1 operator training simulator for co-generation plant delesto 2 arnhem 3-feb. 2010 henk assink
TRANSCRIPT
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Operator Training Simulator for co-generation plant Delesto 2
Arnhem 3-feb. 2010
Henk Assink
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Chemical site Delfzijl
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Delesto bv
• 50/50 Joint Venture between AkzoNobel 50/50 Joint Venture between AkzoNobel Energy and Essent EnergyEnergy and Essent Energy
• Supplier of power, heat and utilities to Supplier of power, heat and utilities to 14 chemical plants on the site Delfzijl in 14 chemical plants on the site Delfzijl in the Netherlands the Netherlands
• One of the largest co-generation plants in One of the largest co-generation plants in Europe(530 MW,750 t/h LP/IP steam)Europe(530 MW,750 t/h LP/IP steam)
• 76 employees, operated by Akzo Nobel 76 employees, operated by Akzo Nobel
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Delesto bv
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IP steamIP steam
Delesto 1Delesto 1 Delesto 2Delesto 2
LP steamLP steam
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Delesto 2
• 9FA single shaf co-generation unit • Power output 350 MW• Extraction flow: 0-300 tons/hr• Partial upgrade to FA+e technology
during HGPI 2002 • Base load unit, load flexibility within
premix steady state (approximately 100 MW)
• Honeywell TDC-3000 control systemHoneywell TDC-3000 control system
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Maintenance schedule Delesto 2
• Start commercial operation July 1999
• Combustion Inspection September 2000 (8k)
• Hot Gas Path Inspection April 2002 (12k)
• Combustion Inspection March 2004 (16k)
• Major Inspection April 2006 (16k/32k)
• Combustion Inspection May 2006 (16k)
• Hot Gas Path Inspection April 2010 (12k)
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Overview Delesto 1 system
AM 13/14
LCN
FIBER OPTIC
HM 12 (red)
HPM 05
HPM 07
HPM 15
AM 24
UCN4
NIM 22/23
HPM 09
HPM 11
HPM 13
HPM 05
UCN3
NIM 20/21
HPM 09
FIBER OPTIC
EST 27EST 26
Fault Tolerant Ethernet
ESVT
PHDLevel 3,5
Klok EST 2EST 3EST 1
HPM 07
HPM 13
TPS File server
HPM 15
DC
HPM 17
HPM 11
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Overview Delesto 2 system
AM 45/46
LCN
NIM 41/42
UCN 5
Remote I/O
FIBER OPTICS
NIM 43/44
UCN 6 Remot
e I/O
SafetyManager
HPM 05
HPM 07
HPM 09
HPM 11
HPM 13SMM 17
HPM 05
HPM 07
HPM 09
HPM 11
AM 47
FIBER OPTIC
DELESTO 1
FIBER OPTIC EST 4
DELESTO 1
Fault Tolerant Ethernet
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Why an operator training simulator (OTS)
• Because of high reliability the operator is not familiar to abnormal situations (other side of success)
• Fully automated startup and shutdown sequences (two times push the button)
• One unit start/shutdown per year with a five shift organizations this means one start/shutdown per five years
• New operators do not have feeling with unit• Dynamic simulator
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starting-point OTS
• Operator interface look and feel • Modular system • Part of real DCS system • Part of LCM (Life Cycle Management) contract• Maintainable date-base• Dynamic simulation• Different scenarios by instructor• Use engineering system hardware• Time manipulation possible
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Overview engineering / OTS system
AM HM
LCN
NIM
UCN
UCN
SafetyManager
HPM
SMM
HPM
NIM
EST 27EST 26
Fault Tolerant Ethernet
EST 1 EST 2ESVT
DC
TPS File server
SX 3
Plant Model
TPS Emulation
InstructorFacility
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UniSim Plant Simulator
• Process Area Models– Cooling Water Systems– Gas Turbine & Auxiliaries– Condensate Boiler Feed Water– Steam Turbine & Auxiliaries– Generator & Auxiliaries
• Control / Logic Model– GE Speedtronic MK 5 Governor
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DCS Emulation
• Plant Control / Logic• Start-Up & Shutdown Sequences• Triconex Protection System
– Produced from actual plant configuration:EB & AM filesAM / HPM CL filesConfiguration files ( .NCF )Custom Data Point / Segment Definition filesParameter files ( .SP )
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LCN – Simulation Interface SX003
• Virtual Plant Control (VPC) for TPS Interface( SX003 ) provides interface between:– LCN and DCS Emulation / Plant Simulator– Instructor Station and DCS Emulation / Plant
Simulator
• Operates as an active node on the LCN– mimics the presence of NM41, NM43 & AM45
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Operator & Instructor Stations
• Operator Station ( EST )– with same set of graphics as actual plant
• Instructor Station– Graphical interface to access the facilities of the
system( Running / Controlling the simulation & training )
– Student Monitoring– Field Operator Duty / Role Playing– Scenario Generation / Management
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Operator Station Graphics ( 1 / 5 )
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Operator Station Graphics ( 2 / 5 )
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Operator Station Graphics ( 3 / 5 )
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Operator Station Graphics ( 4 / 5 )
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Operator Station Graphics ( 5 / 5 )
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Instructor Graphics ( 1 / 4 )
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Instructor Graphics ( 2 / 4 )
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Instructor Graphics ( 3 / 4 )
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Instructor Graphics ( 4 / 4 )
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Demo Delesto OTS System
• Booth #50
AM HM
NIM
UCN
UCN
HPM
SMM
HPM
NIM
Fault Tolerant Ethernet