Honeywell project at Grootvlei power station

September 2012 System Integration & Control Systems Design

Eskom, the largest producer of electricity in Africa, operates power stations, including Kendal, Matimba and Majuba, amongst the largest coal-fired power stations in the world, and Koeberg, the only nuclear power plant in Africa. Eskom’s Grootvlei station was built in the late 1960s and was generating electricity until 1990. In 2004, demand for power and favourable government policy encouraged Eskom to re-commission the plant.

The return to service of a decommissioned plant carried a plethora of challenges, including dated equipment, space constraints and a need for up-to-date technology and advanced engineering services. In 2005, Eskom hired Honeywell for the Grootvlei return to service project to provide its Experion PKS, field instrumentation, fire detection systems, training simulator, as well as design, engineering, installation, commissioning and optimisation services. The project encompassed the complete replacement of the automation and control systems for six power units.

Solution

Honeywell implemented Experion PKS, Uniformance PHD, Enterprise Buildings Integrator, safety management system (Failsafe Controller), operator training simulator, actuators and field instrumentation. It also managed the refurbishment of the central control room. The upgrade replaced the automation and control systems for six power units, improving operational efficiency and maximising production output. With the Honeywell control solutions, it is anticipated that the Grootvlei plant will deliver a reliable supply of peaking power, 1130 megawatts, to the Eskom grid over the coming years.

After commissioning unit one, the operators found it difficult to manage the alarms due to the high volume. Eskom decided to implement Honeywell’s platform independent Advanced Alarm Management R300 solution: reducing the number of alarms that require operator intervention makes Grootvlei power station operators more effective. Since implementing Honeywell’s alarm management solution, Grootvlei power station has realised a decrease in alarms from 14 000 events per hour to just over 80 per hour.

Benefits

Grootvlei power station achieved the following benefits from the control system upgrade:

* Improved control and audit trail of changes.

* Reduced need for manual intervention.

* Increased limits of process capabilities.

* Constraint-driven alarm configuration management to ensure alarms are consistent with plant fundamentals.

* Auxiliary notification provides reminders to operators and other plant personnel without cluttering the alarm system.

* An event analysis tool assists in quickly identifying cause and effect relationships.

“The combination of Honeywell’s solutions and its engineering and services teams has provided Eskom with the robust, consistent support needed to provide a reliable power source for the people of South Africa,” Deon Smit, RMDC manager, Eskom Grootvlei.

For more information contact Boni Magudulela, Honeywell Southern Africa, +27 (0)11 695 8000, [email protected], www.honeywell.co.za

Further reading:

The state of the SI industry remains strong and is expanding
System Integration & Control Systems Design
The system integration (SI) industry is expanding with the adoption of AI, automation and data sharing, allowing companies to improve operational efficiency and competitiveness across diverse sectors.

Read more...

---

The symbiotic relationship between OEMs and SIs
Schneider Electric South Africa Editor's Choice System Integration & Control Systems Design
While businesses tend to turn directly to original equipment manufacturers OEMs or vendors when embarking on IT projects, the role of the SI as a key facilitator and partner cannot be overstated.

Read more...

---

Flexible and precise dispensing technology
Beckhoff Automation System Integration & Control Systems Design
The Scheugenpflug ProcessModule axis system forms the basis of Atlas Copco’s dispensing and screwing cells and a flexible integration platform for general contractors and machine builders. Precise process sequences are ensured by TwinCAT CNC and servo drive technology from Beckhoff.

Read more...

---

The time is now for systems integrators
Editor's Choice System Integration & Control Systems Design
Integrators combine sophistication regarding technology innovation with practical, hands-on experience. Collaborating with systems integrators is the means to significant productivity improvement, powered by the convergence of automation and information and operations technology.

Read more...

---

System integrators are a diverse market
Editor's Choice System Integration & Control Systems Design
System integrators (SIs) combine expertise on emergent technologies with real world experience. Working with SIs, it’s inevitable that at some point someone will say, “We’re not a typical SI.” And in many ways, it’s true. SIs come in all shapes and sizes.

Read more...

---

Avoiding the pitfalls of PLC and scada control system integration
Iritron System Integration & Control Systems Design
Upgrading your control system by integrating PLCs with scada systems should be a simple seamless process. Regrettably, the industry is plagued with control system integration and upgrade myths and misconceptions that can lead to liability issues, project delays, cost overruns and decreased plant performance.

Read more...

---

EtherCAT measurement terminals for vehicle development at Mercedes-Benz
Beckhoff Automation System Integration & Control Systems Design
At the Mercedes Technology Centre plant in Sindelfingen, Germany, car axles are examined with the highest precision on four test benches, in parallel with road tests and simulations. All data is acquired using PC-based control from Beckhoff.

Read more...

---

Loop signature 23: Tuning Part 2.
Editor's Choice System Integration & Control Systems Design
It is my opinion that most tuning methods are very crude. They do of course also offer a starting point for tuning if one is not fortunate enough to have a sophisticated tuning package like a Protuner around.

Read more...

---

PIC microcontrollers with integrated FPGA features in TME
System Integration & Control Systems Design
The new PIC16F131xx microcontrollers in TME’s offering from Microchip are ideal for the evolving and miniaturising electronic equipment market, offering efficient power management and predictable response times for controllers.

Read more...

---

Five smart machine trends you need to know
Adroit Technologies System Integration & Control Systems Design
The last ten years have brought about dramatic advances in technologies that OEMs had never realised would affect their designs or the saleability of their machines, much less impact business models and profits so dramatically. The following discussion will cover key advancements and recommendations all OEMs should be adopting in their design processes to stay current and competitive.

Read more...

---