Yokogawa Romania, leading provider of Industrial Automation and Control solutions, implemented a systems’ upgrade to C.T.E. Vest which modernized the combined cycle heat & power plant to the latest technology standards on the market and reduced the emissions. The project, valued at over 1 M Euro, was executed in just 8 months’ time despite COVID-19 driven remote-working conditions and high complexity. The acceptance tests and final delivery were done as scheduled, in the last months of 2020.
The CHP plant can be operated by the new systems fully automatically, choosing according to consumers’ needs, either an electrical or a thermal mode. These processes translate into a constant heat and hot water supply and increased comfort for Bucharest’s inhabitants. C.T.E. Vest ensures the district heating for 6 of Bucharest’s important neighborhoods, Drumul Taberei, Giulesti, Crangasi, Militari, Politehnica and Valea Cascadelor.
“With this investment C.T.E. Vest has extended the plant life with 10 years without major unscheduled downtime. This contributes to financial savings and enables ELCEN, the owner of C.T.E. Vest, to approach future opportunities in this area.”, said Adrian Tudora, Director Project Development and Implementation Director at ELCEN.
Using Yokogawa Centum VP control system and ProSafe-RS safety system, an integrated solution was put in place which increased the power plant capacity, stability and removed points of failure. The plant units were automated to ensure a high degree of flexibility in responding to fluctuations in demand and to enable automatic plant start-ups and shutdowns.
Furthermore, upgrades of the Alarm Management system in case any incidents occur and advanced Cybersecurity program with an automatic back-up and recovery solution were put in place. One important benefit of the project accomplished by Yokogawa is improving the energy efficiency of the gas compressor which varies between 0.5 and 1MW/h, depending on the operating requirements. The project is a real-world reference of Yokogawa’s Turbine Control solution applied to a Škoda steam turbine by means of reverse engineering, highlighting the company’s expertise in turbo-machinery control.
“We are very honored to be the main contractor of this important project. The implementation was successful, and the work was delivered on time thanks to the confidence given by C.T.E. Vest management to the Yokogawa team. Yokogawa’s Corporate Philosophy to contribute to society through broad ranging activities in the area of measurement, control and information is brought into reality by this project, by contributing to a sustainable supply of heat for the inhabitants of Bucharest”, said Yuko Iizuka, Country Manager, Yokogawa Romania.
The project team included software and hardware engineers from Yokogawa Romania and very supportive personnel from ELCEN – C.T.E. Vest. A major challenge in deploying the system was the COVID-19 pandemic, when all work moved to virtual space. Special protection measures were taken in order to ensure team members’ safety and to avoid communication and commissioning disruptions. The team relied on remote support of Yokogawa world-wide branches from Czech Republic, USA and Australia.
About C.T.E. Vest
Commissioned in 1972, C.T.E. Bucharest Vest is the third longest-running power plant of ELCEN. C.T.E. Bucharest Vest operates in cogeneration (combined production of electricity and heat), in full compliance with the reglementations for efficient recovery of heat from production processes, reduction of water and heat losses and reduction of internal electricity consumption, which allows high thermal efficiencies.
In March 2009, within C.T.E. Bucharest Vest, a Combined Cycle Power Plant (gas compressor operation – gas turbine – recovery boiler – steam turbine) with an installed capacity of 185 MW came into commercial operation. An investment of over 160 million Euro, with government guarantees, it is the first large energy unit that was built entirely after the ’90s in Romania, being also the first Combined Cycle Power Plant put into operation.
The plant has high efficiency (42% net electric efficiency and 89% total central efficiency 89%) and low specific consumption, and is considered ELCEN’s most efficient unit, its operation being continuous 24 hours a day, all year round, with the exception of planned repairs (the operating average being over 7500 hours / year).
The power plant is equipped with a General Electric gas turbine type MS9001 with DLN, PG9171 (E) – generation 2005, a turbine that has three stages and is equipped with Mark VI automation system, a SKODA steam turbine type MTD40B, an Alstom recovery boiler and a an integrally geared centrifugal gas compressor, with 5 compression stages, 5R3MSG – 9RCG / 15 model, manufactured by Cooper.
The company has an important role in the Romanian energy system as it is the main producer of thermal energy in Bucharest (90%) and, at the same time, an important player on the national electricity market. It owns four CHP plants (C.T.E. Bucharest Vest, C.T.E. GrozAvesti, C.T.E. Bucharest Sud and C.T.E. Progresu) which produce electricity and heat in cogeneration. Providing heating and hot water for the population is a public service of general interest, so the company carries out an indispensable activity for the inhabitants of Bucharest. The thermal energy produced by ELCEN is intended to supply the capital’s district heating system, ensuring the energy needs of consumers. ELCEN provides thermal energy for approximately 565,000 apartments, representing over 8,500 blocks of flats and buildings, in which over 1.25 million inhabitants live, as well as for approximately 5,400 institutions, social objectives and economic agents.
The electricity produced by ELCEN is delivered to the National Energy System, thus contributing to the country’s energy security.
Founded in 1915, Yokogawa engages in broad-ranging activities in the areas of measurement, control, and information. The industrial automation business provides vital products, services, and solutions to a diverse range of process industries including oil, chemicals, natural gas, power, iron and steel, and pulp and paper. With the life innovation business, the company aims to radically improve productivity across the pharmaceutical and food industry value chains. The test & measurement, aviation, and other businesses continue to provide essential instruments and equipment with industry-leading precision and reliability. Yokogawa co-innovates with its customers through a global network of 114 companies spanning 62 countries, generating US$3.7 billion in sales in FY2019.