session 2 - garcia, ivanscs.org/wp-content/uploads/2017/02/session-2-garcia-ivan.pdf · • 2003...

2017 POWER PLANT SIMULATION CONFERENCE SAN DIEGO, CA, USA

Development of a Full Scope Web based Simulator

Iván Francisco Galindo García

Instituto Nacional de Electricidad y Energías Limpias (National Institute of Electricity and Clean Energy)

Reforma 113, Cuernavaca, México www.iie.org.mx

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Overview

Presentation 1. Introduction 2. Simulator description 3. Application 4. Concluding Remarks

• INEEL was created on 1975 as the Instituto de Investigaciones Eléctricas (IIE). In June 2016, IIE changed its operating name to Instituto Nacional de Electricidad y Energías Limpias.

• It is a public electricity and energy research center. • INEEL’s mission is to promote sustainable development in electricity and clean energy

through innovation. • INEEL is one of the leading institutions of research and technological development in Mexico. • INEEL employs 530 highly educated researchers (42 percent with bachelor’s degrees, 42

percent with master’s degrees and 16 percent with doctorate degrees).

• Four Divisions: Electric Systems, Mecahanical Systems, Renewable Energy, and Enabling Technologies (Department of Advanced Training Systems and Simulation, GSACyS).


• The Department of Advanced Training Systems and Simulation is part of the Enabling Technologies Division of the INEEL.

• More than 35 years of experience in the development of real-time dynamic simulators and integration of training centers.

• We offer a variety of products and services, including:

• Full-scope simulators, classroom simulators, engineering simulators, part-task trainers, hardware in the loop simulators, and upgrades.

• Maintenance and updating of simulators.

• Computer-based training systems (e-learning, multimedia, knowledge management, virtual reality).


Some of our projects:

• 2015 Simulators with Web technology for training of operators of thermoelectric power plants

• 2014 Simulator for operation training of a VU-60 Boiler

• 2013 Simulator for an Oil Gas Separation Unit

• 2009 Combined Cycle 450 MW Power Plant Simulator

• 2008 Hardware in the loop simulator to test AVR and hydraulic turbine controls

• 2006 Simulator of a 350 MW Dual Unit (Coal and Fuel)

• 2003 Simulator of a 110 MW Geo Thermal-Electric Unit

• … 1991 Laguna Verde Full-scope Nuclear Power Plant training Simulator


Our technology:

• Full scope replica control rooms (control panels)

• In-house real-time simulation platform

• In-house graphic modeling environment

• Full scope simulators accessed via web



Quality Standards

The developed simulators follow the norms: ISA-S77.20-1993 Fossil-Fuel Power Plant Simulators Functional Requirements. ANSI/ANS-3.5-1998 Nuclear Power Plant Simulators for Use in Operator Training

and Examination

Quality : ISO-9001:2000 Environment : ISO-14001:2004 Security : OSHAS 18001:2000 PGC Nuclear : 10CFR50 Reliable Supplier for PEMEX


Development of a Full Scope Web Based Simulator

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1. Introduction and benefits❑ A web based training simulator (WBTS) makes

use of the internet (or a local intranet). ❑ Key feature separating WBTS from typical

simulators: it overcomes physical distancies. ❑ Some advantages of distance independence

are: ❑ It enables to train operators scattered across

different sites, which is very useful in the case of utilities that own several power plants.

❑ Learners have the opportunity to participate in the same instructional activities regardless of physical location.

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❑ It is possible for training centers to share resources and thus avoiding redundancy in developing course materials.

❑ Along with flexibility in physical location, WBTS offers flexibility in timing of participation.

❑ With cloud computing it is no longer necessary to acquire products (computers and software), but to contract a service.

❑ Individualized learning. Learners struggling to learn a topic can pursue remedial work, those interested in learning more can do so, and those already familiar with the topic can move quickly to the next.

❑ Automated record-‐keeping can verify exactly what content learners reviewed and can also document successful completion of a summative assessment.

1. Introduction and benefits

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❑ Full scope simulators (FSS), in contrast with generic, partial scope or classroom simulators, are the most used in the power generation industry for training operators because it allows the student to train “as if he were in the real plant”.

❑ In this presentation a full scope web based training simulator is described. ❑ The simulator is available for any computer with an Internet connection and a

web browser with the necessary plugins and communication infraestructure.

1. Introduction and benefits

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2. Simulator description❑ As in a typical simulator a web simulator also

includes a student and an instructor station.

❑ The student station includes the interactive process diagrams, process control, alarm display and trend charts.

❑ The instructor station features all the typical functions of an instructor console such as: creation and selection of the initial conditions, controls to run, freeze and stop the simulation, to enable and disable external parameters and malfunctions of the equipment involved in the process.

Fig. 2. Student and instructor station.

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2. Simulator description1 The Instructor Console

Fig. 3. Instructor console.

❑ Is the interface of the instructor to conduct the training session.

❑ The main functions of the instructor console are as follow:

• Run/Freeze • Simulation speed • Initial conditions • Malfunctions • External parameters

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2. Simulator description1 The Instructor Console

❑ Module to retrieve all the static information during simulation session. ❑ Module to store information in a data base using SQL programs.

The real time executive coordinates

• The mathematical models. • The interactive process diagrams (HMI). • The global memory area.

• The Instructor Console. • The data base driver.

❑ Module to communicate the console with the real time executive.

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2. Simulator description2 The Interactive process diagrams (HMI)

Fig. 4. Interactive process diagrams.

❑ A web user interface that allows the students to interact with a simulator from a remote location through an HMI.

❑ The HMI is a graphical application based on a multi-‐window environment with interactive process diagrams organized in hierarchical levels that follow the organization of the power plant systems, i.e., boiler, turbine, etc.

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2. Simulator description3 Mathematical models❑ The mathematical models of the processes in the plant are the critical factor that

determines the level of realism and fidelity of a dynamic simulator. ❑ An important (and standard) functional characteristic is that the models are executed

in real time. In these case of a full scope simulator containing a very large number of components this real-‐time represents one of the main challenges to implement in a Web simulator.

❑ For the development of the models a proprietary graphical modeling called AGRADEMOS (Graphical Model Development Environment, for its name in Spanish) is used.

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2. Simulator description3 Mathematical models❑ This tool helps to develop, integrate and validate in an efficient and intuitive way thermodynamic,

mechanical, electrical, logic and control models. ❑ It has libraries for different plant components, for example process libraries for pumps, valves,

tanks, heat exchangers, etc., libraries to construct electrical grids including motors, switches, generator, batteries, etc., and a library of control primitives (logic and analog) for control models.

Modo editor gráfico

Modo

simulación

Fig. 5. AGRADEMOS environment.

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❑ The session manager helps to manage multiple simulation sessions within courses and link automatically each trainee, instructor, simulator and session in a virtual classroom context.

❑ Communication between applications and the simulator is performed with a set of web-‐services.

❑ A security Suite has been developed as an effort to reduce the risk of non-‐authorized access to the platform. It has a user manager with three levels of access: operator, instructor and administrator. These mechanisms contribute to the reliability, integrity and security of the transported data.

2. Simulator description, other characteristics

❑ In addition to all the typical requirements and tools to develop an on-‐site simulator, a few more modules are necessary for building a simulator that can be accessed through a web browser.

❑ Some of the tools developed to optimize and accelerate integration are: a .NET Development platform, an application for the management of simulation sessions, an instructor console for the web and an adapted Graphic Environment for Development of Simulation Models.

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3. Application

The web simulator minimum requirements:

❑ For the client stations, the communication must include an internet connection with exclusive bandwidth of 0.5 Mbps per screen.

❑ The server requirements shall be directly proportional to the simulation sessions in execution and the simultaneous connections.

❑ The server runs in a MS Windows Server 2008 64 Bits, Framework 4.0, WCF 3.0, ASP 3.0.

❑ It requires internet connection with exclusive bandwidth -‐ 10 Mbps for 8 screens.

Hardware and software requirements

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3. Application

❑ A 330 MW thermoelectric and a 450 MW combined cycle web simulators have been developed. ❑ The main characteristics of the 450 MW combined cycle unit simulator are described. ❑ This unit consist of two gas turbines of 150 MW each and a steam turbine of 150 MW. ❑ The gas turbine units have the following characteristics: the unit operates only with combustible

gas and consist mainly of an air compressor, a pressurized combustion chamber, a gas turbine, lubrication and control oil systems, fuel gas system, air and water service systems, electrical network and generator, excitation and voltage control systems, turbine speed, synchronization and control load of the unit, exhaust gas temperature control.

❑ The steam turbine unit considers the following equipment: an HRSG with three steam domes for high, intermediate and low pressure, one evaporator, two superheaters, three economizer and high pressure bypass valves, two intermediate pressure superheater, one evaporator, one superheater, two economizer and intermediate pressure bypass valves, en evaporator, a superheater, an economizer and low pressure bypass valves, high intermediate and low pressure steam turbines, feedwater system with deaerator, condensate system with aerocondenser, lubrication and control oil, air and water service systems, auxiliary steam, electrical networks, generator, excitation, and voltage control system and control systems.

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3. Application

❑ In general, the fidelity of a simulator is based mainly on the behavior of critical parameters. ❑ These parameters are related to the principles of mass and energy conservation of the power plant

and are selected only if they can be accurately measured. ❑ Typical critical parameters are:

o Main steam flow, pressure and temperature o Reheat steam, pressure and temperature o Flow of feed water o Main condenser pressure o Fuel flow o Power generated

❑ The general requirements for the construction of fossil fuel power plant simulators are well defined by the ISA-‐S77.20-‐1993 Fossil-‐Fuel Power Plant Simulators Functional Requirements .

Tests

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3. Application

❑ The combined cycle unit simulator has been tested operating as a complete generation unit under the following transient operating conditions: • Starting from cold metals to rated power • Full shutdown from rated power • Starting from hot metals up to nominal power

Tests

Fig. 6. Results from a turbine startup.

Fig. 6 shows some of the results of the turbine cold start up to rated load.

The values obtained have a variation smaller than 1.5% with respect to the design values of the real unit.

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4. Concluding Remarks❑ A power plant training operator Simulator has been developed to be employed through Web

technology.

❑ All the features of an on-‐site simulator have been implemented for the web environment, including the instructor station and the student HMI.

❑ The aim was to provide a solution to facilities where operators have to travel from their place of work to centralized training centers.

❑ Even though the concept of a Web simulator is not new, the present work describes the development of a full scope power plant simulator where the signals involved are the same to that of an on-‐site simulator.

❑ In a closing remark, the limitations must naturally be recognized. The proper application of a web simulator or aby other web application is dependent on appropriate communication infrastructure which is not always the case in remote power plants.

Thank your for your attention!

Iván F. Galindo García Sistemas Avanzados de Capacitación y

Simulación.Instituto Nacional de Electricidad y Energías

Limpias (National Institute of Electricity and Clean

Energies) Cuernavaca, México

[email protected] tel.: (52) 777 362 3816

mailto:[email protected]

session 2 - garcia, ivanscs.org/wp-content/uploads/2017/02/session-2-garcia-ivan.pdf · • 2003...

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