DCS Based Full Scope Simulator Development Experience

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DCS Based Full Scope Simulator Development
Experience

• Jerry Jen
• President COO
• 6 November, 2008

IAEA Technical Meeting Impact of Digital
Instrumentation and Control Technologies On the
Operation and Licensing of Nuclear Power
Plants 3-6 November 2008, Beijing, China
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Topics

• Introduction of GSE Systems, Inc.
• Simulator Development Process
• Lesson Learned from Implementing DCS Based Full
  Scope Simulator
• Success Story

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GSE Systems Overview

• Over 37 Years Customer Services
• Originally part of Singer Link Co. Provided
  flight, military, power industrial simulation
  since 1929
• First power plant simulator in 1971
• Captured major share of nuclear simulation market
  after TMI
• Changed name to S3 Technologies with divestiture
  of the Singer Co.
• GSE Systems formed April, 1994. www.gses.com
• ISO9001-2000 Certified for Manufacturing
  Simulators

Products and Services

• Training
• Plant Fundamentals
• Plant Operations
• Plant Maintenance

• Real-time Simulation
• Nuclear Power Plants
• Fossil Power Plants
• Chemical Process Plants
• US Navy
• Engineering Services
• Software Licenses

4
Business Updates
Customers Around the World
Full Scope Simulator Record
Office Locations Maryland, USA Corporate
Headquarter St. Mary Georgia USA North America
Office Georgia Tech USA Training Center
Office Nykopin Sweden GSE Power AB Beijing
China GSE China
1332 Londontown Blvd Sykesville,
Maryland 1-410-970-7800
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Simulator Development Process
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Importance of Simulator

• Simulator is a small step within the power plant
  overall construction process
• Simulator is a HUGE STEP to ensure the success of
  plant start-up and operation
• The Major Objective of Simulator
• (Panel Control based Power Plants)
• Operator Training

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Control Room with Hard Panel Controls
Fossil
Nuclear
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Control Room with DCS Controls
Drum CCGT Supercritical Ultra-Supercritical IGCC
Fossil
Nuclear
2G 3G 3G 4G
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Simulator Development with Hard Panels
Contract Award
Spec Proposal Conformation Program Plan
(Schedule Staffing) Engineering Lead Tasks
Software Development
Data Collection Scoping Review and Approval
Model Design Model Programming System Unit Test
Integration Software Hardware
Acceptance Test
Data Collection Scoping Review and Approval
Panel IC Design Panel Fabrication Panel IC
Testing
Ready For Training
Hardware Development
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Simulator Development with DCS
Contract Award
Spec Proposal Conformation Program Plan
(Schedule Staffing) Engineering Lead Tasks
Software Development
Data Collection Scoping Review and Approval
Model Design Model Programming System Unit Test
Integration Software DCS
Acceptance Test
Data Collection Scoping Review and Approval
Hardware Soft Panels
DCS Configuration CI Programming DCS FAT
Ready For Training
DCS Development
Stimulation Virtual Emulation
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Simulator DCS Approaches

• Full Stimulation
• Actual Plant DCS with Controller Cabinets and
  Actual Controllers
• Actual Operator Workstation with identical
  capability
• Actual Engineer Workstation with identical
  capability
• Partial/Hybrid Stimulation
• Actual Operator Workstation
• Emulated Control Logic and simulator specific
  interface
• Engineering Workstation CAN NOT be used
• Virtual Stimulation
• Actual Control Logic from controller to be
  Rehosted to PC
• Actual Operator Workstation
• Actual Engineer Workstation with identical
  capability
• Emulation
• Translated or Hard Coded DCS control logics
• Translated or Hard Codes HMI screens
• Engineering Workstation CAN NOT be used

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Simulator DCS Approaches

• Full Stimulation
• Functions identical to real plant DCS
• Partial/Hybrid Stimulation
• Functions similar to real plant DCS
• Virtual Stimulation
• Functions identical to real plant DCS
• Emulation
• Functions similar to real plant DCS

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Typical Simulator Configuration
Stimulated DCS
DCS Controllers
DCS
DCS Operator Stations
Third Party DCS Operator Station
Server (EWS)
Printers
DCS Data Highway
Hub
Panel I/O
Printers
Simulation Server
Simulation Engineering Station(s)
Instructor Station
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Typical Simulator Configuration
Virtual DCS
DCS
DCS Operator Stations
Third Party DCS Operator Station
Server (EWS)
Printers
DCS Data Highway
Hub
Printers
Simulation Server
Simulation Engineering Station(s)
Instructor Station
Soft Panel Station
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Typical Simulator Configuration
DCS Controllers or Computers
Database

• Plant Performance (Simulated Parameters)
• Plant Malfunctions
• Transmitter Failures
• Equipment Failures
• Instrument Noises
• etc
• Environmental Parameters
• Simulation Unique Functions
• Run, Freeze, Reset, Snapshot, etc

DCS Control Signals
API OPC Scramnet Etc
Database
Simulation Model Computers
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Simulator DCS Data Requirement List

• DCS I/O Database
• Point ID
• Type (AI, AO, DI DO)
• Description
• Range
• Units
• PID with DCS Point Identification
• DCS HMI Screen Captures (with database mapping)
• Third Party DCS/PLC Communication Protocol
• Etc

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Simulator Development with DCS
Contract Award
Spec Proposal Conformation Program Plan
(Schedule Staffing) Engineering Lead Tasks
Software Development
Data Collection Scoping Review and Approval
Model Design Model Programming System Unit Test
Integration Software DCS
Acceptance Test
Data Collection Scoping Review and Approval
Hardware Soft Panels
DCS Configuration CI Programming DCS FAT
Ready For Training
DCS Development
Stimulation Virtual Emulation
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Simulator Retune Process
Contract Award
Spec Proposal Conformation Program Plan
(Schedule Staffing) Engineering Lead Tasks
Software Development
Data Collection Scoping Review and Approval
Model Design Model Programming System Unit Test
Integration Software DCS
Acceptance Test
Data Collection Scoping Review and Approval
Hardware Soft Panels
DCS Configuration CI Programming DCS FAT
Ready For Training
DCS Development
DCS Configuration After Plant Start-up
Stimulation Virtual Emulation
Retune Process
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Lesson Learned
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Critical Path of DCS Development

• DCS Configuration Design
• DCS Venders
• Plant IC Engineering
• DCS IC Implementation
• CI
• HMI
• DCS FAT (Factory Acceptance Test)
• Reconciliation of Database and HMI
• Control Logic Basic Testing
• HMI Validation
• Tie Back Testing
• On-time Delivery of DCS to Plant and/or Simulator
  Vender
• DCS Change/Modification Tracking during Plant
  Start-up and Simulator Testing

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Project Implementation Challenges

• Database Challenges
• Inconsistent between plant and simulator database
• Incorrect point address
• Incorrect HMI point mapping
• CI Design Challenges
• Control logic does not work as designed
• Calculated points (equations, signs and etc) not
  consistent
• DCS Communication APIs
• Special I/O (panel controls, 3rd party DCS, PLCs
  and etc)
• DCS Simulation Unique Functions
• Not always working properly (freeze, run,
  snapshot, reset, etc)

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Critical Support for Simulator DCS Development

• Schedule direct support from DCS venders and/or
  Plant operators
• Simulation Vender should have in-house engineers
  who can operate and debug the DCS
• Simulation Vender should have in-house engineers
  who can develop and maintain the communication
  program between DCS and Simulation Host Computer

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Simulator Retune Process

• After Plant Start-up and Operational
• DCS Vender Uploads the Updated DCS Configuration
• Database (Re-address and/or New Points)
• Controller Logics Revised
• Control Constants Tuned
• Operator Workstation Graphics Revised
• Simulation Vender Retunes the Models
• Match the New DCS Database
• Match New Data of Plant Equipment
• Match Plant Performance (Tuning Process Models)

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Critical DCS Delivery Dates

• Fossil Project (12 to 15 Months)
• DCS final configuration shall be available for
  simulation modeling integration 5 months prior to
  final simulator delivery
• Nuclear Project (28 36 Months)
• DCS final configuration shall be available for
  simulation modeling integration 12 months prior
  to final simulator delivery

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On-going DCS Based Fossil Simulators
New Plants Addition of Systems DCS
Replacement/Upgrade Panel Control to DCS


VV Control Strategy Operator Training
Operator Training
Plant in Operation
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DCS Based Fossil Simulators Last 2 Years
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On-going DCS Based Nuclear Simulators

• Westinghouse AP1000 Human Factor Engineering (US)
• Emerson Ovation
• Validation of Human Factor Engineering
• PBMR Pebble Bed (South Africa)
• ABB Industrial IT
• Validation of Control Strategy
• Sanmen Haiyang AP1000 (China)
• Emerson Ovation
• Operator Training
• HongYanHe VV Platform (China)
• Autocad Based Design conversion to GSE Simulation
  Models
• Validation of Control Strategy and HMI
• Other Systems Specific DCS Upgrades
• Operator Training BOP System Control (Invensys
  Foxboro I/A)
• Operator Training Turbine Control (Emerson
  Ovation)

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Objectives and Benefits DCS Based Simulators

• VV of Control Strategy
• Proactive and preventive testing of plant process
  and DCS control logic
• Minimize the plant start-up and down time (lower
  cost of commissioning and operation)
• IC Engineering
• Training
• IC design and modification
• Operator Training
• Performance relies on
• High Fidelity/Engineering Grade Simulation Models

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Success Story

• Boiler Design Change Validation (Virtual DCS)
• Validation of new boiler (higher temperature) and
  DCS control strategy
• Outage Schedule Reduction (Stimulated DCS)
• Plant Refurbishment Outage reduction from 70 days
  to 40 days
• Feedwater Pump Control Strategy Validation
  (Stimulated DCS)
• Discovered the control error which was used for
  over 10 years
• Initial Plant Start-up Schedule Reduction
  (Stimulated DCS)
• Reduction of new plant initial start-up from 6
  months to 6 weeks
• DCS Network Strategy Validation (Stimulated DCS)
• Discovered the inefficiency/lack of through-put
  of one ring DCS network
• Replace and validate two ring DCS network on
  simulator prior to the installation of plant DCS

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Configurable Simulator Platform
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Q A