Fossil Power Simulator Efficiencies When Using Automated Testing
-
Upload
gse-systems-inc -
Category
Technology
-
view
108 -
download
1
description
Transcript of Fossil Power Simulator Efficiencies When Using Automated Testing
Fossil Power Simulator Implementation Efficiencies When Using Automated Testing
2
Overview
• Objective
• Some history
• JADE scenario-based testing
• SBT comments from engineers
• Use during the build cycle
• SBT summary comments
3
Objective
• In support of our ISO 9001 and customer commitment, GSE continues to seek ways to improve our simulator production processes.
• Increase use of automated testing on fossil
power simulator projects to create greater client value, additional efficiencies and lower costs.
4
Some History
• Simulator vendors traditionally have a Computer-Aided Exercise Program (CAEP)
• GSE uses a system designated as
Automated Plant Procedures (APP) • Generation and run of pre-defined scenarios • Sequential set of expert commands • Often linked to trainee performance review • Student results are documented and saved
5
Automated Plant Procedures (APPs)
• For fossil projects, training-centric • For nuclear projects, also used for testing
6
Automated Plant Procedures (APPs)
• Example of APP user interface Summary and status of all loaded APP exercises Summary and status of all included comments
7
JADE Scenario-Based Testing (SBT)
• SBT is a parallel activity to scenario validation • Prior to the start of SBT, a pre-defined set of
plant parameters is loaded for recording simulator performance
8
Scenario-Based Testing (SBT)
• Through the course of scenario validation plant parameters, alarms and automatic actions are monitored for expected response
• At the completion of SBT, a report is generated
that includes: • An affirmation checklist • Scenario procedures • Various log files • Parameter plots
9
What is the Scenario Tool?
The Scenario tool is split into two parts: Scenario Editor is a graphical user interface (GUI) that allows the instructor/engineer to create an automatic procedure. Scenario Manager is a GUI that manages the different scenarios whether designed through the editor or APP tools.
10
What are the Scenario Editor Capabilities?
• An easy way to write an automated procedure
• Able to incorporate malfunctions, remote functions, global components, etc. into a procedure
• Many default features available
• Able to open procedure and edit as needed
11
How the Scenario Editor Looks
12
Scenario Editor Default Library
• Reset IC • Run, freeze & delay • Action • Message • Command block • Decision blocks (3 types) • Condition • Set value • Trend, diagram & text field • System command • Exit condition
13
An Example Scenario
If an instructor or engineer wishes to write the following scenario: • Reset to IC 74 • Run • Run for 10 seconds • Insert LP FW heater 3-tube leak • Run for 10 minutes • Freeze
14
An Example Scenario
Simple click and drop onto the grid:
With popups to input data:
15
An Example Scenario
The finished product:
16
An Example Scenario
• Once finished, the scenario is saved
• The scenario can be opened and edited as needed
• The scenario is run and managed from the Scenario Manager tool
• The scenario can also be run from the editor, if desired
17
Scenario Manager Capabilities
• Can hit one button, walk away and come back to a finished test
• Can run multiple procedures (one after the other, regression testing)
• Can attach variables to be trended along with the procedure
• Will generate a viewable report once the procedure has finished
18
Scenario Manager User Interface
19
Setting Up a Scenario
20
Setting Up a Scenario
• Can attach a scenario file made from the editor to the new scenario or use a JStation™ Automated Plant Procedure
• Can set the duration of the scenario
• Can set the IC that the scenario starts from
21
Setting Up a Scenario
• Can link multiple variables to the scenario through imports or queries:
22
Using the Schedule List
• Multiple scenarios can be added to the list, where the order can be easily changed:
23
Using the Schedule List
• Scenarios can be scheduled as to when they will run after the “execute” button has been selected
• The options to “execute all” or to execute just the selected scenarios are available
• The same scenario can be run multiple times
24
Running the Scenario
• It will show which scenario is running and for how long:
25
The Scenario Report
• Once the scenario is finished there will be a report of the scenario:
26
The Scenario Report Contents
• Cover Page
• Summary
• Monitor parameter list (variables selected ex:1hdlit0003a_inp)
• Scenario summary
• Parameter charts (trends of variables)
27
Example of the Parameter Chart
28
The Scenario History
• The instructor/engineer has a set of history files for data analysis:
29
Example of the Parameter Chart
30
Example of the Parameter Chart
31
How the Scenario Tool Will Improve a Simulator
• Scenarios that would take hours during the day can be done overnight (e.g., filling the boiler)
• Multiple tests can be run overnight
• A document record of all scenarios is kept, along with any trends produced during the scenario that can be used for later comparison
32
SBT Comments from Engineers
• Examples of SBT possible tests: – Boiler filling – ID fan trip – FD fan trip – PA fan trip – Steam-driven boiler feed pump trip – Turbine trip
• Schedule overnight runs of sequential trips using Scenario Manager and evaluate DCS runback performance
33
SBT Comments from Engineers
• Supercritical boiler fill: – Reset to I/C just before fill process starts – Freeze at, e.g., 45 minutes – Evaluate building level in flash tank – Trends of flow, levels, etc. – Run conditional loops for about five more minutes
or until appropriate level is reached – Objective is to match plant dynamics of filling – Change valve admittance during test runs – Result: Ran many tests but used available day
time with customer for other testing
34
SBT Comments from Engineers
• Simulator turbine model performance tests: – Steam turbine rolling – Steam turbine valve(s) modeling;
changing valve curves and auto retesting – Tuning bearing temperatures – Tuning vibration responses
35
SBT Comments from Engineers
• Combined cycle simulator tests: – Multiple gas turbine MF and transient testing – Run one g/t test with customer – Run others g/t tests overnight with
SBT schedule – Auto-documented results reviewed with
customer for other g/t tests
36
SBT Comments from Engineers
• Simulator black plant testing: – Simulator electrical model allows you to
• See more variables • See greater detail • Run slow mode
– Which fan actually trips first – Develop emergency shutdown procedures
37
Use During Project Build Cycle
• System Unit Testing (SUT) proves the individual models are done and reaching reasonable steady-state results. – Scenario-based testing for system models
• Model Acceptance Testing (MAT) proves the accuracy of models prior to DCS integration. – Complete startup with functional controls – Scenario-based testing for combined models
38
Use During Project Build Cycle
• During integration testing of simulator, models interfaced with DCS controls. – Verifies model performance if operating DCS
configuration is available – Verifies DCS performance prior to plant
commissioning – Scenario-based testing for regression analysis
39
Use During Project Build Cycle
• Factory Acceptance Test (FAT) – Set up scenario-based testing during Pre-FAT
integration phase – Run for formal FAT documentation
• Site Acceptance Test (SAT) – Re-run start-up and FAT scenario-based testing – Faster local start of Ready for Training (RFT)
40
SBT Summary Comments
• Develop once, use many times
• Improve consistency of testing • Use customer available “day time” more
efficiently, run SBT overnight, compare results in morning
• Test more fully MFs and transients
• Potential to shorten project schedule
For more information: Go to: www.GSES.com
Call: 800.638.7912
Email: [email protected]
Follow us on: Twitter @GSESystems
Facebook.com/GSESystems