Efficient control over highly complex power generation at new combined heat and power plant in Zabrze

2017-03-02 - ABB’s Symphony Plus System will control and supervise the power generation processes at a new Fortum combined heat and power plant in Zabrze, Poland, which is expected to be one of the most advanced facilities of its kind in Europe.

Fortum is building a new 220MW multi-fuel cogeneration unit (CHP Zabrze) which will provide district heating to some 70,000 households in Zabrze and Bytom. The new unit will comprise a number of installations and complicated systems (e.g. steam turbine, boiler, fuel and coal handling systems) which shall be integrated into one seamless system and then efficiently controlled to generate power and heat safely with the highest possible efficiency.

ABB has won a contract to supply, install and commission a distributed control system, which will supervise the operation of the new power unit. The order was booked in the fourth quarter of 2016. The tender specifications included not only the price, but also stringent technical requirements, for example a very high level of availability. Advanced technologies implemented in the Zabrze facility will make it one of the most modern heat and power plant in Europe. The boiler will burn fuels in a fluidised bed and thus coal, biomass and alternative fuel or a mixture of these three fuels will be used for power generation. In addition, the boiler will be equipped with a modern flue treatment system which will reduce emissions. The environment-friendly solutions applied at the heat and power station will help meet the goals of the EU Climate Package in Upper Silesia region.

“As part of the purchase order, we will both supply and install the Symphony Plus system and also deliver the cabling diagram of the measurement and analytics instrumentation. The works will include system start-up, participation in the start-up and test run of the entire installation, optimisation of control systems as well as training the operating staff” – explains Krzysztof Fotujma from ABB Industrial Automation Division in Poland.

Symphony Plus is one of the most popular distributed control systems (DCS) in the world. Prepared to meet power industry needs, it is a part of the ABB Ability fully integrated digital offering. The system will ensure the integration of peripheral equipment, process automation and turbine automation systems, electrical parts and maintenance systems at CHP Zabrze. The operator will be able to control all devices of the power unit and auxiliary installations with full supervision of the automatic process of the power generation from start to finish. With nearly 9,500 I/Os and a number of installations to be digitally integrated, it will be one of the most significant Symphony Plus installation among those recently implemented.

ABB in Poland has wide competencies in such solutions. The company executes turnkey projects which include, for instance, projects tailored to customer specifications and expectations, programming, optimisation, commissioning and service. Symphony Plus has been offered for three years in the Polish market. During this time, the system has been installed in several facilities crucial for the Polish power sector, both used to modernise old systems and installed in prestigious new “greenfield” projects.
In 2016 ABB has also won an orders to supply energy-efficient drives and LV motors which will serve to power air and flue gas fans as well as feed water pump in new Fortum combined heat and power plant.

Fortum has been present in Poland since 2003, actively operating in the heat sector. It’s the owner of CHP units in Bytom, Czestochowa and Zabrze and district heating networks in Czestochowa, Plock and Wroclaw. The construction of the new CHP in Zabrze, worth PLN 870 million, is biggest-ever Fortum investment in Poland. The construction works are progressing according to schedule and the project is due to be completed by 2018.

About ABB
ABB (ABBN: SIX Swiss Ex) is a pioneering technology leader in electrification products, robotics and motion, industrial automation and power grids, serving customers in utilities, industry and transport & infrastructure globally. Continuing more than a 125-year history of innovation, ABB today is writing the future of industrial digitalization and driving the Energy and Fourth Industrial Revolutions. ABB operates in more than 100 countries with about 132,000 employees. www.abb.pl