Safety solutions for new power plant unit

20 March 2012

Safety systems, supplied by HIMA Paul Hildebrandt, are helping to ensure boiler protection and burner control in a lignite-fired power station operated by Vattenfall Europe Generation.

Vattenfall Europe Generation operates one of the largest lignite-fired power stations in Europe. For the construction of the new 675 MW power plant unit R, Helmut Mauell commissioned HIMA Paul Hildebrandt GmbH + Co to deliver five HIMax safety systems.

One HIMax safety system is used as an emergency shutdown system (ESD) for boiler protection, while the other four systems are being applied as burner control systems (BCSs) in coal mills that include 24 coal burners, eight oil burners and two slop oil burners.

Over 1,700 input and output signals are safely processed with the HIMax systems. HIMA was also responsible for the project management, engineering, system commissioning (power on and system communication) as well as for programming the safety systems.The controllers are integrated into the control and monitoring functions of the Mauell ME 4012SN control system via Modbus TCP and OPC A&E. The safety systems communicate with one another via the 'safeethernet' protocol, developed by HIMA, which can be used up to SIL 3.

Additionally, the relay output modules are approved for safely shutting down the entire fuel supply system in burner controllers (EN 298, EN 50156-VDE 0116). The use of additional interface relays is therefore not necessary.

The function plans for programming the HIMax controllers were developed in the Helmut Mauell GmbH macro-representation. Control-specific macros from the manufacturer's libraries were implemented in SILworX function blocks. SILworX is HIMA’s fully integrated configuration, programming and diagnostic environment. The SILworX function blocks, such as those for barrel-level measurement and water and gas flow measurement, were grouped in an individual library and can be directly used by Helmut Mauell GmbH for future projects.

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