Simulation technology reduces plant start-up time

Use of the Emerson Scenario simulation technology offers reduced plant start-up time for new power facility projects and upgrades, as demonstrated at a recent Consolidated Edison Project in New York

Use of the Emerson Scenario simulation technology offers reduced plant start-up time for new power facility projects and upgrades.

The Consolidated Edison East River Repowering Project (ERRP) illustrates the gains, having realized a three month start-up time reduction and on-going benefits, including improved operational efficiency and reliability.

ERRP, a truncated combined cycle facility, went into operation several years ago as part of a major improvement project at the Con Edison East River energy complex.

The project was necessary to maintain reliable and reasonably priced steam supply and electricity for Con Edison customers throughout New York City.

The ERRP facility uses two General Electric combustion turbines connected to two heat recovery steam generators (HRSGs) and a steam ring header.

This unique configuration provides steam at 3.2 million lbs/hr for dispatch into Manhattan, where it is used as a key source for the district heating system.

Emerson Ovation technology provides control for a number of critical processes used in this 360-MW plant.

The significant investment by Con Edison in this plant made safe and timely commissioning and start-up crucial.

Because the East River facility is located in Manhattan, Con Edison also had to adhere to strict environmental constraints, such as noise levels during construction, as well as emissions levels during plant commissioning, start-up and operation.

In order to help ensure optimal operation of the East River plant, Con Edison sought a way to efficiently train their operators using equipment and plant models, duplicating the re-powered East River plant, prior to actual commissioning and startup.

Con Edison also wanted a tool to help them verify and validate new control logic prior to its installation into the plant Ovation control system.

Based on a two-decade relationship of proven performance, Con Edison partnered with Emerson to provide the right solution.

Emerson Scenario simulation technology was selected to monitor and control the unique processes associated with the new technology employed at the East River site.

To ensure optimal plant operation, Con Edison engineers and operators teamed with Emerson to configure a high-fidelity Scenario solution.

The ERRP Scenario simulation consists of actual plant control software and duplicate workstations that mimic the East River control room.

Scenario was used extensively to train operators, formerly familiar with traditional boiler/steam turbine plant configurations, on the operation of the new truncated combined cycle plant.

Through utilisation of Emerson simulation technology, operators also became well versed on using the microprocessor-based system, which unlike the previously installed hard-wired controls, enables operators to more quickly recognize and react to abnormal plant process situations.

Scenario simulation was also used to develop optimum operator methodology that is documented in the plant operating procedures.

During the simulation design phase and prior to plant start-up, East River operators and engineers used Scenario to evaluate both steady state and transient conditions based on plant design criteria.

Results of these evaluations provided Con Edison engineers with a better understanding of process dynamics and enhanced troubleshooting tactics, leading to development of accurate control strategies under normal and abnormal operating conditions.

Con Edison also used Scenario to test interfaces of an extensive amount of third-party equipment connected to the Ovation control system, such as the GE Mark V turbine control system and PLC networks for the burner management, gas compressor and water treatment systems.

Pre-testing of the data links helped to further reduce the plant commissioning time.

"Use of Scenario helped to ensure that the Con Edison investment in the new ERRP plant technology would be optimised by well-trained operators and accurate controls," said Hsiu-Chen Wang, senior engineer at Consolidated Edison on the New York East River Repowering Project.

"One major benefit was safe and efficient plant startup that reduced the plant commissioning time from four months to one month".

After a successful plant start-up, Scenario simulation is now used to optimise East River processes for improved efficiency and reliability.

Further plant tuning, as well as the addition of any new equipment, can be tested and confirmed using the simulation technology before integration into the live system.

Additionally, Con Edison is considering using Scenario as a means to realize additional revenue through its Learning Centre outsource training for new co-generation facilities throughout the New York metropolitan area.

Emerson has decades of real-world power industry experience designing, engineering and supporting simulation projects.

Leading power producers around the world rely on Emerson Scenario engineered simulation solutions to enhance the safety, reliability and overall operations of their plants.

Utilising tie-back logic, algorithmic models and comprehensive first-principle models, Scenario can provide a full range of training and engineering simulation solutions tailored to meet the unique operational challenges of each facility.

"Emerson has a long history of designing, engineering, implementing and supporting simulation technologies" said Bob Yeager, president of the Power and Water Solutions division of Emerson: "In today's ROI-driven business climate, we're finding that now, more than ever, power producers understand the value of simulation and are eager to take advantage of using this flexible tool for engineering analyses, validating new control logic and enhancing operator performance, all of which contribute to increased plant reliability and safety".

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