Designing a High-Fidelity Full-Scope Training Simulator for a Triple-Pressure CCGT Power Plant

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Information about Designing a High-Fidelity Full-Scope Training Simulator for a...

Published on February 27, 2014

Author: GSE_systems

Source: slideshare.net

Description

This presentation describes the design and implementation of a high-fidelity, full-scope training simulator for a triple-pressure CCGT Power Plant. For more information, please visit GSES.com, email info@gses.com, or follow GSE on Twitter @GSESystems and Facebook.com/GSESystems. Thanks for viewing!

Design and Implementation of a High-Fidelity, Full-Scope Training Simulator for a Triple-Pressure CCGT Power Plant info@gses.com

Summary •  Introduction •  Plant configuration •  Simulator configuration •  DCS configuration •  Model •  Conclusion 2

Introduction •  Two new CCGT plants •  Commissioned last 2 years •  Training improvement •  18-month project •  New training center in Didcot, England 3

Introduction •  Pembroke, Wales –  Sea water cooled –  ~450 MW –  5 units •  Staythorpe, England –  –  –  –  Cooling water towers ~430 MW 4 units Light oil (not used) 4

Plant Configuration •  Alstom GT26 gas turbine –  Two-stage combustion, HP and LP turbine –  Efficiency 39.6% –  Compression ratio 33.3:1 5

Plant Configuration •  Triple-pressure boiler –  LP system adds ~8 MW –  HP system T = 565 C, P = 138 bar(a) –  Exit flue gas temperature ~85 C –  Allows for higher total efficiency –  Steam turbine output >160 MW •  Overall efficiency >58% 6

Plant Configuration •  Once-through coolers (OTC) –  Compressor air-cooled by feed water •  Single shaft with a clutch –  Allows fast and flexible run-ups –  Cooled air used to cool blades –  Steam feeds back to HRSG –  Preserved efficiency –  Helix type Hx 7

Schematic of Modeled HRSG 8

GSE Simulation Software Overview DCS Operator Stations Simulator DCS Soft Panels JStation SmartTutor I/O Systems SimExec JADE JTopmeret JControl JLogic JElectric ISIS Power Plant 9

Simulator Description •  A high-fidelity full-replica type simulator –  HMI and control system identical –  Hardware (I/O cards) emulated •  Emulator controlled by “ITS Link Tool” –  JStation™ controls emulator via ITS interface •  Both simulators/DCSs on same hardware –  Different domains, requires a system reboot (dual-boot hardware) of DCS –  Same for simulator hardware 10

Simulator Architecture 11

DCS Configuration •  ABB 800xA (Graphics, BoP, common parts) •  ABB AC160 (GT and ST controllers) –  AC160 controller translated to AC400 •  I/O communication done with OPC server –  Reading and writing in SimExec database –  10 Hz •  Allows for on-the-fly snapping of ICs (backtracks) •  Saves 5 h historical data in ICs (trends) 12

Modeling Tools •  JTopmeret™ –  –  –  –  Gas turbine HRSG Main steam BoP •  ISIS™ –  Components –  Mal and remote functions •  JStation™ •  JElectric™ –  Electric generation –  Electric distribution –  Connected to ITS •  JDesigner™ –  Operator hard desk 13

GT and Compressor Model •  Compressor and gas turbine work-based isentropic efficiency •  Efficiency crucial for temperatures •  Non-ideal Rankine •  Air humidity, pressure and temperature impacts on efficiency 14

Combustion Model •  If sufficient oxygen, ideal combustion •  Using available gas species in JTopmeret –  ​"#↓4  +  ​&↓2   → ​"&↓2   +  ​&↓2   +  ​#↓2 & +  ​"#↓4  –  ​'&↓(  and CO based on empirical data •  Combustion energy added into JTopmeret gas enthalpy –  Dynamic flue gas specific heat (Cp), based on temperature and gas species to achieve correct gas temperatures 15

JTopmeret •  JTopmeret –  Mass, thermal and impulse balance –  Two-phase –  Non-condensables –  Oil –  All models run at 40 Hz –  Flexible and robust enough to handle most aspects of a CCGT simulator 16

Gas Turbine System Model •  GT modeled in JTopmeret –  Air inlet –  VIGVs –  Compressor –  Gas turbine –  OTC air side –  GT enclosure –  GT cooling 17

HRSG/Main Steam Model •  HRSG modeled in JTopmeret –  Flue gas side –  Steam/water side –  Drums and evaporators with natural circulation –  Feed water tank, pumps and heaters –  OTC water/steam side •  Main steam modeled in JTopmeret –  Turbines –  Condenser 18

Possible Future Projects •  MXL2 upgrade on Staythorpe and Pembroke commissioned –  Possible simulator upgrade •  Increased air flow •  New LP turbine blades (higher efficiency) •  New control functions: –  ‘M’ mode maximum load (+ 13-23 MW) –  ‘XL’ mode, flexible mode with lower temperatures (longer time between inspections) 19

Conclusions •  JTopmeret flexible and powerful enough for modeling a complete CCGT plant –  New JTopmeret release includes fully integrated combustion, gas turbine and compressor models –  Should be able to handle future upgrades •  Successfully integrated with ABB systems –  Communicating and controlling with 800xA and AC400 emulators –  AC160 can be translated to AC400 20

For more information: Go to: www.GSES.com Follow us on: Call: 800.638.7912 Twitter @GSESystems Email: info@gses.com Facebook.com/GSESystems

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