Provecta has been engaged by the Electric Power Research Institute (USA) to develop a sequence automation and advanced control solution for the Barry Generating Plant in Alabama, United States. The plant has 3,346 MW of operating CCGTs and Coal Fired Units. Provecta’s project involved designing and delivering full startup and shutdown automation and advanced control of a 2-on-1 combined-cycle gas-fired unit.
The project included initial assessment of operating goals and automation options with related costs and benefits. Using a hierarchical sequence philosophy, Provecta developed a design optimising startup times, costs and operational requirements.
Before being implemented on the units, the designs were tested on a replica simulator provided by the plant owner, using comprehensive test procedures developed by Provecta. Sequences now completed include cold, warm and hot starts, duct burner and augmentation steam operation and full shutdown sequences. The largest sequence, the cold start, has now been deployed on a unit and automates over 450 operator actions during the procedure, leaving operators to concentrate on monitoring and diagnosis. Deployment of the remaining sequences is planned for late 2025 following extensive operator exposure using the site’s Operator Training Simulator.
Outcomes from the project include:
- Incorporation of experienced operator ‘best practice’ into all startup/shutdown operations;
- Consistency in startups and timing of unit synchronizations and loading;
- Up to 50% reduction in startup times, due to simultaneous operations and optimised action timing;
- Significant reduction in steam temperature deviations and plant stresses through the introduction of Model Predictive Control.
