PowerWorX™

Power Plant Control System

Design Services

Sahoma Controlware provides Power & Utility Plant Control System Expertise to assist and guide customers in the development of Power & Utility Plant Control System strategies in order to get the required results. 

Our resources have experience in delivering plant control systems.  We are experts in the assessment, development, and life cycle of corporate Power & Utility Plant Control System. 

UTILITY POWER & COGENERATION

APPLICATION EXPERTISE

• Utility Power Plants

• Combined Cycle Power Plants

• Heat Recovery Steam Generators (HRSG) Systems

• Selective Catalyst Reduction (SCR) Systems

• Waste Heat Recovery (WHR) Systems

• OEM Packaged Control Systems

CONTROL SYSTEM SOLUTIONS FOR

UTILITY POWER & COGENERATION

• Combustion Control Systems (CCS)

• Burner Management Systems (BMS)

• Turbine Master Front End Control Systems

• Coal Handling Control Systems

• Water Treatment & Demineralizer Control Systems

• Balance of Plant Control Systems

• Intelligent Motor Control Centre (MCC) Interfaces

CRITICAL SAFETY & PROCESS

CONTROL SYSTEMS

• Fault Tolerant & High Availability Features

• Scalable System Architecture Solutions

• Multiple Communication Protocols Interface Capability

• Seamless Integration of Third-Party Systems

• Client-Server or Stand-alone HMI Architectures

OEM PACKAGED SYSTEMS

HRSG Control Systems

Sahoma Controlware has extensive experience in the design & development of Heat Recovery Steam Generator Control Systems.  These systems are used in the power generation process for modern utility power plants.  Sahoma Controlware can develop control systems on any DCS or PLC based platform.  DCS or PLC platform will selected based on the customer and size of project for HRSG.

Duct Burner BMS Control Systems

Sahoma Controlware has extensive experience in the design & development of Duct Burner Control Systems.  These systems are used in the power generation process for modern utility power plants.  Sahoma Controlware can develop control systems on any DCS or PLC based platform.  DCS or PLC platform will selected based on the customer and size of project for Duct Burner System.

SCR Ammonia Injection Control Systems

Sahoma Controlware has extensive experience in the design & development of SCR Ammonia Injection Control Systems.  These systems are used in the power generation process for modern utility power plants.  Sahoma Controlware can develop control systems on any DCS or PLC based platform.  DCS or PLC platform will selected based on the customer and size of project for SCR Ammonia Injection System.

COMBUSTION

CONTROL SYSTEMS

Sahoma Controlware's offering of a intelligent Combustion Control System, is a turnkey, mass flow air/fuel ratio control system for industrial burners.  The system is comprised of five components that integrate easily with a conventional burner management system and pipe train (Control Panel, Air Valve Actuator & Fuel Valve Actuator, Air Flow Control, and Flow Control).

The Control Panel includes a Burner PLC, 24 VDC Power Supply, and HMI Display. The Burner PLC contains all of the factory-installed, combustion

intelligence (such as burner-specific air/fuel ratio and flow data), enabling the  system to be easily commissioned after field installation. The HMI Display allows the Operator to monitor and adjust the performance of the combustion system. The Valve Actuators are factory-calibrated assemblies that include rugged, high-quality planetary gearheads and stepper motors for highly repeatable and precise control of butterfly valves. The Air and Fuel Flow Control are integrated into Burner PLC each consist of a precision-calibrated thermal mass flow sensor, control electronics, and flow body with integrated flow conditioners for a highly repeatable measurement.

Other system functions include fuel totalizing, air/fuel flow and valve position analog outputs for DCS interfacing, (optional) remote monitoring, and many redundant system safety functions. The Standard system specifications are as follows:

Valve Position: Control 0.1 angular degree resolution

Flow Control: ± 1% of flow reading over a turndown of 20:1

Air/Fuel Ratio Control: ± 2% with turndown of 20:1

Power Supply Input: 100-120 VAC @ 2.5 Amps max, 50-60 Hz,                   200-240 VAC @ 1.5 Amps max, 50-60 Hz

Ambient Temperature: -20°F to 122°F (-29°C to 50°C)

4-20 mA I/O: Output: 350 Ohms max user load resistance

                       Input: 20 mA max current, 250 Ohm input resistance

ControlRelays: Input Coil: 120 VAC @ 7.5 mA, 240 VAC @ 3.8 mA

                        Output Contacts: 250 VAc @ 10 Amps, 30 VDC @ 10 Amps

BURNER

MANAGEMENT

CONTROL SYSTEMS

A Burner Management System (BMS) is a safety solution for power generation facilities that enables the safe start-up, operation, and shut down of the multiple-burner furnace section of a boiler. It reduces maintenance, improves up-time, and provides a safe environment for the boiler and plant personnel.​

What Is It?

​Highly reliable Safety Systems applied to Power Boiler and Recovery Boiler Burner Management applications can improve plant uptime, reduce ownership costs and ensure regulatory compliance compared to relay or general purpose Programmable Logic Controller (PLC)- based applications. A typical solution may also provide protection for the boiler water circulation pump, replacement of the master fuel trip (MFT) relay, and link the burner management system of the auxiliary boiler to the main burner management system.

Sahoma Controlware offers Safety platforms provide up to SIL 3 TÜV approved Burner Management System solutions that cover requirements according to the National Fire Protection Association (NFPA) 85 & 86 standards and European EN 50156-1.

How does It work?

A burner management system is responsible for the safe start-up, operation and shutdown of a boiler. It monitors and controls igniters and main burners; utilizes flame scanners to detect and discriminate between the igniter and main flames; employs safety shut-off valves, pressure, temperature, flow and valve position limit switches and uses blowers to cool the scanners and/or provide combustion air for the igniters. Its proper operation is crucial to the safety of a boiler.

What Problems Does It Solve?

Sahoma Controlware's BMS Solution improves plant uptime, reduces total cost of ownership and ensures regulatory compliance compared to relay or general purpose PLC-based applications. It also improves personnel safety by removing the need to access old relay boxes located in high temperature areas of the boiler.​

balance of plant

CONTROL SYSTEM

Sahoma Controlware Balance of Plant (BOP) control system solution is a programmable plant control system for new applications or as a replacement for an existing plant controller such as a distributed control system (DCS). The BOP Control System uses the same controller and I/O platforms and communications on a common bus sharing all plant parameters.

Typical Systems Include But Not Limited To:

• Liquid Fuel Treatment/Forwarding/Storage

• Gas Fuel Compression

• De-mineralized Water Treatment

• Plant Instrument Air

• Plant Cooling Water Systems

• Switchgear Interface

Traditionally the Gas Turbine Control Systems were autonomous and connected to the rest of the plant via a communications link. With the advances in communications options, I/O types and the capabilities of programmable controllers, Sahoma Controlware implements solutions to where the Gas Turbine Control Systems can be a fully integrated component in an overall Balance of Plant Control System.

AGENCY

APPROVALS & CERTIFICATIONS

• ATEX

• CE

• IEC

• UL-508A

• SIL-2

• SIL-3

• IEC-61131

• IEC-61508

• IEC-61511

PLATFORM SUPPORT

Our  Power Plant Control system Design Services not only integrate seamlessly into your  process operations but also into your legacy systems. 

We offer a broad array of control system platforms to suit any need and environment, from discreet control options to analog control to dazzling HMI screen development.

Control Systems can be placed  in any area classification with operations approval. With so many options for controlling your Control System, the only limit is your imagination.

CODESYS

Allen Bradley Logix & Legacy PLC's

Siemens

GE Fanuc

Modicon

National Instruments

OPTO 22

Yokogawa

Emerson DeltaV

Honeywell

Foxboro

ABB / TotalFlow

Control Microsystems SCADA Pack

Fisher ROC

TBOX

Wago

Phoenix Contact

IDEC

Bedrock Automation

FactoryStudio

Ignition SCADA (Vision / Perspective)

Iconics Genesis 32/64

Wonderware (Intouch / System Platform

Citect

Grafana

CODESYS

Clear SCADA

Cygnet

OASys

Rockwell Automation FactoryTalk View ME/SE/Studio

Rockwell Automation Plant PAx

Siemens WinCC/Portal

Proficy iFix/Cimplicity

OPC Systems.NET

National Instruments LabVIEW

Microsoft.NET

Java

Nodejs

Node-Red

Django

Ethernet/IP

Modbus RTU/TCP

Profibus/ProfiNet

ControlNet

DeviceNet

RS-485, RS-232, RS-422

DNP3

HART

Fieldbus

OEM Proprietary Protocols

OPC DA

OPC UA

MQTT/TLS

1553

CAN

NI-VISA