Fossil Power Simulator Efficiencies When Using Automated Testing

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Information about Fossil Power Simulator Efficiencies When Using Automated Testing

Published on March 4, 2014

Author: GSE_systems



This presentation discusses methods for fossil power simulator implementation efficiencies when using automated testing. It includes information on automated plant procedures and scenario-based testing, as well as comments from real engineers who used the scenario-based testing.

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Fossil Power Simulator Implementation Efficiencies When Using Automated Testing

Overview •  Objective •  Some history •  JADE scenario-based testing •  SBT comments from engineers •  Use during the build cycle •  SBT summary comments 2

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. 3

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 4

Automated Plant Procedures (APPs) •  For fossil projects, training-centric •  For nuclear projects, also used for testing 5

Automated Plant Procedures (APPs) •  Example of APP user interface Summary and status of all loaded APP exercises Summary and status of all included comments 6

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 7

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 8

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. 9

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 10

How the Scenario Editor Looks 11

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 12

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 13

An Example Scenario Simple click and drop onto the grid: With popups to input data: 14

An Example Scenario The finished product: 15

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 16

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 17

Scenario Manager User Interface 18

Setting Up a Scenario 19

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 20

Setting Up a Scenario •  Can link multiple variables to the scenario through imports or queries: 21

Using the Schedule List •  Multiple scenarios can be added to the list, where the order can be easily changed: 22

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 23

Running the Scenario •  It will show which scenario is running and for how long: 24

The Scenario Report •  Once the scenario is finished there will be a report of the scenario: 25

The Scenario Report Contents •  Cover Page •  Summary •  Monitor parameter list (variables selected ex:1hdlit0003a_inp) •  Scenario summary •  Parameter charts (trends of variables) 26

Example of the Parameter Chart 27

The Scenario History •  The instructor/engineer has a set of history files for data analysis: 28

Example of the Parameter Chart 29

Example of the Parameter Chart 30

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 31

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 32

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 33

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 34

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 35

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 36

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 37

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 38

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) 39

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 40

For more information: Follow us on: Go to: Twitter @GSESystems Call: 800.638.7912 Email:

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