Valmet Automation

220 years of industrial history

2 © Valmet | CPe / DNA for Energy/Hydro

Unique offering covers process technology, automation and services
Automation
• Distributed control systems
• Performance solutions
• Process simulators
• Safety solutions

Energy Pulp and Paper

• Multifuel boilers up to 800MWth • Recycled fiber lines
• Biomass and waste gasification • Tailor-made board and paper machines
• Emission control systems • Modularized board and paper machines
• Tissue production lines
• Complete pulp mills

Focus in customer benefits

3 © Valmet | CPe / DNA for Energy/Hydro

Valmet key figures 2017
 Net sales by area

13%
21%

Net sales 10%

EUR 2,928 million
(EUR 350 million*) 11%

Employees
45%
12,306 (1,600*)

North America
*Automation South America
EMEA
China
Asia-Pacific

4 © Valmet | CPe / DNA for Energy/Hydro

Our automation offering

Pulp and paper Energy Chemical Marine

Advanced automation and process monitoring solutions and services:

 Distributed Control System (DCS) –  Vibration monitoring Systems
Valmet DNA  Automation services
 Turbine and Compressor control  Process simulators
 Safety systems and solutions

Over 4,500 automation systems

5 © Valmet | CPe / DNA for Energy/Hydro

Valmet DNA for Energy
One system for all automation in
energy Industries
 Specialized expertise in the energy industry

FLUIDIZED BED BOILERS GASIFICATION PYROLYSIS

Flexible multi fuel combustion, High cycle efficiency, high Environmentally efficiency, high
combustion optimization with availability. availability.
corrosion management.

COAL FIRED COMBINED CYCLE WASTE-TO-ENERGY

High availability, emission High availability, Maximizing waste disposal,
minimization, combustion emission minimizing, flexibility. emission management,
optimization, flexible usage. environmental efficiency.

COGENERATION HYDRO POWER SOLAR POWER

Flexibility, steam network Efficiency, availability, river Efficiency, availability, optimizing
management, high availability. optimization. lifecycle maintenance costs.

7 © Valmet | CPe / DNA for Energy/Hydro

 Product portfolio for power plants

Plant Management
Applications

Valmet DNA
Condition Automation
monitoring system

Process
knowledge
for
sustainable
performance

Analyzers and
measurements Advanced
Control
Applications

Energy
management

9 © Valmet | CPe / DNA for Energy/Hydro

Valmet solutions for hydro power plants
Boosting operational efficiency in energy production
Clean technology for sustainable and profitable growth

Maximized output
99,95%
Availability Reduced shutdowns

Optimized production
Hydro power
expert teams
Minimized losses

87 engineering 24h service

& service centers Engineering cost
close to you optimisation

11 © Valmet | CPe / DNA for Energy/Hydro

Automation solution for hydro power plants
Valmets delivery scope
Valmet DNA Valmet DNA Valmet DNA Valmet DNA Valmet DNA

Pond control
Blade/wicket gate control

Turbine Controller Distributed Control Integrated Information Condition &

System User Interface Management Solution Runnability Monitoring

Valmet DNA
Water Balance Electrical Excitation Control & Field Instruments & Training Simulator
Control Protection LV Distribution/MCC Position-Encoder

Valmet DNA Valmet DNA

12 © Valmet | CPe / DNA for Energy/Hydro

One system for all automation in energy
Valmet DNA

Remote
Connections

CONTROL ROOM Firewall

OFFICE Engineering and Maintenace,
Operation, Maintenance, Reporting Reporting, Enterprise Integration Asset Management, DNA Historian

Star or ring topology Name based communication,

redundant Ethernet network no server-client structure!

Automation Level

Gate / Dam Water Balance Turbine //

Turbine Electrification Auxiliaries
Control Pond Generator 1-n
Generator

13 September 19, 2018 © Valmet | Valmet DNA for all automation in fluidized bed boiler power plants
Process controller & IO cards technical features
ACN-RT ACN-CS
• Typical I/O capacity 500-
4000
• Centralised, distributed and
embedded installation (A4
•Typical I/O capacity 500-6000 footprint)
•Centralised and distributed 19”
• Fan-less cooling
Rack fitting
• Over-pressured air cooling
ACN M80 I/O
 DIN-Rail mounting
• Max. 16 modules per
group
• Field signals directly
connected or to
terminal board via
flat-cable to I/O
module.

ACN-MR ACN-SR1 ACN M120 I/O

• Typical I/O capacity 100- • Max. 256 I/O ‘s • DIN-Rail mounting

3000 • Can be fitted in I/O group
• Max. 16 modules per
• Centralised, distributed group
and embedded installation.
• Can be fitted in I/O group • Field connection via
cable and connector
module

14 © Valmet | CPe / DNA for Energy/Hydro

Valmet DNA user interface for effective operation
Feeling of control

 Efficient problem solving

Trends with alarms & events
 Time machine by one click
 History mode and replay
 Tracer for trending with alarms and events
One click
 Analyzing alarms and events

Deeper alarms &

events analysis

History mode
indication

Select displayed
moment and replay

15 © Valmet | CPe / DNA for Energy/Hydro

Valmet DNA Turbine Controller & turbine protection

 Speed control
 Load control
 Island mode operation
 Primary and secondary control
 Limiters (e.g. acceleration, load)
 Start-up / shut-down sequences
 Co-ordination of turbine valves
 Position control for servomotor
 Redundant or simplex in all levels
 Fault diagnostics
Benefits
 Local operability
 Overspeed protection (IEC 61508)  Open platform, no black boxesValmet DNA
 Turbine Condition Monitoring System (vibration)  bine
Control and protection in one system
 Training Simulator (river and plant simulation) Monitoring
 High usability
 Performance Monitoring System
 Water Balance Control  Easy and cost-effective maintenance
 Seamless coordination throughout plant
and turbine controls

16 © Valmet | CPe / DNA for Energy/Hydro

Valmet DNA Machine Monitoring
Prevent unplanned downtime by machine health monitoring

 Vibration based condition monitoring for rotating

machinery in Valmet DNA automation system

 Common user interface for process control and

condition monitoring
– Easier to use and share information between operation
and maintenance

 Common history database for all process and

machine condition data
– Efficient analysis and reporting

 One system and one engineering environment

for condition monitoring and process control
– Cost efficient to build and maintain

17 © Valmet | CPe / DNA for Energy/Hydro

Raising automation level at a
Swiss HPP
Felsenau HPP - more than 100 years in operation
• Owner:
Energie Wasser Bern, EWB
• Location:
Bern, river Aare, Switzerland
• Plant Data:
– 1909 3 Francis turbines, total 2,6 MW
– 1918 2 Francis turbines, total 4,5 MW
– 1989 Kaplan bulb turbine 11,5 MW,
Francis put out of service
• Delivery scope for retrofit 2014:
– Valmet DNA control system – Power plant / River simulator
– Trend and Event Archive – Vibration monitoring & mechanical protection
– Turbine controller – Electrical protection for Generator &
– Water balance control Transformer
– Generator excitation
– Synchronization

20 © Valmet | CPe / DNA for Energy/Hydro

Customers requirements

Challenge Solution Results

• Development of the city • Valmet DNA automation • Effectiveness of the
of Bern and population system controls the controls has been visibly
increase has led to the operation of the entire enhanced, especially
steady increase in energy plant. plant’s complex water
consumption. balance control.
• Easy operation,
• Outdated automation transparency in control • Higher automation level
system was no longer algorithms.
• Full auto run-up / shut
reliable.
• Remote operation via down & purge sequences
• Ecological production control room of CHP plant
• Optimized operation point
process.
of turbine

23 © Valmet | CPe / DNA for Energy/Hydro

Modular system architecture of Valmet DNA

Plant Management Valmet DNA Plant Operation Monitoring

Applications Valmet DNA Turbine Performance Monitoring

Reporting & Analyzing Valmet DNA Historian Calculation Environment

Tools Valmet DNA Report (Reporting and Trending)
Condition & Information
Runnability Monitoring Management Solution

Information Services Valmet DNA Historian

Valmet DNA Operate – Alarms & Events Server
(Databases)
Application databases (SQL Server)

Valmet DNA Water Balance Control

Advanced Control Valmet DNA Turbine Controller
Applications Valmet DNA Remote Setpoint Control
Valmet DNA Training Simulator (power plant & river)

Pond control
User Interaction Blade/wicket gate control
Automated Process
Valmet DNA Distributed Control Advanced Process
Secured Lifecycle System Controls
Vibration Monitoring System

24 © Valmet | CPe / DNA for Energy/Hydro

Everything goes automatic in Valmet DNA
Before:
• start/stop of the turbine was not full automatic
• gate control did not support different variations in automatic

More freedom
for operators
Now:
• full automatic turbine start / stop
• gate control supports different variations or priorities in automatic

25 © Valmet | CPe / DNA for Energy/Hydro

Everything in high resolution on video
Before:
• no history mode, no high resolution alarm list
Now:
• full trend, event archive and reporting for all values and alarms
• seamless connection to office (excel, pdf)
• high resolution alarm list

Benefit:
•Better data analyses
•search functions & data access to history data
• faster & more efficient fault analysis
26 © Valmet | CPe / DNA for Energy/Hydro
Maximum power - in balance with environment
• Maximum flow through turbine 100m3/s
• Pond water level to be kept at fixed level (+/-5cm)
• Residual minimum water flow 10-12m3/s, through 500kW turbine

1st priority: 3rd priority:

pond level, head water
flooding emergency emergency level

2nd priority: Residual

flow, compliance with
environmental
regulations 4th priority: power plant
max. power production

27 © Valmet | CPe / DNA for Energy/Hydro

Valmet DNA turbine controller – features

Implemented standard features :

• Speed or frequency control
• Load or flow control
• Start / stop sequences
Main operator display
• Purge programs
• No black box
• Fault diagnostic
Main sequence display

Additionally customer got:

• Same HW & engineering tools
as plant DCS

28 © Valmet | CPe / DNA for Energy/Hydro

Fulfillment of customer’s HW requirements

Main requirements:
• Overspeed protection (IEC 61508)
• Availability > 99,95% Redundant
process station
• Autonomous from rest of system Modell ACN MR

• Local operation via touch panel

• Fault diagnostic possibilities

Additionally customer got:

• Redundant TCS in all levels
• Same HW & engineering tools as plant DCS
• No black box concept , expandable (on-line!)

29 © Valmet | CPe / DNA for Energy/Hydro

Valmet DNA turbine controller - Optimization
• Correlation wicket gate/ runner blades
– Monitoring of actual correlation wicket gate /
runner blades angle
– Runner blades follow wicket gate acc. these
curves Actual
operation point
– Different operating curves, dependent on pond
level (head)

• Optimization wicket gate/ runner blades

– Correlation adjustment to increase the efficiency

• Limitation of opening of wicket gate

– Limitation of max. opening of wicket gate e.g.
for safety reasons (cavitation, acceleration
> 250% / min.)
– Efficiency (optimum operation point in
low./max. flow range)

30 © Valmet | CPe / DNA for Energy/Hydro

Valmet DNA vibration monitoring system
in Felsenau
• Integrated application in Valmet DNA system Operator interface fully
• Same HW & engineering tools as plant DCS integrated for fast analysis

• 4 Eddy probes
• Monitoring of unbalance,
eccentricity, resonance, orbit
• TÜV approved mechanical
protection acc. SIL 3

Turbine graphic display

Turbine protection logic

31 © Valmet | CPe / DNA for Energy/Hydro
Valmet DNA Power plant training simulator

Direct access from

 HPP Simulator to simulate operation, HPP Felsenau
overview display
trending and reporting functions
– to avoid malfunctions
– to understand the plant technology
– operator training for new staff
– realistic simulation
– same HW as in HPP
– training in a safe environment
– skilled operators for
‐ more efficiency
‐ better environmental aspects
‐ less downtime
‐ less equipment wear

Power plant simulator –

same look & feel

32 © Valmet | CPe / DNA for Energy/Hydro

Valmet DNA River simulator
Simulator control

 River Simulator
– wave simulation upstream
HPP Matte
– flood (e.g. heavy
weather conditions)
– simulation of levels upstream
and pond
– how to react in the
power plant
‐ max. additional capacity
through the turbine
Ausgangslage

‐ max. displacement Szenario

1
Ganglinie
Ganglinie 1
OWPengehalde
495,54 m.ü.M
Qnull
140,00 m³/s
QTurb
100,00 m³/s
QGA
0,00 m³/s
Qengehalde
40,00 m³/s

through the river 2

3
Ganglinie 2
Ganglinie 3
495,54 m.ü.M
495,54 m.ü.M
120,00 m³/s
320,00 m³/s
80,00 m³/s
100,00 m³/s
0,00 m³/s
0,00 m³/s
40,00 m³/s
220,00 m³/s
4 Ganglinie 4 495,54 m.ü.M 260,00 m³/s 100,00 m³/s 0,00 m³/s 160,00 m³/s
5 Ganglinie 4 495,54 m.ü.M 260,00 m³/s 0,00 m³/s 60,00 m³/s 200,00 m³/s
6 Ganglinie 5 495,54 m.ü.M 80,00 m³/s 68,00 m³/s 0,00 m³/s 12,00 m³/s
7 Ganglinie 5 495,44 m.ü.M 80,00 m³/s 0,00 m³/s 0,00 m³/s 80,00 m³/s
8 Ganglinie 6 495,44 m.ü.M 160,00 m³/s 0,00 m³/s 0,00 m³/s 160,00 m³/s
9 Ganglinie 7 495,54 m.ü.M 196,00 m³/s 0,00 m³/s 60,00 m³/s 136,00 m³/s

Wave simulation
configuration
HPP Matte

33 © Valmet | CPe / DNA for Energy/Hydro

Enhanced effectiveness of the controls

“The control is now fully

automated and all the
information is easily and
quickly available. The
events and context are
much more visible.“

34 © Valmet | Author / Title

Improved operational effectiveness

“Our expectations for the

new system have been
exceeded by far. The
system is in operation
since June 2014 without
any disturbances.
I am glad that we
selected your system.“

Andres Wäfler
Manager of Power Plants & Contracting
at Energie Wasser Bern

35 © Valmet | Author / Title

References
Valmet DNA for energy
World wide power plant references

37 © Valmet | CPe / DNA for Energy/Hydro

 Selected references: Hydro Power Plants

2012 Irganaiskaya, Dagestan

• Electrical power 2x 205 MW
• Fancis Turbine
• DNA Automation

2013 Djerdap I, Serbia

• Electrical power 6x 201 MW
• Kaplan Turbine
• DNA Automation

2013 Ilarion, Greece

• Electrical power 2x 77 MW
2008 Maneri Bhali Stage II, India • Fancis Turbine
• DNA Automation
• Electrical power 4x 74 MW
• Fancis Turbine
• DNA Automation, Turbine Controller 2010 Allain Duhangan, India
• Electrical power 2x 96 MW
Tammerkosken Vesivoimalaitos, • Pelton Turbine
2012 Finland • DNA Automation, Turbine Controller
• Electrical power 8 MW
• Kaplan Turbine
• DNA Automation, Turbine Controller
2010 Sewa II, India
• Electrical power 3x 40 MW
• Pelton Turbine
2012 Inkeroinen, Finland • DNA Automation, Turbine Controller
• Electrical power 3x 4,5 MW
• Kaplan Turbine
38 • DNA Automation, Turbine Controller
 Selected references: coal fired power plants
PVO-LÄMPÖVOIMA OY
2007 KRISTIINANKAUPUNKI
• Electrical power 248 MW
• Fuel: pulverized coal
• Benson boiler
CHEREPETSK,
2013 SUVOROV, RUSSIA
• Electrical output: 2x225 MWe
• Fuel: Pulverized coal

JEA, ST. JOHNS RIVER POWER PARK

2015 JACKSONVILLE, FLORIDA, USA
• Electrical power 2x640MW (538°C, 168bar)
• Fuel: pulverized coal
• Benson boilers, 2.500 t/h steam / boiler
• DCS retrofit, original plant start up 1987/88
JIANGSU HUADIAN JURONG POWER
2015 XIASHU, CHINA BAJAJ HINDUSTAN LIMITED

• Electrical power 2 x 1000MW,

2015/6 LALITPUR, INDIA

• Fuel: pulverized coal • Electrical power 3x660MW

• Ultra supercritical boiler, 600°C, 262 bar • Fuel: pulverized coal
• supercritical boiler (BHEL)

DAINIK BHASKAR POWER LIMITED

2018 SINGRAULI, INDIA
• Electrical output 2x600MW
• Fuel: pulveriized coal
• supercritical boiler (BHEL)
39 © Valmet | CPe / DNA for Energy/Hydro
 Selected references: coal fired power plants
ISRAEL ELECTRIC CO
2001 RUTENBERG 3,4, ISRAEL
• Electrical power 2x550 MWe
• Fuel: pulverized coal

AES PETERSBURG
2002 PENNSYLVANIA, USA
• Electrical power 530 MWe
• Fuel: pulverized coal

ALABAMA POWER GASTON

2002 WILSONVILLE, ALABAMA, USA
• Electrical power 2 * 270 MWe
• Fuel: pulverized coal

MONTOUR EXELON
2004 STEAM ELECTRIC STATION, USA 2004 EDDYSTONE, USA
• Electrical power 2x750MWe (1020 °F,3830psi) • Electrical power 2x350MW (650°C,358bar)
• Fuel: pulverized coal • Fuel: pulverized coal
• Benson boiler • Benson boiler
• DNA for PP, steam turbine and simulator • DNA for whole PP, steam turbine and simulator

EESTI ELETRIJAAM PKE ELEKTROWNIA LAGISZA S.A.

2004 NARVA, ESTONIA 2007 BEDZIN, POLAND
• Electrical output 200 MWe • Electrical output 460 MWe
• Fuel: oil shale • Fuel: coal
• 2 x Circulating fluidized bed boiler • Circulating fluidized bed boiler, super critical

40 © Valmet | CPe / DNA for Energy/Hydro

 Selected references: combined cycle power plants

EL PASO ENERGY,
2002 LINDEN NJ, USA
• Electrical output 760 MWe
• Fuel: natural gas
• Combined cycle

BAYMINA ENERGJI A.S.

2003 ANKARA, TURKEY
• Electrical output 800 MWe
• Fuel: natural gas
• Combined cycle

EL PASO ENERGY,
2003 PORTO VELHO, BRAZIL
• Electrical output 340 MWe
ALPIQ CSEPEL II CCPP, • Fuel: natural gas
1999 BUDAPEST, HUNGARY • Combined cycle
• Electrical output 390 MWe
• Fuel: natural gas
• Combined cycle

41 © Valmet | CPe / DNA for Energy/Hydro

 Selected references: combined cycle power plants

ENERGIAKI THESSALONIKIS S.A.,

2004 THESSALONIKI, GREECE
• Electrical output 400 MWe
• Fuel: natural gas
• Combined cycle

OMV SAMSUN ELEKTRIK,

2010 SAMSUN, TURKEY
• Electrical output 890 MWe
• Fuel: natural gas
• Combined cycle

LIMAK ENERJI,
2016 HAMITABAD, Turkey
• Electrical output 1200 MWe
ENERJI S.A. • Fuel: Gas
2009 BANDIRMA, TURKEY • 2 single shaft GT+ST

• Electrical output 920 MWe

• Fuel: natural gas
• Combined cycle

© Valmet | CPe / DNA for Energy/Hydro

42
 Waste to Energy Plant References
Europe Finland
• Westenergy Oy Ab, Vaasa
UK
Norway Sweden
• Ineos Runcorn, Manchester phase 1
• BIR Avallsenergi,Bergen • Åmotfors Energi Ab
• Ineos Runcorn, Manchester phase 2
• MES Environmental, Dudley Estonia
• MES Environmental, Wolverhampton • Eesti Energi AS, Tallinn
• Waste Recycling Group, Lincolnshire
• Veolia Environmental Services, Staffordshire
• SITA Suffolk
• Viridor Oxfordshire Ardley
• Viridor Cardiff
• Cory Environmental, Riverside London
• Veolia Environmental Services, Newhaven Austria
• Sita, Cleveland 4&5 •.A.S.A., Zistersdorf
• SSE Ferrybridge FM 1 • AVE Wels II
• FCC Buckinghamshire • AVE Wels I
• H&W Mercia Waste • AVE Lenzing
• SSE Ferrybridge FM 2
• Dundee Energy Recycling, Dundee Italy
• RWE Markinch, Glenrothers •Trattamento Rifiuti Metropolitani, Turin
• London Waste, London • Veolia, Piacenza
• Veolia, Energonut
ValmetPower
FR
Hitachi Zosen Inova (former Von Roll Inova)
• Veolia, Prociner
Keppel Seghers • Veolia, SIAP
CNIM
Martin GmbH
Other Technology or Automation Replacement

© Valmet | CPe / DNA for Energy/Hydro

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