Designing a High-Fidelity Full-Scope Training Simulator for a Triple-Pressure CCGT Power Plant

Design and Implementation of a High-Fidelity, Full-Scope Training Simulator for a Triple-Pressure CCGT Power Plant

[email protected]

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Summary

•  Introduction •  Plant configuration •  Simulator configuration •  DCS configuration •  Model •  Conclusion

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Introduction

•  Two new CCGT plants •  Commissioned last 2 years •  Training improvement

•  18-month project •  New training center in

Didcot, England

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Introduction

•  Pembroke, Wales –  Sea water cooled –  ~450 MW –  5 units

•  Staythorpe, England –  Cooling water towers –  ~430 MW –  4 units –  Light oil (not used)

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Plant Configuration

•  Alstom GT26 gas turbine –  Two-stage combustion, HP and LP turbine –  Efficiency 39.6% –  Compression ratio 33.3:1

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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%

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Plant Configuration

•  Once-through coolers (OTC) –  Compressor air-cooled

by feed water –  Cooled air used to cool

blades –  Steam feeds back to

HRSG –  Preserved efficiency –  Helix type Hx

•  Single shaft with a clutch –  Allows fast and flexible

run-ups

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Schematic of Modeled HRSG

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GSE Simulation Software Overview

JTopmeret JControl JLogic JElectric ISIS

Soft Panels JStation SmartTutor

DCS Operator Stations

JADE

I/O Systems Simulator DCS

SimExec

Power Plant

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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

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Simulator Architecture

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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)

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Modeling Tools

•  JTopmeret™ –  Gas turbine –  HRSG –  Main steam –  BoP

•  JElectric™ –  Electric generation –  Electric distribution

•  ISIS™ –  Components –  Mal and remote

functions

•  JStation™ –  Connected to ITS

•  JDesigner™ –  Operator hard desk

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GT and Compressor Model

•  Efficiency crucial for temperatures

•  Non-ideal Rankine •  Air humidity, pressure

and temperature impacts on efficiency

•  Compressor and gas turbine work-based isentropic efficiency

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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

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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

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Gas Turbine System Model

•  GT modeled in JTopmeret –  Air inlet –  VIGVs –  Compressor –  Gas turbine –  OTC air side –  GT enclosure –  GT cooling

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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

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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)

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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

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