Operator Training Simulator for co-generation plant Delesto 2 Arnhem 3-feb. 2010 Henk Assink

Chemical site Delfzijl

Delesto bv 50/50 Joint Venture between AkzoNobel Energy and Essent Energy Supplier of power, heat and utilities to 14 chemical plants on the site Delfzijl in the Netherlands One of the largest co-generation plants in Europe(530 MW,750 t/h LP/IP steam) 76 employees, operated by Akzo Nobel

Delesto bv

Delesto 1 Delesto 2 IP steam LP steam

Delesto 2 9FA single shaf co-generation unit Power output 350 MW Extraction flow: 0-300 tons/hr Partial upgrade to FA+e technology during HGPI 2002 Base load unit, load flexibility within premix steady state (approximately 100 MW) Honeywell TDC-3000 control system

Maintenance schedule Delesto 2 Start commercial operation July 1999 Combustion Inspection September 2000 (8k) Hot Gas Path Inspection April 2002 (12k) Combustion Inspection March 2004 (16k) Major Inspection April 2006 (16k/32k) Combustion Inspection May 2006 (16k) Hot Gas Path Inspection April 2010 (12k)

Overview Delesto 1 system DC PHD Level 3,5 FIBER OPTIC Fault Tolerant Ethernet ESVT Klok EST 1 EST 26 EST 27 EST 2 EST 3 AM 13/14 TPS File server AM 24 HM 12 (red) LCN UCN 3 NIM 20/21 UCN 4 NIM 22/23 FIBER OPTIC HPM 05 HPM 05 HPM 07 HPM 07 HPM 09 HPM 13 HPM 13 HPM 09 HPM 11 HPM 15 HPM 11 HPM 15 HPM 17

Overview Delesto 2 system Fault Tolerant Ethernet FIBER OPTIC EST 4 AM 45/46 AM 47 LCN DELESTO 1 NIM 41/42 NIM 43/44 FIBER OPTIC Remote I/O HPM 05 HPM 05 FIBER OPTICS UCN 5 UCN 6 Remote I/O HPM 07 HPM 07 HPM 09 HPM 09 HPM 11 HPM 11 HPM 13 SMM 17 Safety Manager

Why an operator training simulator (OTS) Because of high reliability the operator is not familiar to abnormal situations (other side of success) Fully automated startup and shutdown sequences (two times push the button) One unit start/shutdown per year with a five shift organizations this means one start/shutdown per five years New operators do not have feeling with unit Dynamic simulator

starting-point OTS Operator interface look and feel Modular system Part of real DCS system Part of LCM (Life Cycle Management) contract Maintainable date-base Dynamic simulation Different scenarios by instructor Use engineering system hardware Time manipulation possible

Overview engineering / OTS system DC Instructor Facility Fault Tolerant Ethernet ESVT EST 26 EST 27 EST 1 EST 2 SX 3 TPS File server AM HM Plant Model TPS Emulation LCN NIM NIM HPM HPM UCN UCN SMM Safety Manager

UniSim Plant Simulator Process Area Models Cooling Water Systems Gas Turbine & Auxiliaries Condensate Boiler Feed Water Steam Turbine & Auxiliaries Generator & Auxiliaries Control / Logic Model GE Speedtronic MK 5 Governor

DCS Emulation Plant Control / Logic Start-Up & Shutdown Sequences Triconex Protection System Produced from actual plant configuration: EB & AM files AM / HPM CL files Configuration files ( .NCF ) Custom Data Point / Segment Definition files Parameter files ( .SP )

LCN – Simulation Interface SX003 Virtual Plant Control (VPC) for TPS Interface ( SX003 ) provides interface between: LCN and DCS Emulation / Plant Simulator Instructor Station and DCS Emulation / Plant Simulator Operates as an active node on the LCN mimics the presence of NM41, NM43 & AM45

Operator & Instructor Stations Operator Station ( EST ) with same set of graphics as actual plant Instructor Station Graphical interface to access the facilities of the system ( Running / Controlling the simulation & training ) Student Monitoring Field Operator Duty / Role Playing Scenario Generation / Management

Operator Station Graphics ( 1 / 5 )

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Operator Station Graphics ( 5 / 5 )

Instructor Graphics ( 1 / 4 )

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Demo Delesto OTS System Booth #50 AM HM NIM UCN HPM SMM Fault Tolerant Ethernet