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Generic Drum Unit Simulator Boosts Productivity at South African Power Plant
Background
SOUTH AFRICA – Located between Vereeniging and Sasolburg, the Lethabo Power Station, owned by Eskom Holdings, is responsible for over half of the electricity generated on the African continent and provides affordable electrical power to an increasing percentage of the African population.
Eskom Holdings generates, transports and distributes approximately 95% of South Africa’s electricity – making up 60% of the total electricity consumed on the African continent. Eskom is the world’s eleventh-largest power utility in terms of generating capacity, ranks ninth in terms of sales, and boasts the world’s largest dry-cooling power station.
Goals
- Install simulation system to help boost safety, efficiency and profitability at the plant
Challenges
- Improve productivity and plant operations, while increasing operator plant understanding, safety and reducing operating costs
AVEVA Solution
- DYNSIM Dynamic Simulation
Results
- The simulation system has reduced operating costs, while plant understanding and personnel safety have improved
- Assists in providing continuous electricity to 95% of South Africa (around 60% of the total electricity consumed on the African continent)
Improving Safety and Plant Profitability
AVEVA supplied an Operator Training System (OTS) at Eskom’s Lethabo Power Plant in South Africa that is helping to boost safety, efficiency and profitability at the plant.
Operator Training System Solution
Eskom realized that improved productivity depends on improved plant operation, which depends on the quality of its operators. As a result, in March 2004, Eskom took delivery of AVEVA Generic Drum Unit Simulator.
The Generic Drum Unit OTS is based on a sidewall-fired unit boiler coupled with a train of high, intermediate and low-pressure steam turbines. The simulator components include physical, first principles based dynamic simulation models, the instructor station, DCStype controls, and training for up to four operators.
The flexibility of the solution allows the emulation of the DCS interface through a single application, including alarming and trending, execution of the process model, and support of the instructor’s interface. This integrated solution allows the displays to be visible at every operator station for maximum training flexibility. This interface also requires minimal training for an instructor, allowing the focus to be on process training rather than navigating the simulator system.
Dan Wilbers, Managing Consultant of Operator Training Systems and Services, AVEVA said, “The generic drum simulator purchased by Lethabo is the result of AVEVA’s extensive experience delivering training systems to power generators around the world. We are excited that it has been chosen as the platform to build a solid performance improvement strategy at this facility.”
AVEVA delivered the Simulator on time and to budget. We are completing our training program on the Simulator and have been amazed at how easy the system is to learn and work with.”
Abrie Venter, Eskom Training Manager
Benefits Realized
The training program has already produced a lot of benefits. Operating costs have been reduced, while plant understanding and personnel safety have improved. Lethabo operators are able to maintain plant equipment in the normal operating range and prepare for off-normal operations such as valve breakage and tube leaks.
Generic Drum Unit Simulator Boosts Productivity at South African Power Plant
Background
SOUTH AFRICA – Located between Vereeniging and Sasolburg, the Lethabo Power Station, owned by Eskom Holdings, is responsible for over half of the electricity generated on the African continent and provides affordable electrical power to an increasing percentage of the African population.
Eskom Holdings generates, transports and distributes approximately 95% of South Africa’s electricity – making up 60% of the total electricity consumed on the African continent. Eskom is the world’s eleventh-largest power utility in terms of generating capacity, ranks ninth in terms of sales, and boasts the world’s largest dry-cooling power station.
Improving Safety and Plant Profitability
AVEVA supplied an Operator Training System (OTS) at Eskom’s Lethabo Power Plant in South Africa that is helping to boost safety, efficiency and profitability at the plant.
Operator Training System Solution
Eskom realized that improved productivity depends on improved plant operation, which depends on the quality of its operators. As a result, in March 2004, Eskom took delivery of AVEVA Generic Drum Unit Simulator.
The Generic Drum Unit OTS is based on a sidewall-fired unit boiler coupled with a train of high, intermediate and low-pressure steam turbines. The simulator components include physical, first principles based dynamic simulation models, the instructor station, DCStype controls, and training for up to four operators.
The flexibility of the solution allows the emulation of the DCS interface through a single application, including alarming and trending, execution of the process model, and support of the instructor’s interface. This integrated solution allows the displays to be visible at every operator station for maximum training flexibility. This interface also requires minimal training for an instructor, allowing the focus to be on process training rather than navigating the simulator system.
Dan Wilbers, Managing Consultant of Operator Training Systems and Services, AVEVA said, “The generic drum simulator purchased by Lethabo is the result of AVEVA’s extensive experience delivering training systems to power generators around the world. We are excited that it has been chosen as the platform to build a solid performance improvement strategy at this facility.”
To Solve our problems, we implemented an integrated remote operations centre, and the key word there is integrated.”
Ronnie Barnard – Coordinator Metallurgical and Production MIS, BRMO
The Solution
The iROC solution will creates the ability to:
- Integrate systems and information sources to provide a holistic In-Time view across the value chain.
- Create Situational Awareness by using integrated data sets and defined business rules, initiating actions that maximises business benefit.
- Standardise critical workflows to minimise human error and as a result minimise business risk.
The Success
The Business benefits will be:
- By adding the integration of control room operations into the entire mine business value stream, better decision making and operational loss reduction can be achieved.
- Integration of control room operations into the entire mine business value stream will also allow us to visualise impact to business and better manage our mining as well as process operations.
- Machine and people tracking improving both safety and efficiencies.
- Access to more granular information will improve focus on the root causes of problems and variations to which better targeting of corrective actions is possible.
- In-Shift monitoring and control to respond to problems as they occur and minimising deviations to plan, which provides the opportunity to save the shift in the shift.
- Empowering supervision to make more informed decisions to reduce variability.
- Improved equipment utilisation.
- Improved response time to breakdowns implying improved availability.
- Improved mining cycle management implying more effective use of resources both human and machine.
- Improved face utilisation.
- Improved scheduling and planning.
- Platform for continuous improvement and continuous integration of future digital transformation initiatives to the iROC.
We implemented AVEVA System Platform 2020, and specifically the AVEVA OMI, to pull all systems together into one solution. We also integrated [the system] with a 45 metre video wall to enhance situational awareness. In short, we implemented a control system to synchronise our entire value chain.”
Ronnie Barnard – Coordinator Metallurgical and Production MIS, BRMO
Accelerate time to value with AVEVA Industrial Cloud Platform
Enable the connected digital landscape and break down boundaries with an open cloud platform optimised for unlocking industrial insights in real-time.
Advantages of industrial hybrid SaaS solutions:
- Accelerate time to value – Adopt strategic industrial hybrid SaaS that are easy to deploy, access, and manage securely across any global enterprise.
- Flexible digital twin deployment – Enrich existing systems through hybrid SaaS solutions to create an industrial digital twin that delivers fresh value opportunities.
Read the full article by Engineering News who unpacked this topic at IS³’s prestigious annual X-Change User Conference.
Accelerate time to value with AVEVA Industrial Cloud Platform
Enable the connected digital landscape and break down boundaries with an open cloud platform optimised for unlocking industrial insights in real-time.
Advantages of industrial hybrid SaaS solutions:
- Accelerate time to value – Adopt strategic industrial hybrid SaaS that are easy to deploy, access, and manage securely across any global enterprise.
- Flexible digital twin deployment – Enrich existing systems through hybrid SaaS solutions to create an industrial digital twin that delivers fresh value opportunities.
Read the full article by Engineering News who unpacked this topic at IS³’s prestigious annual X-Change User Conference.
Accelerate time to value with AVEVA Industrial Cloud Platform
Enable the connected digital landscape and break down boundaries with an open cloud platform optimised for unlocking industrial insights in real-time.
Advantages of industrial hybrid SaaS solutions:
- Accelerate time to value – Adopt strategic industrial hybrid SaaS that are easy to deploy, access, and manage securely across any global enterprise.
- Flexible digital twin deployment – Enrich existing systems through hybrid SaaS solutions to create an industrial digital twin that delivers fresh value opportunities.
Read the full article by Engineering News who unpacked this topic at IS³’s prestigious annual X-Change User Conference.
Accelerate time to value with AVEVA Industrial Cloud Platform
Enable the connected digital landscape and break down boundaries with an open cloud platform optimised for unlocking industrial insights in real-time.
Advantages of industrial hybrid SaaS solutions:
- Accelerate time to value – Adopt strategic industrial hybrid SaaS that are easy to deploy, access, and manage securely across any global enterprise.
- Flexible digital twin deployment – Enrich existing systems through hybrid SaaS solutions to create an industrial digital twin that delivers fresh value opportunities.
Read the full article by Engineering News who unpacked this topic at IS³’s prestigious annual X-Change User Conference.
“This agreement enables clients to kindle a cultural shift towards anti-fragility and resilience. It accelerates their digital transformation journeys while ensuring alignment to global and regional marketing trends as well as technology. Being chosen for the Select Partnership program is not only a testament to the value that IS³ brings to AVEVA but also signifies the incredible progress that has been made in the reshaping of the industrial automation market”
Dion Govender – CEO, Digital Industries (Pty) Ltd
“An AVEVA Select partner can leverage the full breadth of our portfolio to empower customers as they double down on their digital strategies. Designed for our distributors, the unique AVEVA Select program helps them to optimize on opportunities and support customers to succeed in their digital transition. “We are pleased to welcome IS³ to the AVEVA Select family and look forward to developing and capitalizing on mutually beneficial growth strategies.”
Kerry Grimes – Head of Global Partners, AVEVA.
About IS³
About IS³
Driven by their ability to see the limitless potential of technology to empower people and transform businesses, IS³ provides industry software solutioning and support that enables individuals, teams, and businesses to move efficiently, seamlessly, and compliantly through their digital transformation journey. Their superior industrial software solutions include production, operations, production performance, manufacturing, intelligence, and business process management.
About AVEVA
About AVEVA
AVEVA is a global leader in industrial software, driving digital transformation and sustainability. By connecting the power of information and artificial intelligence with human insight, AVEVA enables teams to use their data to unlock new value. We call this Performance Intelligence. AVEVA’s comprehensive portfolio enables more than 20,000 industrial enterprises to engineer smarter, operate better and drive sustainable efficiency. AVEVA supports customers through a trusted ecosystem that includes 5,500 partners and 5,700 certified developers around the world. The company is headquartered in Cambridge, UK, with over 6,500 employees and 90 offices in over 40 countries.
About AVEVA Select
About AVEVA Select
The AVEVA Select program is designed for partners with full access to AVEVA’s comprehensive software portfolio, enabling them to help companies accelerate their digital transformation journey. AVEVA Select aligns to both market and technology trends, with programs designed to suit every product and solution specialization in the engineering and industrial segments. By leveraging the breadth of the AVEVA software portfolio, AVEVA Select partners can now help customers simplify design, optimize production, and maximize performance.
About IS³
About AVEVA
About AVEVA Select
About IS³
Driven by their ability to see the limitless potential of technology to empower people and transform businesses, IS³ provides industry software solutioning and support that enables individuals, teams, and businesses to move efficiently, seamlessly, and compliantly through their digital transformation journey. Their superior industrial software solutions include production, operations, production performance, manufacturing, intelligence, and business process management.
About AVEVA
AVEVA is a global leader in industrial software, driving digital transformation and sustainability. By connecting the power of information and artificial intelligence with human insight, AVEVA enables teams to use their data to unlock new value. We call this Performance Intelligence. AVEVA’s comprehensive portfolio enables more than 20,000 industrial enterprises to engineer smarter, operate better and drive sustainable efficiency. AVEVA supports customers through a trusted ecosystem that includes 5,500 partners and 5,700 certified developers around the world. The company is headquartered in Cambridge, UK, with over 6,500 employees and 90 offices in over 40 countries.
About AVEVA Select
The AVEVA Select program is designed for partners with full access to AVEVA’s comprehensive software portfolio, enabling them to help companies accelerate their digital transformation journey. AVEVA Select aligns to both market and technology trends, with programs designed to suit every product and solution specialization in the engineering and industrial segments. By leveraging the breadth of the AVEVA software portfolio, AVEVA Select partners can now help customers simplify design, optimize production, and maximize performance.
Generic Drum Unit Simulator Boosts Productivity at South African Power Plant
Background
SOUTH AFRICA – Located between Vereeniging and Sasolburg, the Lethabo Power Station, owned by Eskom Holdings, is responsible for over half of the electricity generated on the African continent and provides affordable electrical power to an increasing percentage of the African population.
Eskom Holdings generates, transports and distributes approximately 95% of South Africa’s electricity – making up 60% of the total electricity consumed on the African continent. Eskom is the world’s eleventh-largest power utility in terms of generating capacity, ranks ninth in terms of sales, and boasts the world’s largest dry-cooling power station.
Improving Safety and Plant Profitability
AVEVA supplied an Operator Training System (OTS) at Eskom’s Lethabo Power Plant in South Africa that is helping to boost safety, efficiency and profitability at the plant.
Operator Training System Solution
Eskom realized that improved productivity depends on improved plant operation, which depends on the quality of its operators. As a result, in March 2004, Eskom took delivery of AVEVA Generic Drum Unit Simulator.
The Generic Drum Unit OTS is based on a sidewall-fired unit boiler coupled with a train of high, intermediate and low-pressure steam turbines. The simulator components include physical, first principles based dynamic simulation models, the instructor station, DCStype controls, and training for up to four operators.
The flexibility of the solution allows the emulation of the DCS interface through a single application, including alarming and trending, execution of the process model, and support of the instructor’s interface. This integrated solution allows the displays to be visible at every operator station for maximum training flexibility. This interface also requires minimal training for an instructor, allowing the focus to be on process training rather than navigating the simulator system.
Dan Wilbers, Managing Consultant of Operator Training Systems and Services, AVEVA said, “The generic drum simulator purchased by Lethabo is the result of AVEVA’s extensive experience delivering training systems to power generators around the world. We are excited that it has been chosen as the platform to build a solid performance improvement strategy at this facility.”
Generic Drum Unit Simulator Boosts Productivity at South African Power Plant
Background
SOUTH AFRICA – Located between Vereeniging and Sasolburg, the Lethabo Power Station, owned by Eskom Holdings, is responsible for over half of the electricity generated on the African continent and provides affordable electrical power to an increasing percentage of the African population.
Eskom Holdings generates, transports and distributes approximately 95% of South Africa’s electricity – making up 60% of the total electricity consumed on the African continent. Eskom is the world’s eleventh-largest power utility in terms of generating capacity, ranks ninth in terms of sales, and boasts the world’s largest dry-cooling power station.
Improving Safety and Plant Profitability
AVEVA supplied an Operator Training System (OTS) at Eskom’s Lethabo Power Plant in South Africa that is helping to boost safety, efficiency and profitability at the plant.
Operator Training System Solution
Eskom realized that improved productivity depends on improved plant operation, which depends on the quality of its operators. As a result, in March 2004, Eskom took delivery of AVEVA Generic Drum Unit Simulator.
The Generic Drum Unit OTS is based on a sidewall-fired unit boiler coupled with a train of high, intermediate and low-pressure steam turbines. The simulator components include physical, first principles based dynamic simulation models, the instructor station, DCStype controls, and training for up to four operators.
The flexibility of the solution allows the emulation of the DCS interface through a single application, including alarming and trending, execution of the process model, and support of the instructor’s interface. This integrated solution allows the displays to be visible at every operator station for maximum training flexibility. This interface also requires minimal training for an instructor, allowing the focus to be on process training rather than navigating the simulator system.
Dan Wilbers, Managing Consultant of Operator Training Systems and Services, AVEVA said, “The generic drum simulator purchased by Lethabo is the result of AVEVA’s extensive experience delivering training systems to power generators around the world. We are excited that it has been chosen as the platform to build a solid performance improvement strategy at this facility.”
AVEVA delivered the Simulator on time and to budget. We are completing our training program on the Simulator and have been amazed at how easy the system is to learn and work with.”
Abrie Venter, Eskom Training Manager
Benefits Realized
The training program has already produced a lot of benefits. Operating costs have been reduced, while plant understanding and personnel safety have improved. Lethabo operators are able to maintain plant equipment in the normal operating range and prepare for off-normal operations such as valve breakage and tube leaks.