Articles & Case Studies

Emerson’s wireless technology helps improve operational efficiency of biomass power plant in Italy

Posted: Monday 15th July 2013

Emerson Process Management’s Smart Wireless technology is enabling Enomondo S.r.l. to improve visibility into the process at its biomass power plant in Faenza, Italy.

Enomondo – a partnership between Caviro Distillerie and Herambiente – is using wireless measurement devices to monitor a complex fuel pre-treatment operation, an incineration process, and a new boiler at the plant. Wireless technology enabled additional measurement devices to be installed quickly and easily, helping to optimize control of the process and contributing to an estimated 5% increase in overall operational efficiency. The availability of diagnostic data also improved predictive maintenance procedures.

The 13.7 MW power generation plant is located at the Caviro Distillerie wine and denatured alcohol plant. It uses 140,000 metric tons per year of by-products from the alcohol production process to produce power for 29,000 neighboring households. This use of alternative fuels helps to reduce Italy’s power generation CO2emissions by 35,500 tons a year.

To increase the efficiency and capacity of the plant, Enomondo installed a new boiler, which created the need for new instrumentation for monitoring temperature and pressure. In addition, the existing fuel pre-treatment process, which ensures nitrogen oxide emissions are less than half the levels set by Italy’s Integrated Environmental Authorization, involves numerous variables that are not easily controlled and would benefit from additional measurement points.

To meet these needs Enomondo chose Emerson’s Smart Wireless technology, which offered simpler installation and lower overall costs than traditional wired solutions. Twenty-two Smart Wireless transmitters, including Rosemount® 3051S pressure and 648 temperature transmitters, transmit measurement data via a wireless gateway into the existing Emerson DeltaV™ digital automation system, giving operators greater visibility into the process so that they can make adjustments to increase efficiency.

As a result, Enomondo has been able to increase operational efficiency and improve output. Installation, maintenance and operating costs have also been reduced. Installation was very easy and required no external engineering capability. Because the wireless instruments required no cabling or cable ducts, infrastructure costs were around 30% lower than a wired alternative. Layout and wiring costs were halved, and installation and instrumentation control costs reduced by 40%.

Using the existing DeltaV system and AMS Suite predictive maintenance software to receive, store and analyze device data, Enomondo has been able to use the wireless system to meet its predictive maintenance requirements. The additional continuous data made available by the wireless network enables personnel to identify performance degradation trends that signify potential problems, then use this information for better maintenance scheduling that helps optimize operator efficiency.

“The modularity of Emerson’s Smart Wireless technology, the ease and reduced cost of implementation compared to wired devices, and its reliability once installed have encouraged us to expand its use into other applications,” said Alessandro Catani, Enomondo Plant and Energy Manager. “For example, temperatures in some of the air-conditioning systems at the plant were prone to overheating. By installing Rosemount wireless temperature transmitters on a temporary basis, it was possible to obtain the data we needed to identify potential problems and correct them.”

Twenty-six Rosemount inventory tank gauges with Smart Wireless THUM Adapters have also been installed at the Caviro Distillerie production facility to continuously monitor levels and increase safety by preventing overspills within the alcohol storage tank farm.

UCB chooses Emerson automation and operations management technologies for one of Europe’s largest biotech plants

$6.1 million contract includes Syncade™ and DeltaV™ systems to manage complex operations while driving toward paperless production

AUSTIN, TEXAS (January 9, 2013) – Belgium-based UCB has awarded Emerson Process Management a $6.1 million contract to provide integrated process automation and operations management systems for a new biopharmaceutical production center in Bulle, Switzerland. Emerson’s technologies and engineering services will be crucial in meeting the very high standards expected by the UCB project team.

UCB is investing $228 million to construct the first phase of a new plant, its first biopharmaceutical project in Switzerland. The 20,000-square-meterfacility, which will be one of the largest in Europe, will be the main production center for Cimzia® (certolizumab pegol), which is used to treat rheumatoid arthritis and Crohn’s disease.

“The state-of-the-art and largely automated facility at Bulle will be a model for the industry when it opens in 2015,” said Michele Antonelli, UCB executive vice president. “To ensure the project meets its tight build-out schedule, we selected Emerson Process Management for its demonstrated ability to engineer and coordinate fast-track automation projects of this type.”

Emerson’s integrated solution includes its Syncade™ Smart Operations Management Suite, DeltaV™ digital automation system, and AMS Suite predictive maintenance software. Emerson will also provide related engineering services, including design, installation, testing, and commissioning.

The Syncade Suite software integrates real-time plant floor data with business processes, decisions, and asset management – a key advantage in managing complex operations and extensive documentation required in pharmaceutical production. Syncade Suite manages workflow processes, including electronic work instructions, equipment status and material tracking, recipe-driven operations, automated weigh and dispense operations, and exception reporting.

“Typical biotech manufacturing can involve thousands of pieces of paper that can affect the ability to produce ‘right-first-time’ batches,” said Lorenzo Zampini, automation project manager. “With Emerson’s integrated operations management and control systems, we can automate the reporting process as well as gain tighter process control for increased productivity and smoother regulatory compliance.”

The Syncade software integrates with Emerson’s DeltaV automation system to facilitate operational activities and information flow from the plant floor up to UCB’s SAP system. In the UCB plant, the DeltaV system will control 163 process units including fermentation, purification, filtration, and bottling. Emerson’s new electronic marshalling technology with CHARMs (characterization modules) will help minimize installation time by eliminating up to two-thirds of the wiring and connections needed with traditional control systems.

Emerson’s AMS Suite predictive maintenance software that will be supporting HART instrumentation will make it easy for technicians to calibrate critical instruments, check their status, and even detects potential problems before they affect operations.

“Emerson is delighted that UCB has chosen us to automate this ground-breaking facility,” said Steve Sonnenberg, president of Emerson Process Management. “Our proven ability to provide a single source for both plant automation and operations management systems will help UCB seamlessly manage operations from the plant floor to the head office. We look forward to working with them as they bring the Bulle facility to life.”

Emerson upgrades automation for 800 MW unit at one of Europe’s largest thermal power plants

State-of-the-art Ovation™ control system helps improve operational efficiencies and reliability at Russia’s Surgut-2 Power Plant

CHELYABINSK, RUSSIA (February 20, 2013) – Emerson Process Management has completed an automation upgrade for an 800 MW unit in Russia’s Surgut-2 Power Plant, one of the largest thermal power stations in Europe. Emerson, the main automation contractor for the project, completed the upgrade during a four-month shutdown.

Unit 3 of the Surgut-2 Power Plant, owned and operated by E.ON Russia, will now take advantage of Emerson’s PlantWeb™ digital automation architecture with the Ovation™ expert control system, which was designed specifically for power applications. Previously, the unit used vintage analog controls. Emerson’s technology will help operators improve operational efficiencies and reliability.

Emerson’s technology and power-plant expertise helped to enhance the manageability of station equipment, tighten control across all operating ranges, and improve the unit’s dynamic behavior.

In addition to upgrading the Unit 3 control system, instrumentation, control valves, and other related equipment, Emerson also modernized controls for the fluid end of the turbine set, reconstructed and equipped the Unit 3 control room, provided engineering and installation services, certified compliance with requirements of Russia’s System Operator of Central Dispatch Administration of the Unified Energy System, and assisted with unit startup.

The new integrated system enables automated operation of the entire power unit, including electrical controls for turbine generators and pumps, boiler and burner controls, and unit power and frequency control and coordination. It also provides real-time monitoring of equipment and timely notification of abnormal situations, and helps determine equipment health so technicians can schedule maintenance and repairs more efficiently.

“Implementing a full-scale, high-performance control system and ensuring its full availability for launch during a four month shutdown was a real technical challenge,” said Stepan Okunkov, manager of the CIS Power & Water Solutions Engineering Center of Emerson Process Management. “But we were able to achieve this goal through the excellent teamwork between Emerson and Surgut-2 power plant specialists from E.ON Russia.”

A team of specialists from Emerson`s St. Petersburg Engineering Center used their experience on power-industry projects to ensure the timely implementation of the control system. Special software tools, standardized approaches to automation challenges, and the modular architecture of the Ovation system helped minimize adjustments and significantly reduce overall project execution time.

As part of the project, Emerson also installed AMS Suite predictive maintenance software, which uses advanced diagnostics to enable Surgut-2 technicians to make better decisions based on a better view into the performance of their instrumentation. The Ovation system’s user interface is also consistent with previously upgraded units, simplifying user adoption.

The upgraded automation enables the Surgut-2 Power Plant to adjust the unit’s output to meet market needs. As the Surgut-2 Power Plant supplies power and heat to Western Siberia and the Ural region and is the most powerful thermal plant in Russia, customers in those regions should notice the improvements soon.

The Surgut-2 station uses natural gas coming from the Tyumen Region’s oil fields. Based on annual output, the plant is one of the biggest thermal power stations in the world, producing more than 35 billion kWh per year.

“Implementing a full-scale, high-performance control system and ensuring its full availability for launch during a four month shutdown was a real technical challenge,” said Stepan Okunkov, manager of the CIS Power & Water Solutions Engineering Center of Emerson Process Management. “But we were able to achieve this goal through the excellent teamwork between Emerson and Surgut-2 power plant specialists from E.ON Russia.”

A team of specialists from Emerson`s St. Petersburg Engineering Center used their experience on power-industry projects to ensure the timely implementation of the control system. Special software tools, standardized approaches to automation challenges, and the modular architecture of the Ovation system helped minimize adjustments and significantly reduce overall project execution time.

As part of the project, Emerson also installed AMS Suite predictive maintenance software, which uses advanced diagnostics to enable Surgut-2 technicians to make better decisions based on a better view into the performance of their instrumentation. The Ovation system’s user interface is also consistent with previously upgraded units, simplifying user adoption.

The upgraded automation enables the Surgut-2 Power Plant to adjust the unit’s output to meet market needs. As the Surgut-2 Power Plant supplies power and heat to Western Siberia and the Ural region and is the most powerful thermal plant in Russia, customers in those regions should notice the improvements soon.

The Surgut-2 station uses natural gas coming from the Tyumen Region’s oil fields. Based on annual output, the plant is one of the biggest thermal power stations in the world, producing more than 35 billion kWh per year.




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