Fossil Power Simulator Implementation Efficiencies When Using Automated Testing

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Overview

•  Objective

•  Some history

•  JADE scenario-based testing

•  SBT comments from engineers

•  Use during the build cycle

•  SBT summary comments

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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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Some History

•  Simulator vendors traditionally have a Computer-Aided Exercise Program (CAEP)

•  GSE uses a system designated as

Automated Plant Procedures (APP) •  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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Automated Plant Procedures (APPs)

•  For fossil projects, training-centric •  For nuclear projects, also used for testing

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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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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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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: •  An affirmation checklist •  Scenario procedures •  Various log files •  Parameter plots

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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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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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How the Scenario Editor Looks

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Scenario Editor Default Library

•  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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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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An Example Scenario

Simple click and drop onto the grid:

With popups to input data:

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An Example Scenario

The finished product:

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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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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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Scenario Manager User Interface

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Setting Up a Scenario

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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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Setting Up a Scenario

•  Can link multiple variables to the scenario through imports or queries:

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Using the Schedule List

•  Multiple scenarios can be added to the list, where the order can be easily changed:

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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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Running the Scenario

•  It will show which scenario is running and for how long:

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The Scenario Report

•  Once the scenario is finished there will be a report of the scenario:

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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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Example of the Parameter Chart

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The Scenario History

•  The instructor/engineer has a set of history files for data analysis:

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Example of the Parameter Chart

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Example of the Parameter Chart

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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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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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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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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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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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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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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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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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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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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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