This presentation shares his insights on design simulation and the new role of the simulator in Simulator Assisted Engineering. For more information, go to GSES.com, email info@gses.com, or call 800-638-7912. You can also follow GSE at @GSESystems and Facebook.com/GSESystems.

1. Real-time Engineering Simulators:
A High Value Component for Design and Validation
info@gses.com

2. Imagine. Empower. Improve.
2

3. Company Evolution
Singer Link Miles
Dawn of a Market
1929
S3 Technologies
The Singer Company
Link Simulation
ManTech Int’l
1st Nuclear
1971
1979
TMI & Chernobyl Drive Market
1990
GSE Systems
GPI / S3 Technologies / EuroSim
Graphical Technology
1994
Engineering V&V
2007
Aging Workforce
2013
3

4. Leveraging our Simulation Heritage
TRAINING
ENGINEERING
CHANGING THE WAY THE ENERGY INDUSTRY
LEARNS
TECHNOLOGY TO MITIGATE RISK, SAVE TIME &
MONEY
• Situated learning
• View design scenarios virtually
• High engagement, powerful content
• Identify and correct problems before construction
• Triggers profound reflections
• Avoid delays
• Rapid understanding of complex environments
• More effective human machine interface
• Demonstrates how actions affect context
• Avoids limits of “chalk & talk”
4

5. Changing the Way the Energy Industry Learns
High-Fidelity
Simulation
NUCLEAR SYSTEMS
VIRTUAL WALK-THROUGH
CRITICAL EQUIPMENT DIAGNOSTIC
EQUIPMENT FUNDAMENTALS
5

6. GLOBAL REACH
1,000+ INSTALLATIONS / 160+ CUSTOMERS / 50+ COUNTRIES
•
•
Global HQ
Branch Office
10 Locations
6 Countries
6

7. Introduction
• Digital Instrumentation and Control (I&C) and
Digital Control Rooms have become a key focus
of the Power industry.
• New plants’ designs and the life extension of
older plants require the industry and the
regulator to understand and validate these
system designs.
• The Real-time or Dynamic Simulator is playing a
valuable role in the design of these new systems.
7

8. Background
• Real-time simulators came to the Nuclear
industry as training tools in the 1970s
– Full plant modeled but computing power limited the fidelity
– Models often “hand crafted” to mimic plant dynamics
– Basic models adequate for analog controls, traditional hard
panel control panels and “Old School” plant process computer
• Today’s NPP Simulator is high fidelity
– Scope is the same, but…
• High-definition (HD) predictive models used to model plant systems
• Engineering grade models for Thermodynamics and Neutronics
• HD first principle models used for all other systems
– Digital Controls and Modern HSI’s provide detailed view of
systems
Today the Real-time simulator is a true engineering tool, as a
holistic dynamic plant model.
8

9. Critical issues for new plant design
and construction
• Plants are using new technology.
• New control and information systems are being
introduced that have extensive and complex
control and logics.
• The plant will integrate disparate technologies
often for the first time.
• Coordination of the technology providers for the
unit operations, and the integration and design of
the plant is a huge concern.
• Aggressive scheduling is required to improve the
return on investment (ROI).
9

10. Role of the “Engineering” Simulator
• Holistic engineering V&V platform
• Controls system design and V&V
• Human factors engineering platform
• Develops and validates operating procedures
• Provides the plant buyer an ANS 3.5 Simulator
for training & licensing operators early in the
plant design and construction process
10

11. High Fidelity Predictive Models
• Idaho National Lab’s RELAP5-3D
– Real-time version of the industry standard
reactor transient analysis code
• Studsvik’s Simulate-3R Neutronics
Model
– Real-time version of the Simulate 3 Fuel Analysis
Code
• EPRI’s MAAP5
– Containment and severe accident analyses
11

12. GSE’s High Fidelity Predictive Models
• GSE’s High Fidelity Modeling Tools
–
–
–
–
JTopmeret: Two phase BOP system modeling
JControl: High fidelity control modeling
JElectric: High fidelity electrical system modeling
JDesigner: Flexible HIS development environment
The Key: Predictive models are necessary for
engineering simulators.
12

13. I&C Design Platform
• The platform is an integration of:
– JControl (control & logic design and modeling tool),
– JDesigner (HMI design tool), and
– ISIS Information Management System.
• The JControl and JDesigner have been deployed
in hundreds of projects worldwide over the past
decade.
13

14. The ControlSim Environment
14

15. DCS Validation
• Test DCS control strategy & Implementation
– Interaction between safety and non-safety systems
– Interaction with local (remote) plant controls (non-CCR
operators)
• Test DCS implementation
– Ensure logic and control is implemented properly
– Ensure setpoints are properly determined and implemented
Dynamic Model
Control Design
Test Results &
Performance
15

16. Typical Problems Found During
Simulator Development
Finding these problems before construction and
commissioning saves time and money:
• Logic
– Incorrect permissives preventing equipment to start
– Signals connected incorrectly
• Graphics
– Incorrect tags so data not displayed correctly
– Incorrect feedback
16

17. Typical Problems Found During
Simulator Development cont’d
• Control
– Control loops not connected
– Feedback loops not connected
– KP/KI inverted
• Transmitters
–
–
–
–
Range incorrect
Units inconsistent
Range inconsistent with logic
Instrument calibration and signal scaling
17

18. New Uses Simulation – Human Factors
Engineering
• New Control Room Layouts
• New DCS based operator
interface
•
•
•
•
•
•
•
•
•
Location of information
Navigation through 300+ screens
Density of information
Information overload
Problem diagnosis and resolution
Alarm management
Supervisor’s role and information
system
Electronic procedures
Regulator comfort
18

19. HFE Simulators
• USNRC
– Upgrade and convert existing
simulator with Digital Human
System Interface
– RELAP5-HD primary model
– Digital Control Room interface
• USNRC
– Generic PWR (ANS 3.5 Simulator)
– VPanel Interface Platform
– Developing Digital HIS
• INL
– Generic PWR (ANS 3.5 Simulator)
19

20. GSE First of a Kind/Engineering Simulator Experience
Westinghouse AP1000
Ultra Supercritical Korea
NuScale Power
Pebble Bed
Modular Reactor
HYH CPR-1000 HFE
and Control V&V
Platform
IGCC China
SMART Korea
Atomic Energy
Research Institute
B&W mPower
Engineering
and HFE
Simulator
20

21. Chinese CPR1000
• Project
Objectives/Deliverables
– Deliver a DCS V&V Platform
Simulator
– Using simulator to design
and V&V Control Strategy,
DCS HMI and Automated
Operating Procedures
– V&V in total of 9 revisions of
DCS I&C and HMI
synchronize with design
progress
– Plant Automated Operating
Procedure and Alarming
System was constructed
using the simulator
Configuration Menus
For Importing AutoCAD Drawings
Test/Scenario Preparation
Building and Running the Test
Report Generation
Post Test Analysis
Export Functions
Test Observations/Comments
Exit
21

22. Chinese CPR1000
• Project Status
– Project has been completed and delivered
– Purchaser engineers have been trained for continuing the DCS
V&V during plant construction
• Project Duration
– December 2007 to December 2009
22

23. GSE Project Success Factors
• Engineering grade predictive models
• Successful approach for teaming with plant
vendors:
– Development of a flexible team
• Team made up of GSE and Customer Engineers to facilitate Sim
Technology Transfer
• Reach Back to experienced system experts to support data gaps
– Integrated development environment
• VPN access between development site and customer
• Leveraging of electronic data to automate development
• Just in time collaboration and support.
– GSE’s experience on full scope projects reveals that the
relationship between the parties should be viewed as a
partnership
23

24. The Value
Reduce design cost and project risk for the
following:
Validate Plant System Process Designs
Design & Validate Digital I&C Strategy
Design & Validate Human Machine Interface
Use as a Platform for Human Factor Engineering (Control Room
Design)
– Validate Plant Operation Procedure
–
–
–
–
Bottom line: identify and correct design flaws early in
the design process.
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25. Thank You
We hope you enjoyed this presentation. View the recording of this
webinar here: www.gses.com/resources/presentations#HFE
For more information:
Visit: gses.com
Call: +1.800.638.7912
Email: info@gses.com
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