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High Fidelity Operator Training Simulator Implemented Ahead of
the Plant Commissioning for a South American Utility
Power Plant Simulation Conference Tampa, FL January 28th-30th 2013
Alex Lekich for Mike Cabaniss – GSE Systems, Inc. Chad Butler – Emerson Process Management Power & Water Solutions
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Overview
• Simulator project Goals & Objectives
• South American Project schedule
• Unique Challenges
• Execution strategy
• Virtual OvationTM System
• High fidelity modeling approach with JADETM
• Summary
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Simulator Project Objective
• GSE and Emerson provided a high fidelity simulator with models and controls indistinguishable from a real-time running plant
• Simulator allows for extensive DCS testing/tuning and operator training prior to plant commissioning
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Project Goals
• Test the Distributed Control System (DCS) logic thoroughly ahead of plant commissioning
• Begin training operators ahead plant commissioning
• Configure simulator interface with Emerson OvationTM Virtual Controllers
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Simulator Project Example
• South American coal-fired drum unit located in Chile
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Key Project Stake Holders
• Coordinated effort between
– Simulation vendor, GSE
– DCS vendor, Emerson
– Utility company
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Commissioning Schedule Presented at Kickoff Meeting
The customer requested that we analyze
block diagram and test the DCS logic
ahead of the startup
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Delivery Milestones Aligned with Commissioning Dates
Milestone Commissioning Schedule Description
Commissioning Date
File Upload to FTP Date
1 Initial Firing 9/10/2010 11/1/2010
2 TBN Initial Roll 12/6/2010 11/15/2010
3 Gen First Syncho 12/20/2010 11/29/2010
4 Initial Coal Firing 1/5/2011 12/15/2010
5 72 Hour Test 3/24/2011 3/3/2011
•A set of key target milestone dates were
established as a result
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Project Implementation Challenges
• Unique project management approach focused on creating a comprehensive simulator within a limited time frame
• Bi-lingual communication to Spanish-speaking customers by lead project engineer
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Project Execution Strategy
• High resource staffing levels due to compressed schedule
• Simulator logistics focused on maximizing productivity and customer interaction
• Operator training available ahead of plant startup
• Simulator retune at site - update the DCS & models with running plant controls after commissioning is complete
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High Resource Staffing Levels
• GSE provides 3 to 4 simulator team Engineers
• Emerson provides simulator lead project global simulation Engineer and one project management lead Engineer
• Utility provides operators for testing and I&C technicians for the first initial startup
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Project Schedule
• Simulator Schedule
– 8 month compressed schedule
– (12 - 14 months typical)
• Extensive review of P&IDs versus scope
• Analysis of external logic outside of the DCS some typical examples include:
– Smart breakers
– Plc logic
– Relay logic
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Project Schedule
• Model Acceptance Testing (MAT) at GSE proves the accuracy of models prior to DCS integration
– Complete startup with functional controls
– Reduces schedule risk since models with be fully tested before linking them to new controls
• Simulator models interface directly with DCS controls verifies DCS performance prior to plant commissioning
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Customer Acceptance
• Factory Acceptance Testing (FAT) at GSE involves plant operators working directly with simulation team to perform startup and shutdown testing
• Variances are documented and corrected
• Site Acceptance Testing (SAT) at customer site. Ensures system performs the same as it does on the factory floor
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Simulator Logistics
• A copy of the non-commissioned DCS controls were used for staging at GSE in Maryland
• International component of the project required eight weeks of customer/operator participation in the US
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Operator Training and Retune
• Operator Training began prior to DCS implementation on the newly constructed plant
• Simulator retune was performed at the plant site by Emerson and GSE to update the simulator to the commissioned DCS controls
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• DCS converted to OvationTM virtual controller drops on a virtual controller host (VCH)
• DCS application software (control logic, database, and graphics) are installed on the simulator
Simulator System Architecture
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Typical Virtual OvationTM Layout 1
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Typical Virtual OvationTM Layout 2
Model Server
Workstation
Domain Controller /
Database Server
Workstation2
Operator
Workstation
Operator
Workstation
Ovation
Switch
Emulated Hard
Panel
Workstation
Instructor
Workstation
Virtual
Controller
Host /
Operator
Workstation
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High Fidelity Modeling Approach
GSE JADETM software:
High Fidelity models of plant systems using a two-phase dynamic solution based on conservation of mass, momentum, and energy
GSE SimExec software:
Controls and monitors the execution of solutions in Real-Time
Interactively via freeze, run, snap, and reset
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Variance Recording System
• GSE, Emerson, and Utility communicate using a discrepancy reporting database accessible via the web called Mantis
• Allows quick and efficient documentation and resolution of data requests, model discrepancies, and DCS discrepancies
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GSE Testing Checkpoints for Model Readiness Verification
• Simulator schedule incorporates testing checkpoints throughout project to ensure model readiness
– System Unit Test (SUT):
Models tested stand-alone
– Model Acceptance Test (MAT):
Models tested integrated together
– Factory Acceptance Test (FAT):
Models tested integrated with the DCS
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The Advantage of Testing a DCS on a Simulator Prior to Plant Installation
• Allows correction of errors in DCS and ensures the DCS works properly
• Prevents complications during operation of the real plant
• Saves time and money spent on attempting to debug the DCS while controlling real equipment
• Avoids multiple startups/shutdowns needed to make DCS changes
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Other Major Benefits of Simulator
• Mimics the real plant for life-long testing and training
• Allows for first pass at field tuning to be performed prior to DCS delivery
• Capable of updating and retuning simultaneously to real plant
• Extensive training for emergency scenarios
• Future DCS logic updates can be tested on the simulator before the real plant
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Questions
Mike Cabaniss – GSE Systems Inc.
Alex Lekich – GSE Systems Inc.
Chad Butler – Emerson Process Management Power &
Water Solutions