Project Description

International Power plc. Rugeley Power Station Flue Gas Desulphurisation

The Large Combustion Plant Directive (LCPD) (2001/80/EC) aims to reduce acidification, ground level ozone and particles throughout Europe by controlling emissions of sulphur dioxide (SO2), oxides of nitrogen (NOx) and dust (particulate matter (PM)) from large combustion plants.

In compliance with these regulations International Power (IPR) have installed Flue Gas Desulphurisation (FGD) plant at their coal-fired power station in Rugeley, Staffordshire. A turn-key EPC contract was awarded to Lentjes UK in 2006, who were responsible for the design, construction and commissioning of the FGD plant and its integration into the existing power station.

Lentjes appointed Capula in 2007 as the control systems supplier for this project, with the scope of work including:

  • PLC and SCADA based control systems
  • Safety and protection systems > Field Instrumentation supply and installation
  • Installation of field cabling
  • Local man-machine interface equipment
  • Cable marshalling equipment
  • Integration of the new control systems into existing generating unit control systems

The contract was awarded in 2007, and commissioning of the plant was successfully achieved with flue gas scrubbing operational in mid- 2009, removing approximately 96%of the SO2.

Business challenges

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 creating 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.

Why Capula

Capula was chosen because of the company’s extensive experience on the boiler control systems at Rugeley, which is based on APACS and APMS, and there are only a limited number of companies who can provide this level of support for these systems.

The ability to work closely with the main contractor on this project, together with their responsiveness and delivery ethos, all contributed to the success.