Transcript No Slide Title

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
Energy and Essent Energy
• Supplier of power, heat and utilities to
14 chemical plants on the site Delfzijl in
the Netherlands
• One of the largest co-generation plants in
Europe(530 MW,750 t/h LP/IP steam)
• 76 employees, operated by Akzo Nobel
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Delesto bv
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Delesto 1
Delesto 2
IP steam
LP steam
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Delesto 2
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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 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
DC
PHD
Level 3,5
FIBER
OPTIC
Fault Tolerant Ethernet
EST 1
EST 26
EST 27
Klok
ESVT
EST 2
EST 3
AM 13/14
TPS File server
AM 24
HM 12 (red)
LCN
NIM
22/23
NIM
20/21
FIBER
OPTIC
HPM 05
HPM 05
UCN
4
UCN
3
HPM 07
HPM 07
HPM 09
HPM 13
HPM 13
HPM 09
HPM 11
HPM 15
HPM 15
HPM 11
HPM 17
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Overview Delesto 2 system
DELESTO 1
Fault Tolerant Ethernet
FIBER
OPTIC
EST 4
AM 45/46
AM 47
LCN
DELESTO 1
NIM
41/42
FIBER
OPTIC
NIM
43/44
HPM 05
FIBER
OPTICS
UCN
6
UCN
5
HPM 09
HPM 09
HPM 11
HPM 11
HPM 13
Safety
Manager
12
Remote
I/O
HPM 07
HPM 07
SMM 17
Remote
I/O
HPM 05
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
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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
Overview engineering / OTS
system
DC
Instructor
Facility
Fault Tolerant Ethernet
ESVT
EST 26
EST 1
EST 27
EST 2
SX 3
TPS File server
Plant
Model
HM
AM
LCN
NIM
NIM
HPM
HPM
UCN
SMM
Safety
Manager
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UCN
TPS
Emulation
UniSim Plant Simulator
• Process Area Models
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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 files
 AM / HPM CL files
 Configuration files ( .NCF )
 Custom Data Point / Segment Definition files
 Parameter 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
Fault Tolerant Ethernet
AM
NIM
HPM
HM
NIM
HPM
UCN
SMM
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UCN