Society for Modeling & Simulation

2013 Conference

Successful implementation of a circulation dry scrubber in a PC fired simulator

Kyle Greene, Tom Kane – TRAX International

Plant Details

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Deerhaven Unit 2 : Gainesville Regional Utilities (GRU) • Constructed 1981 • Coal Fired Riley Stoker Boiler • 236 MW, 1800psig • Westinghouse Tandem Compound Turbine • Babcock Power Turbosorp Circulating Dry Scrubber • Hydrated Lime • Dry Scrubber operational 2009 • Selective Catalytic Reduction (SCR) • “Zero Discharge” plant

• Interested in training for all aspects of plant operation, not just back end

• HMI Upgrade to ABB PPA

• Low nox burner mod

• HRH modification

• Predictive ability of simulation

• Retirements

• New Hires

• Structured STP (Simulator Training Program)

Motivation

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0 3 6.5 10 12

Contract Award

Kickoff Meeting

Design Review

Integrate Models & Controls

High-Fidelity Simulator Ready for Training

Ready for FAT

Month

Project Approach

Prepare Design Spec

Heat Balance &

Model Development Startup Testing Acceptance Testing

1

• Kickoff meeting – discuss simulator scope and schedule (12 month)

• Model development and review with customer

• Integration of models, I/O, controls, and HMI

• Startup Testing with Customer Participation

• Factory Acceptance Test

• Site Acceptance Test

• STP Delivery

Begin Development

Simulator Details

Layout

• ABB Virtual HTS • PPA Operator HMI • Single Hardpanel

• Boiler

• Air/Gas

• Steam/Water

Modeling Details

Front End

Back end

• Turbosorp CDS

• Fabric Filter

• Air Slide

• Lime prep • Lime Hydration

• Riley Stoker Boiler • 1980 psig at drum

• 1.9 Mlbs/hr combustion air

• 3 Mills, 2 feeders each

• 186 Kpph Coal Flow

• Westinghouse Turbine • 235 MW

• 1800 psig/1005 degF Throttle

• 1.65 Mlbs/hr Main Steam

• 1.40 Mlbs/hr HRH

Modeling Details

Front End

Image courtesy of GRU

Circulating Dry Scrubber

Image by Babcock Power

Back End

Modeling Details

Back End

Turbosorp Circulating Dry Scrubber (FGDCDS) The Turbosorp circulating dry scrubber (FGDCDS) module passes flue gas through a circulating bed of hydrated lime for the purpose of removing SO2 from the flue gas. The following features are implemented in this module: • Fluidization of lime, reaction products, and residual ash • Calculate bed and overall pressure drops • Allow for process water injection • Reaction modeled: Ca(OH)2 + SO2 CaSO3 + H2O • Solids removal from bottom port following system upsets • Heat loss to Ambient

Modeling Details

Back End

Baghouse (BAGHOUSE) The BAGHOUSE module removes solid material from the flue gas stream and collects it in a bottom hopper (SLHOPPER module) for routing to the air slides. The following features are implemented in this module: • Solid material/ash accumulation on filter • Pulse jet cleaning air effects on filter ash accumulation – drop out to bottom hopper • Differential pressure calculation based on filter loading • Heat loss to ambient • One port for material removal connects to an SLHOPPER module

Modeling Details

Back End

Air Slide (AIRSLIDE) The air slide (AIRSLIDE) module receives solids from the BAGHOUSE/SLHOPPER modules and return them to the Turbosorp reactor module (FGDCDS). The following features are implemented in this module: • Fluidization of solids based on fluidizing air flow • Blower pressure or level based on amount of solids

present • Product recirculation to Turbosorp reactor • Built-in dosage roller for controlling solids flow to Turbosorp • Solids removal to waste • Fluidizing air • Heat loss to ambient • Heaters for startup and shutdown operation to prevent

bed material from sticking

Modeling Details

Back End

Lime Hydration Tank (FGDHYD) The lime hydration tanks mixes lime (CaO) with water to form hydrated lime (Ca(OH)2). The following describes some of the features implemented in this module: • Optional number of mixing zones • Independent composition and temperature calculated for each mixing zone • Reaction modeled: CaO + H2O Ca(OH)2 + Heat • Water evaporation calculation for each mixing zone • Heat loss to ambient for each zone • One set of mixing paddles for each zone • Vent for evaporated water to escape

Modeling Details

Back End

Lime Hydration Tank (FGDHYD)

HMI Image courtesy GRU

Back End

Turbosorp R CDS

Pebble Lime Day Bin

Baghouses

Issues Along the Way

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• Module Development & Dynamics • Circulating Dry Scrubber module tuning • Lime Hydration

• Operator HMI Modifications • HMI modification in progress at control vendor • Implementation & testing in simulator

• Process modeling changes mid-project • Anticipated HRH changes delayed • Simulator built with design data

Issues Along the Way

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• Module Development & Dynamics • Information gathering and development began before the kickoff meeting • Communication with the customer

• Operator HMI Modifications • Control vendor dedicated to get modifications in place • Extensive use of remote login to EWS for implementation • Remote verification of mods by customer prior to visits

• Process modeling changes mid-project • Importance of detailed heat balance • Process model changed to “as-built” efficiently • Simulator delivered with minimal schedule impact • Design case saved for later use

Solutions and strategy

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Simulator Training Program

SIMULATOR TRAINING PROGRAM OVERVIEW Program designed to help the instructor to: • Implement the Simulator Training Program for operator training • Conduct effective simulator training • Prepare students to derive maximum benefit from simulator training • Document student performance to ensure adherence to training standards

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Simulator Training Program

SIMULATOR TRAINING PROGRAM OVERVIEW

• Instructor Guided Lessons

• Teaching

Assistant

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Simulator Training Program

SIMULATOR TRAINING PROGRAM OVERVIEW

• Instructor Guided Lessons

Level 1 Lesson 1 Filling Cooling Tower Basin Lesson 2 Filling Hotwell Lesson 3 Starting Condensate Pump and Filling DA Lesson 4 Starting BFPump and Filling Drum Lesson 5 Establishing Air Flow Lesson 6 Placing 2nd Condensate Pump in Service Lesson 7 Changing Boiler Feedpump Service Lesson 8 Pulverizer Startup Lesson 9 Placing Hydrolyser/SCR in Service Lesson 10 Placing Turbosorp in Service

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Simulator Training Program

SIMULATOR TRAINING PROGRAM OVERVIEW

• Instructor Guided Lessons

Level 2 Lesson 1 Unit Preparation - Cold Startup Lesson 2 Boiler Startup Lesson 3 Turbine Startup Lesson 4 Increasing Load Lesson 4a Increasing Load with Malfunctions Lesson 5 Unit Shutdown

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Simulator Training Program

SIMULATOR TRAINING PROGRAM OVERVIEW

• Instructor Guided Lessons

• Malfunctions and abnormal operation

Level 3 Lesson 1 Loss of Two Condensate Pumps Lesson 2 Loss of BFP West Lesson 3 Loss of One Pair of Burners Lesson 4 Flame Scanner Failure Lesson 5 Loss of Hydrated Lime Feed to Turbosorp Lesson 6 Trip of Crushed Lime Hammer Mill Lesson 7 Loss of Pebble Lime Flow to Hammer Mill Lesson 8 Ammonia Injection Skid Trip Lesson 9 Loss of Urea Feed to Hydrolyser Lesson 10 Loss of Control of Steam Valve for Hydrolyser Lesson 11 High Humidity at Hydrator Outlet Lesson 12 High Amps for First Stage Hydrator Motor Lesson 13 Lime Hydrator Trip

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Simulator Training Program

• Instructor Guided Lessons

• Teaching

Assistant

Training Activity

TA: Instructorless training with assistance

• Pulverizer startup

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Simulator Training Program

• Instructor Guided Lessons

• Teaching

Assistant

TA: Instructorless training with assistance

• Pulverizer startup

Media window hint

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Simulator Training Program

• Instructor Guided Lessons

• Teaching

Assistant

TA: Instructorless training with assistance

• Pulverizer startup

• Simulator delivered on schedule

• Training began as anticipated

• Satisfied customer

• Training program growing

Net results…

Simulator Delivery

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Conclusion

• Planning • Development

• Tools • Detailed heat balance and remote access

• Relationships • Effective teamwork between ABB, GRU, and TRAX • Dedicated customer / good communication

Society for Modeling & Simulation

2013 Conference

Thank you

Kyle Greene, Tom Kane – TRAX International