TRAX has partnered with ABB and Walleye Power to energizethe training program at the Bay Shore Plant. This effort involved updating thetraining simulator to match the plant's current configuration and controls. Thejoint effort continued an established history of responsible maintenance andoperation, aiming to improve operational efficiency while maintainingsustainable practices.
Bay Shore is a small,independent power producer with a co-generation facility on the shore of LakeErie, providing both power and steam to clients. Formerly part of theFirstEnergy fleet, the Bay Shore Plant changed hands in 2018 to Walleye Power,LLC.
The Bay Shore Plant configuration is complex and requireshighly skilled and trained operators. The circulating fluidized bed (CFB)boiler is more intricate than the average drum boiler, and uses limestoneinjection to capture SO2 and NOx from the petroleum coke (petcoke) the plantuses for fuel. Bay Shore provides 171 MW of power to their clients, as well assteam to a nearby refinery, which is in turn a supplier of the petcoke used tofuel the boiler.
TRAX first simulated the BayShore Plant in 2005, with a hybrid simulation of the ABB Symphony controls.After delivery, TRAX trained Bay Shore operators on a variety of plantoperating modes including startup, shutdown, and normal and abnormal conditions.
Bay Shore has maintained thistraining tool with periodic updates, including a control system update and thena major activated carbon injection (ACI) addition in 2016 that reflectedchanges in the plant’s configuration. TRAX modeled the injection of powderedactivated carbon into the boiler flue gas ductwork, which uses carbon solids toadsorb the mercury vapor. The simulation of this system included the storagesilo for the powdered carbon, hoppers, fans and blowers, solids meteringdevices, ducts, and valves. All changes within ABB's DCS were modeled.
The 2025 Bay Shore simulator upgrade effort involved workingwith ABB to replace the old hybrid simulator configuration (using emulatedcontrols and actual ABB HMI) with a new ABB virtual control system. TheABB virtual control system is an exact replicate of the plant controls and HMIgraphics providing an ideal training platform. During this upgrade, thesimulator was retuned to match the current plant operating conditions.
The importance of having the control vendor and simulatorvendor work closely and effectively together cannot be stressed enough. Thelevel of cooperation and familiarity between ABB and TRAX is unparalleled,having delivered over 70 full-scope power plant simulators together, of whichover 25 were as market partners. Together, we work to optimize performance,smooth processes, enhance transparency, and ensure satisfaction for ourclients.
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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