Simulator

1. Basic structure of simulator

The simulator is mainly composed of two parts: the hardware part and the software part.

1.1. Simulator hardware

The hardware system of the simulator mainly includes:

Main computer;

I / O interface;

The DCS console is made of materials close to the site, and the BTG panel and control panel are realized by virtual console technology;

Engineer / coach desk;

Process control computer simulation microcomputer;

Local operation station equipment;

Main control room environment simulation device;

Computer network, etc.

1.2. Simulator software

The software system of the simulator mainly includes:

Computer operating system software;

Simulation support system software;

Process mathematical model software;

Function software of Engineer / coach desk;

Process control computer simulation software (DCS, DEH operator station simulation software);

The local operation station software adopts 3D animation virtual scene environment;

Virtual disk platform software;

I / O software;

Main control room environment simulation software.

The simulator system is composed of computer, network equipment and other equipment systems.

 

2. Scale and technical level of simulation object

2.1. Object

2.1. 1.Thermal power unit

The simulation objects of thermal power units are from 50MW, 100MW, 125MW, 200MW, 300MW, 500MW, 600MW, 660MW to 1000MW generating units and heating units with different capacities. Besides Harbin, Dongfang and Shanghai, there are Beijing Bawei, Beijing heavy machinery plant, Wuhan boiler plant, Russia, USA GE, etc.

2.1.2.Power grid and substation

The simulation objects of power grid and substation are from 10kV, 35kV, 110KV, 220kV to 500kV substations with different voltage levels, various combinations and virtual network.

The simulation objects include the units produced by domestic technology, imported technology and imported units; Both the scale and technical level of thermal power units and substations are advanced. For example, the boiler of thermal power unit simulation object includes supercritical boiler and subcritical boiler; Drum furnace, once through furnace and liquid slag discharge furnace; The coal pulverizing and combustion system includes direct blowing medium speed coal mill, fan coal mill and steel ball coal mill with intermediate silo; Burners are arranged in front and back walls, four corners and six corners.

2.2. Technical level

2.2.1. Monitoring systems for process computer simulation

There are many kinds of monitoring systems for process computer simulation.

The monitoring system of process computer simulation includes microcomputer monitoring system;

I/A distributed control system of Foxboro company

WDPF and OVATION distributed control system of Westinghouse

Siemens Teleperm-ME, XP distributed control system

INFI-90 (N-90) distributed control system

ABB's SYMPHONY, PGP and Procontrol  P control systems

Hitachi HIACS-5000 distributed control system

XDPS-400 + distributed control system of Xinhua power station

HS2000 distributed control system of Hollysys company

Monitoring system of Solar units

CETUNM distributed control system

Russian computer information management system

MAX-1000 / plus distributed control system

EDPF distributed control system of Guodian Zhishen

Honeywell TPS distributed control system

Toshiba distributed control system

Luneng 2000 distributed control system

Simulation of TCS-3000 distributed control system and monitoring station of substation system

2.2.2. Various ways to realize DCS system

2.2.2.1. Virtual DPU mode 1: the corresponding translation software is developed by recognizing the electronic text of DCS control logic configuration and interface configuration. The simulation degree of DCS system is high (1:1), the construction period is short, and it is easy to upgrade. For the vast majority of domestic control systems, we basically use this method.

2.2.2.2. Virtual DPU mode 2: this mode is to convert the control logic part of DCS, and the interface part is to purchase the actual operation interface software / hardware of DCS manufacturer, and then we develop the corresponding interface communication software. 

2.2.2.3. Incentive simulation mode: the process model adopts the development mode, and the DCS part purchases the actual DPU equipment from the DCS manufacturer and communicates with the process model. This method can not only train the operation personnel, but also train the thermal configuration personnel.

2.2.2.4. Traditional development method: using the DCS data provided by users, using our STAR-90 development platform, using modular modeling method for development, the effect is consistent with the actual.

 

3. Main functions of simulation system

3.1. Coach platform function software

The function software of the teacher platform is a function software for enhancing the training efficiency and for teachers. There are many flexible functions of the teacher platform in STAR-90 simulator system.

Loading the model;

Initial loading conditions;

Access initial conditions (200 can be saved in total, and the quantity can be expanded);

Freezing model and thawing model;

Add the simulated fault of the power plant;

Add local operation of power plant and change boundary parameters. It can also be added as a fault;

Model acceleration and deceleration, a. The local acceleration and deceleration is 0-10 times, B. all of them are 0-10 times;

Repeat: time is optional;

Return: time is optional;

Parameter curve display (divided into multi window display and single window display);

Event records;

Snapshot (pumping point to storage), a. Manual, B, automatic, C, time interval variable;

Model list display;

Model parameter monitoring;

Instrument failure;

Student performance evaluation;

Check the status of dial;

Panel equipment diagnosis;

The panel equipment diagnosis can realize the test and diagnosis of all hardware equipment in the main control room of the simulator. Before training is started daily, hardware engineers or coaches should check the dial equipment in the control room. Each dial can be tested independently. The test contents mainly include:

-Test all indicator lights, including light plate;

-Test all analog indicator;

-Test all analog input equipment;

-Test all panel switches and buttons;

-Test all digital display equipment;

The parameter distribution of disc mounted recorder;

Bar chart display;

Group of power plant simulation fault is added.

 

3.2. Process control computer simulation software (DCS, DEH operator station simulation software)

On the premise that users can provide recognizable electronic text, the first choice of DCS operator station interface simulation software is translation conversion mode, followed by traditional configuration mode. The software is an application software running in the simulation operator station. Each DCS Simulation operator station runs the same simulation software, which is combined with the thermal control mathematical model software to fully realize all functions of the actual unit DCS operator station.

DCS operator station interface simulation software can achieve the following functions: configuration monitoring system process screen; Pop up window of configuration monitoring system; Bar graph of configuration monitoring system; The screen display, mouse or keyboard operation mode, sub window pop-up mode, data refresh mode, curve, bar graph display and other functions of the operator station are consistent with the actual DCS operator station of the actual unit; The I/O number, name and identification method are consistent with the actual DCS operator station of the actual unit; The name of control circuit and control logic are consistent with the actual DCS operator station of the unit. The virtual HMI technology is used to simulate the interface of DCS operator station.

 

3.3.  DCS simulation Implementation

The transformation mode is the first choice for DCS simulation, that is, the bid inviting party provides identifiable control logic configuration and picture configuration files, and the transformation software developed by the bidder is used to realize the transformation Simulation of DCS system.

The most popular design idea of DCS control system is function block configuration, which is completely consistent with STAR-90 modular modeling idea. For example, Foxboro I/A system has function code library, abb and Siemens TXP systems also have graphic algorithm library and text algorithm library, XDPS system has predefined standard function block library, each function code, block or algorithm completes a specific calculation or function, and the actual control strategy on site is connected by these function codes, blocks or algorithm configurations. The STAR-90 support system has its own power station algorithm library, general algorithm library and control algorithm library. The mathematical model of each power station and the mathematical model of control system are configured by these algorithms, and there is no need for modelers to program. This is the advantage of modular modeling in STAR-90 integrated simulation environment, and also provides a means for automatic conversion of control model.

 

When it comes to transformation, it requires something prototype. That is, there must be sufficient and cognitive electronic documents of actual DCS configuration strategy, such as text document, database document, etc. this needs to be negotiated or cooperated with DCS supplier. DCS supplier can only provide documents containing these information to conduct transformation. In these documents, the following contents must be read: the identification of each module, the algorithm used, execution cycle, execution sequence, reference relationship between modules, etc., and so on. With this information, the actual DCS configuration policy can be automatically converted into the STAR-90 control system model.

In addition, if the page display method is exactly the same as the actual DCS configuration drawing, the following contents must be included: the page number of each module, the coordinate position in the drawing page, the instance of the element used, the coordinate information of the connection and the information of the border of the drawing page, etc. With this information, the actual DCS configuration strategy can be automatically converted into a control model under STAR-90 graphical modeling environment. It has the same visual effect as the actual DCS configuration drawing.

For the conversion of LCD screen in DCS operator station, it is also required to have the text or database document for reading the actual DCS picture configuration, which must include the following contents: the static content of the picture, including graphics and text, etc; The dynamic content of the screen, including control mode, dynamic display content, control variable or label, etc. This also needs to be negotiated with DCS supplier or user to achieve.

In summary, if DCS system simulation is realized by conversion mode, the tenderee shall provide the necessary electronic document and data information for developing model and interface conversion software.

 

The simulation of computer monitoring system has been realized

FOXBORO I / A distributed control system

WDPF OVATION distributed control system of Westinghouse

Siemens Teleperm-ME, XP distributed control system

INFI-90 (N-90) distributed control system

ABB's SYMPHONY, PGP and Procontrol P control systems

Hitachi HIACS-5000 distributed control system

Xinhua power station XDPS-400 + distributed control system

HS2000 distributed control system of Hollysys company

Monitoring system of SOLAR units

CETUNM distributed control system

Russian computer information management system

MAX-1000 / plus distributed control system

EDPF distributed control system of Guodian Zhishen

Honeywell TPS distributed control system

Toshiba distributed control system

Luneng 2000 distributed control system

TCS-3000 distributed control system of Guodian Nanzi

 

4. Local operation station software

In order to ensure the continuity and integrity of the training process, the local operator station is used to selectively place the operation items outside the main control room of the actual unit and closely related to the unit start-up and shutdown process on the local operator station. The configuration mode of local operator station software is the same as that described in section 3.6, and its display and operation screen are reflected in the way of production process flow chart, including main system equipment and local operation equipment. It is used to realize local display and operation during operation. The simulation software adopts three-level software process control mode

a. System menu level: the local operating system menu is displayed, and the name of the system diagram is included in the menu box. The operator only needs to click the menu box in the mouse to call up the corresponding system flow chart.

b. System flow chart level: on the system flow chart screen, special marks are used to indicate that some equipment are local operation equipment, and the monitoring and control function of local operation is realized through data refresh, color change and graphic transformation. In the effective area, the operator can hit the effective area with mouse or keyboard for local operation. At this time, a dialogue window will appear in the selected area of the system diagram, so that the operator can realize the operation control of valves, motors and other equipment.

c. Window Dialog control level: when a dialog window appears, the corresponding operating equipment (switch, button, operator, etc.) and its status information will be displayed in the window. The operator can carry out the corresponding operation or cancel the operation. When the operation is confirmed, the flow chart will be restored and the window will be cancelled. At the same time, the relevant data and picture of the local operation point will be refreshed.

The operation mode of system menu single level, system flow chart level and window dialogue level can make the operator conveniently realize the monitoring and control function of local operation.

d. 3D virtual reality technology

Through our company's latest upgraded product, 3D virtual scene technology, we can not only browse the actual scene of the whole plant, but also operate the equipment in the scene by moving the mouse, and the operation results directly affect the operation of the simulator.

 

5. Environment simulation software for main control room

5.1. Audio simulation of main control room

The driver software of audio simulation equipment is the application software running on the audio simulation equipment. The driver software of audio simulation equipment is the application software running on the audio simulation equipment in the main control room. The software uses multimedia technology to play the environmental noise recorded from the actual power plant in real time according to the actual working conditions of the simulation model.

The audio simulation in the main control room is responsible for the management of the audio simulation equipment. When the process value in the simulation model changes, the simulation software forms a data packet according to the communication protocol and sends it to the audio simulation computer. When the sound simulation computer receives the data packet, it analyzes and processes it, and plays the background sound file.

5.2. Simulation of water level monitor

The driving software of water level monitoring equipment is an application software running on the water level monitoring equipment. The software uses multimedia technology to display and update the display screen of water level monitoring equipment in real time according to the actual working conditions of the simulation model.

Water level monitoring simulation software is responsible for the management of water level monitoring simulation equipment. When the water level process value in the simulation model changes, the software forms data packets according to the communication protocol and sends them to the water level simulation computer. When the water level simulation computer receives the data packet, it analyzes and processes the data packet and dispatches the water level display screen.

5.3. Simulation of flame monitor

The driving software of the flame monitoring equipment is an application software running on the flame monitoring equipment. The software uses multimedia technology to display and update the display screen of the flame monitoring equipment in real time according to the actual working conditions of the model.

The flame monitoring simulation software is responsible for the management of the flame monitoring simulation equipment. When the flame process value in the simulation model changes, the simulation software forms data packets according to the communication protocol and sends them to the flame simulation computer. When the data packet is received by the flame simulation computer, the data packet is analyzed and processed, and the flame simulation file is scheduled.