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By David Wagman, Managing Editor
Improving plant operations and enhancing workflows were two primary goals behind a process control upgrade at the 618 MW Cane Run generating station, a 50-year-old coal-fired unit operated by Louisville Gas & Electric, a unit of E.On US.
The plant is the utlity's oldest facility, but it still plays a critical role due to its location within a transmission-constrained area near Louisville, Ky., said Alan Crone, senior control specialist. He spoke at a recent Honeywell Users Group meeting in Phoenix. Earlier performance enhancements included adding scrubbers to the three-unit plant between 1973 and 1979 and installing low NOX burners in 1995 and 1996.
Early Upgrades
In 1986, the utility added multi-function controllers on two of the scrubbers, the first step in automating the plant's distributed control system (DCS). That work was followed by a 1992 upgrade to the plant's water treatment area using Honeywell logic manager software and a multi-year upgrade starting in 1995 to install advanced process management controls, logic manager and universal stations.
In 2005, the utility decided to upgrade its TDC3000 DCS and native Windows operating environments. The project focused on levels 2 and 3 of the plant control architecture. Project managers chose Experion modem and an open control plan that offered enough flexibility to add functionality.
The project also involved centralizing multiple power plant control rooms. Constructing the new control room proved to be an advantage, in part because the software and equipment upgrades were made without disturbing ongoing operations. Once the upgrades were in place, operators could troubleshoot and train on the new system without pressure. If a problem arose that they could not immediately handle, the old control room could be called upon.
The new configuration allows Cane Run plant managers to remotely operate a nearby hydroelectric facility. Plans are in the works to incorporate a wireless tablet PC, which will allow controllers to move around the plant while maintaining full control room functionality. And the plant undertook a steam turbine and gas turbine control update, in conjunction with Wood Group.
Data Security
The software upgrades offer more data security, which will help the plant meet NERC critical infrastructure protection (CIP) standards. In particular, the blackstart capability of one Cane Run unit means the plant falls under the definition of a critical asset. Still to be determined is how to accomplish mandatory CIP system testing and recovery planning functions without disrupting ongoing operations.
Crone said it is "vitally important" to involve information technology staff in a project such as this. "There are a lot of communications issues with opening ports and getting permission to open ports," he said. "Upfront you need the network people involved because it will save you a lot on the back end."
As for benefits, Crone said the upgrades will save the plant around $25,000 a year in reduced node count and spare parts inventory. He said the plant already has benefited from improved process control capabilities and expanded information access.
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