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Yokogawa Generic 660MW Coal-fired Subcritical Power Plant Simulator

Yokogawa Generic 660MW Power Plant Simulator

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ACTUAL PLANT SPECIFICATION

The simulator replicates a 660 MW coal-fired subcritical power station controlled by a Yokogawa CS3000 control system. The simulator provides high fidelity replication of the power station plant control room and plant behaviour. All major systems of the plant are simulated.

BOILER

The boiler has the following basic characteristics:

� IHI

� Drum type with natural circulation

� Sub bituminous coal firing

� Rated 540 kg/s, 18 MPa, 540°C/540°C

� 7 tube ball mills, 28 PF burners

� Front and rear wall firing

TURBINE

� Toshiba

� 660MW

� Condensing Turbine

� Two main Stop and Control Valves

� Turbine bypass system

� TOSTAC turbine controls

DCS CONTROLS CONFIGURATION

� Yokogawa CS3000

� Unit Coordinated Controls including:

o Manual 1, 2, 3

o Turbine Follow

o Boiler Follow

o Local Coordinated Control Mode

o Remote Coordinated Control mode

� Integrated boiler protection system known as the Burner Management System (BMS) (in the NFPA codes)

� Integrated Turbine run-up system

� HV Switchyard Control System/Station Electrical – fully operational

KEY FEATURES OF SIMULATOR

• The plant modelling is high fidelity meaning that all dynamic transients are realistic and follow the laws of physics. To the trainee, they appear to be operating a real plant

• The DCS HMI and logic are fully stimulated which is a copy of the DCS in reference plant. It allows basic and advanced DCS engineering training to be conducted on the simulator

• The simulator allows training scenarios to be available at any time and the training program can be tailored to any of the many plant malfunctions and operating conditions which could be anticipated or previously experienced on a power plant.

• The simulator is supplied with an extensive training exercise system that allows objective trainee competency testing. The training exercise is fully configurable and an automatic scoring calculation is used for evaluating the trainee performance.

• 39 initial conditions (ICs) and 100 malfunctions are provided

• All the software runs on standard PC and server hardware

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PLANT OVERVIEW & DCS GRAPHICS

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SIMULATOR HARDWARE CONFIGURATION

The following is the typical hardware configuration. All computers are standard desktop PCs and server (ESXI server). The reduced-hardware architecture is made possible by employing the latest best practice in virtualisation, through the VMWare® ESX package. This not only reduces the overall hardware requirement but also offers greater reliability and a greatly extended range of features. The hardware configuration is very flexible and can be tailored to suit customer’s requirements.

HIS Operator Station159

HIS Operator Station161

HIS Operator Station163

HIS Operator Station160

Main Simulation Computer : ESXi Server

Instructor Station

Gigabit Ethernet

HIS Operator Station 164/ Engineering Work Station

Each HIS Operator Station will use vSphere software to logon to the corresponding HIS virtual machine

With single 23" monitor

HIS0159 Virtual Machine HIS0161 Virtual Machine HIS0163 Virtual MachineHIS0160 Virtual Machine Linux Virtual MachineHIS0164 Virtual Machine

With single 23" monitor With single 23" monitor With single 23" monitor With single 23" monitor With single 23" monitor

Typical Hardware Layout

INSTRUCTOR FUNCTIONS

The Trainer's interface with the simulator is through the graphical user interface in the Instructor Station. The main functions the trainer can do are:

• Loading an IC (Initial Condition) or Snapshot: Introducing a Condition of plant, ready for a training session;

• Saving an IC or Snapshot: Saves a particular situation for continued running at a later date for the same trainee, or for use during some other training period;

• Setting the simulator to Run/freeze mode: Runs the simulator and so permit a trainee to perform operating situations, guided by the various monitoring and alarm systems; Freeze the simulator for detailed analysis of the plant status or pause in the training session;

• Applying malfunctions: Initiating a single event or pre-program a set of plant or equipment failure situations that a Trainee has to address and to take appropriate actions, so as to rectify poor operating or plant alarm situations;

• Applying scenario: Introduce a pre-programmed operating exercise that forms the basis for a class training session;

• Backtracking: Go back in time, to allow a trainee to operate in a different manner from a previous time and to establish an alternative outcome;

• Develop automatic training exercises and reporting of trainee training session results;

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• Trainee management: record trainee details and recall trainee history;

• Signal forcing and parameter manipulation like ambient temperature;

• Changing speed: models can be running slower or faster than real time to suit training purpose like reduced the time needed for turbine heat soak;

• Dynamic logic display: dynamic values of the coslog logic can be seen and logic variables can be forced. Coslog is the Yokogawa logic package to emulate logic like protection relay logic, PLC logic, etc.

Instructor Graphical User Interface

Malfunction Menus

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HISTORY OF YOKOGAWA SIMULATION

In 1998 Yokogawa Electric Corporation acquired TechComm Simulation of Australia. TechComm Simulation was a simulator manufacturer specialising in high fidelity replica Fossil Fuel Fired Power Plant training simulators. TechComm was established as Costec Pty Ltd in 1983 and had built simulators around the world.

The TechComm Simulation business was merged with Yokogawa Australia and operates from offices in Sydney, Australia. The simulator design and development group in Sydney supports all Yokogawa worldwide affiliates in the Power Plant Training Simulator and Services market.

Over the past 25 years the Yokogawa Simulator Group in Sydney has built an enviable reputation for the design and delivery of power plant simulators with a wide variety of control systems vendors in diverse locations such as Korea, Australia, Middle East, Singapore, Vietnam, Thailand, Mexico, Zimbabwe and Egypt.

For more information please contact Max Barry, Director Yokogawa Simulation Email: max.barry@au.yokogawa.com Telephone: +612 8669 1302 Richard Porter, Simulation Group Manager Email: richard.porter@au.yokogawa.com Telephone: +612 8669 1333