Automated Simulation Integration

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Automated Simulation Integration

• Supporting Digital Control System Upgrade Projects

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Presentation Overview

• Investigate a control response issue on a digital
  turbine governor control system
• Determine root cause
• Determine why the issue wasnt detected during
  pre-commissioning software verification and
  validation tests
• Integrate control software into full-scope and
  desktop simulators
• Summary

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1. Control Response Issue
60 Load Rejection Control Response
Turbine Valve Configuration
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2. Determining Root Cause (1 of 3)
Turbine Valve Configuration
Standard IEEE Cross-Compound Model
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2. Determining Root Cause (2 of 3)

• Representative Turbine Model

Simulated 60 Load Rejection Response
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2. Determining Root Cause (3 of 3)

• Connecting the process model to the vendor
  control software, the problems were summarized as
  follows
• Tracking behaviour of the vendors PID block
• Intercept valve control after fast valving

Projected 60 Load Rejection with Corrections
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3. Software VV Review

• Problem
• The original control software was not validated
  with a representative turbine model or the
  vendor's actual controller software
• Conclusions
• Simulation models must be sufficiently complete
  to model all controlled devices that effect
  controlled variables
• It is not valid to apply simplifications to the
  control software under test. All control
  features like fast valving in this case can
  have side effects

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4. Simulator Integration (2 of 3)
Solution Write a configuration translating code
generator
/
/ / Function block FX
03.01.05.7971 / / Control logic document
'30105110 NR SPEED STATION' sheet 'Sheet1'
/ FC001RT(FB0301057971) /

/ / Function block FX 03.01.05.7972 / /
Control logic document '30105110 NR SPEED
STATION' sheet 'Sheet1' / FC001RT(FB0301057972)
/
/ / Function block
M/A-M 03.01.05.7973 / / Control logic document
'30105110 NR SPEED STATION' sheet 'Sheet1' / /
Refresh conversion variables / U7BM5SPEEDSTATIONE
LD_3 U7B0301050000_O_B0_3 U7BM5SPEEDSTATIONAOB_
3 U7B0301050000_O_B0_3 FC080RT(FB0301057973)
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4. Simulator Integration (1 of 3)

• Integrating the control software into the
  plants full-scope and desktop simulators
• Issues
• Storepoint synchronization eliminates hardware
  in the loop options
• Scalability to both targets eliminates
  third-party emulation options
• Large control program size
• Maintenance

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4. Simulator Integration (3 of 3)
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5. Summary

• The control response problem has been resolved.
• The code generator has been developed and model
  integration has been completed
• Bruce Power plan to integrate another control
  system using this code translation approach, and
  this time simulator integration will be prior to
  installation
• Simulator integration efficiency is much improved
• This approach will enable the Bruce Power
  simulator team to play a significant role in
  software and operating procedure validation in
  the future