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.

1. Yokogawa Vigilance at your service worldwide - representative projects
Mongolia
8 x 420 t/h
coal fired
revamping & simulator
Bulgaria
8 x 200 t/h
flue gas desulfurization
Italy
400 MW
combined cycle
UK
37 MW
waste to energy
Taiwan
2 x 550 MW
coal fired
Algeria
369 MW
IWPP
India
2 x 600 MW
2 x 500 MW
coal fired
Saudi Arabia
360 MW
IWPP
Kuwait
90,000 t/d
desalination
Canada
120 MW, cogeneration
Trinidad and Tobago
720 MW
combined cycle
Vietnam
2 x 600 MW
coal fired
Brunei
110 MW
combined cycle
Indonesia
110 MW & 95 MW
geothermal
Australia
4 x 550 MW
brown coal fired revamping
simulator & training
Australia
solar (CSP)
in the power industry
Brazil
460 MW,
combined cycle
Australia
4 x 500 MW
coal fired revamping
Australia
4 x 720 MW
coal fired revamping
simulator & training
turbine upgrading
Sustainable energy solutions
for reducing CO2 emissions
Venezuela
460 MW
combined cycle
Vietnam
2 x 300 MW, coal fired
simulator & training
Thailand
2 x 110 MW
combined cycle
Singapore
2 x 600 MW
oil fired
simulator & training
U.S
3 x 70 MW, gas & oil fired
Japan
375 MW & 350 MW
gas fired
India
3 x 660 MW
supercritical
coal fired
Egypt
750 MW
750 MW
750 MW
combined cycle
U.S
100 MW, combined cycle
Japan
2 x 1,050 MW
flue gas desulfurization
China
6 x 300 MW
coal fired
China
450 MW
wind power
Nigeria
530 MW & 2 x 450 MW
simple cycle
U.S
480 MW, combined cycle
Korea
800 MW supercritical
training simulator
Romania
4 x 330 MW
flue gas desulphurization
Turkey
130 MW
combined cycle
Spain
800 MW
combined cycle
w/ LNG terminal
Korea
9 x 100 MW
coal fired
Brazil
2 x 75 MW,
oil & gas fired
Fossil fired power plants
Gas turbine power plants
Renewable energy power plants
Plant services and/or plant simulators
Yokogawa service offices
YOKOGAWA ELECTRIC CORPORATION
World Headquarters
9-32, Nakacho 2-chome, Musashino-shi, Tokyo 180-8750, Japan
http://www.yokogawa.com/
Represented by:
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)

2. 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

3. Sustainable energy solutions for a promising future
Yokogawa has been providing
control solutions for generating
Carbon dioxide (CO2)
is one of the major greenhouse
power from solar, wind, hydro,
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

4. Leading-edge technology for reduc ing CO2 emissions
The advanced technology, excellent product quality, and extensive
application know-how that go into Yokogawa’s optimum solutions help
you reduce your power plant’s 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
plants to operate more efficiently.
Contr
Field control station (FCS)
ol LA
N(V
net/IP
Solar
power
STARDOM with FAST/TOOLS provides an innovative
web-based SCADA solution for renewable energy plants.
Wind
power
Fossil
power
Hydro
power
)
Turbomachinery
control & protection
Boiler & BOP
controls
Combined
cycle
power
Susta inable
ene rgy
solu tions
Nuclear
power
Multi-sensing digital
technology solution
Combustion gas analysis solution
The TruePeak TDLS200 analyzer utilizes powerful and
highly sensitive lasers and can detect and analyze
combustion gases under a wide variety of conditions.
Biomass
power
Geothermal
power
DPharp series transmitters with multi-sensing digital
technology offer unmatched performance and precision.
Waste to energy
DPharp
ISA100.11a
field wireless
5
DPharp
Open access
to field intelligence
6

5. Yokogawa’s 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.
E
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 Yokogawa’s control strategy for reducing
CO2 emissions. Our unparalleled control
schemes for coal-fired power plants help
reduce CO2 emissions and create clean power.
fficiency improvement
E
Optimal combustion and soot blowing inside the boiler
enhance the heat rate, reduce outages, and reduce fuel
consumption.
missions reduction
E
Control strategies reduce emissions by optimizing
combustion and improve emissions measurement.
conomic returns
7
Improved performance reduces fuel and operating costs.
8

6. 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
E
DSH
Condenser
fficiency improvement
E
Approx.
0.3 - 1%
CO 2 3 - 10
kilotons/year
conomic returns
Make up water
RH
HP
heaters
Feed
water
ECO
Burner
Pulverizer
Boiler
efficiency
Demineralizer
CP
Coal bunker
Approx.
Raw water
Reheated steam
PSH
FSH
Drum
missions reduction
E
LP
IP
BFP
DeNOx
LP
heaters
Deaerator
Condensate
polishers
Turbine &
BOP efficiency
Flue gas
Stack
Fuel oil
Hot air
FOP
Approx.
Hot air
0.3 - 1.1
million US$/year
PAF
Coal yard
Bottom
ash
AH
FGD
EP
FDF
IDF
BUF
Ambient air
Plant
output
Waste water
Fly ash
Gypsum
Ash pond
Coal -fired power plant
9
10

7. 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
Optimizes closed-loop combustion
Estimated 3Es
Quickly analyzes hotspots inside boiler
In a power generation unit, the
Performs multivariable predictive control
main conversion process takes place in
E
Enables smart automatic soot blowing
the boiler, where superheated steam is generated
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,
E
missions reduction
E
Approx.
CO 2 3 - 9
kilotons/year
G
and appropriate optimizing algorithms are used to
HP
improve the heat rate and minimize fuel
consumption.
DSH
Approx.
0.3 - 0.9
million US$/year
Condenser
PSH
FSH
Drum
The resultant fuel saving is converted to an
equivalent emissions reduction. The economic
conomic returns
LP
IP
Reheated steam
returns are calculated from both the optimal heat
Make up water
HP
heaters
Feed
water
rate and emission reduction initiatives.
ECO
Burner
Pulverizer
Demineralizer
CP
RH
Coal bunker
Raw water
BFP
DeNOx
Deaerator
LP
heaters
Condensate
polishers
Flue gas
Stack
Fuel oil
Hot air
FOP
Hot air
PAF
Bottom
ash
Coal yard
AH
FDF
FGD
EP
IDF
BUF
Ambient air
Waste water
Fly ash
Gypsum
Ash pond
11
Coal-fired power plant
12

8. 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
E
turbines, the condenser back pressure loss, steam
fficiency improvement
Approx.
pressure loss, and temperature loss can all be
minimized.
Up to 0.1%
For BOP, which is vulnerable to variations in fuel
Superheated steam
feed, improvements can be attained by closely
E
missions reduction
E
Approx.
CO 2 up to 1
kilotons/year
G
coordinating control strategies to optimize the
HP
operation of the feed pump and minimize auxiliary
power consumption.
DSH
Condenser
PSH
FSH
Drum
Reheated steam
conomic returns
Make up water
HP
heaters
Feed
water
Approx.
ECO
Burner
Pulverizer
Raw water
Demineralizer
CP
RH
Coal bunker
Up to 0.1
million US$/year
LP
IP
BFP
DeNOx
Deaerator
LP
heaters
Condensate
polishers
Flue gas
Stack
Fuel oil
Hot air
FOP
Hot air
PAF
Bottom
ash
Coal yard
AH
FDF
FGD
EP
IDF
BUF
Ambient air
Waste water
Fly ash
Gypsum
Ash pond
13
Coal-fired power plant
14

9. 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,
Highly reliable DCS & instruments for reduction in forced outages
HP
and reduction of start-up plant operation.
LP
IP
DSH
PSH
FSH
Drum
E
Condenser
conomic returns
Make up water
HP
heaters
Feed
water
Approx.
ECO
Burner
Pulverizer
Demineralizer
CP
RH
Coal bunker
Up to 0.1
million US$/year
Reheated steam
Raw water
BFP
DeNOx
Deaerator
LP
heaters
Condensate
polishers
Flue gas
Stack
Fuel oil
Hot air
FOP
Hot air
PAF
Bottom
ash
Coal yard
AH
FDF
FGD
EP
IDF
BUF
Ambient air
Waste water
Fly ash
Gypsum
Ash pond
15
Coal-fired power plant
16

10. Key services and products for
reducing CO2 emissions
Improving plant efficiency
Improving plant availability
Reducing CO2 emissions
Building a lasting future
Envision a plant where people are watchful and attentive while your
power generation business responds to changes quickly and efficiently.
Now picture an operation that delivers non-stop power generation while
confidently improving your plant efficiency and reducing CO2 emissions
long into the future. Imagine no further. This is the reality attained by
VigilantPlant, the clear path to operational excellence.
1
2
3
step
Auditing your plant performance
step
Improving operation skills
Improving asset management
Reducing maintenance cost
step
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
Long-term partnership for your business
From planning to project execution, operations, and
maintenance, Yokogawa helps power plant users achieve
operational excellence throughout their facility’s lifecycle
with the following sophisticated solutions:
During the relatively long life cycle of a power plant, there comes a time
when the instrumentation and control systems must be renewed to maintain
a competitive edge. Yokogawa supports power plants with expert services
that maximize efficiency and minimize cost over the entire life cycle.
From initial planning, design, engineering, construction, and operation to
revamp and re-instrumentation, Yokogawa stands by your power plant.
This long-term partnership ensures bottleneck-free performance and
ongoing optimization that bring speed and flexibility to your business.
Plant audits
Plant simulators
Advanced management
Total power plant control
Renewable energy control
Combustion gas analyzers
Intelligent field devices
17
18

11. 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 today’s 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)
Audit items
Benchmarks against other facilities of similar age
Review of organizational structure
Review of maintenance management
Review of costs, routine, and capital
General plant condition and life expectancy
19
20

12. 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.
Simulation computer
Features
Flexible training
and evaluation
・ Plant logics
・ Mathematical models
・ Executive process
Turbine running up system
・ Training scenarios
・ Malfunctions
・ Trainee database
• 99% accuracy (>99% steady state; >95% dynamic state)
Freely devise any training scenario to improve and evaluate operator skills
in the following areas:
• Executing routine operational procedures
• Responding to plant malfunctions
• Performing unusual operations such as forced cooling and cold start-ups
Etherne
t
Human interface station
Benefits
Faster
commissioning
Instructor system
Power plant DCS
• The DCS is fully tested before it is installed, drastically reducing the
number of modifications to logic, set points, and tuning parameters
during the commissioning phase.
Performance-based operation
10
20000
18000
16000
7
6
5
4
Steam pressure
Flue gas oxygen
9
8
14000
12000
10000
8000
3
0
500
400
Plant resource management
300
200
2000
0
• Before a DCS is installed at a power plant, it is fully tested using
dynamic simulation. In this way, both operators and engineers become
familiar with the DCS operation and controls.
4000
1
Smoother
plant start-up
6000
2
600
MW,level,temperature
High fidelity
Full-replica power plant simulator
100
0
10
20
21
• By dynamically testing the safety interlocks prior to DCS
installation, the simulator reduces the risk of major equipment
damage occurring during the commissioning process.
40
50
60
Time ( Min. )
Turbine control
Contr
Boiler / BOP control
Minimized risk of
plant damage
30
ol LAN
( Vne
t/IP )
Safety system
22

13. 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
operation
Our key performance indicator (KPI) monitoring solution makes KPIs
visible and enables you to efficiently operate the production.
Plant information
at your fingertips
Exaquantum, a comprehensive plant information management package
integrates and delivers operational information that helps enterprises
meet complex business requirements.
Increase operational
efficiency
Exapilot, an easy-to-use tool can be used to standardize operating
methods by creating automatic sequences that incorporate the
know-how of experienced operators.
Benchmark your
operational efficiency
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
and benchmark your operational and controllability performance.
Predict availability
Plant Resource Manager (PRM) provides easy-to-use tools for asset
management and intelligent diagnostics for field instrumentation,
actuators, and rotating equipment to increase plant availability.
Performance-based operation with Exaquantum
Exapilot
Operation efficiency improvement package
Exaplog
Event analysis package
PRM
Plant Resource Manager
23
24

14. 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
16000
7
6
5
14000
12000
10000
4
3
4000
1
0
500
400
300
2000
0
Field control station (FCS)
6000
2
Turbomachinery
control & protection
8000
600
MW,level,temperature
18000
8
Steam pressure
20000
9
Flue gas oxygen
10
200
100
0
10
20
30
40
50
60
Time ( Min. )
Plant resource management
The FCS provides powerful control functions
with a highly reliable dual redundant
configuration that incorporates Yokogawa’s
own pair-and-spare technology.
Boiler & BOP
controls
Steam turbine
FGD
EP
Coal yard
Plant safety
system
Safety control station (SCS)
The ProSafe-RS SCS is a TÜV SIL3 certified safety
system that incorporates Yokogawa’s pair-and-spare
technology.
Con
trol
LAN
( Vn
et/I
P)
Fuel
25
26

15. 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
controllers have remote management and stand-alone capability, and reduce running
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.
FAST/TOOLS supports remote web-based operations and maintenance.
Remote
devices
Wireless LAN
STARDOM
engineering tool
Plant information
management system
Plant resource
manager
GPS receiver,
SNTP server
Safety instrumented system
R e n e w a
b l e
Optical
fiber ring
e n e
r g y
Modem
Field control node
Proce
ss ne
twork
PSTN. xDSL.
and more
Wind power
Modem
Solar power
Small hydro power
Field control junction
Geothermal power
GSM/GPGR,
Satellite,
RF,and more
Waste to energy
27
Remote terminal unit
Biomass power
28

16. 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
Features
Measures gases directly in the process (no sampling system required)
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
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.
The TruePeak TDLS200 utilizes powerful lasers that are highly sensitive and selective for CO. In boilers it can
directly measure CO, eliminating lag time in detecting CO breakthrough and producing no false low readings.
PSH
Reheated steam
Drum
RH
Coal bunker
Feed
water
NH3 measurement for NOx reduction
Ammonia (NH3) gas is injected to remove NOx and thus reduce the NOx concentration in the stack flue gas, as
well as to increase the dust collection efficiency of the electrostatic precipitator (EP) and prevent corrosion.
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.
NH3
injection
ECO
Burner
Flue gas
Pulverizer
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
29
PAF
Bottom
ash
Hot air
TruePeak
TDLS200
30

17. 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
technology that provides superior stability and repeatability in the most demanding process applications.
They are ideal for use in highly critical power plant processes.
This intelligent field device a best-in-class and reliable digital solution that meets present and future needs
in the power industry by being fully interoperable with an extensive range of open industrial protocols.
DPharp
DPharp
ISA100.11a
field wireless
Open access
to field intelligence
For all ultra critical processes
Boiler drum level measurement
Main steam flow and pressure
Very high static pressure
Superheated steam
Varying pressure affecting density
PX
FX
Very small measurement span
Best-in-class
performance
Precision and quick response time
Feed water flow measurement
FX
Very high pressure surges (water hammer)
Varying flow for varying load
Field - proven
reliability
Spray flow
No-error-prone A/D converter:
Full end-to-end digital communications from process to control system
DSH
Drum level
Drift free,
long-term stability
LX
Unparalleled stability guarantee
FSH
PSH
Reheated steam
Drum
RH
Coal bunker
Multi-sensing
Measurement of differential pressure and static pressures (DP and SP) by
a single transmitter minimizes your instrumentation cost.
Feed water flow
Feed
water
FX
ECO
Burner
Multi-variable
DP, SP, and inline temperature measurement in a single transmitter enables
mass flow to be calculated by an on-board flow computer.
Full interoperability
Open industrial communications:
Whether you choose BRAIN, HART, FOUNDATION™ fieldbus or Profibus,
our transmitters will deliver their full benefits.
Flue gas
Pulverizer
AH
Air flow
Fuel oil
Hot air
31
DeNOx
FX
PAF
Bottom
ash
Hot air
FDF
Ambient air
32

18. A case study of CO2 emissions
reduction
Retrofit of Mongolia’s largest thermal power plant
Plant name
Owner
:
Mongolian Ministry of Minerals and Power
:
8 x 420 t/h (including steam for town heating)
:
560 MW (4 x 100 MW and 2 x 80 MW)
:
Lignite coal
:
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
33
Ulaanbaatar, Mongolia
Construction
TES4 is the largest coal-fired power plant in Mongolia and it
generates 70% of the electricity for Mongolia’s central energy
system and 65% of the heat energy used by Ulaanbaatar
district heating system.
:
Fuel
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.
Location
Electricity outputs (turbines)
Project background
Thermal Power Plant No. 4
Steam outputs (boilers)
Plant information
:
:
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.
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19. 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.
Customer’s requirements
Yokogawa’s solutions
Full automation of boilers, burners,
and balance of plant (BOP) facilities
Design of fully automated control logic
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 TES4’s engineers. Yokogawa
succeeded in designing a fully automated burner management system that replaced the old manually
A highly reliable and expandable
distributed control system (DCS)
operated system. Other major controls for the boilers and BOP facilities were also reviewed and
designed based on the new control strategy and Yokogawa’s expertise.
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
training DCS operators
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
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.
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TES4 plant control room before refit
36

20. A case study of CO2 emissions reduction
Achievements
Coal consumption rate
for electricity generation
g/kWh
400
409
Coal consumption rate
for district-heating steam
22% reduction
from 1997 to 2007
417
kg/Gcal
190
7% reduction
from 1997 to 2007
188
186
393
389
388
186
389
184
365
184
184
365
182
350
181
180
349
180
177
337
E
fficiency improvement
E
missions reduction
E
174
317
The new control system for TES4’s eight boilers was changed over
one boiler at a time, starting at the end of 1998 and finishing in 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
Ulaanbaatar.
170
300
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
1997
1998
2000
2001
2002
2003
2004
2005
2006
2007
Total CO2 emissions amount
of electricity & district-heating steam
kilo tons
3,000
Improved boiler efficiency and reduced coal and heavy oil
consumption have made it possible for this power plant to generate
more electricity from the same amount of fuel, and has significantly
reduced CO2 emissions.
1999
2,957
2,930
2,846
17% reduction
from 1997 to 2007
2,817 2,811 2,818
2,696 2,690
2,614
2,537
2,500
2,426
2,000
conomic returns
1997
Improved reliability and operation safety at TES4 have decreased the
number of plant outages caused by boiler trips and accidents and
reduced the amount of oil consumed for boiler start-ups. With the
improved reliability of this plant, the Mongolian government no
longer has to purchase as much electricity from other countries.
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
Total heavy oil consumption
tons
15,000
88% reduction
from 1997 to 2007
13,897
10,300
10,000
7,280
4,793
5,000
4,757 4,755
4,012 3,852
2,808
1,897
1,682
0
1997
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TES4 plant control room with CENTUM system
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.
Calorific value: 29.3 GJ/ton
Emission coefficient: 0.0247 ｔC/GJ
CO2 conversion coefficient: 3.6667
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