Case Study | January 27, 2014

Progress Energy Realizes Savings Of $4.0M With Emerson's Ovation® Controls At Roxboro

Source: Emerson Process Management, Power & Water Solutions
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The four-unit, 2,462 MW Roxboro Steam Plant is one of the largest power plants in the United States. As a base load facility, reliable operation of the Roxboro units is essential for dependable service to Progress Energy customers. Plant controls, originally installed between 1966 and 1980, were replaced in the 1990s with Taylor Mod 300 systems, which were data linked to a host of other PLC-based systems distributed throughout the plant. The Mod 300 systems and PLCs all used Genius® I/O blocks for 20,000 remote I/O points. In 2000, Progress Energy sought to once again upgrade the control technology at all four units with a centralized, integrated system. Replacing the existing Genius I/O with new modules was out of the question due to tight outage schedules and added costs. Challenges associated with the four-unit controls upgrade included supplying reliable and affordable redundant interfaces to the station’s 2,700 Genius I/O blocks, furnishing operators with a centralized, coordinated system for improving plant operation, installing the system within a 30- day outage schedule, and providing fl exibility for adding new plant controls.

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