Published on March 4, 2014
Fossil Power Simulator Implementation Efficiencies When Using Automated Testing firstname.lastname@example.org
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: www.GSES.com Twitter @GSESystems Call: 800.638.7912 Email: email@example.com Facebook.com/GSESystems
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