In addition to its easy implementation, TOPKAPI’s redundancy function allows performing modification and maintenance operations without interrupting daily operations. This benefit attracted the users of the Endesa Group for their thermal plants.


The Hornaing plant is a 250-MW coal thermal plant, operated by Endesa France.

In 2004, SNET (1) launched a major investment program to extend the lifetime of the facilities, and reduce its environmental impacts.

Within this framework, it sought a modern networked supervision to replace operating panels designed back in the 70s, and they chose the TOPKAPI supervisor.

The latter was already implemented in one of the other plants the group operates in Saint Avold (2), and with its redundant version it guaranteed the level of reliability required by Endesa.

Within an initial work program run in 2005, FORCLUM implemented the supervision application for water demineralization by reverse osmosis required by the boiler’s operation.



In 2006, NOREALP, which has a long history in using TOPKAPI, was entrusted with a major work program including:

  • the implementation of status loggers
  • the monitoring of temperatures on rotating machinery bearings
  • the automatic generation of summary reports to control and reduce rejections into the environment.

The purpose of the status logger, when faults are cascaded, is the easy determination of the initial fault, the one having caused the stoppage.


To this effect, NOREALP implemented in the controller (a Premium by Schneider Electric) a fast task allowing to date the information with a relative accuracy of about 10 ms.

By using this accurate time-stamping provided by the controller, TOPKAPI sorts events chronologically, and hence determines which fault triggered the incident.


The application was implemented by NOREALP, while applying a particular care to structuration, and using at best the latest developments of TOPKAPI version 4.0. Therefore, the user has an application which is easy to maintain and upgrade.

Environment reports are generated by TOPKAPI’s Reports module and EXCEL. They are addressed to the Environment Manager, who validates them, and transmits rejection declarations to the Audit Authorities.

Avoiding the use of heavier database applications, they are easy to modify and maintain over time.

The global system currently manages about 4000 variables, including:

  • A main server in the control room, also used as an operating station
  • A secondary server with hot redundancy, located in the premises dedicated to water treatment and also used as an operating station. Beyond backing up a failed station by another, a geographical localization of the servers in two different places allows limiting the effects of network failures (for controllers and operating stations maintaining their link with one or the other server) or problems related with the premises (fire, pollution, access issues, etc.)
  • 3 operating stations (in addition to the main server) in the control room
  • 1 operating station, also used for parameter setting, located in the premises of the maintenance department. Application modifications are made and validated on this station; taking into account the changes requires no intervention on other stations. As this integration is delayed on the two server stations, no loss of information is to be feared, and maintenance interventions are performed practically without interrupting the control operations.

As the implementation of work was fully satisfactory, NOREALP was entrusted with building a new application for processing ash, using TOPKAPI supervision.


(1) - Société Nationale d'Electricité et de Thermique 

(2) - Émile Huchet power plant