Client Challenge
A mixed fuel power plant faced ongoing challenges with its existing ash handling system, which had been retrofitted to handle only fly ash after the original system—designed for both bottom ash and fly ash—was modified. The plant’s tertiary filters required constant monitoring, as ash accumulation frequently blinded them, resulting in inefficiencies and increased manual intervention by operators.
The system’s control logic had never been upgraded, leaving operators to manually run the process on a periodic basis. This not only increased labor demands but also raised the risk of operational delays and equipment strain due to inconsistent ash removal. The client sought an automated solution to streamline operations, reduce manual oversight, and improve system reliability.
Our Solution
DSI Innovations designed and implemented a comprehensive system upgrade to fully automate the ash handling process, enhancing efficiency and reducing the need for manual intervention. Key aspects of the solution included:
- Automated Control Logic:
- Upgraded the existing PLC program to introduce continuous monitoring and control of the ash removal process.
- Developed new logic to automatically clean tertiary filters, preventing ash buildup and ensuring consistent system performance.
- Configured real-time system checks to maintain optimal operating conditions with minimal operator supervision.
- Enhanced HMI Functionality:
- Installed an additional HMI in the control room, providing operators with improved visibility into system performance and the ability to notify maintenance teams immediately when issues arise.
- Modified existing HMI graphics to more accurately represent the system while preserving familiar design elements for an easier operator transition.
- Operational Efficiency:
- Automated ash removal reduced the frequency of manual interventions, allowing plant personnel to focus on other critical tasks.
- Integrated fault detection and alarm notifications to alert operators of potential issues before they could impact system performance.
The Results
The upgraded ash handling system delivered significant operational improvements for the power plant:
- Automated Ash Removal: The new control logic enabled continuous ash removal, eliminating the need for periodic manual intervention and ensuring consistent system performance.
- Improved Filter Management: The system now proactively cleans tertiary filters, preventing blinding and reducing maintenance demands.
- Enhanced Operator Oversight: The additional HMI in the control room provided operators with real-time system visibility, allowing faster issue identification and response.
- Increased Workforce Efficiency: With less time spent on ash system management, plant personnel were freed up to focus on higher-priority tasks, improving overall plant productivity.
- Seamless Transition: The modified HMI graphics retained the original system’s look and feel, making it easier for operators to adapt to the upgraded functionality.
This project highlighted DSI Innovations’ ability to modernize legacy systems, enhancing automation, efficiency, and reliability while minimizing disruptions to plant operations.
