Hornbill Automates Coal Shuttle System
Hornbill News

Aberthaw Power Station is a 1500MWe Coal Fired Station comprising of three generating unites. Each unit is supplied with coal at a rate of 180 T/Hr from six bunkers. The process of filling the bunkers was originally achieved by manually moving the shuttle over a bunker and waiting until a required level was reached. The bunker filling order and coaling level was achieved by operator interaction with the shuttles dated controls. Each unit has two shuttles.

Hornbill designed and installed a complete replacement control system to enable the shuttles to be automatically positioned over a bunker and deposit coal to a predetermined fill level.

Project Details:

  • Design & Manufacture of Shuttle Position Control System
  • Design of Control Architecture
  • PLC Hardware
  • PLC, HMI & SCADA Software
  • Bunker Level Monitoring System
  • Radio Communications
  • Variable Speed Drives
  • Installation of Communications & Low Voltage Services
  • CCTV System
  • Commissioning
  • Training
  • Documentation

Dynamic level measurement was achieved by installing laser level instrumentation on each shuttle. Owing to the mobile nature of the shuttles, a radio communications network was incorporated to transfer data to the shuttles on-board PLC system, minimising the use of the existing troublesome cable reeling drums. The project also included the designing of a control interface for the operation of the Bunker House ventilation fans and swinging chutes to allow coal to be directed to one of the generating units.

The coaling of the station is now automatically controlled and monitored from the Coal Plant Control Room. The order of coaling and bunker levels are programmable via an existing SCADA system which was modified to accommodate the bunker automation. Additionally each bunker has been fitted with a CCTV camera for remote viewing.

To find out how Hornbill could help with your control automation project,

Contact us on 01792 818111 or email sales@hornbill.co.uk


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