International Power - Rugeley Flue Gas Desulphurisation
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The new FGD plant receives flue gases from the existing boiler plant. Therefore, the FGD control systems had to integrate with the generating unit control systems at the power station to safely control the flue gas path through the entire plant.
Furthermore, IPR required that the operator control facilities were fully integrated into the existing power plant control room to enable the safe, efficient control of the boiler and FGD plant. Capula was challenged with coming up with an innovative solution and system designs which would allow this seamless integration, both during installation and commissioning, and following project completion.
A large number of field instruments (approximately 350) were supplied for the measurement of the process parameters (ie. flows, pressure, temperature, levels, chemical composition etc).
The FGD control system relies on precise measurement and control of the process, and Capula was responsible for the specification, supply, installation, fitting and commissioning of each instrument.
The timescales of the project were also a significant challenge. It involved major plant design and construction whilst minimising the disruption on the power station.
Major outage tie-ins were provided, but much of the installation and commissioning had to be carried out whilst the power plant was operational. This exerted significant pressure on the design and site commissioning teams, but careful planning and co-ordination on the part of Lentjes and all sub-suppliers, including Capula, allowed the project to be successfully completed.
How We Helped
The FGD control system installed by Capula was based upon a Rockwell ControlLogix PLC platform, and supervisory plant control was via the established platform used at Rugeley (Rtap/APMS Scada).
Safety and protection systems based on Rockwell's PLCGuard provided functional safety protection of the plant and personnel in accordance IEC61508. Capula is CASS accredited to deliver safety systems which are properly designed and installed in accordance with the IEC61508 guidelines.
Capula took responsibility both for the complete implementation of the FGD control system and the modifications to the existing power plant control systems.
We ensured that the integration was done efficiently, minimising downtime, and applied the established standards and techniques used on the power station to the design of the new systems to simplify future operations and maintenance.
Capula now provides long-term support of the systems at Rugeley from its headquarters office at Stone, Staffordshire, approximately 15 miles away.