Yokogawa Vigilance at your service worldwide - representative projects

Mongolia
Bulgaria 8 x 420 t/h Korea
8 x 200 t/h coal fired 9 x 100 MW
flue gas desulfurization revamping & simulator coal fired

Italy U.S
400 MW 480 MW, combined cycle
Romania Korea
combined cycle 800 MW supercritical
4 x 330 MW
flue gas desulphurization training simulator

Sustainable energy solutions

U.S
UK 100 MW, combined cycle
Turkey
37 MW 130 MW Japan
waste to energy combined cycle
China 2 x 1,050 MW
U.S
6 x 300 MW flue gas desulfurization

for reducing CO2 emissions

3 x 70 MW, gas & oil fired
China coal fired
Spain 450 MW
800 MW wind power Japan
combined cycle Canada
375 MW & 350 MW 120 MW, cogeneration
w/ LNG terminal India gas fired
3 x 660 MW
supercritical
coal fired Taiwan

in the power industry

2 x 550 MW Trinidad and Tobago
Algeria
coal fired Vietnam 720 MW
369 MW
2 x 600 MW combined cycle
IWPP
coal fired
Venezuela
India 460 MW
Vietnam combined cycle
Nigeria 2 x 600 MW
2 x 300 MW, coal fired
530 MW & 2 x 450 MW 2 x 500 MW
simulator & training
simple cycle coal fired

Brunei
110 MW Brazil
Egypt Thailand 460 MW,
combined cycle
750 MW 2 x 110 MW combined cycle
750 MW combined cycle
750 MW
combined cycle Indonesia
110 MW & 95 MW Australia Brazil
Singapore geothermal 4 x 500 MW
2 x 600 MW 2 x 75 MW,
Saudi Arabia coal fired revamping oil & gas fired
oil fired
360 MW
simulator & training
IWPP
Fossil fired power plants
Australia
Australia 4 x 720 MW Gas turbine power plants
Kuwait 4 x 550 MW coal fired revamping Renewable energy power plants
90,000 t/d brown coal fired revamping Australia simulator & training
desalination simulator & training solar (CSP) turbine upgrading Plant services and/or plant simulators
Yokogawa service offices

YOKOGAWA ELECTRIC CORPORATION

World Headquarters Represented by:
9-32, Nakacho 2-chome, Musashino-shi, Tokyo 180-8750, Japan
http://www.yokogawa.com/

YOKOGAWA CORPORATION OF AMERICA

12530 West Airport Blvd, Sugar Land, Texas 77478, USA
http://www.yokogawa.com/us/

YOKOGAWA EUROPE B.V.

Euroweg 2, 3825 HD Amersfoort, The Netherlands
http://www.yokogawa.com/eu/

YOKOGAWA ENGINEERING ASIA PTE. LTD.

5 Bedok South Road, Singapore 469270, Singapore
http://www.yokogawa.com/sg/

YOKOGAWA CHINA CO., LTD.

3F Tower D Cartelo Crocodile Building
No. 568 West Tianshan Road, Shanghai 200335, China
http://www.yokogawa.com/cn/

YOKOGAWA MIDDLE EAST B.S.C.(c)

P.O. Box 10070, Manama
Building 577, Road 2516, Busaiteen 225, Muharraq, Bahrain
http://www.yokogawa.com/bh/

Trademarks
All brand or product names of Yokogawa Electric Corporation in this bulletin are trademarks or registered trademarks of Yokogawa Electric
Corporation. All other company brand or product names in this bulletin are trademarks or registered trademarks of their respective holders.
Bulletin 53T01A01-02E

Subject to change without notice

All Rights Reserved. Copyright 2010, Yokogawa Electric Corporation
[Ed:03/b] Printed in Japan, 105(KP)
 VigilantPlant: smart ideas for a sustainable future

Redefining VigilantPlant
For years, Yokogawa has used the word VigilantPlant as our vision for operational excellence.
What this meant was bringing out the best in your plant and people through visibility of information,
predictability of process, and agility of business.

We now believe VigilantPlant means much more than just what goes on in your plant.

Yokogawa is committed to sustaining your business, the environment, and the society that we all are a part of.
We are doing this by developing more energy-efficient technology, helping operations produce a smaller
carbon footprint, and building rock solid products that protect our environment from contaminants.
Sustainability is not just a job for Yokogawa but for all industry.

Will you join in embracing a new VigilantPlant?

1 2
 Sustainable energy solutions for a promising future

Yokogawa has been providing

control solutions for generating

Carbon dioxide (CO2) power from solar, wind, hydro,
is one of the major greenhouse biomass, geothermal, and other
gases causing climate change renewable energy sources based
and global warming. on its extensive experience in
In the power industry, this field and technologies.
Yokogawa has taken the lead For a brighter future, Yokogawa
in providing solutions to improve offers sustainable energy solutions
power efficiencies by reducing that minimize the impact of CO2
emissions. emissions and achieve the

operational excellence that is the

hallmark of the VigilantPlant.

3 4
 Leading-edge technology for reduc ing CO2 emissions
The advanced technology, excellent product quality, and extensive
application know-how that go into Yokogawas optimum solutions help
you reduce your power plants CO2 emissions.

Efficiency improvement control solution

Renewable energy control solution
CENTUM VP is a core platform and a key component of our
comprehensive control solutions that make it possible for power STARDOM with FAST/TOOLS provides an innovative
plants to operate more efficiently. Solar Wind web-based SCADA solution for renewable energy plants.
power power

Fossil Hydro
Contr
ol LA
N(V
power power
net/IP
Field control station (FCS) )

Turbomachinery
control & protection
Boiler & BOP

Susta inable
controls

Combined
ene rgy
cycle solu tions Nuclear
power
power
Multi-sensing digital
Combustion gas analysis solution technology solution
The TruePeak TDLS200 analyzer utilizes powerful and
highly sensitive lasers and can detect and analyze DPharp series transmitters with multi-sensing digital
Biomass Geothermal
technology offer unmatched performance and precision.
combustion gases under a wide variety of conditions. power power

Waste to energy

DPharp DPharp
ISA100.11a Open access
field wireless to field intelligence

5 6
 Yokogawas control strategy to reduce CO2 emissions
Protecting the environment has become a
pressing concern in many industries, and the
power industry is no exception.
Many new regulations are forcing businesses
to reduce their emissions of CO2 and other
greenhouse gases to prevent global warming.
CO2 emissions reduction is crucial at coal-fired
power plants, which discharge much greater
amounts of this gas into the atmosphere than
other types of fossil-fired power plants.
By bringing to bear its technologies and expertise,
Yokogawa is focused on improving environmental
control over the entire plant lifecycle and ensuring
clean air for generations to come.
The 3Es of efficiency improvement, emissions
reduction, and economic returns are a key part
of Yokogawas control strategy for reducing
CO2 emissions. Our unparalleled control
schemes for coal-fired power plants help
reduce CO2 emissions and create clean power.

E
fficiency improvement
Optimal combustion and soot blowing inside the boiler
enhance the heat rate, reduce outages, and reduce fuel
consumption.

E
missions reduction
Control strategies reduce emissions by optimizing
combustion and improve emissions measurement.

E
conomic returns
Improved performance reduces fuel and operating costs.

7 8
 Benefit estimation of CO2 emissions
reduction and cost saving

Improvements

Example of typical benefit estimation Superheated steam

Annual returns from 3Es for a 300 MW coal - fired unit
G

HP IP LP

Boiler
efficiency

E
DSH
Condenser
Raw water
fficiency improvement Reheated steam
FSH PSH
Approx. Drum
CP Demineralizer
0.3 - 1%
RH Make up water
Coal bunker
Condensate
HP LP polishers
Deaerator

E
Feed heaters BFP heaters
missions reduction water
Turbine &
Approx. Burner
ECO
DeNOx
BOP efficiency
CO 2 3 - 10 Pulverizer Flue gas
Stack
kilotons/year Fuel oil

Hot air

E
FOP AH FGD
conomic returns FDF EP IDF BUF
Bottom
Approx. PAF ash Ambient air
Hot air
0.3 - 1.1 Plant
million US$/year output
Coal yard Waste water Fly ash Gypsum
Ash pond

Coal -fired power plant

9 10
Benefit estimation of CO2
emissions reduction and cost saving

Example of boiler efficiency improvement

Know-how & technology
Improves heat rate
Improves steam temperature control
Implements coordinated control
Minimizes opacity violations
Overview Adapts to various fuel properties
Enables optimal use of fuel-air mixing

Estimated 3Es Optimizes closed-loop combustion

Quickly analyzes hotspots inside boiler
In a power generation unit, the
Performs multivariable predictive control
main conversion process takes place in
Enables smart automatic soot blowing
the boiler, where superheated steam is generated

E
fficiency improvement to drive the turbine. The thermodynamics inside the

Approx. boiler are a complex, multivariable process, where

0.3 - 0.9% it is possible to both to improve the efficiency and
reduce emissions. Hence, the boiler model is
Superheated steam
constantly updated based on the operating status,
G

E
and appropriate optimizing algorithms are used to
missions reduction improve the heat rate and minimize fuel
HP IP LP

Approx. consumption. DSH Condenser Raw water

CO 2 3 - 9
kilotons/year Drum
FSH PSH
Reheated steam CP Demineralizer
The resultant fuel saving is converted to an
Make up water
RH
equivalent emissions reduction. The economic Coal bunker

E
Condensate
HP LP polishers
conomic returns returns are calculated from both the optimal heat Feed
water
heaters BFP Deaerator heaters

Approx. rate and emission reduction initiatives.

Burner ECO

0.3 - 0.9 Pulverizer

DeNOx
Flue gas Stack
million US$/year Fuel oil

FOP Hot air AH FGD

Bottom FDF EP IDF BUF
PAF ash
Hot air Ambient air

Coal yard Fly ash Gypsum

Waste water

Ash pond

Coal-fired power plant

11 12
Benefit estimation of CO2
emissions reduction and cost saving

Example of turbine and BOP efficiency improvement

Know-how & technology

Minimizes condenser back pressure loss

Minimizes feed heater loss
Overview Minimizes high/low-steam pressure loss
Minimizes low-steam temperature loss
Minimizes auxiliary power consumption
Estimated 3Es
Optimizes feed pump operation
Efficiency can also be greatly Reduces forced outages
improved in the turbines and BOP. For the
turbines, the condenser back pressure loss, steam

E
fficiency improvement pressure loss, and temperature loss can all be

Approx. minimized.
Up to 0.1%
For BOP, which is vulnerable to variations in fuel
Superheated steam
feed, improvements can be attained by closely
G

E
coordinating control strategies to optimize the
missions reduction operation of the feed pump and minimize auxiliary
HP IP LP

Approx. power consumption. DSH Condenser Raw water

CO 2 up to 1
kilotons/year Drum
FSH PSH
Reheated steam CP Demineralizer
Make up water
RH
Coal bunker

E
Condensate
HP LP polishers
conomic returns Feed
water
heaters BFP Deaerator heaters

Approx. ECO
Burner
Up to 0.1 Pulverizer
DeNOx
Flue gas Stack
million US$/year Fuel oil

FOP Hot air AH FGD

Bottom FDF EP IDF BUF
PAF ash
Hot air Ambient air

Coal yard Fly ash Gypsum

Waste water

Ash pond

Coal-fired power plant

13 14
 Benefit estimation of CO2
emissions reduction and cost saving

Example of plant output improvement

Know-how & technology

Improves plant availability

Improves operating procedures

Overview Improves maintenance procedures

Improves ancillary plant performance
Smoothens plant operations
Recovers megawatts of power

Plant output can be improved Reduces oil usage for start-ups

by carrying out proper operating and Enables the creation of feasible maintenance schedules
maintenance procedures, having advance warning
of tube leaks, and optimizing soot blowing
operations.

The resulting benefits are calculable based on the

Superheated steam
recovered megawatt-hours from the reduction in
G
forced outages, improvement of plant availability,
HP IP LP
Highly reliable DCS & instruments for reduction in forced outages and reduction of start-up plant operation.
DSH Condenser Raw water

FSH PSH
Drum Reheated steam CP Demineralizer
Make up water
RH
Coal bunker

E
Condensate
HP LP polishers
conomic returns Feed
water
heaters BFP Deaerator heaters

Approx. ECO
Burner
Up to 0.1 Pulverizer
DeNOx
Flue gas Stack
million US$/year Fuel oil

FOP Hot air AH FGD

Bottom FDF EP IDF BUF
PAF ash
Hot air Ambient air

Coal yard Fly ash Gypsum

Waste water

Ash pond

Coal-fired power plant

15 16
 Key services and products for
reducing CO2 emissions

Auditing your plant performance

1
step

Building a lasting future

Improving plant efficiency
Improving plant availability
Reducing CO2 emissions
step
2
3
Envision a plant where people are watchful and attentive while your
power generation business responds to changes quickly and efficiently.
Improving operation skills
Now picture an operation that delivers non-stop power generation while
confidently improving your plant efficiency and reducing CO2 emissions Improving asset management
step
long into the future. Imagine no further. This is the reality attained by Reducing maintenance cost
VigilantPlant, the clear path to operational excellence.

With the VigilantPlant vision, Yokogawa delivers comprehensive

solutions to ensure that environmentally friendly plants run continuously
at maximum efficiency and optimal profitability throughout their lifecycle.

Comprehensive solutions for your plant lifecycle
From planning to project execution, operations, and
maintenance, Yokogawa helps power plant users achieve
operational excellence throughout their facilitys lifecycle
with the following sophisticated solutions:
Long-term partnership for your business
Plant audits During the relatively long life cycle of a power plant, there comes a time
Plant simulators when the instrumentation and control systems must be renewed to maintain
Advanced management a competitive edge. Yokogawa supports power plants with expert services
that maximize efficiency and minimize cost over the entire life cycle.
Total power plant control
From initial planning, design, engineering, construction, and operation to
Renewable energy control
revamp and re-instrumentation, Yokogawa stands by your power plant.
Combustion gas analyzers This long-term partnership ensures bottleneck-free performance and
Intelligent field devices ongoing optimization that bring speed and flexibility to your business.

17 18
Key services and products for reducing CO2 emissions

Plant audits

Maximize your cost benefits and returns

Yokogawa delivers cost benefits through the refurbishment of power plant controls and instrumentation.
This improves the performance of older plants and ensures that they can operate competitively
in todays open power markets, and also reduces their CO2 emissions.

Audit your plant performance

Yokogawa assists power plant owners and operators to identify areas of plant operations that
will benefit from modern controls running on the latest digital control system platform, with
modern field instrumentation.

Our experts will visit your site to carry out field surveys and assess the status of your plant. We
collect plant operating data and cost details, then prepare a plant survey report along with our
recommendations on a control system and field instrumentation upgrade.

Based on this data and these recommendations, a cost-benefit report is drawn up. This report,
along with pricing information for a control and instrumentation upgrade project, is provided to
the plant owner for consideration, discussion, and action.

Plant availability, reliability, and efficiency

Operating regime (daily and seasonal load profiles)
Benchmarks against other facilities of similar age
Audit items Review of organizational structure
Review of maintenance management
Review of costs, routine, and capital
General plant condition and life expectancy

19 20
Key services and products for reducing CO2 emissions

Plant simulators

Reassure supreme accuracy

You no longer have to ignore the complexity of real-life processes. No other simulators available
today can match the accuracy of a Yokogawa power plant simulator. Flexible training scenarios can
help your operators learn how to control the entire plant with complete confidence. Experience the
reassurance that comes from having a Yokogawa power plant simulator.
Full-replica power plant simulator
Simulation computer Instructor system Turbine running up system
Features Plant logics
Mathematical models
Training scenarios
Malfunctions
Executive process Trainee database
High fidelity 99% accuracy (>99% steady state; >95% dynamic state)

Freely devise any training scenario to improve and evaluate operator skills
in the following areas:
Flexible training Executing routine operational procedures
and evaluation Responding to plant malfunctions Etherne
t
Performing unusual operations such as forced cooling and cold start-ups

Human interface station

Benefits
Power plant DCS
Faster The DCS is fully tested before it is installed, drastically reducing the
number of modifications to logic, set points, and tuning parameters
commissioning during the commissioning phase. Performance-based operation
10 20000 600
9 18000

MW,level,temperature
500
8 16000

Flue gas oxygen

Steam pressure
7 14000
400
6 12000

Plant resource management

5 10000 300

4 8000
200
3 6000
2 4000
100
1 2000
0 0 0
10 20 30 40 50 60

Smoother
Time ( Min. )

Before a DCS is installed at a power plant, it is fully tested using

dynamic simulation. In this way, both operators and engineers become
plant start-up familiar with the DCS operation and controls.
Turbine control

Boiler / BOP control Contr

ol LAN
( Vne
t/IP )
Minimized risk of By dynamically testing the safety interlocks prior to DCS
Safety system
plant damage installation, the simulator reduces the risk of major equipment
damage occurring during the commissioning process.

21 22
Key services and products for reducing CO2 emissions

Advanced management

Secure the predictability of your critical process

Making plant information fully visible is vital in preventing disruptions to your critical plant
processes. Our knowledge-based tools and advanced management solutions help you steadily
improve efficiency and attain operational excellence.

Performance-based Our key performance indicator (KPI) monitoring solution makes KPIs
operation visible and enables you to efficiently operate the production.
Performance-based operation with Exaquantum

Plant information Exaquantum, a comprehensive plant information management package

integrates and delivers operational information that helps enterprises
at your fingertips meet complex business requirements.

Exapilot
Increase operational Exapilot, an easy-to-use tool can be used to standardize operating
methods by creating automatic sequences that incorporate the
Operation efficiency improvement package
efficiency know-how of experienced operators.

Exaplog
Benchmark your Exaplog is an easy-to-use suite of tools that analyze the historical logs of
the DCS plant and the results on various graphs, allowing you to analyze
Event analysis package
operational efficiency and benchmark your operational and controllability performance.

Plant Resource Manager (PRM) provides easy-to-use tools for asset

Predict availability management and intelligent diagnostics for field instrumentation,
actuators, and rotating equipment to increase plant availability.

PRM
Plant Resource Manager

23 24
Key services and products for reducing CO2 emissions

Total power plant control Coordinated control

Coordinated control

Turbomachinery control

Steam turbine area

Boiler control
Balance of plant control
Boiler control area
Air and flue gas oveview

Raise plant availability and performance

With its state-of-the-art architecture, the highly reliable CENTUM VP platform is fully up to
the challenge of monitoring and controlling an entire power plant s turbines, boilers, and
balance of plant (BOP) facilities.

Human interface station/

engineering station

Performance-based operation
10 20000 600
9 18000

MW,level,temperature
500
8 16000

Flue gas oxygen

Steam pressure
7 14000
400
6 12000
5 10000 300

4 8000
200
3 6000
2 4000
100
1 2000
0 0 0

Plant resource management

10

Turbomachinery
20 30 40 50 60

Field control station (FCS)

Time ( Min. )

control & protection

The FCS provides powerful control functions
with a highly reliable dual redundant
configuration that incorporates Yokogawas
own pair-and-spare technology.

Boiler & BOP

controls

Steam turbine

Con
trol
Plant safety LAN
system
Safety control station (SCS) ( Vn
FGD et/I
The ProSafe-RS SCS is a TV SIL3 certified safety
P)
EP
system that incorporates Yokogawas pair-and-spare
technology.
Coal yard

Fuel

25 26
Key services and products for reducing CO2 emissions

Renewable energy control Wind turbine view

Wind turbine details

Shift to renewable energy

STARDOM is a network-based control system that brings operational excellence to
renewable energy plants that may be widely distributed. STARDOM autonomous
Remote
controllers have remote management and stand-alone capability, and reduce running devices

costs by making flexible use of e-mail, the web, and supervisory control and data
acquisition (SCADA) technology. STARDOM is widely used in the renewable energy
industry with the FAST/TOOLS distributed SCADA system. FAST/TOOLS is a scalable
product to cover a wide range of very small up to large distributed applications.
STARDOM
FAST/TOOLS supports remote web-based operations and maintenance. Wireless LAN engineering tool

Plant information
management system

Plant resource
manager

GPS receiver,
SNTP server
Safety instrumented system

Optical
R e n e w a fiber ring
b l e
e n e
r g y
Modem Proce
ss ne
twork
Field control node

PSTN. xDSL.
and more

Wind power Modem

Solar power

Small hydro power

GSM/GPGR,
Field control junction
Satellite,
Geothermal power RF,and more

Waste to energy

27 Remote terminal unit

28
Biomass power
Key services and products for reducing CO2 emissions

Combustion gas analyzers

O2
CO
H2O
O2
H 2O

CO

H2O
O2 CH4
CO2

Enhance combustion control

The TruePeak TDLS200 is a pioneering combustion gas analyzer with a powerful tunable diode
laser that is ideal for making direct measurements in harsh process environments. It can be used
to optimize the combustion process in boiler plants to reduce both CO2 and NOx emissions, and
is a highly cost-effective solution that makes no compromise in speed, accuracy, or reliability.

Superheated steam
Measures gases directly in the process (no sampling system required)
Features Powerful laser overcomes the effects of high particulate loading (fly ash and dust)
Measures gases continuously, accurately, sensitively, and selectively
with no lag time

DSH

CO measurement for highest efficiency improvement

FSH PSH
Continuous measurement of carbon monoxide (CO) and oxygen (O2) concentrations allows operators at fossil
fuel power plants to fine tune the air-fuel ratio to boost combustion efficiency and reduce NOx emissions.
Drum
Reheated steam

The TruePeak TDLS200 utilizes powerful lasers that are highly sensitive and selective for CO. In boilers it can
RH
directly measure CO, eliminating lag time in detecting CO breakthrough and producing no false low readings. Coal bunker

Feed NH3
NH3 measurement for NOx reduction water injection

ECO
Ammonia (NH3) gas is injected to remove NOx and thus reduce the NOx concentration in the stack flue gas, as Burner Flue gas
well as to increase the dust collection efficiency of the electrostatic precipitator (EP) and prevent corrosion.
Pulverizer
However, excess ammonia injection increases running costs and residual NH3, resulting in foul odors.
Therefore, the NH3 concentration in the stack flue gas is measured, controlled, and monitored.
DeNOx
With conventional ammonia analyzers that perform measurements indirectly, NH3 concentrations are obtained
through a sampling system, causing problems with the maintenance and running costs of the sampling
system, and time delays in measurement. The TruePeak TDLS200 solves all these problems.
Fuel oil
Hot air TruePeak
Bottom
ash TDLS200
PAF
Hot air

29 30
Key services and products for reducing CO2 emissions

Intelligent field devices

Silicon resonant sensor

Take your plant into the digital era

DPharp digital pressure transmitters are the first to use a revolutionary silicon resonant sensor DPharp DPharp
ISA100.11a Open access
technology that provides superior stability and repeatability in the most demanding process applications. field wireless to field intelligence
They are ideal for use in highly critical power plant processes.
For all ultra critical processes
This intelligent field device a best-in-class and reliable digital solution that meets present and future needs
Boiler drum level measurement Main steam flow and pressure
in the power industry by being fully interoperable with an extensive range of open industrial protocols.
Very high static pressure
Varying pressure affecting density Superheated steam FX PX

Very small measurement span

Best-in-class Precision and quick response time Feed water flow measurement FX
performance Very high pressure surges (water hammer)
Varying flow for varying load
Spray flow

Field - proven No-error-prone A/D converter:

DSH
reliability Full end-to-end digital communications from process to control system

Drum level
FSH PSH

Drift free, Unparalleled stability guarantee

LX
Drum
Reheated steam
long-term stability
RH
Coal bunker

Measurement of differential pressure and static pressures (DP and SP) by Feed water flow
Multi-sensing a single transmitter minimizes your instrumentation cost. Feed
water FX

ECO DeNOx
Burner
DP, SP, and inline temperature measurement in a single transmitter enables Flue gas
Multi-variable mass flow to be calculated by an on-board flow computer.
Pulverizer

AH
Air flow
Open industrial communications:
Full interoperability Whether you choose BRAIN, HART, FOUNDATION fieldbus or Profibus, Fuel oil FX
our transmitters will deliver their full benefits. Hot air
Bottom
ash
PAF FDF
Hot air
Ambient air
31 32
 A case study of CO2 emissions
reduction
Retrofit of Mongolias largest thermal power plant
Plant information
Project background
In Mongolia, temperatures fall as low as -40 in mid-winter.
The heat and electricity generated by Thermal Power Plant
No.4 (TES4) in the capital city of Ulaanbaatar is an important
lifeline for the people living there.
TES4 is the largest coal-fired power plant in Mongolia and it
generates 70% of the electricity for Mongolias central energy
system and 65% of the heat energy used by Ulaanbaatar
district heating system.
33
Plant name : Thermal Power Plant No. 4
Location : Ulaanbaatar, Mongolia
Owner : Mongolian Ministry of Minerals and Power
Steam outputs (boilers) : 8 x 420 t/h (including steam for town heating)
Electricity outputs (turbines) : 560 MW (4 x 100 MW and 2 x 80 MW)
Fuel : Lignite coal
Construction : 1980 - 1990
Retrofit : 1997 - 2007
Output/fuel : Boilers - 8 x 420 t/h, lignite-fired
Turbines - 2 x 80 MW, 4 x 100 MW with town heating
Scope of replacement : Retrofit of control and safety systems,
and replacement of field instruments and actuators
TES4 was built many years ago and has been severely affected by the
scarcity of spare parts for its legacy systems. Plant shutdowns were a
frequent occurrence due to equipment malfunctions and accidents,
disrupting the supply of heat and power. In addition, the plant caused
severe air pollution due to inefficient control of coal combustion. Efforts
to correct these problems were also hampered by the loss of many of
the plant s original blueprints and other design related documents.
To solve these problems, the Mongolian government decided to execute
a plant revamping project in two phases using an official development
assistance (ODA) loan. Phase one for boilers one to four started in 1996
and was completed in 2000. Phase two for boilers five to eight started in
2002 and was completed in 2007. For this project, Yokogawa delivered
control systems and field instrumentation for all eight boilers.
34
A case study of CO2 emissions reduction

The challenges
The existing combustion boilers employed an indirect firing system.
This system stores pulverized coal in a silo and feeds it to the boilers as required.
The indirect firing system caused frequent equipment troubles and there was a high risk of explosion.

The boilers and mill burners were manually controlled by operators except for feed water control.
The combustion air was always sent by fans fully opened, thus the combustion efficiency was extremely low.
The control operation system was a board operation type equipped with analog and discrete control logics.
Only a few very old Russian documents for the control logic scheme were available.

Customers requirements Yokogawas solutions

Full automation of boilers, burners, Design of fully automated control logic

and balance of plant (BOP) facilities TES4 converted the existing indirect combustion system to the new direct combustion type. Yokogawa
performed a detailed investigation of the original boiler combustion control system and the direct
combustion control logic together with a new burner vendor and TES4s engineers. Yokogawa
succeeded in designing a fully automated burner management system that replaced the old manually

A highly reliable and expandable operated system. Other major controls for the boilers and BOP facilities were also reviewed and
designed based on the new control strategy and Yokogawas expertise.
distributed control system (DCS)
Replacement with state-of-art DCS
The control systems for all eight boilers at TES4 were changed over to a state - of - the - art Yokogawa
A power plant simulator for CENTUM CS 3000 DCS, which provides a highly reliable platform for the comprehensive control and
operation of the entire power generation plant. As a result, operation efficiency and safety were
training DCS operators dramatically improved. For interfacing with the existing I/O signals, a redundant remote fiber - optic
network was installed that reduced the cabling cost and improved both safety and reliability.

Supply of power plant simulator

In line with the replacement of the DCS, a power plant simulator was supplied for operator training,
allowing operators to get experience with plant operating procedures, gain familiarity with the DCS,
and improve their skills. As the result, they achieved a smooth transition from the conventional analog
control panels to an all-new graphical user interface.

35 TES4 plant control room before refit 36

A case study of CO2 emissions reduction

Achievements

Coal consumption rate Coal consumption rate

for electricity generation for district-heating steam
g/kWh kg/Gcal
22% reduction 7% reduction
417 190
409 from 1997 to 2007 188 from 1997 to 2007
400 186 186
393
389 389 184
388 184 184
365 365 182
181
180
349 180
350 177
337

E
317 174

The new control system for TES4s eight boilers was changed over
fficiency improvement one boiler at a time, starting at the end of 1998 and finishing in 2007.
300 170
1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007
Fuel consumption was dramatically reduced thanks to improved
boiler efficiency. This has enabled the power plant to provide a stable
supply of electricity and district-heating steam to the city of Total CO2 emissions amount
Ulaanbaatar. of electricity & district-heating steam
kilo tons
17% reduction

E
3,000
2,930
2,957
2,846 from 1997 to 2007
missions reduction 2,817 2,811 2,818

Improved boiler efficiency and reduced coal and heavy oil 2,696 2,690
2,614
consumption have made it possible for this power plant to generate 2,537

2,500
more electricity from the same amount of fuel, and has significantly 2,426

reduced CO2 emissions.

E
2,000

conomic returns
1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007

Improved reliability and operation safety at TES4 have decreased the

number of plant outages caused by boiler trips and accidents and
Total heavy oil consumption
reduced the amount of oil consumed for boiler start-ups. With the tons
improved reliability of this plant, the Mongolian government no 15,000 88% reduction
longer has to purchase as much electricity from other countries. 13,897 from 1997 to 2007
10,300
10,000
7,280

5,000 4,793
4,757 4,755 4,012 3,852
2,808
1,897
1,682

0
1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007

Note : Coal consumption and CO2 emissions are estimated based on coal consumption rate at 7,000 kcal in 1997 with the following values.

37 TES4 plant control room with CENTUM system Calorific value: 29.3 GJ/ton Emission coefficient: 0.0247 C/GJ CO2 conversion coefficient: 3.6667
38