Operator Training Simulator for Power Plant Combustion Optimization System Design

摘要

An Operator Training Simulator (OTS) provides many valuable services in support of power plant operation and design. The primary objective is operator training for start-up, shut downs, load management, equipment malfunctions and special case scenarios. Such training provides substantial operating cost savings by lowering unforced outage rates due to operator error and speeding startup and shutdown rates for additional revenue and fuel savings. OTS systems have supported control system upgrades and plant design enhancements by confirming design changes prior to installation in the actual plant. Such capability has become increasingly important for cyber security compliance. In this project a Combustion Optimization System (COS) was integrated with an OTS, comprised of both a process model and a complete emulation of the DCS control design. The OTS process model includes models of the air and fuel within the furnace and heat transfer models, allowing it to provide detailed predictions of emissions values, steam temperatures, spray flows and other parameters impacted by adjustments to fuel and air distribution. The complete emulation of the DCS control design allowed the full integration of the COS interface logic and graphic displays. The integrated system was applied to conduct parametric testing for COS model development. The faster than real time feature coupled with the full time availability provided for rapid generation of modeling data. The design of the COS was confirmed and potential benefits were quantified. Operator graphics and operating scenarios were available to train operators in the details of the impact of COS on operations. By applying the OTS, the interface logic and graphics were fully designed and checked out with preliminary models prior to touching the actual plant. This greatly reduced any operational concerns to the plant for the implementation of the COS and is yet another illustration of the value of an OTS.