UK power plant turns to simulation

Fawley, UK - RWE npower is employing simulation technology at Fawley Power Station to help it achieve efficient start-up and better synchronise to the grid to meet spikes in demand. Emerson Process Management’s Scenario system was installed at the 1,000-MW power generation facility in Hampshire, UK in January to mirror the plant’s actual Ovation expert control system, which monitors and controls the boiler, turbine and other critical plant processes/systems.

The simulator at the oil-fired plant features virtual controller technology, in which up to five virtual controllers reside in a single PC, offering opportunities for achieving higher levels of affordability and scaleability with a significantly reduced footprint. At Fawley, 4,100 simulated I/O points exist within twelve Ovation virtual controllers.

The simulation technology is used both for the ongoing education of existing employees as well as for qualifying new employees for safe and efficient plant operation. This training capability is particularly valuable for operators in peaking plants, which operate based on fluctuating demand. In this environment, simulation technology can be used to train new operators, while keeping current operators sharp and helping them become familiar with new control strategies – even when the plant is not in operation.

According to Emerson, well-trained operators who are prepared to handle abnormal operating situations can significantly reduce costly plant trips. With that in mind, Fawley had 20 malfunctions – including critical malfunctions – pre-programmed into the simulator to train operators on how to respond to emergency situations.

“With the simulator, new operators can come up to the standards of more experienced and trained operators much sooner than would be possible if they were interacting with the control system only when the unit was operating,” said David Marmot, electrical & instrumentation lead, RWE npower, who notes that the simulator is a key component of a formal operator training programme.