High availability control system ensures critical cooling water supply to major UK power station
Client Requirement
When an adjacent, older power plant was planned for closure, the shared services, such as cooling water, needed to be transferred and controlled directly from the remaining gas-fired CCGT plant.
The client required a low-risk, phased implementation, ensuring the majority of the work was completed well ahead of the older plant’s closure. The new system needed to provide the highest possible availability, using commercially available off-the-shelf (COTS) equipment. As a cooling water outage of more than a few minutes would result in the station shutting down, system resilience was critical.
Our Solution
To meet the client’s requirements, we delivered a comprehensive, phased solution designed to minimise risk and ensure maximum system reliability. A detailed System Design and Functional Design Specification formed the foundation of the project, addressing all client and operational requirements. We supplied and programmed a Siemens S7-400H PLC for enhanced resilience and implemented a WinCC SCADA system to provide robust and efficient control.
The project involved the design, build, and modification of control panels, ensuring seamless integration with existing systems. A resilient fibre Ethernet network, complete with a copper backup link, was installed to ensure redundant communication pathways for critical operations. Additionally, comprehensive integration with the existing plant guaranteed smooth functionality across both new and legacy systems.
We also conducted a detailed site survey and drawing verification, reducing risks and ensuring system accuracy. The phased implementation was supported by thorough system commissioning, ongoing system support, and meticulous project management, ensuring all works were completed on time and to specification.
