Control System Upgrades

Representative Projects:

Emerson

  • Central Electric Power Cooperative, Chamois Station, Chamois, Missouri
    Obsolete control and instrument systems were replaced on two coal-fired generating units. Unit 1 is a 20-MW boiler burning pulverized Illinois coal. Unit 2 is a 60-MW cyclone unit burning Wyoming Powder River Basin coal. Before the upgrade, both units relied on a significant percentage of their original pneumatic control devices for operation. Full implementation of the new distributed control system included the installation of 144 new transmitters, I/P converters, positioners, signal converters, and miscellaneous control devices. Systems and equipment replaced include: combustion control, burner management system, motor control, data acquisition, feedwater heater level control, boiler feed pump control, ash handling, coal feeder drives, flame scanners, interfaces to soot blowing and water lane systems, and interface to SCADA system.

 

  • Basin Electric Power Cooperative, Leland Olds Station, Bismarck, North Dakota
    Leland Olds is a 240-MW pulverized-lignite fired generating station. This upgrade replaced an existing DCS, incorporating into the controls new subsystems and coincident turbine and boiler upgrade projects. Plant control systems and equipment replaced were: combustion control, burner management system, motor control, data acquisition, alarm management, sequence of events, turbine controls with EHC, Fieldbus I/O, water intake structure remote I/O, BTG console, transmitters, and miscellaneous control devices.

 

ABB

  • Associated Electric Cooperative, Inc., Thomas Hill Energy Center, Springfield, Missouri
    Sega Inc. provided all engineering services required for the replacement of existing control and information systems to resolve equipment obsolescence problems and to provide the more complex control strategies required for fuel conversion to Western coal. Plant systems that were replaced include combustion control, burner management, data acquisition, alarm/sequence of events, motor control, and BTG board.

 

  • Ameren, Labadie Power Plant, St. Louis, Missouri
    Obsolete control and instrumentation systems were replaced on four coal-fired generating units. All are similar 600-MW pulverized-coal drum-type units with identical Alstom (CE) boilers. Units 1 and 2 have Westinghouse steam turbines and Units 3 and 4 have General Electric steam turbines. Plant control systems and equipment replaced for each unit were: combustion control, motor control, data acquisition, digital alarm monitor, sequence of events, turbine controls (Units 1 and 2 only), interfaces to ash handling and coal handling systems, interfaces to sootblowers and precipitator controls, BTG consoles and vertical control panels, transmitters, I/P converters and positioners, and control valves.

 

Rockwell

  • University of Massachusetts Medical Center, Worcester, Massachusetts
    Sega Inc. has completed several projects at the UMass Medical Center central plant relating to field control services and control system upgrades. The medical campus uses a variety of control and building automation systems from manufacturers including Eaton, GE, Siemens, Allen-Bradley, Honeywell, and Johnson Controls. Sega Inc.’s upgrades include: Balance-of-Plant (BOP) PLC Controls upgrades, Human-Machine-Interface (HMI) upgrades, network communication configuration, interfacing with campus control systems, historian deployment, boiler tuning, and real-time performance monitor deployment.

 

Foxboro

  • Kansas City, Kansas Board of Public Utilities, Nearman Creek Power Station, Kansas City, Kansas
    This project included configuring a plant control system for a new water processing facility used to produce 36 million gallons of water per day. Five separate distributed control units are connected via a Nodebus network. All system graphics are designed using Foxboro’s FoxDraw graphics package for operator interface terminals. Sega Inc. also configured a plant information network of personal computers for dissemination of system information (graphic displays, reports, and data) to workstations throughout the entire facility.