This document describes the design and implementation of a high-fidelity simulator for two combined cycle gas turbine (CCGT) power plants. The simulator models the Alstom gas turbines, triple-pressure boilers, once-through steam generators, and steam turbines. It is fully integrated with the actual control system used at the plants, including the ABB 800xA DCS. The simulator allows for training operators on the CCGT plants in a realistic but safe environment.

1. Design and Implementation of a
High-Fidelity, Full-Scope Training Simulator for a
Triple-Pressure CCGT Power Plant
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2. Summary
• Introduction
• Plant configuration
• Simulator configuration
• DCS configuration
• Model
• Conclusion
2

3. Introduction
• Two new CCGT plants
• Commissioned last 2 years
• Training improvement
• 18-month project
• New training center in
Didcot, England
3

4. Introduction
• Pembroke, Wales
– Sea water cooled
– ~450 MW
– 5 units
• Staythorpe, England
–
–
–
–
Cooling water towers
~430 MW
4 units
Light oil (not used)
4

5. Plant Configuration
• Alstom GT26 gas turbine
– Two-stage combustion, HP and LP turbine
– Efficiency 39.6%
– Compression ratio 33.3:1
5

6. Plant Configuration
• Triple-pressure boiler
– LP system adds ~8 MW
– HP system T = 565 C, P = 138 bar(a)
– Exit flue gas temperature ~85 C
– Allows for higher total efficiency
– Steam turbine output >160 MW
• Overall efficiency >58%
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7. Plant Configuration
• Once-through coolers
(OTC)
– Compressor air-cooled
by feed water
• Single shaft with a
clutch
– Allows fast and flexible
run-ups
– Cooled air used to cool
blades
– Steam feeds back to
HRSG
– Preserved efficiency
– Helix type Hx
7

8. Schematic of Modeled HRSG
8

9. GSE Simulation Software Overview
DCS
Operator Stations
Simulator
DCS
Soft Panels
JStation
SmartTutor
I/O Systems
SimExec
JADE
JTopmeret
JControl
JLogic
JElectric
ISIS
Power Plant
9

10. Simulator Description
• A high-fidelity full-replica type simulator
– HMI and control system identical
– Hardware (I/O cards) emulated
• Emulator controlled by “ITS Link Tool”
– JStation™ controls emulator via ITS interface
• Both simulators/DCSs on same hardware
– Different domains, requires a system reboot
(dual-boot hardware) of DCS
– Same for simulator hardware
10

11. Simulator Architecture
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12. DCS Configuration
• ABB 800xA (Graphics, BoP, common parts)
• ABB AC160 (GT and ST controllers)
– AC160 controller translated to AC400
• I/O communication done with OPC server
– Reading and writing in SimExec database
– 10 Hz
• Allows for on-the-fly snapping of ICs (backtracks)
• Saves 5 h historical data in ICs (trends)
12

13. Modeling Tools
• JTopmeret™
–
–
–
–
Gas turbine
HRSG
Main steam
BoP
• ISIS™
– Components
– Mal and remote
functions
• JStation™
• JElectric™
– Electric generation
– Electric distribution
– Connected to ITS
• JDesigner™
– Operator hard desk
13

14. GT and Compressor Model
• Compressor and gas turbine work-based
isentropic efficiency
• Efficiency crucial for
temperatures
• Non-ideal Rankine
• Air humidity, pressure
and temperature
impacts on efficiency
14

15. Combustion Model
• If sufficient oxygen, ideal combustion
• Using available gas species in JTopmeret
– ​"#↓4 + ​&↓2 → ​"&↓2 + ​&↓2 + ​#↓2 & + ​"#↓4
– ​'&↓( and CO based on empirical data
• Combustion energy added into JTopmeret gas
enthalpy
– Dynamic flue gas specific heat (Cp), based on
temperature and gas species to achieve correct
gas temperatures
15

16. JTopmeret
• JTopmeret
– Mass, thermal and impulse balance
– Two-phase
– Non-condensables
– Oil
– All models run at 40 Hz
– Flexible and robust enough to handle most aspects
of a CCGT simulator
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17. Gas Turbine System Model
• GT modeled in
JTopmeret
– Air inlet
– VIGVs
– Compressor
– Gas turbine
– OTC air side
– GT enclosure
– GT cooling
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18. HRSG/Main Steam Model
• HRSG modeled in JTopmeret
– Flue gas side
– Steam/water side
– Drums and evaporators with natural circulation
– Feed water tank, pumps and heaters
– OTC water/steam side
• Main steam modeled in JTopmeret
– Turbines
– Condenser
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19. Possible Future Projects
• MXL2 upgrade on Staythorpe and Pembroke
commissioned
– Possible simulator upgrade
• Increased air flow
• New LP turbine blades (higher efficiency)
• New control functions:
– ‘M’ mode maximum load (+ 13-23 MW)
– ‘XL’ mode, flexible mode with lower temperatures
(longer time between inspections)
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20. Conclusions
• JTopmeret flexible and powerful enough for
modeling a complete CCGT plant
– New JTopmeret release includes fully integrated
combustion, gas turbine and compressor models
– Should be able to handle future upgrades
• Successfully integrated with ABB systems
– Communicating and controlling with 800xA and
AC400 emulators
– AC160 can be translated to AC400
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22. For more information:
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www.GSES.com
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