cory Environmental, Riverside London
• Veolia Environmental Services, Newhaven
• Sita, Cleveland 4&5
•SSE Ferrybridge Multifuel project
•Dundee Energy Recycling, Dundee
• RWE Markinch, Glenrothers
• London Waste, London
•WtE Peterborough
Austria • A.S.A., Zistersdorf
• AVE Wels II
• AVE Wels I
• AVE Lenzing
Italy •Trattamento Rifiuti Metropolitani, Turin
• Veolia, Piacenza
• Veolia, Energonut Hitachi Zosen Inova (former Von Roll Inova)
Keppel Seghers
CNIM
Valmet Power
Posco
Other technology or automation replacement
Norway • BIR Avallsenergi, Bergen
Waste-to-Energy references in Europe About 50% market share
© Valmet |
38
Finland • Westenergy Oy Ab, Vaasa
•Ekokem, Riihimäki
•Lahti Energia
Poland • LECH, Bialystok
• Krakow Waste, Krakow
WtE Plants references in Korea
Busan Environment Incinerator, 1996
Busan Haeundae Incinerator, 1997 / 2013
Jeounju Incinerator, 1996 / 2015
Icheon Incinerator, 2006
Geoje Incinerator, 2006
Chungwon Incinerator, 2008
Anyang WtE Plant, 2013
Daegu RDF Plant, 2015
Several others by our local partners
Valmet supplied first ones already 20 year ago
2007-2016:
12 Waste-to-
Energy plants
delivered
Example project: Riverside Resource Recovery Ltd,
London - England
Delivery Scope from Valmet:
The Valmet DNA automation
and information system monitors
and controls total plant operation
Integrated HIMA System
Results
• Electrical efficiency
of 27% expected to
exceed
• Increased energy
recovery
• Decreassed
emissions
Hitachi Zosen Inova W-to-E plants run with Valmet’s DCS
Hitachi Zosen Inova is a leading global
technology provider and contractor in
the field of Energy from Waste facilities
Plant sections and turn-key plants from
design to construction and operation &
maintenance & overhaul
Close to 500 W-to-E plants delivered –
mostly in Europe and Asia
2016 © Valmet | Automation Business Line 40
Process Data of the Plant
Incinerator Units: 3
Waste Throughput: 29,8 t/h / Line
Average Heat Value: 9.600kJ/kg
Thermal Power: 81 MW / Line
Steam Production: 96 t/h / Line
Electr. Power of Turbine: 73MW
Start up: 2009
General Supplier:
Hitachi Zosen Inova AG
Owner:
A.S.A.
Plant Location:
Zistersdorf, Austria
Technology:
Grate 57,8 MWth; 405C; 42bar; 12,18MWel; 135.000t/a municipal waste
Delivery Scope of Valmet Automation:
•ValmetDNA Automation System (signals 2200HW, 800GW)
•Information Management Solution
ASA, Zistersdorf
Start up: 2010
General Supplier:
Von Roll Inova
Owner:
BIR
Plant Location:
Bergen - Norway
Technology:
Grate, 2x45 MWth, 2x110 000t/a municipal waste, 2 steam turbines
Delivery Scope of Valmet Automation:
•ValmetDNA Automation System (4200 Signals)
•Information Management Solution
BIR, Bergen
Start up: 2012
General Supplier:
Hitachi Zosen Inova AG
Owner:
Riverside Resource Recovery Ltd.,
subsidiary of Cory Environmental
Plant Location:
Belvedere, London, UK
Technology:
Grate 3x81 MWth, 427C, 72bar, 65 MWel, 585.000t/a municipal waste
Delivery Scope of Valmet Automation:
•ValmetDNA Automation System (signals 4000HW, 1000GW, 11000 profibus DP))
•Information Management Solution
Cory, Riverside
44
Start – up: 2012
General Supplier:
Hitachi Zosen Inova AG
Owner:
Veolia Environmental Services
Plant Location:
Newhaven - UK
Technology:
•Grate 2x36 MWth, 400°C, 50bar, 2x19,4 MWel, 2x105.000t/a waste
Delivery Scope Valmet Automation:
•ValmetDNA Control + BPS System (signals 2300HW, 350GW, 2850 Profibus DP)
•Information Activity Server
Veolia, Newhaven
45
Start – up: 2012
General Supplier:
Hitachi Zosen Inova AG
Owner:
Westenery Oy Ab
Plant Location:
Mustasaari, Finland
Technology:
•Grate 61 MWth, 400°C, 40bar, 13 MWel, 150.000t/a waste
Delivery Scope Valmet Automation:
•ValmetDNA Control + BPS System (signals 2300HW, 250GW, 1400Profibus DP)
•Information Activity Server
Westenergy, Vaasa
46
Start – up: 2013
General Supplier:
Hitachi Zosen Inova AG
Owner:
SITA South Tyne and Wear Ltd.
(part of SUEZ group)
Plant Location:
Tees Valley, Billingham, UK
Technology:
•Grate 2x45,85 MWth; 410°C; 50bar; 24,2 MWel; 2x152.000t/a waste
Delivery Scope Valmet Automation:
•ValmetDNA Control + BPS System (signals 3000HW, 2500 via Profibus DP and GW)
•Information Activity Server
SITA, Tees Valley unit 4 & 5
47
Start – up: 2013
General Supplier:
Hitachi Zosen Inova AG
Owner:
Ferrybridge Multifuels Energy Ltd.
Plant Location:
Knottingley, West Yorkshire - UK
Technology:
•Grate 2x117,4 MWth; 430°C; 70bar; 76,5 MWel; 2x250.000t/a waste
Delivery Scope Valmet Automation:
•ValmetDNA Control + BPS System (signals 6000HW and Profibus DP, 2300GW)
•Information Activity Server
SSE, Ferrybridge
48
Start – up: 2015
General Supplier:
Hitachi Zosen Inova AG
Owner:
FCC Environment, Northampton
Location:
Calvert, Buckinghamshire – UK
(Greatmoor EfW Facility)
Technology:
•Grate 102 MWth; 402°C; 51,5 bara; 28,2 MWel; 300.000t/a
waste
Delivery Scope Valmet Automation:
•ValmetDNA Control System incl. Information Activity Server
•Integrated Boiler Protection System
FCC, Buckinghamshire
49
Start – up: 2016
General Supplier:
Hitachi Zosen Inova AG
Owner:
Mercia Waste,
Location:
Hereford & Worchestershire – UK
Technology:
•Grate 68 MWth; 415°C; 58,5 bara; 20,4 MWel; 220.000t/a
waste
Delivery Scope Valmet Automation:
•ValmetDNA Control System incl. Information Activity Server
•Integrated Boiler Protection System
Mercia Waste