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

2. Chemical site Delfzijl

3. Delesto bv
50/50 Joint Venture between AkzoNobel Energy and Essent Energy
Supplier of power, heat and utilities to 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

4. Delesto bv

5. Delesto 1
Delesto 2
IP steam
LP steam

6. Delesto 2 9FA single shaf co-generation unit Power output 350 MW
Extraction flow: 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

7. 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)

11. Overview Delesto 1 systemDC
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

12. 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

13. 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

14. 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

15. Overview engineering / OTS systemDC
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

16. 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

17. 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 )

18. 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

19. 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

20. Operator Station Graphics ( 1 / 5 )

21. Operator Station Graphics ( 2 / 5 )

22. Operator Station Graphics ( 3 / 5 )

23. Operator Station Graphics ( 4 / 5 )

24. Operator Station Graphics ( 5 / 5 )

25. Instructor Graphics ( 1 / 4 )

26. Instructor Graphics ( 2 / 4 )

27. Instructor Graphics ( 3 / 4 )

28. Instructor Graphics ( 4 / 4 )

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