Designing a High-Fidelity Full-Scope Training Simulator for a Triple-Pressure CCGT Power Plant
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This document describes the design and implementation of a high-fidelity simulator for two combined cycle gas turbine (CCGT) power plants. The simulator models the Alstom gas turbines, triple-pressure boilers, once-through steam generators, and steam turbines. It is fully integrated with the actual control system used at the plants, including the ABB 800xA DCS. The simulator allows for training operators on the CCGT plants in a realistic but safe environment.
Designing a High-Fidelity Full-Scope Training Simulator for a Triple-Pressure CCGT Power Plant
- 1. Design and Implementation of a High-Fidelity, Full-Scope Training Simulator for a Triple-Pressure CCGT Power Plant info@gses.com
- 2. Summary • Introduction • Plant configuration • Simulator configuration • DCS configuration • Model • Conclusion 2
- 3. Introduction • Two new CCGT plants • Commissioned last 2 years • Training improvement • 18-month project • New training center in Didcot, England 3
- 4. Introduction • Pembroke, Wales – Sea water cooled – ~450 MW – 5 units • Staythorpe, England – – – – Cooling water towers ~430 MW 4 units Light oil (not used) 4
- 5. Plant Configuration • Alstom GT26 gas turbine – Two-stage combustion, HP and LP turbine – Efficiency 39.6% – Compression ratio 33.3:1 5
- 6. Plant Configuration • Triple-pressure boiler – LP system adds ~8 MW – HP system T = 565 C, P = 138 bar(a) – Exit flue gas temperature ~85 C – Allows for higher total efficiency – Steam turbine output >160 MW • Overall efficiency >58% 6
- 7. Plant Configuration • Once-through coolers (OTC) – Compressor air-cooled by feed water • Single shaft with a clutch – Allows fast and flexible run-ups – Cooled air used to cool blades – Steam feeds back to HRSG – Preserved efficiency – Helix type Hx 7
- 8. Schematic of Modeled HRSG 8
- 9. GSE Simulation Software Overview DCS Operator Stations Simulator DCS Soft Panels JStation SmartTutor I/O Systems SimExec JADE JTopmeret JControl JLogic JElectric ISIS Power Plant 9
- 10. Simulator Description • A high-fidelity full-replica type simulator – HMI and control system identical – Hardware (I/O cards) emulated • Emulator controlled by “ITS Link Tool” – JStation™ controls emulator via ITS interface • Both simulators/DCSs on same hardware – Different domains, requires a system reboot (dual-boot hardware) of DCS – Same for simulator hardware 10
- 12. DCS Configuration • ABB 800xA (Graphics, BoP, common parts) • ABB AC160 (GT and ST controllers) – AC160 controller translated to AC400 • I/O communication done with OPC server – Reading and writing in SimExec database – 10 Hz • Allows for on-the-fly snapping of ICs (backtracks) • Saves 5 h historical data in ICs (trends) 12
- 13. Modeling Tools • JTopmeret™ – – – – Gas turbine HRSG Main steam BoP • ISIS™ – Components – Mal and remote functions • JStation™ • JElectric™ – Electric generation – Electric distribution – Connected to ITS • JDesigner™ – Operator hard desk 13
- 14. GT and Compressor Model • Compressor and gas turbine work-based isentropic efficiency • Efficiency crucial for temperatures • Non-ideal Rankine • Air humidity, pressure and temperature impacts on efficiency 14
- 15. Combustion Model • If sufficient oxygen, ideal combustion • Using available gas species in JTopmeret – "#↓4 + &↓2 → "&↓2 + &↓2 + #↓2 & + "#↓4 – '&↓( and CO based on empirical data • Combustion energy added into JTopmeret gas enthalpy – Dynamic flue gas specific heat (Cp), based on temperature and gas species to achieve correct gas temperatures 15
- 16. JTopmeret • JTopmeret – Mass, thermal and impulse balance – Two-phase – Non-condensables – Oil – All models run at 40 Hz – Flexible and robust enough to handle most aspects of a CCGT simulator 16
- 17. Gas Turbine System Model • GT modeled in JTopmeret – Air inlet – VIGVs – Compressor – Gas turbine – OTC air side – GT enclosure – GT cooling 17
- 18. HRSG/Main Steam Model • HRSG modeled in JTopmeret – Flue gas side – Steam/water side – Drums and evaporators with natural circulation – Feed water tank, pumps and heaters – OTC water/steam side • Main steam modeled in JTopmeret – Turbines – Condenser 18
- 19. Possible Future Projects • MXL2 upgrade on Staythorpe and Pembroke commissioned – Possible simulator upgrade • Increased air flow • New LP turbine blades (higher efficiency) • New control functions: – ‘M’ mode maximum load (+ 13-23 MW) – ‘XL’ mode, flexible mode with lower temperatures (longer time between inspections) 19
- 20. Conclusions • JTopmeret flexible and powerful enough for modeling a complete CCGT plant – New JTopmeret release includes fully integrated combustion, gas turbine and compressor models – Should be able to handle future upgrades • Successfully integrated with ABB systems – Communicating and controlling with 800xA and AC400 emulators – AC160 can be translated to AC400 20
- 22. For more information: Go to: www.GSES.com Follow us on: Call: 800.638.7912 Twitter @GSESystems Email: info@gses.com Facebook.com/GSESystems