The Role of Steam Simulators for Advanced Controls Implementation, Operator Training, Process Safety and Plant Operational Excellence

Advanced Process Controls (APC) is usually the solution for improving steam plant runnability, safety and profitability. However, commissioning of an APC package on a steam system is risky and the long-term maintenance of these packages is so cumbersome that most APC are eventually turned off after just a few years of operation. This presentation shows how first-principle simulations can be used to reduce commissioning risk, improve the long term operability of an APC package, and train operators. The speaker will also present recent APC project results where simulators were used to test the logic, tune the controllers and train the operations team. In these projects, the “virtual steam plant” approach allowed the new APC logic to be commissioned with no production losses and with the expected long-term safety and profitability goals.