KEPCO selects control system for its first 1,000 MW ultra-supercritical units in South Korea

Emerson works with Babcock-Hitachi K.K. to install PlantWeb digital architecture with Ovation system for the Dangjin Thermal Power Plant project.


Emerson Process Management has received a contract from Korea Electric Power Corporation and Babcock-Hitachi K.K. to install its PlantWeb digital plant architecture with the Ovation expert control system at units 9 and 10 of the Dangjin Thermal Power Plant in South Korea. These are the country’s first 1,000-MW ultra-supercritical units and, when commissioned in 2016, will provide electricity needed to support the country’s economic growth.

The Dangjin plant, located approximately 40 miles southwest of Seoul, is owned by Korea East West Power Co., a Korea Electric Power Corporation enterprise.

“This is an important ‘first’ for South Korea,” said S.J. Kang, electrical & control team manager, Korea East West Power Co. “Emerson’s proven automation, control, and asset management technologies will help these new units operate at peak performance over the long term, thereby maximizing our investment in these valuable power generation assets.”

At each unit, Emerson’s Ovation system will monitor and control the Babcock-Hitachi boiler, as well as manage ash handling, the flue gas desulphurization system, the electrostatic precipitator, the condensate polishing plant system, the chemical feed system, and balance-of-plant processes.

“Using ultra-supercritical technology will enable Dangjin units 9 and 10 to operate at elevated steam temperature and pressure for increased efficiency and reduced fuel-related emissions,” said Hironori Mihara, general manager, control system design department, thermal power division, Babcock-Hitachi K.K. Kure Division. “Emerson’s proven capabilities automating large, ultra-supercritical plants were central to our decision to select the company for this important project.”

Emerson will supply a total of 71 redundant Ovation controllers, 51 operator workstations, and 26 additional workstations for historical data collection, alarm management, thermal stress monitoring, engineering, and diagnostic functions. In all, the Ovation system will manage nearly 57,000 I/O points, including 50 Profibus DP segments (25 per unit) that will be utilized for each boiler’s motor operated valves (MOVs) and sootblower.

Use of Emerson’s AMS Suite asset management software will streamline initial configuration of intelligent measurement and control devices, enabling cost savings and increased unit startup efficiency. On an ongoing basis, AMS Suite will further increase the availability and performance of the two units by providing online access to instrument and valve predictive diagnostic information, and automatic documentation of field device maintenance.

The efficiency of each unit will be further enhanced by Ovation’s embedded steam temperature and unit response optimization technology. Steam temperature optimization utilizes both multi-regional models and fuzzy neural technology to provide the most stable and accurate model for power generation. This plant model permits faster ramp rates, improved turbine life, and reduced stress on boiler pressure parts. Unit response optimization uses advanced unit analysis and modeling techniques to provide optimal load trajectory and control for improved unit startup, ramping, turndown, and overall performance.

As part of its comprehensive automation and control solution, Emerson will also supply high-fidelity Scenario simulation technology. Configured using control logic identical to that of the plant, high-fidelity simulators offer a highly realistic training and engineering analysis environment. In addition to training operators, the simulator will be used to test and verify control logic prior to synchronization to the grid.

“Emerson has a successful global track record automating plants utilizing ultra-supercritical technologies,” said Bob Yeager, president of Emerson’s Power & Water Solutions. “We are pleased to be selected to manage the automation of critical power generation processes for Dangjin, and, in doing so, to help ensure a reliable supply of electricity in the region.”

Visit the Control Engineering Process Control Channel.

Read Supercritical Control: Boiler Technologies Become More Sophisticated

Edited by Peter Welander,

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