Photo 1 | JST control room: With the modernization of the combined cycle power plant (CCPP) at the BASF Schwarzheide GmbH site, the control room was also completely renewed. JST – Jungmann Systemtechnik® implemented innovative control technology, large-screen visualization and ergonomic furniture to warranty superior control of all processes.
Photo 2 | JST planning: Even before the actual project implementation, those responsible were able to inspect the new control room thanks to extensive 3D graphics.
Photo 3 | Saving resources and reducing CO2: The waste gas heat generated in the combined cycle power plant is used to produce steam, which is ultimately used in the plant's production operations for various chemical processes. In this way, BASF succeeds in supplying the Schwarzheide site with climate-friendly energy. Photo: BASF / Kai Abresch
Photo 4 | View into the old control room: In particular, the rigid assignment of sources to individual displays and the resulting uncomfortable operating situation made monitoring and control tasks difficult.
Photo 5 | JST control room: Not only technically a quantum leap, also visually and ergonomically a step into the future - the new control room with the Stratos control room desk and special 24/7 control room chairs performs all requirements of modern control room workplaces.
Photo 6 | JST acoustic ceiling sail: Reduction of sound levels and innovative lighting solution - the OPAL X11® ceiling sail offers an attractive alternative to the costly acoustic ceiling in the control room.
Photo 7 | JST Planning: An important step in involving all parties in the planning of the new control station at an early stage is the detailed 3D sketches, which provide photorealistic impressions of the planned premises.
Photo 8 | JST Control room: Implementation of the previous plans into reality: Spatial conditions were taken into account as well as colors and light influences.
Photo 9 | Large screen: Design strips with a high-quality aluminum brushed surface and wall panels behind which all cables are concealed give the large screen its unmistakable JST look. The same applies to the control room consoles: A clean, clear appearance contributes to optimized concentration.
Photo 10 | JST technology: The technical infrastructure for JST control room solutions can be accommodated in "invisible" supply rooms.
Photo 11 | JST furniture: One of the many visible details that give the BASF control room its individual look. At the customer's request, the side panels of the Stratos operator consoles were designed in the company's corporate design.
Photo 12 | JST control room furnishings: Design and functionality are among the main strengths of JST control room furnishings. The furniture in and around the control room was realized in detail according to the specifications of the BASF project team.
Photo 13 | JST control room furniture: The visual requirements and special wishes for the BASF control room were performed in the JST furniture manufacture - from the integrated charging station to the customized cabinet system. According to BASF project manager Vitali Goldnik: "With these solutions, JST was able to prevail over the competition."
Photo 14 | JST conference table: The AllMedia Conference system in the meeting room, here complemented by comfortable free-swinging chairs, combines timelessly elegant style with durable materials and smart technical solutions. In the background: Flexible display options of sources from the control room are enabled by a 75-inch display with brilliant color reproduction thanks to high brightness and low-reflection surface coating.
Photo 15 | JST meeting room: Integrated table installation units for all desired supply connections are just one advantage of the AllMedia conference table. For example, the system connects the meeting room directly to all control room applications via MultiConsoling® technology, which can be displayed on site and also operated if required.
Photo 16 | JST conference table system: The modular AllMedia was specially developed for conference or crisis rooms. Advantage in the context of the BASF installation: Depending on the current situation, the meeting room can be viewed from the outside, or...
Photo 17 | ...thanks to a shutter wall that can be switched from clear to frosted glass, also suitable for meetings that require discretion.
Photo 18 | JST Control Room Solutions: Yet another component that has been integrated into the video wall; this time in its side panel to exclude unintentional access: the emergency stop panel. From here, operators can switch off any system of the CCGT power plant in critical situations immediately and without control commands.
Photo 19 | JST ControlRoom automation: A solution for shorter response times and more convenience in the control room - the CommandButton Box. The panel with the individual buttons was integrated into the surface of the Stratos control room console. Each button can be assigned an individual preset and thus, for example, switch on the myGUI® user interface for the MultiConsoling® control system at the push of a button.
Photo 20 | JST MultiConsoling®: a behind-the-scenes look at the new BASF control room. From above: The "heart" of control room operation via MultiConsoling® - the MultiCenter; here for maximum availability in redundant implementation. Below, the myGUI® controller for intuitive control of all systems via the user interface of the same name and the GrabberVM® for the integration of virtual machines.
Photo 21 | JST Technik: Innovative control room technology - the PowerUnit shown below supplies the grabbers above it, which are needed to connect the individual computers.
Renewable energy: Modern control room monitors processes
They set the course for sustainable growth early on and were thus able to create a robust basis for a future-proof site against the backdrop of the current energy crisis. In 2019, BASF already invested 73 million euros in the modernization of the combined-cycle gas turbine (CCGT) power plant at the Schwarzheide site in Lusatia. A state-of-the-art control room, which was implemented by BASF in cooperation with the control room experts from JST – Jungmann Systemtechnik®, is responsible for monitoring and controlling this plant. The declared aim of the project is to enable the use of renewable energies as the basis for sustainable value creation.
“As a medium-sized, self-supplied industrial site, we want to take new, innovative paths when it comes to energy,” says Jürgen Fuchs, Managing Director of BASF Schwarzheide GmbH, on the background to the CCGT modernization. In order to use renewable energies on an industrial scale for production in the future, a more flexible operating regime for the company’s own power plant and seamless monitoring of the processes are required. This is precisely where the new control room comes into play.
Recommendation of colleagues was best reference
Whether pressure or temperature, filling level or valve position – the operators in the CCGT control room not only use state-of-the-art technology for their tasks, but also ergonomic furniture. Vitali Goldnik, responsible for E&I Engineering at BASF’s Brandenburg site, remembers the first steps on the way to the new control room well: “We had the best reference you can imagine. Our colleagues at the Ludwigshafen site had already worked successfully with the Jungmann team. In addition to the recommendations of our colleagues, we even had a JST sample control station at our disposal in Ludwigshafen. We were able to test all systems there and quickly saw the benefits of the existing solutions.”
Flexibility and performance "a great experience"
The project manager was convinced by the effortless handling and the comprehensive operating options with MultiConsoling® technology. Advantages of control room operation with MultiConsoling®: Any source can be switched to any desired screen. Only one mouse and keyboard are required for all applications. And all this with intuitive operation using the myGUI® interface. “The high flexibility, the reliable performance, no more annoying chair moving – that was already a great experience,” reports Vitali Goldnik.
Interactive experience in the new control room: Zoom, rotate, nighttime view and change of perspective – here you can experience control room concepts in interactive 360 degree visualisations! How does the new control room look? How can the operator consoles be optimally positioned? How big should the monitor wall be? With professional 3D studies and virtual tours – here at BASF in Schwarzheide – these and many other questions can be answered at an early stage of the project. Light influences, colours, spatial conditions – there are almost no limits to the design possibilities. Go on a three-dimensional journey of discovery now!
Technically, ergonomically and visually convincing
But in addition to intelligent technology, the expert for process control technology had another demand on the JST control room professionals. The measuring station for the power plant not only had to be state of the art in terms of technology, but the furniture also played a decisive role. Functional and visually convincing solutions for a conference room, for the reception area and other special furniture were required. Vitali Goldnik: “When comparing with other equipment suppliers, it was clear to see that JST has great experience in terms of ergonomics and design.” Thus, the Jungmann team was able to convince with individual custom-made products from its furniture manufacture and prevail over the competition.
A "very good" for the cooperation with JST
A decision that the project manager would make again at any time when looking at the new control room. Planning including 3D visualizations, consulting on smart control room concepts with the OPAL acoustic ceiling sail, the latest large-screen technology or proactive alarming options – “this was really a very good cooperation,” Vitali Goldnik sums up.
Control room before and after renovation
Reference projects of JST (selection)
- s.Oliver, Rottendorf
- SachsenEnergie, Dresden
- SAG, Berlin
- SAG, Nürnberg / Nürnberg Messe
- Salzgitter Flachstahl
- Senvion SE, Osterrönfeld
- SGL Carbon Group, Bonn
- SIEMENS, Wegberg
- Spenner Zement, Erwitte
- Städtische Werke Magdeburg
- Stadtwerke Gießen
- Stadtwerke Ratingen
- Stadtwerke Schwerin, Kraftwerk Süd
- Stadtwerke Steinburg GmbH, Itzehoe
- Stadtwerke Wolfenbüttel
- Starlim Sterner, Marchtrenk
- STORAG ETZEL, Friedeburg
- Straßenverkehrsamt Frankfurt am Main
- Swisscom, Zurich