The document discusses the development of a simulator for DTE Energy's Belle River Power Plant Unit 2. It describes the plant's history and recent control system upgrades. A collaboration between GSE Systems, DTE Energy, and ABB created a high-fidelity simulator to train operators, test control system changes, and eliminate extensive testing during the unit's startup. Lessons learned helped improve the simulator's model, data sources, and ability to keep in sync with the actual unit. Future objectives include expanding training and validating environmental solutions.
2. 2
Speakers
George McCullough
Vice President
GSE Systems
Baltimore, MD
Fred Ihimodu
Staff Engineer – Engineering
Support Organization
DTE Energy
Detroit, MI
Speaker:
Title:
Company:
Location:
3. 3
Belle River Power Plant:
A Brief History
5 Diesel Peakers – 13.75 MW commissioned 1981
2 Coal Units – 1,396 MW commissioned 1984 - 1985
3 Natural Gas Peakers - 256 MW commissioned 1999
4. 4
Project History:
Recent Control Systems Upgrades
2002 - Unit 2 conversion to ABB Harmony
2008 - Unit 1 conversion to ABB Harmony
2012 - Unit 2 conversion from VMS OIS to 800xA 5.1
- Unit 2 simulator development
2013 - Unit 1 upgrade from 800xA 5.0 to 5.1
- Environmental solutions
5. 5
Proposed Benefits
Training operators & others
Platform to simulate future environmental solutions control system
for units 1 & 2
Complete graphics review prior to unit 2 start-up in fall 2012
Eliminate typical extensive IO checkout during unit 2 fall 2012
Platform to test control philosophy, software configuration
and graphic changes prior to implementing on unit 1 & 2
6. 6
Partners & Teams
GSE Systems
Lead engineer and design team
Project management
ABB
Lead engineer and design team
Project management
DTE Energy
Plant operations
Plant engineers and I&C specialists
Process controls engineering support
Major enterprise project management
7. 7
Unit 2 Simulator Team:
Preparation
Simulator conference exposure
Same personnel on both simulator and unit DCS upgrades
Critical to have continuity across all projects
Experienced operators familiar with units
Engineers & specialists with vast knowledge of control systems
Travel commitments
8. 8
Model:
GSE Concepts
Power Generation Modeling Tools
Thermal hydraulic systems
Flow networks
Electrical systems
Logic & controls
High Fidelity
Fully modeled
Simplified model
Not modeled
16. 16
Decisions:
Not Always Black & White
Immersion vs. feedback
Immersion vs. human performance
Redundancy needs vs. test environment completeness
Access to information vs. role clarification
18. 18
Lessons Learned
Uncovered and resolved existing configuration, logic & graphics
HTS limitations & compatibilities
– Unsupported function codes
Comprehensive startup procedure
Model – Data sources handshake
19. 19
Lessons Learned
System health checks
VMware vCPU allocation
Event concentrator error
Ensure overall system is truly ready for customer
20. 20
Current/Future Objectives
Establish core training program
Expand training benefits beyond operations to
technicians & engineers on engineering tools
− Composer
− Bulk data manager
− Bulk configuration manager
− Graphics builder
− Alarm analysis
− Import/export tool
− Consistency checker, etc.
21. 21
Current/Future Objectives
Model future environmental solutions
- Validate plant design & procedures prior to start-up
Implement management of change to keep the
simulator & unit in sync
Enhancement request
- vICI and HTS manager services