Expertise, Services, and Technologies
for Power Generation
Europe, Middle East, and Africa
Process Management
EMERSON. CONSIDER IT SOLVED™.
Table of Contents
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About Emerson
Power & Water Solutions
A Long History of Leadership
Presence and Experience
Expertise
Power Plant Retrofits
New Generation
Digital Plant of the Future
Turbine Control Solutions
Coordinated Unit and Boiler Control
Desalination Solutions
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Services
24
Project Management & Execution
26
Customer Support
27
Consultation Services & Training
29
Technologies
0
Expert Control & Information
2
Connectivity
4
Plant Optimization
Ovation Simulation Suite
About Emerson
About Emerson
Our Business Focus
Emerson has been in business since 1890. Today, we are one of the world’s leading
manufacturing companies, with operations around the globe. We are comitted to helping
our customers succeed in their various businesses, which we accomplish through strong
technology leadership, engineering excellence, and an unwavering commitment to
customer relationships. Emerson’s eight brands deliver comprehensive customer solutions
in the following areas:
Process Management
Professional Tools
Network Power
Motor Technologies
Climate Technologies
Industrial Automation
Storage Solutions
Appliance Solutions
When the stakes are high,
Emerson delivers
Emerson leverages global engineering and
innovative technology to provide solutions for
a world in action.
Breakthrough Technology
Emerson technology is driven by the needs of our customers. In our 60-plus divisions,
we emply more than 100.000 men and women who are passionate about developing
superior products and services to make life easier, safer, more pleasant, and productive.
With a significant R&D budget and dedication to our customers, our commitment is to
develop breakthrough technologies and products that inspire.
For decades, Emerson’s widely recognised management excellence and financial
strength, combined with our focus on cost control and operating efficiency, have driven
strong sales and earnings growth. In fact, Emerson has achieved 49 consecutive years
of increased dividends - a testimony to our financial stability.
About Emerson
Emerson Process Management Power & Water Solutions
Solutions for Power & Water
Emerson Process Management’s Power & Water Solutions division partners with
power generation, water treatment, and wastewater treatment utilities to create and
implement intelligent solutions to control automation systems for critical applications
throughout Europe, the Middle East, Africa, and the rest of the world.
We are committed to helping our customers realize the full potential of their operations
through an unparalleled combination of industry experts, best-in-class technologies, and
engineering centers of excellence that are dedicated to the power and water industries.
In addition to our ground-breaking solutions, such as the Ovation® control system,
SmartProcess® plant optimization technologies, and SureService customer support
program, we are leading the way for the next generation of digital control systems
featuring predictive diagnostics with our proven PlantWeb® digital plant architecture.
Intelligent solutions
and superior technologies
Superior Process Technologies
From measurement and analysis to automation and process control, Emerson Process
Management offers complete solutions to optimize your production processes
through robust diagnostic and control hardware and software and intelligent field
devices, backed by superb engineering expertise. We have the most comprehensive
array of superior technologies in the industry, including Rosemount® transmitters,
Fisher® valves, AMS™ Suite software, and the Ovation control system, all connected
through our award-winning PlantWeb digital plant architecture.
About Emerson
A Long History of Leadership
Legacy of performance,
decades of experience
Emerson’s Power & Water Solutions division traces its history as Westinghouse
Electric Company, one of the most widely respected engineering companies of
the past century. As Westinghouse Process Control, we revolutionized the process
control industry.
Not only were we the first company to apply digital computers for gas turbine
control, steam turbine control, and utility boiler control, but we are also the first to
create an entirely distributed computing system for data acquisition and control
functions utilizing a common hardware and software platform.
Through the 1960s and 1970s, we unveiled a long list of technologies that impacted
the process control industry. These technologies included the first mini-computer,
We have a long, proud history of supplying
the first analog electro-hydraulic turbine control system, the first digital electro-
control and monitroing solutions for multiple
hydraulic turbine control, and the first split-architecture system.
industries around the world, but our key focus is
In early 1997, we again redefined process control with the Ovation system, a
on the power and waer/wastewater industries.
powerful, evolutionary technology that utilized open standards.
Emerson Electric, one of the most successful manufacturing companies in the
world, recognized the potential of Westinghouse Process Control and acquired
the company as a critical element of Emerson Process Management.
Today, we lead the process control industry in innovative solutions for power
generation and water/wastewater treatment. Combining proven, state-of-the-art
products and strong application engineering resources, we will continue to be an
undisputed world leader in process control.
About Emerson
Presence and Experience
Europe, the Middle East, and Africa are home to
over 25,000 Emerson employees based in 350
manufacturing , design, engineering, and sales
centers. These extensive resources enable us to
provide an exceptional level of service to all of
our customers.
Choose a partner trusted by the largest utilities
in Europe, Middle East, and Africa
Serving the Unique Needs of the Region
Emerson’s Power & Water Solutions division maintains a strong presence throughout
Europe, Middle East, and Africa (EMA) with established offices in 23 countries
including the United Kingdom, France, Spain, Italy, Netherlands, Denmark, Sweden,
Russia, Hungary, Romania, Turkey, Egypt, Saudi Arabia, and the United Arab Emirates.
Additionally, we have full-service engineering centers of excellence devoted entirely
to the power and water industries in Warsaw, Poland, St. Petersburg, Russia, Prague,
Czech Republic, and Dubai, United Arab Emirates.
Our offices in the EMA region have the resources to engineer and support process
control products and systems. These offices allow us to provide customized
services that address the unique needs and understand the many regulations and
requirements of power generation.
With an experienced staff of highly skilled engineers, we offer comprehensive support
services including sales and marketing, project management, engineering, training,
field installation and service, and repairs and spare parts processing. Emerson Process
Management Power & Water Solutions is the only I&C supplier who specializes in the
power generation, water treatment, and wastewater treatment industries. All of our
resources from engineering talent to research and development are dedicated to
our target markets.
About Emerson
Today, we are proud to say that our products, services, solutions, and support
capabilities meet a wide range of automation requirements for thousands of utilities
in Europe, the Middle East and Africa (EMA) and other world areas. We attribute our
success to advanced technology, proven project engineering expertise, and the
capability for long-term support.
With each of our projects, we build mutually beneficial partnerships that focus on the
needs of our customers. We help our customers realize a fast return on investment
with our robust array of services and technologies. Through their partnerships with
Emerson, hundreds of critical EMA utilities have realized exceptional project success
through increased availability and reliability, faster time to operation, efficient and
exact performance capabilities, and, most importantly, increased safety for their
employees.
Our exceptional performance and expertise have helped us to become a trusted
business partner of some of the largest power producers in this region, such as
RWE in the United Kingdom, EDF in France, E.ON in Sweden, RAO UES in Russia,
BOT and Vattenfall in Poland, CEZ in the Czech Republic, ENEL in Italy, Endesa and
Iberdrola in Spain, Electrabel (Suez Group) in Hungary, SEC in Saudi Arabia, AES in
Kazakhstan, and many others.
We focus on building committed, long-term relationships. The success of our
customers is our prime motivating factor. We strive to help customers meet their
long-term objectives in a constantly changing business environment.
Expertise
Expertise
Solutions for
every power application
For more than 40 years, our customer-based
strategies, value-driven focus, and unwavering
concentration on our core industries have enabled
us to lead the market by helping our customers
achieve continuous process improvement.
Emerson provides flexible, reliable automation systems for plants across Europe, the
Middle East, and Africa. We specialize in control and fleet management, including
remote monitoring, dispatching, and resource management capabilities. Our
systems control drum, once-through supercritical, ultra-supercritical, and fluidized
bed boilers from every manufacturer.
We provide main automation contractor (MAC) services, where we act as the
prime contractor for all vendors, ensuring a unified, consistent team working
toward a successful project. Our experience with power plant retrofits in EMA and
throughout the world remains unmatched. In addition, we also supply technologies
for greenfield plants.
Hundreds of combined cycle, cogeneration, simple cycle, and combined heat and
power plants in EMA have selected our control technologies for turbine, boiler,
HRSG, and BOP control systems to provide reliable, cost-effective control and
monitoring. We supply complete turbine control solutions for every major turbine
manufacturer, including GE, Westinghouse, Siemens, Zamech, LMZ, Turboatom,
Skoda, MHI, Toshiba, BBC, FIAT, Alstom, Ansaldo, and Pratt & Whitney.
Expertise
Power Plant Retrofits
For existing plants, Emerson’s retrofit strategies are custom-developed for each
We have spent decades focusing on the needs
individual project. Retrofit projects are initiated with a project kickoff meeting to
of the power industry and have emerged as
ensure that customer expectations, such as intended outage time frame and level
of customer involvement, are fully understood. No one knows a power plant like the
the undisputed industry experts in power plant
plant staff, and we take time to listen to our customers to learn what they already know
retrofits.
about their operations.
Emerson replaces the existing vintage control technology, such as controllers, cabling,
I/O, workstations, and various subsystems, with the latest Emerson hardware and
software. Ethernet-, Modbus-, or TCP/IP-based data links may be used to link to thirdparty systems, such as burner management systems, PLCs, SCRs, and electrostatic
precipitators.
Our turbine replacements, including steam, combustion, and hydroelectric, offer
speed and load control, rotor stress, automatic turbine startup and sequencing, as well
as mechanical/hydraulic packages.
Over 1,000 retrofits
in the past decade
Emerson’s power industry capabilities include control of the following applications:
Steam Turbine
Supercritical Boiler
Motor Control
Combustion Turbine
Coal Handling
Plant Protection
Hydro Turbine
Balance of Plant (Logic, Binary)
Performance Optimization
Boiler Feed Pump Turbine
Combined Cycle
Supervisory Information
Rotor Stress Monitoring
Continuous Emissions Monitoring
Sequence Control
Boiler Combustion
Electrical Control
Selective Catalytic Reduction
Burner Management System
Energy Management
Sootblowing
Fluidized Bed Boiler
Flue Gas Desulfurization
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10
Simulator
Expertise
Experience Counts - E.ON Karlshamn Power Plant
The Karlshamn power plant consists of three oil-fired units, each
generating 340 MW of power. The contract, which calls for the
installation of Emerson’s PlantWeb digital plant architecture with
the Ovation control system, was awarded by Karlshamn Kraft AB,
a company within E.ON Nordic and partly owned also by Fortum
Generation. Emerson offered a comprehensive solution that addressed
the full scope of the instrumentation and control technologies
An Ovation retrofit
extends the life of
the largest oil-fired
plant in Scandinavia
required to modernize unit 3 of the plant.
Emerson’s Ovation system will provide monitoring and automatic
sequence control for the boiler, main turbine, and feed pump turbine.
Under the contract, Emerson will also upgrade the existing sootblower
controls, burner management system, hydraulic equipment, vibration
monitoring system, and turbine governor and protection system.
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Expertise
New Generation
Benefits of Working with Emerson
Emerson offers the broadest scope of plant automation with a full spectrum of
intelligent field instruments and valves specifically designed for power applications.
Furthermore, Emerson provides PlantWeb-based integration of such field
intelligence.
Whether a new generation power plant is coal-fired simple cycle, supercritical,
integrated gasification combined cycle, or any other plant architecture, an Ovation
system combined with digital instrumentation and digital I/O bus protocols, offers
a tremendous economic impact in engineering, construction, startup, system
selection, and overheads. If needed, the Ovation system seamlessly links to the third
party control systems provided by turbine OEMs, so all equipment, irrespective
of the manufacturer, can be managed from a single Ovation workstation. We can
control boilers, turbines, scrubbers, burner management systems, and all other
plant equipment with the Ovation system, or we can use data links to connect to
another supplier’s control system. The result is a unified architecture that can be
controlled from one centralized location.
Partnering for Power and leveraging Front-End Engineering & Design
With new power plant projects, utilities can realize substantial cost and time savings
by involving Emerson early in the design process. We partner closely with all parties
involved in the construction and successful completion of the project, including
the customer, architect engineers (A/Es), contractors, and original equipment
manufacturers (OEMs).
By utilizing a Front-End Engineering & Design (FEED) process during the planning
and engineering phases of a construction project, Emerson helps utilities identify
the best path for the quickest return on investment through performance, reliability,
safety, and cost efficiencies.
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Optimized design
and faster return
on investment
Expertise
Experience Counts - the Digital Plant of the Future
How can you lay the best foundation to support future
needs, while realizing the highest return today? It requires an
understanding of the operational foundation that will sustain a plant
for the next 30 years of its life, and prove flexible enough to adapt to
changing business realities. Emerson will lead you toward a digital
future.
The digital plant of the future will extensively use fieldbus-qualified
field devices to provide the diagnostic information, equipment status,
and configurations to a centralized control system with integrated
asset management tools.
Emerson has been working with leading power utilities and
Building your plant
on a strong foundation
engineering firms on various new coal generation projects to evaluate
what financial benefits can be derived from managed, effective
automation deployment. Studies collaboratively conducted by
Emerson indicate that the deployment of what Emerson describes as
“Digital Power Plant of the Future” automation concepts, can lead to
capital, construction and installation cost savings of $15M to $20M, as
well as O&M savings of $2M to $4M per year for a typical 600MW to
800MW coal-fired unit.
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Expertise
Turbine Control Solutions
Steam, Combustion, and Hydroelectric Turbine Control
As Westinghouse Process Control, we engineered and implemented the controls
for Westinghouse steam and combustion turbines until 1997. Today, as part of
Emerson, we continue to focus strongly on engineering turbine control solutions for
turbines from all major manufacturers.
Across the globe, we have dedicated turbine controls experts who understand the
impact of efficient turbine control on your ability to achieve maximum levels of
reliability and availability.
The Ovation turbine control system is engineered to accommodate the speed
sensing requirements and hydraulic interfaces needed for expert controls. Whether
your turbine is powered by steam, gas, or water, the Ovation system offers a reliable,
cost-effective solution for turbine control.
One Integrated Solution
Our turbine control specialists have experience in designing a complete, integrated
solution including the electronic governor and the critical mechanical equipment
used by a modern turbine.
Ovation uses the same base hardware and software for turbine control as it uses for
the burner management system, combustion controls, balance-of-plant controls,
SCR controls, and more. This single, integrated solution offers tremendous cost
savings in both the initial cost and over time with operation and maintenance.
Specialized I/O Cards
Ovation offers specialized I/O cards to meet the control requirements of all types of
turbine controls.
The Speed Detector Module determines the speed of the equipment by measuring
the frequency output from a magnetic speed pickup. With 16- and 32-bit resolution,
the output signal is used to control speed and protect equipment from an overspeed
condition.
The Valve Positioner Module provides closed-loop position control of the hydraulic
steam turbine valves. These hydraulic valves include throttle, governor, intercept
control, and stop valves.
Automated Turbine Startup
Ovation’s basic turbine startup package includes two functional pieces, the turbine
startup sequencer (TSQ) and the turbine stress evaluator (TSE). These pieces interact
to provide a smooth, efficient automated start-up of the turbine from turning gear
to full load. The TSQ/TSE system is instrumental in providing consistent, efficient
turbine operations.
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The leading solution for
precise turbine control
Expertise
Traditionally, startup and loading curves provided by the turbine OEM were utilized
for rolling the turbine and loading of the turbine. With the implementation of a TSQ/
TSE system, the startup and loading time of the turbine can be reduced to minimize
the time to reach the desired speed or load.
Startup & Loading Program
For our turbine controls package, Emerson integrates a starting and loading
program that emulates the existing OEM startup recommendations. The starting
and loading logic sheets are placed into the turbine controllers without requiring
the implementation of additional Ovation hardware.
Rotor Stress
The turbine rotors produce a high number of temperature variations during speed
and load changes, which can lead to thermal stress and potentially dangerous
conditions. Ovation replaces existing chart- and graph-based loading procedures
with a dynamic model of the turbine rotor. The result is a system that maintains
thermal stress well below the allowable limit, while operating at a maximum rate of
change to the requested speed or load.
Special Calculations for Turbine Islands
Emerson provides an engineered solution that designs and verifies performance,
thermal, and stress calculations. We apply calculations based on ASME, European, and
local country standards. As part of our suite of solutions, we also offer performance
advisor software that measures turbine efficiency, lifecycle, and performance.
Auto Synchronization
Ovation’s turbine control system will interface with the existing turbine generator
panel equipment and control schemes to ensure automatic synchronization. An
external auto synchronization device ensures that the generator breaker is working
appropriately per grid conditions. Even when switched in manual synchronization
mode, the auto synchronization device continues to monitor this action to prevent
possible turbine damage.
Hydroelectric Turbine Solutions
For hydroelectric applications, Ovation replaces vintage turbine governor controllers
to offer the highest level of water control and management, maximizing turbine
life.
The experts in steam, gas,
and hydro turbine control
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Expertise
Hydraulic Solutions
Whether the scope entails a full
Emerson’s in-house engineering staff has the ability to design and install the
replacement or an interface to an
mechanical component of a hydraulic system. Our turbine mechanical capabilities
existing system, Emerson can update
include the ability to replace the entire OEM hydraulic system.
existing mechanical devices with the
latest hydraulic control technology.
Emerson provided the hydraulic components for 1,300 MW Brown Boveri steam
turbines, the largest fossil turbines in the world.
Modernization of Turbine Governors
Emerson offers servomotor controls through a variety of solutions ranging from
the use of simple current-to-pressure (I/P) converters to the installation of precise
actuators controlling sliders of servomotor’s pilot. We are experienced with both
hydraulic and electrical actuators including precise state-of-the-art Exlar actuators
operated by Emerson’s digital servo drive technology.
Improved Safety with Triple Redundant Turbine Trip Manifold
The turbine trip manifold is designed to rapidly de-pressurize a turbine trip header.
The manifold assembly is triple redundant and is testable while the turbine is online.
The operator initiates the testing sequence of the dump manifold solenoid/ cartridge
valve sets. The control system automatically steps through the test, and verifies
successful completion of each step before proceeding. The operator is notified of a
successful test and an alarm is generated indicating any failures.
Solutions for
turbine hydraulics
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Expertise
Experience Counts - Volzhskaya GES Hydroelectric Plant
Volzhskaya GES selected Emerson’s Ovation technology
to meet the goals of the Volzhskaya Unit 8 control
system modernization. Ovation merged the unit’s
hydroelectric generation processes into a single unified
system for efficient plant monitoring and control.
Working with Volzhskaya specialists, Emerson designed
the Ovation system to use two independent operational
steps with high and low pressure oil. This approach
helped Volzhskaya Unit 8 reach UCTE requirements
without causing degradation to the unit’s mechanical
equipment.
The largest hydro power plant in Europe
selects Ovation control technology
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Expertise
Coordinated Turbine and Boiler Control
Unit Coordinated Control
The Ovation System offers unit coordinated control (UCC) that provides a coordinated
front-end control strategy that ties the boiler and turbine controls together. The
Improve combustion,
optimize unit control
UCC generates and regulates the setpoint for unit load (MW). The unit load setpoint
or UCC MW demand may be generated from local operator entry, remote increase/
decrease contact inputs, or internally generated contingencies such as runbacks and
rundowns.
The UCC controls unit load (megawatts) and throttle pressure by sending out parallel
demand signals to the boiler and turbine control loops through the Boiler Master and
Turbine Master M/A stations, respectively. The Boiler Master demand is used as a
feed-forward signal to the loops controlling feedwater, fuel and air flow to improve
The Ovation system offers unit coordinated
unit response to load changes. The Turbine Master demand controls the turbine
control (UCC) that provides a coordinated
control valves by sending an analog output signal to the turbine controls.
front-end control strategy that ties the boiler
Drum-Type Boilers
With standard drum-type boilers, Ovation uses proven control schemes to offer a full
range of operating modes that control megawatts and throttle pressure.
The Ovation system provides efficient management of combustion, feedwater,
drum level, stack oxygen, and steam header pressure. Precise, automatic control
helps maintain steam pressure, which enhances plant efficiency, reduces upsets,
and minimizes costs.
Supercritical Boilers
For supercritical boiler control, Ovation provides precise controls in all modes
of operation, including startup, cycling, and boiler shutdown. Ovation offers
coordinated control of boilers from all major manufacturers, including CE, B&W,
Foster Wheeler, Podolsk, Taganrog, and others.
Ovation control designs have been employed in the once-through Benson design,
where water is preheated, evaporated, and steam superheated in a single pass. As
technology evolves, Ovation adapts to meet the long-term changing demand for
efficient and safe once-through plant operation.
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and turbine controls.
Expertise
Experience Counts - ENDESA As Pontes Power Plant
With 1,400 megawatts of capacity, ENDESA’s As
Pontes Units 1, 2, 3, & 4 generate more than five
percent of Spain’s energy needs. Because of our
vast experience in the power industry, ENDESA
chose Emerson and our Ovation control system to
automate the plant.
Emerson coordinated and supervised the project,
which included installation of Emerson’s Ovation
system to control the boiler, steam turbine,
feedwater turbine, burner management, balance of
plant, and auxiliaries at the As Pontes plant. Ovation
also integrated information from several existing
PLCs via data links.
The largest coal-fired
power plant in Spain
implements Ovation
Emerson’s contract included the engineering,
hardware, software, factory acceptance testing,
installation, and startup.
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Expertise
Desalination
Emerson systems control all major desalination applications:
Balance of plant
Distillate, condensate, and sea water recirculation
Water treatment
Desalination chemical dosing system
Chemical treatment
Remineralization subsystems
Brine concentrator/heater
Water booster pumps
Evaporator heat recovery and heat rejection
Valves
Sea water vacuum deaerator
Electrical equipment
Stream desuperheater
Energy management
Vacuum system
Process control
Pumps
As experts in both power generation and water treatment, Emerson offers control
solutions that meet the unique needs of desalination plants. For the desalination
process, the Ovation system controls pressure, temperature, and brine concentrations
to optimize the water extraction efficiency.
Energy Management
Energy consumption is the most costly component of the desalination process, and
the Ovation system provides superior process control solutions to minimize excess
energy consumption. Ovation orchestrates the movement of valves, monitors
transmitters, and ensures all equipment is operating at the most efficient levels. In
addition, Ovation controls the process more precisely, which allows the system to
perform with high levels of accuracy and energy savings.
Integrated Power & Desalination Plants
The Ovation system is an excellent choice for desalination plants that integrate
a power station on site. Built specifically for the power generation and water
treatment industries, Ovation offers power-generation-specific applications, such as
boiler control and turbine control, and can connect to the desalination plant onto
the same network, or connect multiple Ovation networks. Control strategies unify
control of both the power station and desalination plant from a single control station.
Moreover, the Ovation controller is easily configurable and flexible enough to control
both the fastest turbine logic and the relatively slow desalination processes.
Equipped for Multiple Desalination Strategies
Emerson’s engineering team offers control strategies for multiple desalination
processes. Whether it is a distillation process such as multi-stage flash (MSF) or a
membrane process such as reverse osmosis, the Ovation system offers seamless
control of all processes and the coordination of high-pressure pumps and
instrumentation.
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Superior control
with one Ovation platform
for both power generation
and desalination
Expertise
Experience Counts - Ras Laffan Power & Water Plant
Ras Laffan Power and Water Plant in Qatar, owned jointly
by AES, Qatar Petroleum, QEWC, and GIC, consists of a
new, 800-megawatt combined cycle power plant and a
227 MLD (million liters per day) desalination plant. It runs
on a common Ovation control system, allowing for unified
configuration based on a well-proven platform. The system
integrates third-party control systems through data links
that offer two-way communication.
The Ovation control system was chosen because of the
system’s capability to integrate large amounts of I/O and
Emerson’s vast experience with the power generation
industry. Emerson provided the project management,
Unified configuration
based on a single,
well-proven platform
functional design, system software design, startup,
commissioning, and engineering services. The project has
been operational since 2003.
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Services
Services
Expert Solutions and Services
Emerson offers an array of support solutions
At Emerson, we believe that outstanding solutions and services enable our customers
and services designed to help you achieve your
around the world to realize continuous process improvement.
business objectives, reduce or contain your
Emerson is a partner you can trust to deliver the best solutions and expertise
whenever it is needed. To ensure the highest levels of responsiveness, reliability,
and competency, we have an ever-expanding network of local service capabilities
operating and service costs, and keep your
systems running at peak performance.
throughout Europe, the Middle East, and Africa. These resources have direct access
to system developers and applications experts at our global headquarters and
industry centers.
From expert consultant services to world-class technologies, to comprehensive
project management, field service and technical support, Emerson Process
Management can provide total solutions for a single unit, or your entire generating
fleet.
Attaining and Sustaining Excellence
With our project management strategies, around-the-clock support, and expert
training, Emerson offers support and service solutions that keep your business
operations running smoothly. All our services are backed by our unequalled expertise
in all aspects of power generation, water treatment, and wastewater treatment,
allowing us to work with you to develop custom solutions designed to meet your
unique requirements.
We apply advanced software, engineering strategies, and automation technologies
to your control systems with the goal of attaining and sustaining operational
excellence. We help you achieve the full potential of your operation.
Enhance performance, improve availability
with customized services and support
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Services
Project Management & Execution
Emerson Capabilities
Our project management capabilities include engineering, procurement, and
construction (EPC) services from consulting to systems design, to installation,
startup and post-operation services. With over four decades of experience, we
have provided project management and execution services for thousands of power
applications of all sizes, including the most complex projects where we acted as the
main automation contractor (MAC).
Unparalleled experience
and advanced engineering
capabilities for on-time and
on-budget delivery
Emerson FEED Work Process
Emerson’s proven front-end engineering and design (FEED) process is a five-stage
program, consisting of planning, data gathering, basis for design, cost estimation,
and a final document. As part of this process, project team members are trained to
ensure consistency and efficiency throughout all phases of the process.
FEED Planning
Emerson assists with the development of the FEED team to ensure all key stakeholders
contribute to, and align themselves with the project objectives.
Data Gathering
Data can be collected in the field using Emerson data management software, which
helps to expedite checkout and accurately benchmark the existing equipment and
installation.
Basis for Design
From detailed design to startup, Emerson helps you to attain the best solution to
meet all appropriate standards and codes. Together, we examine project alternatives
to ensure that the proper strategy is being used to meet process and business
objectives, while reducing costs and tightening schedules.
With Emerson’s proven FEED work process,
customers have a single point of accountability for
their projects, and our PlantWeb expertise ensures
FEED Estimate
The FEED process typically narrows the cost and benefit estimate down to +/- 10%,
that your project is technically sound, safe, timely,
and that it derives the most benefit from today’s
and identifies the risks and issues that support this estimate.
Final Document
digital technologies.
The final FEED documentation is the definitive technical and business project
summary to be used by your organization and your project team. These documents
include scope definition such as engineering and design, execution/procurement
planning, and economic justification.
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Services
Emerson’s Engineering Talent
Project
Management
Our projects are overseen from start to finish by engineers experienced in the needs
and nuances of the power generation industry. Our project managers are chosen
for their superb technical knowledge, leadership abilities, and experience necessary
FEED
Expertise
for safe, on-time, and on-budget delivery. Each member of our engineering team
averages more than 15 years of experience, giving you access to thousands of
man-years of hands-on know-how in designing and implementing effective and
reliable systems. No supplier has more experience in power generation automation
Process
Automation
Process
Engineering
Power
Engineering
Safety
System
Engineering
projects.
Strategic Flexibility
Instrumentation
& Electrical
Emerson has the flexibility to work on your automation project under direct contract
to you or as a subcontractor to engineering, procurement, and construction (EPC)
organizations. We have successful, long-term working relationships with the best
EPCs in the business.
Emerson is a low-risk automation solutions partner
with full automation scope, including front-end
engineering expertise, detailed engineering and
design, installation, configuration, startup, and
lifecycle support.
Performance Testing & Acceptance
Unit Commissioning
DCS Commissioning
Site Acceptance Tests
Startup
DCS Installation
Factory Acceptance Tests
Field Equipment Installation
Field Preparation
DCS Configuration
Engineering & Design
Procurement
Defining Project Objectives & Scope
Field Audit
From the field audit to performance testing and acceptance, Emerson’s project management
methodology utilizes decades of experience in power generation industry.
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Services
Customer Support
Emerson’s Customer Service
The ultimate success of a utility relies not only on the right controls supplier and
smooth deployment of the automation system, but also in the daily system operation
and personnel performance. Factors such as system availability, process variability,
or personnel effectiveness have a high impact on your mission-critical processes.
Thanks to our widespread infrastructure and local resources throughout the EMA
region, you can be sure that the Emerson expert support team will be there to help
- whenever you need them.
SureService™ Support
To ensure continuous control system availability, SureService provides you with
the expertise and support required to achieve the required system uptime not only
today, but throughout the entire life of your system. Emerson’s suite of SureService
modules includes:
Help Desk - 24 hours a day, seven days a week, highly qualified and experienced
SureService engineers are available to support your plant personnel.
Remote System Diagnostics - For issues that cannot be solved by phone, Emerson
personnel has the ability to remotely log in to the system to directly troubleshoot
and resolve the problem.
SureService Internet Information Access - A dedicated SureService web site offers
you access to the latest system manuals, software and security, repair tracking, and
Emerson’s array of services has helped
customers worldwide avoid production losses
by ensuring high levels of unit reliability,
availability, and performance.
other useful resources.
Onsite Emergency Response
If there is an emergency, when production or plant assets are at risk, Emerson
ensures that you receive onsite emergency support within the required time. This
includes dispatching a qualified engineer to the site, as well as ensuring that the
required system parts are available to resolve the emergency situation.
Evergreen System Coverage
Modern control systems incorporate fast-changing, off-the-shelf technologies.
With Ovation® Evergreen, you can maintain your system with the latest available
technologies, avoiding the impact of hardware and software becoming obsolescent.
This ensures that high levels of availability are maintained throughout the system
life cycle.
Under a single agreement with payment flexibility, Emerson upgrades many control
system components, including controllers, I/O, workstations, and network devices,
to the latest available technology. Contracts are customized and can include
software upgrades, as well as the installation of replaced hardware.
26
Ensure peak performance
of your critical operations
Services
Consultative Services & Training
Web-Enabled Backup for Critical Data
Data is one of the most valuable assets of any company. With Emerson’s webenabled support modules, we ensure that hard-to-replace data and information
is periodically archived and saved in a secure external facility. In accordance with
ISO-approved standards, our web-enabled modules offer a high level of security,
ensuring the fastest return to production after any unanticipated loss of data.
Customized Training Programs
Emerson is ready to work closely with you to create the training program that best
suits your personnel and plant requirements. Whether conducted on-site or offsite, Emerson training programs provide instruction on system operation, system
maintenance, and personnel effectiveness with courses covering control strategies
and application of the latest technology.
Consultative Services
To help you get the most out of your system, while still meeting changing regulatory
policies, Emerson offers a team of consultative engineers who will evaluate your
plant equipment, control system capabilities, and resource strength.
System Security Assessment - With a System Security Assessment, Emerson ensures
that your control system complies with applicable security policies, helping you to
avoid production losses caused by security issues.
Alarm Management Assessment - With an Alarm Management Assessment,
experienced Emerson engineers help you to streamline your existing alarm system
according to industry-accepted standards and plant requirements.
Control Performance - Emerson control experts are ready to work closely with you
to evaluate and enhance your existing application performance in consideration of
your operational requirements.
27
Tailor support services
to fit your needs
Technologies
Technologies
It Takes Expert Control
The Ovation control system was designed specifically for power and water
applications to help you achieve operational excellence and create a sustainable
competitive advantage. Ovation’s field-proven control design techniques provide
tighter, more precise control, while advanced algorithms and process optimization
software further enhance and balance your operations.
From basic control and monitoring, to fleet-wide or district-wide integration, Ovation
offers seamless communication with fieldbus networks, intelligent field devices,
and integrated asset management solutions to deliver the power of predictive
intelligence to operations and management personnel.
The Power of PlantWeb
Emerson’s proven PlantWeb digital plant architecture takes process automation
one step further by delivering the information and performance you want, when
and where you need it. PlantWeb is a proven architecture that delivers asset
management, process control, and management execution through intelligent field
devices, industry standard platforms, and integrated modular software. When fully
integrated with the Ovation control system, PlantWeb digital plant architecture
gives you access to a wealth of information, including diagnostics that enable you
to predict and prevent problems before they affect the process. This gives you the
ability to achieve a smarter plant process.
We are a leading supplier of process
management products and solutions, including
the Ovation control system, and a wide range
of plant optimization software, control valves,
regulators, transmitters, and analyzers.
29
Technologies
Expert Control & Information
Dedicated native cards for the power industry including turbine control —
Ovation system is equipped with special-purpose I/O modules to handle the
unique control requirements associated with steam turbine, gas turbine, and boiler
feedpump turbine controls. These include: speed detector module, valve positioner
module, servo driver module, Foundation™ fieldbus, Profibus DP-V2, and SOE with
channel-to-channel resolution of 0.125 ms and wire break detection.
Short control loop cycles for critical applications — The Ovation Controller, with
its Intel processor, is capable of simultaneously executing as many as five process
control tasks at loop speeds ranging from 10 milliseconds to 30 seconds.
Plant-wide system integration network — The Ovation Network, with a
200,000 point capacity, is a robust, fault-tolerant, 100 Mbps, commercially
available communications network designed for mission-critical process control
applications.
Multi-network architecture — The Ovation architecture permits personnel in a
central control room to monitor and control multiple units just as if they were at any
single units console. It also simplifies the collection and correlation of historical data
for all units.
Abnormal situation prevention — With powerful technology, embedded industry
specific applications, integrated asset optimization software, and an evolutionary
design, Ovation delivers the power of predictive intelligence. Key components of the
Ovation system include:
Ovation Alarm Management - Ovation offers an alarm
management strategy via the Ovation Operator Workstation
that detects and displays abnormal plant conditions, such as
points out of range, digital state changes, and drop time outs.
With multiple types of fully configurable, easy-to-understand
alarm displays, the Ovation system provides convenient access
to past alarms, returns, and state changes.
Ovation PlantWeb Alerts - Ovation’s Operator Workstation
reports alarms regarding performance issues in field devices.
PlantWeb Alerts include advisory alerts to assist in maintenance
planning, maintenance alerts to indicate when immediate
maintenance is required, and failure alerts to indicate when a
device has failed. With PlantWeb Alerts, plant operators are able
to react before issues impact plant operations.
30
Ovation is designed
for the power
generation industry
Technologies
Expert Technology
Built using the latest commercially available hardware platforms, operating systems,
and network architectures, Ovation offers seamless communication with intelligent
Easy to use,
easy to maintain
field devices and integrated AMS™ Suite software to deliver the power of predictive
intelligence. Embedded advanced control applications, tailored to meet the
challenges of the power generation industry, ensure full optimization of missioncritical processes.
It’s Better With Busses
Ovation offers seamless integration with field-proven bus technologies like HART,
Foundation fieldbus, DeviceNet, and PROFIBUS.
Open Modbus RTU TCP
DeviceNet
By incorporating widely adopted commercial
Seamless communication between
Ovation’s DeviceNet interface connects
Ovation and third-party equipment
technologies, Ovation offers an architecture
to the Ovation Controller using Ethernet
through a Modbus link allows values
connectivity to pass process data. It
and time stamp transfer. Because
is configurable over this link and the
the system as your needs change or as other,
Ovation Controllers are typically
Ovation Network using an Ovation
redundant, they can be used as
workstation.
more advanced technologies are introduced.
a datalink platform to provide
Profibus DP-V2
complete “bumpless” automatic
fail-over to a back-up controller in
case of a system failure. The Ovation
Controller datalink platform supports
multi-tasking and preemptive task
scheduling addressing up to 2,000
soft points per virtual PCI device.
Ovation’s PROFIBUS DP interface
uses standard RS485 transmission
technology and cabling for data
transmission. It is used in areas where
high transmission speed and simple,
inexpensive installation are required.
Foundation Fieldbus
The Ovation Foundation fieldbus
solution provides a mechanism for
communicating field information
to the Ovation system for better
diagnostics and predictive
maintenance. Built-in fieldbus
configuration software in the Ovation
Developer Studio allows transparent
and automatic download of control
strategies to all devices on a fieldbus
segment.
Built using industry-standard hardware platforms, operating
systems and network architectures, only the Ovation control
system stays new in the face of rapidly advancing computing
technology.
31
that allows you to modify, expand, and evolve
Technologies
Connectivity
Industry-Standard Connectivity Protocols
Ovation integrates plant control systems with corporate networks, providing
and receiving accurate process data when and where it is most needed. By using
various connectivity tools, the Ovation system can transfer specific types of process
information to and from third-party desktop applications.
Through customized and standards-based connectivity software and data links,
Ovation provides the ability to retain previous investments in third-party devices
and protocols while expanding system capabilities. Emerson’s connectivity solutions
include:
OPC, which integrates
plant data with any OPC-enabled plant analysis
application.
WAVE Web Viewer, which
provides thin client graphic process data to any
desktop computer connected to the company network.
EDS, which offers remote visualization of process graphics, trends, and alarms
via a rich client.
Seamless, integrated connectivity sends
process data right where you need it
Communication to Third-Party Devices
To connect to existing third-party control devices, Emerson uses OPC-based data
links to exchange a stream of information from devices such as PLCs, analyzers, and
specialty sensors to the Ovation system.
Based on customer requirements, the data link platform can be one of three
components: an Ovation Workstation, an Ovation Link Controller I/O module, or
an Ovation Controller. Each platform provides unique capabilities and Emerson
works with each customer to determine the best platform to use. Because customer
needs are always changing, Emerson can develop customized data links for Ovation
systems.
Communications Protocols Designed for the Power Generation Industry
The Ovation communication server interfaces with third-party devices using widely
adopted multi-industry protocols such as Ethernet TCP/IP, Foundation fieldbus, or
Profibus DP-V2. Additionally, system supports specific protocols designed for power
industry, like: DNP3.0, IEC 60870-5-101/104, or ICCP protocol for data exchange
between generating facilities and independent system operators (ISO).
Interface to GE Mark V and VI Turbine Controls
Ovation seamlessly communicates with existing GE Mark V and VI turbine controls
over a network connection, providing greater data throughput and access to
additional system functions. These functions include management of GE turbine
alarms from the Ovation system, a single synchronized sequence of events system,
and command transmission from Ovation to the GE turbine control system.
32
Technologies
Experience Counts - Polaniec Power Plant
The Polaniec Power Plant, located in southeastern Poland,
consists of eight, 225-megawatt, coal-fired units. Polaniec
modernization was a complex plant reengineering project
leading to long-term increased operation efficiency. All
units were equipped with new Ovation-based digital control
technology. Eleven local control rooms were replaced with a
single centralized control room, enabling more efficient and
effective monitoring and control of critical processes.
As part of the plant’s large-scale modernization strategy, we
also implemented SmartProcess Combustion Optimizer and
Steam Temperature Optimizer on the new Ovation systems
at each unit. The results were immediate. NOx emissions
were reduced by 10%-17% when combined with heat rate
Efficient and effective
control and optimization
improvements of 0.5%-1.2% depending on the unit. The
customer estimates a full return on the SmartProcess
investment within two years.
33
Technologies
Plant Optimization
SmartProcess plant optimization software incorporates fuzzy logic, neutral
With SmartProcess, Emerson offers adaptive
networks. Predictive control and other tools developed specifically for the needs of
improvement solutions to help power plants
our customers, to offer the most advanced suite of optimization solutions available.
By building plant-specific models to simulate process variations and changing load
levels, SmartProcess identifies the precise control settings for continuous optimal
achieve optimized equipment performance for
emissions compliance, temperature control,
performance. The plant model incorporates self-learning features that allow
efficiency, and overall continuous operational
SmartProcess to adapt to long-term changes in the plant.
improvement.
SmartProcess is a truly dynamic approach that balances a plant’s multiple objectives
and varying conditions to optimize and improve plant processes, regardless of plant
size or configuration.
The SmartProcess modules optimize targeted processes, sending new setpoints and
biases directly to the control system, even as the plant ramps to meet market and
grid demands. SmartProcess can also operate in advisory mode, alerting operators
to changing settings so they can take action necessary.
SmartProcess can be integrated with any suppliers’ control system or deployed
using other technologies, such as PI or the open industry standard OPC protocol. Its
non-invasive implementation process is conducted with no outage.
SmartProcess improves the profitability
of power generation
34
Technologies
Ovation Simulation Suite
Emerson’s Simulation Suite includes low-, medium-, and high-fidelity simulation
Ovation simulator packages are customized
based on state-of-the-art technologies.
for each customer’s specific needs and offer
Low Fidelity
unique solutions to verify and ensure correct
Ovation’s low-fidelity simulator option offers a cost-effective strategy to test
and efficient operation of control applications.
software and train personnel. As an operator-training tool, the Ovation low-fidelity
version simulates graphics, runs startup and shutdown sequences, and simulates
When used as a training tool, Ovation simulators
drive operation. Engineered to work without the help of Emerson personnel, the
provide real-life scenarios to increase operator
low-fidelity simulator runs applications that are used on the actual plant system.
Medium Fidelity
With a medium-fidelity simulation, regulatory loops, sequencing, and object
responses are more accurately simulated to better match actual plant conditions.
We also offer a second approach to medium-fidelity simulation, which is based on
a mixed-fidelity strategy where components of the model, typically the boiler and
turbine, are programmed in a high-fidelity environment.
High Fidelity
Ovation’s high-fidelity simulator combines Ovation workstations and customized
plant models to create a real-time dynamic representation of all plant processes and
relevant plant components, providing an environment that duplicates the plant’s
actual control system and equipment. With high-fidelity simulation, a modular
design provides flexibility to simulate a section of the plant, putting focus where it is
most needed. We provide complete modeling of all contributing systems, including
boiler, turbine, feedwater, condensate, and auxiliary systems.
Ovation Simulator with Virtual Controller Technology
Ovation simulators offer a virtual architecture option that is identical to the traditional
architecture with one exception: a Windows-based PC running controller software
is used in place of actual Ovation controllers. The benefits of virtual controller
technology are numerous - in addition to being a cost-effective simulation strategy,
the virtual controller technology offers ease of application transfer to and from the
actual plant control system, as well as simplified DCS software upgrades.
35
skill level to handle any event.
Europe, Middle East, and Africa
Network of Offices and Authorized Representatives
Austria
Emerson Process Management AG
Industriezentrum NÖ Süd
Strasse 2a, Obj. 29
A-2351 Wiener Neudorf
Tel. (43) 2236 607
Italy
Emerson Process Management srl
Via Pavia, 21
I-20053 Muggiò (MI)
Tel. (39) 039 27 021
Switzerland
Emerson Process Management AG
Blegistrasse 21
CH-6341 Baar
Tel. (41) 41 768 61 11
Belgium
Emerson Process Management nv/sa
De Kleetlaan, 4
B-1831 Diegem
Tel. (32) 2 716 7711
Netherlands
Emerson Process Management bv
Patrijsweg 140
NL-2289 EZ Rijswijk
Postbus 212
NL-2280 AE Rijswijk
Tel. (31) 70 413 6666
Turkey
Emerson Process Management
Ticaret Limited Sirketi
Icerenköy Mah. Topçu Ibrahim Sok.
No. 17, Kat 3-4 Kadiköy
Istanbul
Tel. (90) 216 573 98 48
Norway
Emerson Process Management AS
Floodmyrvegen 23
P.O. Box 204
N-3901 Porsgrunn
Tel. (47) 35 57 56 00
Dubai, United Arab Emirates
Emerson Process Management
Emerson FZE
Jebel Ali Free Zone
P.O. Box 17033
Dubai
Tel. (971) 4 883 5235
Croatia
Emerson Process Management AG
Representative office
Tratinska 19
10000 Zagreb, Croatia
Tel. (385) 130 94 220
Czech Republic
Emerson Process Management s.r.o.
Hajkova 2747/22
130 00 Prague 3
Tel. (420) 2 710 356 00
Denmark
Emerson Process Management
Hejrevang 11
DK-3450 Allerød
Tel. (45) 7025 3051
Finland
Emerson Process Management Oy
Pakkalankuja 6
FIN-01510 Vantaa
Tel. (358) 201 111 200
France
Emerson Process Management SAS
14, Rue Edison - B. P. 21
F - 69671 Bron Cedex
Tel. (33) 4 72 15 98 00
Germany
Emerson Process Management
GmbH & Co OHG
Argelsrieder Feld 3
D-82234 Wessling
Tel. (49) 8153 9390
Great Britain
Emerson Process Management Ltd
Horsfield Way
Bredbury
Stockport SK6 2SU
Tel. (44) 870 240 1978
Hungary
Emerson Process Management Kft
Hungária krt. 166-168
H-1146 Budapest
Tel. (36) 462 4000
Ireland
Emerson Process Management
2200 Cork Airport Business Park
Kinsale Road
Cork
Tel. (353) 21 480 7500
Poland
Emerson Process Management
Power and Water Solutions Sp. z o.o.
ul. Konstruktorska 11a
02-673 Warsaw
Tel. (48) 22 45 89 100
Portugal
Emerson Process Management Lda
Rua General Ferreira Martins 8-10B
1495-137 Algés
Tel. (351) 214 134 610
Romania
Emerson Process Management AG
Str. Cpt. Av. Nicolae Drossu, nr. 9
Sector 1
012071 Bucuresti
Tel: (40) 21 206 25 00
Russia
- Moscow
Emerson Process Management AG
Power & Water Solutions
10 Bldg 2 Letnikovskaya Street
115114 Moscow
Tel. 7 095 981 9811
- St. Petersburg
Emerson Process Management
7, Torfiana Road, office 214,
197374, St. Petersburg
Tel. 7 812 441 2496
Slovakia
Emerson Process Management s.r.o.
Zelezniciarska 13
811 04 Bratislava
Tel. (421) 2 5245 1196
Spain
Emerson Process Management S.A.
Ctra Fuencarral-Alcobendas Km 12,2
Edificio AUGE, 1
E-28049 Madrid
Tel. (34) 910358 6000
Sweden
Emerson Process Management AB
Box 1053
SE-651 15 Karlstad
Tel. (46) 54 17 27 00
Associate Companies
Bahrain
Mohammed Jalal & Sons W.L.L.
Technical & Automotive services
239 Sheikh Salman Highway
P. O. Box 747, Kingdom of Bahrain
Tel. (973) 252 606
Egypt
IBN Ltd.
27, Kabul Street , District 6
Nasr City, Cairo
Tel. (20) 2270 1109
Iraq
Aqua Power Projects Limited
115 Baker Street
London - W1U 6RT
Tel. (44) 20 7486 5056
United Kingdom
Jordan
SAM Engineering &Trade
PO Box 142470, Amman 11844
Tel. (962)-6-581-2693
Kuwait
Almeer Technical Services Company
Plot 118-121, East Ahmadi Industrial Area,
PO Box 9240, Ahmadi 61003
Tel. (965) 398 6594
Qatar
Doha Petroleum Construction Co. Ltd.
- Sales Division
P. O. Box 1744, Doha-Qatar
Tel. (974) 441 7111
Saudi Arabia
Saudi Fal Company Ltd.
Controls Division
P.O. Box 3070
Al Khobar 31952
Kingdom of Saudi Arabia
Tel. (966) 3 857 3157
The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be
construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by our
software licensing agreement and terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of our
product and services at any time without notice.
Emerson and the Emerson logo are trademarks and service marks of Emerson Electric Co. ©2006 Emerson Electric Co. Ovation, SureService, SmartProcess, PlantWeb,
AMS, Rosemount, and Fisher are marks of Emerson Process Management. All other marks are the property of their respective owners.
Please contact us at:
Emerson Process Management
Power & Water Solutions
Tel. (48) 22 458 91 91
E-mail: PWS-EMAcontact@EmersonProcess.com
Our dedicated staff will be happy to assist you.
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