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!

1. Fossil Power Simulator Implementation
Efficiencies When Using Automated Testing
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2. Overview
• Objective
• Some history
• JADE scenario-based testing
• SBT comments from engineers
• Use during the build cycle
• SBT summary comments
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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.
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4. Some History
• Simulator vendors traditionally have a
Computer-Aided Exercise Program (CAEP)
• GSE uses a system designated as
Automated Plant Procedures (APP)
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Generation and run of pre-defined scenarios
Sequential set of expert commands
Often linked to trainee performance review
Student results are documented and saved
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5. Automated Plant Procedures (APPs)
• For fossil projects, training-centric
• For nuclear projects, also used for testing
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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
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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
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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:
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An affirmation checklist
Scenario procedures
Various log files
Parameter plots
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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.
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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
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11. How the Scenario Editor Looks
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12. Scenario Editor Default Library
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Reset IC
Run, freeze & delay
Action
Message
Command block
Decision blocks (3 types)
Condition
Set value
Trend, diagram & text field
System command
Exit condition
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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
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14. An Example Scenario
Simple click and
drop onto the grid:
With popups to
input data:
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15. An Example Scenario
The finished product:
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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
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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
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18. Scenario Manager User Interface
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19. Setting Up a Scenario
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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
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21. Setting Up a Scenario
• Can link multiple variables to the scenario
through imports or queries:
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22. Using the Schedule List
• Multiple scenarios can be added to the list,
where the order can be easily changed:
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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
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24. Running the Scenario
• It will show which scenario is running and
for how long:
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25. The Scenario Report
• Once the scenario is finished there will be a
report of the scenario:
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26. The Scenario Report Contents
• Cover Page
• Summary
• Monitor parameter list
(variables selected ex:1hdlit0003a_inp)
• Scenario summary
• Parameter charts (trends of variables)
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27. Example of the Parameter Chart
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28. The Scenario History
• The instructor/engineer has a set of history
files for data analysis:
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29. Example of the Parameter Chart
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30. Example of the Parameter Chart
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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
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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
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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
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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
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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
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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
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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
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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
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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)
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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
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41. For more information:
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