The Tucson Electric Power (TEP) Springville Station
AVEVA™ Dynamic Simulation Power Validates Controls and Trains Operators on new DCS for TEP Springville Station
Goals
- Replace original Leeds and Northrup analog control system and ABB Turbotrol turbine control system with Foxboro DCS
- Use high-fidelity simulator to do DCS control checkout, DCS HMI validation and plant procedures verification with new controls.
- New simulator to replicate the actual dynamic response of the operations and without any significant loss of megawatt production.
- Repurpose simulator for operator training, continuous improvement and knowledge capture
Challenges
- Validate the control logic against actual operations
- Build operator knowledge and confidence in the new DCS prior to going online in the actual unit
- Eliminate unplanned downtime or emergency shutdowns
Results
- Reduced lost generation costs by $250,000 to $500,000 a day
- Identified and fixed numerous errors using Simulator Factory Acceptance Testing saving unplanned downtime
- Reduced commissioning time by seven days due to the operator’s familiarity with the new controls
- Smoother unit startup due to repeated testing and training in the simulator
“I can’t believe how smoothly the actual unit startup went; especially with this complex interaction between IPS and Alstom.”
-Mike Puzzi,
TEP Project Manager for the DCS upgrade project
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