Dr. Alexander Frick, PSP-E2 Simulator-assisted pre-commissioning of a power plant Experiences and Outlook © ABB 22.09.2018 Enter filename via "View - Header and Footer...". Apply to all. | 1

Outline Introduction Simulator-assisted Pre-Commissioning Approach Experiences and Best-Practices on the example Datteln power plant Outlook and future perspectives

Power Plant Simulators Applications Design & Verification Commissioning Optimization PP Simulators Marktanforderung und Situation: Bisher hatten Simulatoren in Deutschland wegen hoher Kosten und der guten Ausbildung der Anlagenfahrer eine untergeordnete Rolle. Zudem war Training on the Job durch die Training: Engineering / IBN: Losvergabe bei Kraftwerken führt zu vielen technischen Schnittstellen. Der Leittechnik hat die Aufgabe die Komponenten der einzelnen Lose zu integrieren. Es gibt Tendenzen auch die eine verfahrenstechnische Überprüfung dem Leittechniklos zuzuschlagen. Überprüfung der leittechnischen Vorgaben der Verfahrenslieferanten soll frühzeitig durchgeführt werden. Kurze Inbetriebnahmezeiten führen zu Qualitätsproblemen nach dem kommerziellen Betreib, da viele Dinge nicht ausreichend geprüft werden können. Training

Approach without Simulator Customer Comp. Supplier Customer Comp. DCS Supplier Supplier Customer Comp. DCS Supplier Supplier Design Meetings DCS Design Meetings Commissioning Basic V&V Detail + DCS V&V Comm. Cost

Approach without Simulator Customer Comp. Supplier Customer Comp. DCS Supplier Supplier Customer Comp. DCS Supplier Supplier Design Meetings DCS Design Meetings Commissioning Basic V&V Detail + DCS V&V Comm. Cost

Approach with Simulator Customer Comp. Supplier Customer Comp. DCS Supplier Supplier Customer Comp. DCS Supplier Supplier Design Meetings DCS Design Meetings Commissioning Process Simulator Proc.+DCS Simulator Training Simulator Basic V&V Detail + DCS V&V Comm.

Approach with Simulator Experience Customer Comp. Supplier Customer Comp. DCS Supplier Supplier Customer Comp. DCS Supplier Supplier Design Meetings DCS Design Meetings Commissioning Process Simulator Proc.+DCS Simulator Training Simulator Basic V&V Detail + DCS V&V Comm.

Configuration for configuration and training RDE

Approach System 800xA Simulator Configuration Workplaces Diagnose Asset Management Engineering System Server Emulator Prozess Simulator Plant Network Instruktor Workplace > 35000 I/Os BI > 12000 BO > 5000 AI > 6000 AO > 1000 38 CPUs Communication interval of I/Os: 100ms

Experience Automation Concept Blockleitprogramm Antriebsebene Ein/Ausgabe Ölversorgung Hilfsdampf Evakuierung SpW-Reg KSP Wellendrehen Frischlüfter Gruppenebene Blockleitebene Saugzug SpW-Pumpe Umwälzung Ölbrenner 11 Ölbrenner 1n LP Turbine Regler-Struktur Programm SWF Block Öl-Reg E1 Öl-Reg E5 Zut-Reg Mue1 Zut-Reg Mue5 Luft-Reg Br 11 Luft-Reg Br 44 Turbinen-Regler Blackbox FG Luft/RG FG SpW-Sys Lu/O2-R Enth-R Block-Regelung MODAKOND Kondensat-Reg FG Feuerung Kohlemühle 1 FG Feu E1 Ölbrenner 41 Ölbrenner 5n Kohlemühle 5 FG Feu E5 Brst E1 Brst E5 Brst-HR LP Kessel LP REA LP Allgem LP Denox

Experience Automation Concept Blockleitprogramm Antriebsebene Ein/Ausgabe Ölversorgung Hilfsdampf Evakuierung SpW-Reg KSP Wellendrehen Frischlüfter Gruppenebene Blockleitebene Saugzug SpW-Pumpe Umwälzung Ölbrenner 11 Ölbrenner 1n LP Turbine Regler-Struktur Programm SWF Block Öl-Reg E1 Öl-Reg E5 Zut-Reg Mue1 Zut-Reg Mue5 Luft-Reg Br 11 Luft-Reg Br 44 Turbinen-Regler Blackbox FG Luft/RG FG SpW-Sys Lu/O2-R Enth-R Block-Regelung MODAKOND Kondensat-Reg FG Feuerung Kohlemühle 1 FG Feu E1 Ölbrenner 41 Ölbrenner 5n Kohlemühle 5 FG Feu E5 Brst E1 Brst E5 Brst-HR LP Kessel LP REA LP Allgem LP Denox 70 percent of works

Work flow commissioning 1. Pre-Testing with RDE 2. Main Test mit E.ON und RDE 3. Overall Simulator

Technical Challenges Detailed process information Interface specification especially for more complex drive types (Profibus) Positions of binary transmitters, for example in tanks Pump and Fan curves Flow calculations FG Luft/RG FG SpW-Sys FG Feuerung Gruppenebene FG Feu E1 FG Feu E5 Ölversorgung Hilfsdampf Frischlüfter Saugzug SpW-Pumpe Umwälzung Ölbrenner 11 Ölbrenner 1n Kohlemühle 1 Ölbrenner 41 Ölbrenner 5n Kohlemühle 5 Wellendrehen Evakuierung Antriebsebene Ein/Ausgabe Blackbox

Organizational Challenges Commissioning of simulation requires the presence of the component suppliers Transfer of DCS functions from the design data base into the simulator environment Transfer of commissioned functions from the simulator environment back to the design database Customer Comp. DCS Supplier Supplier DCS Design Design Meetings DCS Proc.+DCS Simulator

Simulator Data Back-Transfer A&E Back-transfer 1:1 likely Controller Para. FG MP Back-transfer maybe Consoles Graphics Controller Parameters Data sustainability Back-transfer unlikely Run (up) Times Simple Complex Simple Complex Sequences / Open Loop Control Graphics / Faceplates Dynamics and Closed Loop Controls

Outlook and Perspectives Simulator assisted pre-commissioning of a power plant requires The pre-commissioning of a power plant is to be handled like a „real power plant“ project. Decision regarding changes to the process simulator or DCS application must be taken fast at the simulator site.