Belle River Simulator: A GSE, DTE and ABB Collaboration

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Presented at ABB Automation & Power World. For more information, visit www.gses.com.

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Belle River Simulator: A GSE, DTE and ABB Collaboration

  1. 1. Belle River Simulator: A GSE, DTE & ABB Collaboration info@gses.com
  2. 2. 2 Speakers George McCullough Vice President GSE Systems Baltimore, MD Fred Ihimodu Staff Engineer – Engineering Support Organization DTE Energy Detroit, MI Speaker: Title: Company: Location:
  3. 3. 3 Belle River Power Plant: A Brief History  5 Diesel Peakers – 13.75 MW commissioned 1981  2 Coal Units – 1,396 MW commissioned 1984 - 1985  3 Natural Gas Peakers - 256 MW commissioned 1999
  4. 4. 4 Project History: Recent Control Systems Upgrades 2002 - Unit 2 conversion to ABB Harmony 2008 - Unit 1 conversion to ABB Harmony 2012 - Unit 2 conversion from VMS OIS to 800xA 5.1 - Unit 2 simulator development 2013 - Unit 1 upgrade from 800xA 5.0 to 5.1 - Environmental solutions
  5. 5. 5 Proposed Benefits  Training operators & others  Platform to simulate future environmental solutions control system for units 1 & 2  Complete graphics review prior to unit 2 start-up in fall 2012  Eliminate typical extensive IO checkout during unit 2 fall 2012  Platform to test control philosophy, software configuration and graphic changes prior to implementing on unit 1 & 2
  6. 6. 6 Partners & Teams GSE Systems  Lead engineer and design team  Project management ABB  Lead engineer and design team  Project management DTE Energy  Plant operations  Plant engineers and I&C specialists  Process controls engineering support  Major enterprise project management
  7. 7. 7 Unit 2 Simulator Team: Preparation  Simulator conference exposure  Same personnel on both simulator and unit DCS upgrades  Critical to have continuity across all projects  Experienced operators familiar with units  Engineers & specialists with vast knowledge of control systems  Travel commitments
  8. 8. 8 Model: GSE Concepts Power Generation Modeling Tools  Thermal hydraulic systems  Flow networks  Electrical systems  Logic & controls High Fidelity  Fully modeled  Simplified model  Not modeled
  9. 9. 9 Model: GSE Concepts Instructor Station Initial Conditions Malfunctions Remote functions & overrides Trainee actions review, backtracking & replay
  10. 10. 10 Data Sources & Connections Harmony Training Simulator (HTS)  vICI • Harmony connectivity • Composer • DBDOC  HTS manager
  11. 11. 11 Data Sources & Connections Harmony Training Simulator (HTS)  vICI • Harmony connectivity • Composer • DBDOC  HTS manager
  12. 12. 12 Data Sources & Connections Third Party PLC OPC: No Modbus emulator required Matrikon OPC Scada Modbus vs. KEPServerEX
  13. 13. 13 Data Sources & Connections Non DCS Emulated HMI - Soot Blowing - Precipitator - CEMS - ZoloBOSS Hard Panel Emulation - Ethernet IO - Meters
  14. 14. 14 Activities  9 to 12 month commitment  Simulator testing  Factory Acceptance Testing (FAT)  Site Acceptance Testing (SAT)  Train the trainer
  15. 15. 15 Activities  Issue Tracking - ABB Teamtrack – GSE Mantis  Management of Change  Remote Collaboration – ABB teamwork – GSE VPN access – DTE VPN access
  16. 16. 16 Decisions: Not Always Black & White  Immersion vs. feedback  Immersion vs. human performance  Redundancy needs vs. test environment completeness  Access to information vs. role clarification
  17. 17. 17 Plant & Simulator Unit 2 Unit 2 Simulator
  18. 18. 18 Lessons Learned  Uncovered and resolved existing configuration, logic & graphics  HTS limitations & compatibilities – Unsupported function codes  Comprehensive startup procedure  Model – Data sources handshake
  19. 19. 19 Lessons Learned  System health checks  VMware vCPU allocation  Event concentrator error  Ensure overall system is truly ready for customer
  20. 20. 20 Current/Future Objectives  Establish core training program  Expand training benefits beyond operations to technicians & engineers on engineering tools − Composer − Bulk data manager − Bulk configuration manager − Graphics builder − Alarm analysis − Import/export tool − Consistency checker, etc.
  21. 21. 21 Current/Future Objectives  Model future environmental solutions - Validate plant design & procedures prior to start-up  Implement management of change to keep the simulator & unit in sync  Enhancement request - vICI and HTS manager services
  22. 22. 22 Contact Fred Ihimodu DTE Energy ihimoduf@dteenegry.com George McCullough GSE Systems gsmccullough@gses.com For more information, please contact: OR
  23. 23. For more information: Go to: www.GSES.com Call: +1 800.638.7912 Email: info@gses.com Follow us on: Twitter @GSESystems Facebook.com/GSESystems
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