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3 April 2006 - Metso Automation has been selected to provide the controls and data acquisition for the Flue Gas Desulphurization (FGD) project at PPL Corporation's Montour power plant in Washingtonville, Pennsylvania, USA.
Metso will work with PPL and its prime contractor, Shaw Stone & Webster to expand the existing maxDNA Distributed Control System (DCS) that now controls the boilers, turbines, and Selective Catalytic Reduction (SCR) systems for units 1 and 2.
The Montour plant consists of two 750 MW coal-fired supercritical units built in the early 1970s. Main steam conditions are 3,830 psig (264.1 bar) and 1,010 °F (543 °C). The fuel for the units is Eastern bituminous coal.
The wet FGD systems will consist of one absorber per unit. Limestone will be delivered to the site by truck and rail. The FGD process creates gypsum as a byproduct. Gypsum will be dewatered and sent via conveyor to a new wallboard plant that will be one of the larger wallboard manufacturing lines on the East coast.
The existing maxDNA control system will be expanded to accommodate new booster fans and the FGD system including limestone preparation and gypsum drying. The project requires significant control and data acquisition to support the new equipment. There are approximately 3,000 new hardwired I/O points and several hundred data link I/O points. Metso will provide process I/O for each unit's absorber island, the common limestone slurry prep area, and the dewatering area. Metso will also provide data links to remote PLCs controlling make-up water, wastewater treatment, gypsum transfer, oxidation air compressors, limestone unloading and forwarding, and other air compressors using a redundant gateway. These remote processes will be supervised though the maxDNA DCS from the unit 1 and 2 control room.
Modernization of the control room will include the addition of maxVUE operator stations with dual display monitors that allow the operators for each unit to manage the FGD in addition to their other duties. The absorber island and limestone prep areas will each have their own local operator stations. The DCS system will collect and disseminate information over data links to vibration monitoring systems, CEMS, the plant historian, and PMAX performance monitor.
The existing high fidelity simulator will undergo a major upgrade to include the new FGD equipment. The simulator will use maxDNA virtual controllers that run an exact copy of the plant control system in a workstation.
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