Fossil Power Simulator Implementation
Efficiencies When Using Automated Testing

info@gses.com
Overview
•  Objective
•  Some history
•  JADE scenario-based testing
•  SBT comments from engineers
•  Use during the buil...
Objective
•  In support of our ISO 9001 and customer
commitment, GSE continues to seek ways to
improve our simulator produ...
Some History
•  Simulator vendors traditionally have a
Computer-Aided Exercise Program (CAEP)
•  GSE uses a system designa...
Automated Plant Procedures (APPs)
•  For fossil projects, training-centric
•  For nuclear projects, also used for testing
...
Automated Plant Procedures (APPs)
•  Example of APP user interface

Summary and
status of all
loaded APP
exercises
Summary...
JADE Scenario-Based Testing (SBT)
•  SBT is a parallel activity to scenario validation
•  Prior to the start of SBT, a pre...
Scenario-Based Testing (SBT)
•  Through the course of scenario validation plant
parameters, alarms and automatic actions a...
What is the Scenario Tool?
The Scenario tool is split into two parts:
Scenario Editor is a graphical user interface
(GUI) ...
What are the Scenario Editor Capabilities?
•  An easy way to write an automated procedure
•  Able to incorporate malfuncti...
How the Scenario Editor Looks

11
Scenario Editor Default Library
• 
• 
• 
• 
• 
• 
• 
• 
• 
• 
• 

Reset IC
Run, freeze & delay
Action
Message
Command bloc...
An Example Scenario
If an instructor or engineer wishes to write
the following scenario:
• Reset to IC 74
• Run
• Run for ...
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 scen...
Scenario Manager Capabilities
•  Can hit one button, walk away and come back
to a finished test
•  Can run multiple proced...
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 ...
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 selecte...
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)
• ...
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....
SBT Comments from Engineers
•  Examples of SBT possible tests:
–  Boiler filling
–  ID fan trip
–  FD fan trip
–  PA fan t...
SBT Comments from Engineers
•  Supercritical boiler fill:
–  Reset to I/C just before fill process starts
–  Freeze at, e....
SBT Comments from Engineers
•  Simulator turbine model performance tests:
–  Steam turbine rolling
–  Steam turbine valve(...
SBT Comments from Engineers
•  Combined cycle simulator tests:
–  Multiple gas turbine MF and transient testing
–  Run one...
SBT Comments from Engineers
•  Simulator black plant testing:
–  Simulator electrical model allows you to
•  See more vari...
Use During Project Build Cycle
•  System Unit Testing (SUT) proves the
individual models are done and reaching
reasonable ...
Use During Project Build Cycle
•  During integration testing of simulator,
models interfaced with DCS controls.
–  Verifie...
Use During Project Build Cycle
•  Factory Acceptance Test (FAT)
–  Set up scenario-based testing during Pre-FAT
integratio...
SBT Summary Comments
•  Develop once, use many times
•  Improve consistency of testing
•  Use customer available “day time...
For more information:

Follow us on:

Go to:

www.GSES.com

Twitter @GSESystems

Call:

800.638.7912

Email:

info@gses.co...
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Fossil Power Simulator Efficiencies When Using Automated Testing

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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.

For more information, visit GSES.com, email info@gses.com, and follow us on Twitter @GSESystems and Facebook.com/GSESystems. Thanks for viewing!

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Fossil Power Simulator Efficiencies When Using Automated Testing

  1. 1. Fossil Power Simulator Implementation Efficiencies When Using Automated Testing info@gses.com
  2. 2. Overview •  Objective •  Some history •  JADE scenario-based testing •  SBT comments from engineers •  Use during the build cycle •  SBT summary comments 2
  3. 3. 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
  4. 4. 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
  5. 5. Automated Plant Procedures (APPs) •  For fossil projects, training-centric •  For nuclear projects, also used for testing 5
  6. 6. 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
  7. 7. 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
  8. 8. 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
  9. 9. 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
  10. 10. 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
  11. 11. How the Scenario Editor Looks 11
  12. 12. 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
  13. 13. 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
  14. 14. An Example Scenario Simple click and drop onto the grid: With popups to input data: 14
  15. 15. An Example Scenario The finished product: 15
  16. 16. 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
  17. 17. 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
  18. 18. Scenario Manager User Interface 18
  19. 19. Setting Up a Scenario 19
  20. 20. 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
  21. 21. Setting Up a Scenario •  Can link multiple variables to the scenario through imports or queries: 21
  22. 22. Using the Schedule List •  Multiple scenarios can be added to the list, where the order can be easily changed: 22
  23. 23. 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
  24. 24. Running the Scenario •  It will show which scenario is running and for how long: 24
  25. 25. The Scenario Report •  Once the scenario is finished there will be a report of the scenario: 25
  26. 26. The Scenario Report Contents •  Cover Page •  Summary •  Monitor parameter list (variables selected ex:1hdlit0003a_inp) •  Scenario summary •  Parameter charts (trends of variables) 26
  27. 27. Example of the Parameter Chart 27
  28. 28. The Scenario History •  The instructor/engineer has a set of history files for data analysis: 28
  29. 29. Example of the Parameter Chart 29
  30. 30. Example of the Parameter Chart 30
  31. 31. 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
  32. 32. 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
  33. 33. 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
  34. 34. 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
  35. 35. 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
  36. 36. 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
  37. 37. 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
  38. 38. 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
  39. 39. 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
  40. 40. 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
  41. 41. For more information: Follow us on: Go to: www.GSES.com Twitter @GSESystems Call: 800.638.7912 Email: info@gses.com Facebook.com/GSESystems
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