Emerson Offers Unit Response Optimizer as Embedded Advanced Control Application in Ovation® Expert Control System
PITTSBURGH, PA (December 12, 2006) - Today Emerson Process Management announced that the Unit Response Optimizer is now available as an embedded advanced control application in its Ovation® expert control system. This model-based control solution can mean greater profitability for peaking or regulating units, where the ability to move faster and more accurately translates into significant dollars and cents. The Ovation system is a key technology that powers Emerson's PlantWeb® digital plant architecture.
The Unit Response Optimizer uses advanced unit analysis and modeling techniques to provide optimal load trajectory and control for improved ramping, startup, unit turndown and overall performance, as well as reduce equipment wear/tear. Based on historical data, the Unit Response Optimizer models process response and unit characteristics, then calculates a variable derivative ramp rate to optimize plant maneuverability and AGC (automated generation control) capabilities, eliminate overfiring and provide a greater degree of unit control precision.
The Unit Response Optimizer can improve ramp rates 1-2 percent. By optimizing ramping capabilities, generating units are able to maintain heat rate at a lower capacity and avoid heat degradation, even when operating below generating capacity. Increased ramp rates, achieved through tightly coordinated boiler and turbine operations, improve operational flexibility, maneuverability and, ultimately profitability of generating units.
Beta test results from Constellation Energy's C.P. Crane Station Unit 2 in Baltimore demonstrate the improvements that are possible with the Unit Response Optimizer. This 205-MW facility has been operating as a regulating unit to help maintain regional grid frequency. In this role, the unit frequently ramps from 100 MW to a full load of 205 MW at a rate of 7 MW per minute.
Prior to installation of the Unit Response Optimizer in June 2006, C.P. Crane Unit 2 experienced overfiring when ramping up to its full load megawatt target. This overfiring - which ranged from 80-100 degrees Fahrenheit over the operating temperature of 1050 F main steam and 1000 F reheat - was caused by the inherent lag time in the combustion and steam flow that is ultimately required for the unit to meet its target ramp rate and megawatt production. Over time, temperature excursions can damage a unit: The excess heat causes metal fatigue that, in turn, results in boiler tube leaks and maintenance outages.
Since its installation in June, the Unit Response Optimizer has eliminated over-fueling and the temperature excursions it causes. The result: reduced fuel consumption, fewer tube leaks and, consequently, less frequent maintenance outages. "We've experienced dramatic results with the Unit Response Optimizer," said William Soltysiak, senior engineer at the C.P. Crane station. "By preventing overfiring, we've been able to greatly reduce equipment wear and tear so we can operate the plant more reliably and maintain our regulation status, which not only has important implications for this plant, but for the region's electricity needs, as well."
Incorporating the Unit Response Optimizer into the Ovation system is just the latest illustration of how Ovation continues to evolve and be enhanced to meet the unique challenges of the power generation industry. "Emerson knows that for peaking units, in particular, time is money by the minute," said Bob Yeager, president of the Power & Water Solutions division of Emerson. "By utilizing the Unit Response Optimizer, our customers' units are able to be more responsive, which translates into greater operational reliability, stability and, ultimately, profitability."
About Emerson Process Management
Emerson Process Management (www.emersonprocess.com), an Emerson business, is a leader in helping businesses automate their production, processing and distribution in the power, water and wastewater treatment, chemical, oil and gas, refining, pulp and paper, food and beverage, pharmaceutical, and other industries.
Emerson's Power & Water Solutions division (www.emersonprocess-powerwater.com) is a global supplier of advanced distributed process control and information systems. The Pittsburgh-based company is a recognized leader in developing plant-wide process control solutions for the power generation, water treatment and wastewater treatment industries. Power & Water Solutions plays a key role in the Emerson mission of combining superior products and technology with industry-specific engineering, consulting, project management and maintenance services.
Emerson brands include PlantWeb®, Ovation®; SmartProcess®; Fisher®; MicroMotion®; Rosemount®; Mobrey®, Daniel®, Bristol®, DeltaV(TM); and AMS(TM) Suite.
About Emerson
Emerson (NYSE: EMR), based in St. Louis, is a global leader in bringing technology and engineering together to provide innovative solutions to customers through its network power, process management, industrial automation, climate technologies, and appliance and tools businesses. Sales in fiscal 2006 were $20.1 billion. For more information, visit www.GoToEmerson.com.
