Major process changes have the potential to dramatically alter system dynamics in a power plant, and changing fuel can affect upstream and downstream pressures, temperatures, and airflow in surprising ways. When one of TRAX's recent energy industry customers made the switch to firing natural gas on two of their units, they may not have expected the extent of the impact their decision would have.
TRAX examined several modeled scenarios for the customer's modified unit configuration, and found three significant potential problems that could cost the client millions in reinforcement costs:
Several of the test cases TRAX investigated for this client produced severe excursions or undesirable consequences such as trips. TRAX worked with the client to develop a suite of controls strategies to reduce or eliminate the problematic behaviors. Three of the studies' key mitigating strategies included:
Although this client had excellent controls in place before TRAX studied the units, equipment changes still meant some scenarios were not correctly addressed in the new configuration. TRAX was able to provide mitigations to reduce the severity of the pressure and temperature excursions, allowing the client to reduce or avoid expensive stiffening or repairs, and resulting in a safe, efficient unit that better aligns with the client’s energy goals.
TRAX has delivered a carbon capture simulator for a 150 MW coal-fired unit that models the capture of the full flue gas stream. The system provides both CO2 and SO2 capture, delivering the captured CO2 to a pipeline for industrial use and underground storage.
—CO2 and SO2 capture
—Sulfuric acid plant
—CO2 and SO2 amines filtration and purification
—CO2 compression
—CO2 pipeline and cavern
As shown below, TRAX built a modular simulation replicating the plant layout using our software, ProTRAX. ProTRAX contains a full suite of modules specific to carbon capture functions and can model a wide variety of processes. TRAX also virtually replicated the user interface that appears in the plant.
Upon initial delivery, the TRAX simulator was used to debug control logic and processes prior to site installation and to provide operations training prior to plant startup. There was a clear need to begin training operators as early as possible since they had multiple unfamiliar systems to learn.
Thanks to the ProTRAX simulator, our customer gained considerable insight into control functionality and system interactions, resulting in modification to some control logic and correction of simple errors. TRAX was able to assist with controls tuning, and helped in development of initial plant Operating Procedures.
The latest upgrade brings the model into alignment with the as-built plant condition by updating and tuning the simulator models to match the current plant dynamics. In addition, TRAX has updated the simulator controls and HMI graphics to the as-built state. Keeping the simulator aligned with the current plant condition is critical to maintaining a positive training value, and is of paramount importance to the customer.
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