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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