Process Control Systems

Reference List
Process Control Systems

forPower Plants
Power Station
Control Systems
Power Distribution
Control Systems
Control Room
Technology
Automation
Equipment
Contents
Page
General Information
Generating Unit Control Systems
Fail-Safe Burner Control
Turbine Control Systems
10
Flue Gas Desulfurization Plants
13
Hydropower Stations
14
Coal Feeder Plants
18
Water Treatment Plants
19
DeNOx Plants
20
Ammonia (NH3) Tank Farms
20
Waste Incineration Plants
22
Expert Systems
23
Soot Reinjection Plants
26
Block-Type Thermal Power Stations
27
Building Services Control
28
Gas and Steam Power Plant
30
Power Plant Simulators
31
General Information
Demands on Modern Automation
Today, in all fields of engineering, industrial production which
is economical and at the same
time goes easy on resources
and environment is not possible
without a high degree of automation. Process control systems
used for the automation of power
stations must meet particularly
high requirements for increased
availability, large functional range
and decentralized architecture.
Our ME 4012 process control system meets these high demands.
Not only does it provide all the
facilities necessary for the acquisition, preparation and processing of
plant data; it is also equipped with
sufficient intelligence for sequence
and closed-loop control tasks and
for the monitoring and optimization
of plants and plant components.
Observation, monitoring and
operator control of the plant as a
whole are done in a central control
room equipped with monitors.
The architecture of the ME 4012
process control system is based
on the decentralized, redundant
SUB-NET process bus, the
AE4012 programmable controllers
and the ME-VIEW operator control
and process monitoring system.
ME 4012 structures the entire

process in a hierarchy of horizontal
control levels thus fulfilling the
different tasks of the plant:
Interfacing to plant and
processes
S
equence, logic and closed-loop
control of individual drives
Individually automated function
groups providing a high degree
of plant automation
In addition, the plant is sectioned
vertically into a number of
functional units. This division is
governed by criteria such as:
Process correlations
Standby requirements
Minimization of signal exchange
ME4012 ensures complete
standby facilities in the areas of
data communication and operator
control.
Economical Solutions
The hardware of the ME 4012 process control system is of modular
design. Therefore, with ME4012
you will be able to find a made-tomeasure solution for your specific
problem whatever the automation
task is.
Economical solutions for small applications may comprise just one
AE 4012 programmable controller. These can be expanded as
required, responding to increasing
demands in the areas of:
Plant and process control
Geographical expansion
Standby and redundant

configurations
Plant automation
Auxiliary machinery can easily be
integrated using the programmable
controller which is compatible
with the process bus and can be
configured and programmed by
the machine manufacturer.
Field-proven Solutions and
Technological Know-how
For many years now, our application experts have proven their
experience and know-how in the
design of automation and process
control schemes for technological
processes in the fields of:
Block-type thermal power stations (lignite or coal boilers)
Fail-safe burner control (oil,
gas or coal)
Steam turbine control
Gas turbine control
Flue gas desulfurization
DeNOx plants / Ammonia (NH3)
tank farms
Coaling plants, supply and
disposal installations
Waste incineration
Water treatment
Water power stations
Training schemes for power
station control
Field instruments and installation

For all applications mentioned in
this Reference List we supplied the
control system (inner plant control).
In almost all cases, we also provided, installed and commissioned
the complete instrumentation,
measuring and control equipment
for the process peripherals. This
includes in particular the transducers for measured quantities such
as temperature, pressure, flow,
level, water and flue gas analysis,
revolutions per minute, position
etc.
according to the high technical

VGB Standards, R 170 C (VGB
=German Association of the
Power Station Industries).
Equipment and systems are usually installed by our own personnel.

Our responsibilities also cover the
installation of hook-ups according
to our own design, and all pipework in connection with stepping
lines, which is mostly welded and
always carried out using standard
and quality-approved conduit
material. The frames required
for the installation of transducers
and the cable subdistributors are
manufactured by ourselves to
the highest quality standards and
adapted to the specific application.
Modernization of hydraulic
systems (units, pipelines, control
modules) and adaptation on
existing machines
Inline components such as control

valves, fittings, covers, nozzles etc.
were purchased and provided by
us according to the specification
of the plant supplier or planning
engineers, ready for being installed
by the plant supplier.
Our project engineers prepare

hydraulic diagrams, define the
component specifications and
develop concepts for the constructing engineers. The configuration and design documentation
is created with 3D (Solid Works
Software (SW)) and 2D (Auto CAD
Software) systems.
After completion of all mounting and installation work by our

personnel, we commissioned the
systems and finally provided a
complete set of system documents
Hydraulic Mechanical Systems

The scope of our services
comprises:
Planning and layout of hydraulic
components and systems
Design and delivery of hydraulic
mechanical components
Optimization tests of all hydraulic
components in our own testing
bays before they are shipped
Commissioning of hydraulic
systems and plants
Delivery and installation of all
systems required for turbine
strain, vibration, speed, etc.
measurement
Maintenance services after
project completion
Training of customer personnel
for direct plant maintenance/
monitoring
Cooling tower with flue gas passes
Flue gas
desulfurization
Induced draft
Electric filter
Steam generator
Power house
Coal power station
Computer Animation Power Plant

Computer Animation Power Plant
Brown coal-fired power plant Boxberg Unit R

Base load operation
Availability: > 91 %
Controllability: 50 % to 103 %
High level of automation
Transmission Code compliance
Net efficiency> 43.7 %
Live steam: T = 600 C; p = 285 bar
IS steam: T = 610 C; p = 52 bar
Coal consumption: 4.5 million t/a
Specific CO2 emissions: 924 g/kWh
Hard coal-fired power plant Moorburg Unit A

Combustion heat output: 3700 MW max.
Combustion heat output: 3354 MW under design cond.
Gross electrical output: 1654 MW under design cond.
District heating output: 650 MW max.
Live steam: T = 600 C, p = 276 bar
IS steam: 610 C, p = 52 bar
Controllability at load operation: 35 to 103%
Hard coal consumption: 480 t/h; 4.21 million t/a approx.
Ashes produced: 63 t/h; 0.56 million t/a approx.
Hard plaster produced: 18 t/h; 0.16 million t/a approx.
6
Generating Unit Control Systems

Excerpt
Customer
Location
Block
Output Power
Mechanical Engineering
E.ON Kraftwerke
Ingolstadt
3+4
420 MW each
EVT
GDF Suez-Gruppe
Zolling
450 MW
VKW-Babcock
E.ON Kraftwerke
Irsching
300 MW
EVT
STEAG-RWE
Voerde
750 MW
Auxiliary plant
STEAG-RWE
Voerde
750 MW
Auxiliary plant
STEAG-VEW
Bergkamen
750 MW
Auxiliary plant
swb
Bremen-Hafen
320 MW
EVT
E.ON Kraftwerke
Shamrock
130 t / h
Babcock
E.ON Kraftwerke
Shamrock
130 t / h
Steinmller
E.ON Kraftwerke
Shamrock
130 t / h
EVT
E.ON Kraftwerke
Shamrock
130 t / h
Drr
E.ON Kraftwerke
Scholven
FWK-Buer
District heating
Steinmller
Stadtwerke Duisburg
HKW
III
District heating
Standardkessel
Daimler Benz
HKW
District heating
EVT
Eletrosul, Brasilien
Jorde Lacerda lll
125 MW
Skoda
Jorde Lacerda lll
125 MW
Skoda
Kasseler Fernwrme
Kassel
AllessaChemie
Frankfurt
Process heat
Steinmller
AllessaChemie
Frankfurt
Process heat
Steinmller
AllessaChemie
Frankfurt
Process heat
Steinmller
swb-Erzeugung
Mittelsbren
240 MW
EVT
Freundenberg Service Weinheim
45 t / h
Standardkessel
Vattenfall Europe
Boxberg
700 MW
Hitachi Europe
Vattenfall Europe
Moorburg
820 MW
Hitachi Europe
Vattenfall Europe
Moorburg
820 MW
Hitachi Europe
Fluidization 180 t / h Lurgi / Lentjes
Computer Animation Power Plant Boxberg
Waste Incineration Plant

8
Fail-Safe Burner Control

Excerpt
Customer
E.ON Kraftwerke
E.ON Kraftwerke
GDF Suez-Gruppe
E.ON Kraftwerke
swb
swb
swb
swb
E.ON Kraftwerke
E.ON Kraftwerke
E.ON Energy f. Waste
E.ON Energy f. Waste
Kasseler Fernwrme
Freudenberg Service
Freudenberg Service
RWE
RWE
RWE
Technische Werke
Gemeinschaftkraftwerke
AllessaChemie
Casella AG
Stadtwerke Frankfurt
AWG Wuppertal
AWG Wuppertal
AWG Wuppertal
AWG Wuppertal
Stadtwerke Duisburg
Holtzmann
Vattenfall Europe
Vattenfall Europe
Vattenfall Europe
Location
Block
Ingolstadt
4
Ingolstadt
3
Zolling
5
Irsching
3
HKW Hafen
6
HKW Hastedt
1
HKW Hastedt
2
Mittelsbren
4
Scholven
F
Scholven
FWK-Buer
Stapelfeld
1
Stapelfeld
2
Kassel
2
Weinheim
3
Weinheim
4
Jorde Lacerda lll
5
Jorde Lacerda lll
6
Wesseling
1
Wesseling
2
Wesseling
6
Stuttgart
23
Veltheim
1
Output Power
420 MW
420 MW
450 MW
300 MW
320 MW
100 t / h
100 t / h
240 MW
750 MW
District heating
165 000 t / a
165 000 t / a
Fluidization 180 t / h
Process heat
Process heat
125 MW
125 MW
Process heat
Process heat
Process heat
35 MW
100 MW
EVT
EVT
VKW-Babcock
Balcke Drr
EVT
MACCI
MACCI
Babcock
EVT
Steinmller
Steinmller
Steinmller
Lurgi / Lentjes
EVT
EVT
Skoda
Skoda
Balcke Drr
Balcke Drr
Balcke Drr
Babcock
Balcke Drr
Veltheim
100 MW
Balcke Drr
Veltheim
300 MW
Babcock
Veltheim
300 MW
Balcke Drr
Veltheim
HK
35 t / h
Eisenw. Baumgarte
2
3
Process heat
Process heat
District heating
Waste incineration
Waste incineration
Waste incineration
Waste incineration
Heating and power station
Process heat
700 MW
820 MW
820 MW
Steinmller
Steinmller
Standardkessel
Lentjes
Lentjes
Lentjes
Lentjes
Standardkessel
Standardkessel
Hitachi Power Europe
Frankfurt
Frankfurt
HKW Messe
Wuppertal
Wuppertal
Wuppertal
Wuppertal
Duisburg
Karlsruhe-Maxau
Boxberg
Moorburg
Moorburg
12
14
15
16
I
R
A
B
9
Turbine Control Systems

Excerpt
Customer
swb-Erzeugung
E.ON Kraftwerke
RWE Power AG
RWE Power AG
RWE Power AG
ESKOM Engineering Group, Sdafrika
ESKOM Engineering Group, Sudafrika
ESKOM Engineering Group, Sudafrika
IEC Israel Electric Corporation Limited
Rheinbraun AG
Vattenfall Europe
EPON, Niederlande
EPON, Niederlande
ENSO Gutzeit OY, Finnland
VSE
RWE Energie AG / VSE
Haindl Papier
Voest AG, sterreich
Vattenfall Europe
Vattenfall Europe
Vattenfall Europe
Vattenfall Europe
Vattenfall Europe
Vattenfall Europe
Location
Hafen
Buschhaus
Frimmersdorf
Huckingen
Huckingen
Lethabo
Lethabo
Lethabo
Lethabo
Lethabo
Lethabo
Matimba
Matimba
Matimba
Matimba
Matimba
Matimba
Rutenberg
Rutenberg
MD-B, Hadera
MD-B, Hadera
Wachtberg
Tiefstack-Ersatz
Bergum
Bergum
Imatra
Ensdorf
Ensdorf
Augsburg
Linz
Jnschwalde
Jnschwalde
Jnschwalde
Jnschwalde
Jnschwalde
Jnschwalde
Matla
Matla
Matla
Matla
Block
6
1
Q
A
B
1
2
3
4
5
6
1
2
3
4
5
6
1
2
5
6
1
1
2
TU 7
1
3
VII
IV
A
B
C
D
E
F
1
2
3
4
10
Turbine *
ME
ME
AEG
ME
ME
ME
ME
ME
ME
ME
ME
ME
ME
ME
ME
ME
ME
ME
ME
ME
ME
ME
ME
ME
ME
ME
AEG
ME
ME
ME
LMZ
LMZ
LMZ
LMZ
LMZ
LMZ
ME
ME
ME
ME
Output Power
320 MW
350 MW
350MW
300 MW
300 MW
620 MW
620 MW
620 MW
620 MW
620 MW
620 MW
665 MW
665 MW
665 MW
665 MW
665 MW
665 MW
550 MW
550 MW
550 MW
550 MW
90 MW
160 MW
300 MW
300 MW
92 MW
110 MW
315 MW
25 MW
85 MW
500 MW
500 MW
500 MW
500 MW
500 MW
500 MW
600 MW
600 MW
600 MW
600 MW
Function *
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
Matimba, South Africa
Installation
Customer
E.ON Kraftwerke
STEAG
MVA Kiel
Tha Toom
Tha Toom
VALA
PCK Schwedt
PCK Schwedt
NOK Thei, Austria
E.ON Kraftwerke, KW Heyden
Electrabel MV NP, Belgium
Power Plant Doel, Belgium
Location
Matla
Matla
G. Knepper
Lnen
Kiel
Thailand
Thailand
Finnland
Schwedt
Schwedt
Thei
Petershagen
Grootvlei
Doel
Tihange, Huy
2 x SPAT/TFP
Block
5
6
C
7
L1 + L2
1
2
1
1
2
4
1-6
4
3
3
* Turbine / turbine
ME = M
AN-ENERGIE, Nrnberg
AEG = AEG-AG, Berlin
LMZ = L
eningrader Metallwerke
Sankt Petersburg
GAE = GEC-Alsthom Energie,
Nrnberg
B&V = Blohm & Vo, Hamburg
** T
urbine Control System
Functions:
TCS = Turbine control system
retrofit
THS = Turbine hydraulic system
retrofit
Turbine
11
Turbine *
ME
ME
AEG
AEG
B&V
GAE
GAE
GAE
GAE
GAE
GAE
Siemens
ME
Alstom
Alstom
Ratau
Output Power
600 MW
600 MW
350 MW
350 MW
9 MW
160 MW
160 MW
230 MW
90 MW
90 MW
250 MW
920 MW
6 x 200 MW
1100 MW
1100 MW
3000 t/h
Function *
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS
TCS / THS
TCS / THS
TCS / THS
Coal power station (Flue gas desulfurization)
Lignite-fired power plant

12
Flue Gas Desulfurization Plants

Excerpt
Customer
E.ON Kraftwerke
Location
Ingolstadt
Block
3+4
Output Power
420 MW
STEAG-VEW
Bergkamen
750 MW
Steinmller
STEAG-RWE
Voerde
750 MW
Steinmller
STEAG-RWE
Voerde
750 MW
Steinmller
VEBA KW Ruhr AG
Shamrock
1+2
District heating 2x130 t / h
Thyssen
VEBA KW Ruhr AG
Shamrock
3+4
District heating 2x130 t / h
Thyssen
swb
Hafen
300 MW
Babcock
swb
Hafen
420 MW
Babcock
VSE / RWE
Ensdorf
315 MW
NIRO / KRC
VSE / RWE
Ensdorf
150 MW
NIRO / KRC
E.ON Kraftwerke
Scholven
300 MW
Thyssen
E.ON Kraftwerke
Scholven
300 MW
Thyssen
E.ON Kraftwerke
Scholven
300 MW
Thyssen
E.ON Kraftwerke
Scholven
300 MW
Thyssen
E.ON Kraftwerke
Scholven
FWK-Buer
District heating
Thyssen
VEAG Berlin
Jnschwalde
540 MW
KRC-Umwelttechnik
VEAG Berlin
Jnschwalde
540 MW
KRC-Umwelttechnik
VEAG Berlin
Jnschwalde
540 MW
KRC-Umwelttechnik
VEAG Berlin
Jnschwalde
540 MW
KRC-Umwelttechnik
VEAG Berlin
Jnschwalde
540 MW
KRC-Umwelttechnik
VEAG Berlin
Jnschwalde
540 MW
KRC-Umwelttechnik
VEAG Berlin
Boxberg
540 MW
L. & C. Steinmller
VEAG Berlin
Boxberg
540 MW
L. & C. Steinmller
Vattenfall Europe
Boxberg
700 MW
Babcock Noell
Vattenfall Europe
Moorburg
820 MW
Babcock Noell
Vattenfall Europe
Moorburg
820 MW
Babcock Noell
AllessaChemie
Frankfurt
Process heat
Steinmller
Casella AG
Frankfurt
Process heat
Steinmller
Stadtwerke Frankfurt HKW Messe
District heating
KRC-Umwelttechnik
Standardkessel
AWG Wuppertal
Wuppertal
12
Waste incineration
Lentjes
AWG Wuppertal
Wuppertal
14
Waste incineration
Lentjes
AWG Wuppertal
Wuppertal
15
Waste incineration
Lentjes
AWG Wuppertal
Wuppertal
16
Waste incineration
Lentjes
Heating and power station
Standardkessel
Process heat
Standardkessel
Stadtwerke Duisburg Duisburg

Holtzmann
Karlsruhe-Maxau
Vattenfall Europe
Boxberg
700 MW
Vattenfall Europe
Moorburg
820 MW
Vattenfall Europe
Moorburg
820 MW
13
Hydropower Plants
Excerpt
Customer
Location
Type of Plant
Output
Power
Mechanical
Engineering
E.ON
Wasserkraft
Eitting
Run-of-river power station

Turbosets
4 x 10 MW
VOITH
4 x 10 MW
VOITH
3 x 4 MW
0,25 MW
VOITH
3 MW
Escher-Wyss
4 MW
Escher-Wyss
NOELL
Scope of delivery:
Start and stop automatics, ME 4002
E.ON
Wasserkraft
Aufkirchen

Turbosets
Scope of delivery:
E.ON
Wasserkraft
Finsing

Turbosets
Turboset
Scope of delivery:
E.ON
Wasserkraft
Niedernach
Walchensee

Turbosets
Scope of delivery:
E.ON
Wasserkraft
Haag
Oberzolling

Turboset
3 Weir control systems
Scope of delivery:
Start and stop control, level control, ME 4012
Remote control of the weirs at Oberzolling,
ME8018
Remote data transmission to the central control
station at Zolling, ME 8008
Remote control of the plant, ME-VIEW
Centralized alarm and event monitoring ,
ME2015
14
Customer
Location
RWE Energie AG Herdecke /

Ruhr
E.ON
Wasserkraft
Ettling
Type of Plant
Pumped storage power station
Scope of delivery:
Signal conditioning and drive control, ME 4012
Automatic synchronization,
Distributed visual/acoustic alarm handling ME
3008 / ME 7002
Event and alarm recording system , ME 2015M
Mechanical protection , ME 4002
Equipment for central control room: control
desks, mosaic boards and panels as well as
complete indoor installation and furnishing ,supply of the machine control panel
Turbosets
4 Weir control systems
Scope of delivery:
Start /stop automatic with automatic synchronization of the turbosets, ME 4002
Control system for 4 weirs
Complete equipment for central control room and
machine control panel
BKW Bernische
Kraftwerke AG
Unterwerk
Schwarzenburg (CH)
ME 400 Signalling and monitoring system
BKW Bernische
Kraftwerke AG
Wasserkraft- ME 400 Signalling and monitoring system

werk
Brgg(CH)
BKW Bernische
Kraftwerke AG
Unterwerk
Schwarzenburg (CH)
BKW Bernische
Kraftwerke AG
Unterwerk
Amsoldingen
(CH)
BKW Bernische
Kraftwerke AG
Unterwerk
Heimiswil
(CH)
15
Output
Power
Mechanical
Engineering
150 MW /
200 MVA
VOITH / SEW
3 x 4 MW
Escher-Wyss
NOELL
Hydropower Plants
Excerpt
Customer
Location
Type of Plant
WeiachtalKraftwerks eG
Oberstaufen Run-of-river power station

Werk III
Turboset
Pump turboset
Output
Power
Mechanical
Engineering
0,5 MW
VOITH
0,15 MW
VOITH
25 MW
Escher-Wyss
Scope of delivery:
Automatic machine control with automatic
synchronization, ME 4012, Level control, Reference control
EnBW
Kraftwerke
Rudolf
Fettweis
Werk
Pumped storage power station
Nordost Schweizerische
Kraftwerke AG
Beznau, CH

11 x 2,5 MW Bell /
Turbosets
Escher-Wyss
Scope of delivery:
ME4012 for the control and monitoring of the
machine groups and of the 8kV switchgear
stations, Sequence and closed-loop control in
various auxiliary plant, Plant operator control and
VDU operator control system ME-VIEW
in redundant configuration, Central configuration
and diagnostics station ME-PC
E.ON
Wasserkraft
Pfrombach

7 Turbosets
Scope of delivery:
Automation of the pump turbine, machine 6,
ME4012, Supply of machine control panel
Remote central control room with integrated
process bus for the communication with
16substations for remote level measurement in
the water collecting area , and for a connection
to the load distribution plant at Daxlanden Report
generator (ME-AIS) for status and accounts
reports on the inlets and outlets Operator control
and process monitoring system, ME-VIEW
Configuration and diagnostics station, ME-PC
20 MW total
Scope of delivery:
Start and stop automatics with ME 4002
16
VOITH
Customer
Location
Type of Plant
E.ON
Wasserkraft
Pielweichs

Turbosets
4 weir control systems
Output
Power
Mechanical
Engineering
3 x 4 MW
Escher-Wyss
NOELL
Scope of delivery:
Start and stop automatics with automatic
synchronization, Level control with respect to
the power stations at Oberlieg, Surge control,
ME4012, (Complete instrumentation and
measurement equipment), Remote control of the
weirs , ME 8008, Complete equipment for central
control room and machine control panel
Weiachtalkraft- Oberstaufen Run-of-river power station
werke AG
Werk I
3 Turbosets
Peak power output

Diesel generator
VOITH
1100 kW
450 kW
100 kW
1100 kW
2 x 880 kW
Scope of delivery:
Automatic machine control with automatic
synchronization, ME 4012, Level control, reference control, master control system for diesel
generators, Machine control panel
Nordost
Schweizerische
Kraftwerke AG
WildeggBrugg, CH

Turbosets
Scope of delivery:
Control of machine groups and auxiliary plant,
ME 4012, Analysis of water resources , control of
proportioning machines and 110kV switchgear
Control of station service equipment, ME-VIEW
VDU system in redundant configuration for operator control, Plant information system ME-AIS
Central configuration and diagnostics station
ME-PC
17
2 x 23 MW
Bell /
Escher-Wyss
Coaling Plant
Excerpt
Customer
Location
Block
Control and Monitoring of
swb-Erzeugung KW Hafen
5, 6
Coal loading bridge
STEAG
Voerde
A, B
Bunker coaling, Up and down coal stacker, Ash removal and loading
Shipper with surge guard, Coal sampler
STEAG
Voerde West
1, 2
Bunker coaling, Up and down coal stacker, Ash removal and loading
Shipper with surge guard, Coal sampler
GDF
Suez-Gruppe
Zolling
Bunker coaling, Coal up and down stacker, Ash removal and loading
Kasseler
Fernwrme
Kassel
Coaling plant, Ash removal and loading
Vattenfall
Europe
Moorburg,
Hamburg
A/B
Bunker coaling; Ash removal and loading, Shipper with surge guard
coaling plant; coal bunker, belt conveyor; grinding mill, coal pulveriser,
circular coal storage, reclaimer system, weighing scale; from-bin
transfer; block distribution
18
Water Treatment Plants

Excerpt
Customer
E.ON Wasserkraft
Location
Ingolstadt
Block
4
Control and Monitoring

Waste water treatment, Company: Hager & Elssser
GDF Suez-Gruppe
Zolling
5
5
District
heating
5
Desalinization plant, Company: WABAG

Condensate treatment, Company: WABAG
Component current cleaning
Heating water, Company: WABAG
Waste water treatment, Company: Philipp Mller
STEAG-RWE
Voerde
A, B

Cooling tower make-up water treatment, Philipp Mller
Condensate treatment
STEAG-VEW
Bergkamen
Desalinization plant, Company: Steinmller
swb,
HKW Hastedt
2 Desalinization plants, Company: Babcock
swb,
HKW Hafen
5, 6
RWE
MhlheimKrlich
Gemeinschafts-KW
Weser
Veltheim
Desalinization plant, Company: Polysius
ARA Buholz
Emmenbrcke
(CH)
Alarm and event indication system for the entire waste treatment plant with interface to the ME 4012 SUB-NET process
control system of the sludge incineration plant
6 off ME300 event data acquisition systems connected to
the SUB-NET bus
Stadtwerke Mnchen HKW

Mnchen-Sd
Vattenfall Europe
Moorburg /
Hamburg
ME 4012 screen control in central control room

A, B
ME-REG with printer in central control room

Chemicals supply: HCC, NaOH, FeCl3,
Antiscalant, Biocid, NaHSO3
Component current cleaning
Heating water, Company: WABAG
Process water treatment, Fa. ELGA, Berkefeld (VWS
Deutschland)
19
De-NOx Plants
Excerpt
Customer
Location
Block
E.ON Kraftwerke
Ingolstadt
De-NOx, Fa. EVT
GDF Suez-Gruppe
Zolling
De-NOx, Fa. Uhde
swb-Erzeugung
Hafen
5, 6
De-NOx, Fa. EVT
E.ON Kraftwerke
Shamrock
1+2, 3+4
De-NOx, Fa. Thyssen
E.ON Kraftwerke
Scholven
FWK Buer
De-NOx, Fa. Thyssen
Vattenfall Europe
Boxberg
Vattenfall Europe
Moorburg, Hamburg
A, B
Block
Ammonia (NH3) Tank Farms

Excerpt
Customer
Location
STEAG
Bergkamen
De-NOx, Fa. EVT
Gemeinschaftskraftwerk
Veltheim
Veltheim
De-NOx, Fa. Uhde
swb-Erzeugung
Hafen
De-NOx, Fa. EVT
GDF Suez-Gruppe
Zolling
De-NOx, Fa. Thyssen
Vattenfall Europe
Boxberg
De-NOx, Fa. Thyssen
Vattenfall Europe
Moorburg, Hamburg
Vattenfall Europe
Moorburg, Hamburg
A, B
20
DeNOx Plant for Nitrogen Oxide

Reduction
Coal contains small amounts of
nitrogen that is partly formed into
nitrogen oxide during the combustion process. In the DeNOx plant,
the nitrogen oxide is removed from
the flue gases of the coal combustion process. This is done by
injecting ammonia into the flue gas
and then conveying the mixture
across catalyzers. A catalyzer
stimulates chemical reactions
but is chemically unchanged at
the end of the reaction (selective
catalytic reaction, SCR). In the
power station catalyzers, ammonia
and nitrogen oxide react with each
other and produce nitrogen and
steam, which are natural components of our breathing air.
Coal power station (Flue gas desulfurization)
Ammonia Tank Farm

Ammonia (NH3 ) is a chemical
compound derived from the
reaction of nitrogen and hydrogen.
Ammonia is pungent smelling,
colorless, water-soluble and toxic
gas and must be safely stored and
transported in compliance with
the regulations of the Hazardous
Incident Ordinance. The necessary process control measures are
thus very complex, especially with
respect to the protection against
risk from fire and explosion.
Ammonia tank farm

21
Waste Incineration Plants

Excerpt
Customer
Location
Boiler No.
Output Power
MVA Stapelfeld
Hamburg
Linie 1,2
je 165.000 t / a
Steinmller, H. Petersen, v. Roll
Scope of delivery:
Automation of the incineration lines no. 1 and 2 and all auxiliary plant,
such as flue gas washery, DeNOx plants, flue gas secondary treatment,
cyclone combustion chamber, water treatment, evaporation plant, district
heating output and electrical station service equipment.
AWG Wuppertal
Wuppertal
Kessel 11 bis 16
Lentjes-Umwelttechnik
Scope of delivery:
Automation of boilers, general plant, flue gas treatment using openhearth furnace coke filter and SCR nitrogen removal of lines 1 to 3
Modernization of central control room
KVA Bern
Bern (CH)
Linie 23, 24
von Roll
Scope of delivery:
Automation of combustion, boiler, DeNox, washery and fly-ash treatment
of lines 23 and 24, and of radiant type boiler, hot water boiler, threepass
boiler, district heating supply and steam turbine, flue gas treatment
MVA Oftringen
Oftringen (CH)
Scope of delivery:
Control of station services and local control
MVA Zricher
Oberland
Hinwil (CH)
Scope of delivery:
Papierfabrik
Ziegler
Grellingen (CH)
Scope of delivery:
SVA Buholz
Emmenbrcke
(CH)
Slurry incineration
Thyssen
Scope of delivery:
Automation of the slurry incineration and general plant
Modernization of the central control room
22
Expert Systems
Excerpt
Definition of Process Quality

There is not yet a generally accepted definition of the term
Process quality in conjunction
with power plant processes. We

use the definition illustrated in
Figure 1 on the basis of the following explanations.
Process Quality
Fig. 1
Index "IST" represents the actual

unit efficiency factor under the
present operating conditions.
Index "SOLL" represents the
maximum unit efficiency factor
theoretically possible under the
same operating conditions, or the
specific heat consumption determined for that unit.
The term Process quality can
therefore be understood as a
complex status description of the
overall system according to the
above definition. Determination of
the process quality by continuous
comparing actual and required
values allows efficient monitoring
of the entire power plant process.
Process quality monitoring of the water-steam cycle
Customer
Location
Application
Vattenfall Europe
Boxberg
ower/path diagnosis pipeline

P
Main steam line service life calculation
Unit allowance computer
Energetic calculation for the process quality
PIGM interface balances and reports
Vattenfall Europe
Moorburg, Hamburg
ower/path diagnosis pipeline

P
Main steam line service life calculation
Unit allowance computer
Energetic calculation for the process quality
PIGM interface balances and reports
PI system OSI-Soft balances and reports
swb
HKW Hafen, Block 6,

Bremen
Process quality monitoring for sustained plant management and

efficiency enhancement in cogeneration plant Hafen, unit 6, 320MW
23
Plant Management System

Monitoring the remaining service
life of components subjected to
high stress is an important task
in the responsible operation of a
power plant, which becomes even
more pressing the longer these
components stay in operation.
In order to assess the effects of
the operating conditions on the
life span of the steam generator
components, appropriate measurements and calculations must
be carried out. The analysis of
these results in compliance with
the specifications of the technical
rules and standards acc. to DIN EN
12952 provides information about
any reduction of the components
initial life expectancy that may
become necessary.
Service Life Management of

Mechanical Components
(components subjected to high
stress and pressure; failure is not
permitted)
Time-oriented Maintenance
Maintenance cycles are specified
on the basis of experience observing high safety margins. (Periodic
inner test 3 years max.).
The service life reserve of a
component can be continuously monitored with diagnostic
methods. When optimally implemented, this condition-oriented
maintenance represents the most
efficient way.
Failure-oriented maintenance
is the most efficient if safety and
availability of the overall system is
not a relevant factor.
Preventive Maintenance
Condition of the component
Time-oriented Maintenance
Condition-oriented Maintenance
Failure-oriented Maintenance
Time
24
Pipeline monitoring
Load condition:
Operation
Weight
Thermal
expansion
Display:
Shift
unscheduled
Application example: Process

quality monitoring in power plant
Hafen Unit 6, 320MW for sustained system management and
efficiency enhancement
The process quality monitoring
system (PG) was modeled, and
thus on the basis of the valid data,
the closed water-steam cycle as
well as the air-flue gas system
including the fuel model.
The successful implementation in

the utility company swb generation, Hafen power plant Bremen,
coal unit 320MW, is used as a
reference example.
To enable online usage of this
important tool for plant efficiency
enhancement, the results of the
process quality monitoring (PG)
are entered in the ME-VIEW user
interface. Deviations from the
optimum capacity are displayed
in color and recorded by the
Process quality monitoring fluegas-air path

25
signalling system. The data is

transmitted over a bidirectional line
in the form of 5-minute values via a
database interface.
Some excerpts from the ME-VIEW
user interface are shown below:
Soot Reinjection Plants

Excerpt
Customer
Location
Application
STEAG RWE
Voerde A
108 ED, 4 Luvo und 46 LS
STEAG RWE
Voerde B
STEAG RWE
De-NOx, Block A
30LS
STEAG RWE
De-NOx, Block B
40LS
STEAG KW-West
STEAG KW-West
II
RWE-Ensdorf
2 Luvo und 14 LS
RWE-Ensdorf
2 Luvo und 14 LS
Vattenfall Europe
Moorburg A
73 DB, 8 WB
Vattenfall Europe
Moorburg B
73 DB, 8 WB
Vattenfall Europe
Boxberg R
118 DB, 56 WB
swb
Heizkraftwerk Hafen, Block 6
D = Single jet blower

E
Luvo = Preheater blower
LS = Long or lance screw-motion blower
WB = Water blower
DB = Steam blower
Steam blower
Water blower
26
Block-Type Thermal Power Stations

Excerpt
Customer
Block
Plant
Application
E.ON
Ebersberg
1 Gas motor
1 Gas boiler
1 Electric boiler
1 Storage heater
E.ON
Unterhaching
1 Gas motor
520 kWth / 348 kWel
1 Gas boiler
1,8 MW
1 Electric boiler
1,2 MW
2 Storage heaters 10 m3
E.ON
Puchheim
4 Gas motors
1 Gas boiler
1 Gas boiler
3 Electric boilers
1 Storage heater
822 kWth / 471 kWel

2,4 MW
1,2 MW
13 m3
798 kWth / 542 kWel

2,3 MW
7 MW
1,2 MW
21 m3
Combined Heat and Power Plant (CHP)

27
Automation and ON /OFFlogics

of the heat exchangers, considering the heat requirements and
applied fuel materials.
Heat loop control supplied
by BoB. Remote control, local
control panel in mosaic design.
Building Services Control

Excerpt
Customer
Location
Application
Coutts & Co. AG
Zrich (CH)
Spillway bridge
Building monitoring and gate reception, ME 4012 control system

ME 8018 remote control system, mosaic-type control room
Telekurs AG
Zrich (CH)
Computer Centre
Power distribution control, resource management and gate reception,

ME 4012 system, ME-VIEW / ME 2015, mosaic-type control room,
ME-PC
Schweizerischer
Bankverein
Altstetten (CH)
Computer Centre
Power distribution control, energy control ME 4012 system
Schweizerischer
Bankverein
Altstetten (CH)
Office building
Power distribution control, energy control

ME 4012 system
Schweizerische
Bankgesellschaft
Zrich (CH)
Building control for heating, cooling, air-conditioning and ventilation,

ME 4012 system
Bank Leu
Stettbach (CH)
Computer Centre

ME 4012, ME 2015 systems
Schweizerische
Nationalbank
Zrich (CH)
Telekurs remote monitoring system

ME 8018 systems for SNB, mosaic-type control room
Swiss Stock Exchange
Zrich (CH)
Control system for security centre

AE 4012 systems, mosaic-type control room
Swiss Stock Exchange
Zrich (CH)
Computer Centre
Energy control and energy management system

AE 4012 systems, ME-PC, ME-VIEW
Schweizerische
Nationalbank
Zrich (CH)
Remote monitoring system Seefeld SNB stock exchange,

ME 8018 remote control system, mosaic-type control panel
ME 2025 event indication
Schweizerischer
Bankverein
Opfikon (CH)

ME 4012, ME 2015 systems, mosaic-type control room, H1 bus
coupler, ME-PC
28
Customer
Location
Application
Credit Suisse
Horgen (CH)
Computer Centre

ME 4012-SUB-NET system, mosaic-type control room, ME-VIEW
Schweizerischer
Bankverein
Opfikon (CH)
UPS monitoring system, Energy control with LAN coupler

ME 4012-SUB-NET system, ME-VIEW
Zrich Insurance
Schlieren (CH)
Computer Centre
Power distribution control, energy control with LAN coupler,

ME 4012-SUB-NET system, ME-VIEW
Schweizer Rck
Zrich (CH)
Power distribution control for main low-voltage distribution for

securing the energy supply in the event of mains failure or interruption
3 programmable controllers with SUB-NET
1 operator control and process monitoring system
1 active mimic diagram
St. Galler
Kantonalbank
Headquarters
St. Gallen (CH)
Power distribution control for main low-voltage distribution for

securing the energy supply in the event of mains failure or interruption
1 operator control and process monitoring system
ME-VIEW
University Hospital
Zrich
Zrich (CH)
Power distribution control for main medium and low voltage

distribution for securing the energy supply in the event of mains
failure and interruption
2 operator control and process monitoring systems
ME-VIEW
29
Gas and Steam Power Plant

Excerpt
turbine
ST / GT
Customer
Manufacturer
HKW Halle / Trotha
60 MW /
Siemens / Siemens V 64.3
25 MW
Public services
Munich
CHP Munich South
Gas and steam
power plant 1
Siemens / Siemens V 94.1
105 MW /
2 x 100 MW
Overall plant control technology, ME4012 for

control technology and protection
Public services
Munich
CHP Munich South
Gas and steam
power plant 2
ALSTOM Power /
140 MW /
General Electric Frame9E 2 x 140 MW

process bus integration of the Mark 5 gas
turbine control
EnBW KW Altbach /
Deizisau,
GT-A
Siemens V93.0
50 MW

Industrial power plant

Freudenberg Service, Ruston Tornado
Weinheim, GT1
6,3 MW
link up to the block control of boiler 4 by

parallel coupling
Industrial power plant

Turbomach Caterpillar,
Freudenberg Service,
Taurus T60
Weinheim, GT2
5,5 MW
link up to the block control of boiler 5 by

parallel coupling
Control room
Function / Gas turbine (GT)

erial integration of the gas turbine and
S
steam turbine control into the main control
system ME 4012
Power plant Altbach

30
Power Plant Simulators

Excerpt
Customer
Power Station
Trainingsinstitut Faisalabad
WAPDA, Pakistan
KWS-Essen
Stadtwerke Bremen, KW Hafen
Sultan Salahuddin Abdul Aziz
Kraftwerk Abdul Aziz, Malaysia
Krnkraftskerhet och Utbildning AB - Studsvik
Vattenfall AB, Ringhals Block 1, Schweden
STN-Atlas Elektronik, Bremen
Escom, Matimba Block 1-6, Sdafrika
STN-Atlas Elektronik, Bremen
Escom, Kendal Block 1-6, Sdafrika
Leibstadt
KKW Leibstadt, Schweiz
Thomson, Frankreich
Pacific Power, KW Mount Piper, Australien
KSG-Essen
Kernkraftwerk Emsland (nuclear power plant)
KSG-Essen
Kernkraftwerk Biblis
KSG-Essen
Kernkraftwerk Philippsburg 2
KSG-Essen
Kernkraftwerk Brokdorf
KSG-Essen
Kernkraftwerk Philippsburg 1
KSG-Essen
Kernkraftwerk Isar 1
KSG-Essen
Kernkraftwerk Isar 2
Krnkraftskerhet och Utbildning AB-Studsvik
Vattenfall AB, Ringhals Block 2, Schweden
KSG-Essen
Kernkraftwerk Unterweser
KSG-Essen
Kernkraftwerk Neckarwestheim
KSG-Essen
Kernkraftwerk Obrigheim
KSG-Essen
Kernkraftwerk Borssele
Tenagu Nasional Berhadad
Kernkraftwerk Connaught Bridge, Malaysia
Kernkraftwerk Gsgen
KKW Gsgen, Schweiz
Kernkraftwerk Mhleberg
KKW Mhleberg, Schweiz
Siemens, Erlangen
KKW Tianwan, China
KKW Oskarshamn Block 2, Schweden
KKW Oskarshamn Block 3, Schweden
CAE Electronics, Canada
KKW Beznau, Schweiz
Westingshouse, Pittsburgh
Ringhals, Schweden
CAE Electronics, Canada
Hartlepool, England
British Energy
Heysham, England
Siemens, Erlangen
Olkiluoto 3, Finnland
Southern California Edison
San Onofre Nuclear Genarating Station, USA
Soluziona Ing. / Tecnatom
Trillo, Spanien
31
Head office
Germany
Helmut Mauell GmbH
Am Rosenhgel 1-7
42553 Velbert
Germany
Africa
Argentina
Australia
Austria
Brazil
Helmut Mauell do Brasil Ltda.
Estr. Est. Salvador de Leone 2998
06850-000 ITAPECERICA DA
SERRA SAO PAULO
Brazil
Belgium
Czech Republic
Denmark
Netherlands
Helmut Mauell B.V.
Lorentzstraat 31
3846 AV HARDERWIJK
Netherlands
Finland
Switzerland
Mauell AG
Furtbachstrae 17
8107 BUCHS
Switzerland
Hungary
USA
Mauell Corporation
31 Old Cabin Hollow Road
DILLSBURG PA 17019
USA
France
Great Britain
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U.A.E.
01.0000.04E12
www.mauell.com
Subject to change.

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Reference List

Process Control Systems

Generating Unit Control Systems

Fail-Safe Burner Control

Turbine Control Systems

Flue Gas Desulfurization Plants

Coal Feeder Plants

Water Treatment Plants

Ammonia (NH3) Tank Farms

Waste Incineration Plants

Soot Reinjection Plants

Block-Type Thermal Power Stations

Building Services Control

Gas and Steam Power Plant

Power Plant Simulators

ME 4012 structures the entire

Standby and redundant

Field instruments and installation

according to the high technical

Equipment and systems are usually installed by our own personnel.

Inline components such as control

Our project engineers prepare

After completion of all mounting and installation work by our

Hydraulic Mechanical Systems

Cooling tower with flue gas passes

Coal power station

Computer Animation Power Plant

Brown coal-fired power plant Boxberg Unit R

Hard coal-fired power plant Moorburg Unit A

Generating Unit Control Systems

Jorde Lacerda lll

Jorde Lacerda lll

Freundenberg Service Weinheim

Fluidization 180 t / h Lurgi / Lentjes

Computer Animation Power Plant Boxberg

Waste Incineration Plant

Fail-Safe Burner Control

Turbine Control Systems

Matimba, South Africa

Power Plant Doel, Belgium

Coal power station (Flue gas desulfurization)

Lignite-fired power plant

Flue Gas Desulfurization Plants

District heating 2x130 t / h

District heating 2x130 t / h

Stadtwerke Frankfurt HKW Messe

Heating and power station

Stadtwerke Duisburg Duisburg

Hitachi Power Europe

Hitachi Power Europe

Hitachi Power Europe

Run-of-river power station

Run-of-river power station

Run-of-river power station

Run-of-river power station

Run-of-river power station

RWE Energie AG Herdecke /

ME 400 Signalling and monitoring system

Wasserkraft- ME 400 Signalling and monitoring system

ME 400 Signalling and monitoring system

ME 400 Signalling and monitoring system

Oberstaufen Run-of-river power station

Pumped storage power station

Standby and redundant

ower/path diagnosis pipeline

ower/path diagnosis pipeline

D = Single jet blower