Integrated Gasification Combined Cycle (IGCC) Plant Simulator

OPERATOR TRAINING & ENGINEERING SIMULATORS

The IGCC plant concept incorporates an oxygen-blown, solid-fuel gasifier operating at high pressure and producing a raw gas that is cleaned of most pollutants and burned in the combustion chamber of the gas turbine for power generation.

Main IGCC Power Plant Subsystems • Gasification plant including preparation of the

feedstock

• Raw-gas cooling via water quench or heat recovery systems

• Water-gas shift reactor

• Gas purification system with sulfur removal/recovery and optional CO2 removal

• Air separation unit

• Combined cycle unit with gas turbine, heat recovery steam generator and steam turbine

The GSE simulator provides our customers a highly effective simulation of their IGCC plant to meet their objectives in design validation, as well as, operations staff training.

Design Validation & VerificationWhile the customer’s IGCC project is in the design phase, the simulator provides many benefits during this phase. A summary of these benefits are:

• Verify the design of the equipment’s performance.

• Verify each unit/system operations and their functionality

• Verify the integrated plant performs per design

• Verify the throughputs and heat balances

• Perform and study plant transients

• Verify the DCS/PLC control

Operator & Engineer ReadinessBefore the plant commission, the simulator is used for the plant operator & engineer training. The benefits the simulator provides to the operation staff are:

• Improve the understanding of general plant theory and concepts

• Increase the knowledge of plant systems, their functions and interactions with other systems

• Enhance the understanding of plant control philosophy and operation

• Gain operating experience, confidence, and accuracy in normal and abnormal plant operations

• Provide practice following specific operating procedures

• Demonstrate recovery from various upsets and malfunctions

• How to startup the plant effectively

Integrated Gasification Combined Cycle (IGCC)Process Simulator

Simulation Experience Summary

Full-Scope Plant Replica Simulators Oil, Gas, Refinery & Chemical Processes ............96

Oil, Gas & Products Pipelines ............... 10

Fossil Power Plants ............................. 121

Nuclear Plant Simulators .................... 165

Total .................................................... 391

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Key Customers:

Standard & Specific MalfunctionsStandard JPro™ modules can simulate equipment malfunctions, as well as system level malfunctions such as reactor problems, utility outages and non-DCS control failures.

Listed below are standard malfunctions built in with valve or equipment modules:

Standard

• Transmitter drift, freeze “as is” and failure

• Controller failure (fails high, fails low, loss of control signal)

• Limit switch freeze “as is”

• Pump and compressor trips

• Valve failure (fail close, fail open, fail as is, fail leak)

Specific

• Recycle cooling water failure

• External Power supply failure

• External Steam supply failure

• Gasification reactor failure

• Instrument Air Failure

• Air Separation Unit Failure

• Auxiliary Boiler Failure

• Gas Turbine Failure

• Partial Oxidation (POX) Steam

Superheater Failure

Malfunction Activation – observe the effect of failed equipment on process operations

Support for Critical Engineering TasksA GSE high-fidelity, real-time IGCC simulator is the optimum platform for both dynamic evaluations and plant virtual commissioning. It allows engineers to efficiently:

• Support and verify the process control design

• Verify and support of control logic

– Pre-tune control loops – Test motor start/stop logic – Validate interlock and ESD logics – Evaluate controls strategy and stability

• Verify the DCS graphic display HMI diagrams

• Assure proper integration and communication between the various control systems

• Support generation and verification of plant procedures, e.g., Startup and Shutdown, Job Performance Measures, Alarm Response, etc.

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JPro™ IGCC Amine Regeneration Unit

JPro™ IGCC Amine Absorption Unit

Instructor FunctionsThe boundary conditions of the training simulator can be adjusted by the instructor to define the temperature, pressure and composition conditions of the raw feed stream and utilities.

Changing these parameters provides the instructor with a broader scope in specifying the plant conditions in which to train operators. These functions are out of the trainee’s control, but reflect real conditions that they will have to take into account as plant operators.

Below are the boundary conditions available to be changed with this model:

• Inlet Feed – Feed Temperature – Feed Pressure – Feed Composition

• Utility temperature and pressure changes – Cooling Water Temperature – Storage Pressure

• Boundary equipment duty – Heat exchanger duty – Pump capacity – Ambient condition: change in temperature

and pressure

The instructor’s ability to introduce disturbances by inserting noise into the boundary condition produces a realistic dynamic output similar to the plant, and can be used to validate the control tuning parameters and strategy.

JPro™ IGCC Cold Box Unit

JPro™ IGCC Syngas Cooling Unit

Remote FunctionsRemote functions allow the instructor to train operators to recognize the significance of those pieces of equipment which are not directly controlled by the DCS. Elements not controlled by the DCS are still vital to the plant operations, and it is necessary to train the operators in their function and importance, especially for startup, shutdown and emergency operations.

The following are some of the major categories available in the model:

• Local Pump and Compressor Start/Stop Switch and Reset Button

• Isolation, Bypass, and Hand Valve Switch

• Process Equipment Drain/Vent Valve Switch

• ESD Switches/Overrides

MalfunctionsA key value of simulator training is to help trainees practice reacting to abnormal situations they may face in the plant. The ability to challenge trainees with a wide variety of potential plant upsets helps develop the general troubleshooting skills that will help your specific plant.

Instructors can initiate a full range of malfunctions with the following features:

• Malfunction activation – The instructor is able to insert, initiate and monitor concurrent malfunctions at separate initiation times.

• Variable time delays – An adjustable time delay clock, accessible through the malfunction menu, provides the capability to insert malfunctions with time delay variables in one second increments ranging from one second to hours.

• ramping Control – The instructor may gradually change the value by specifying the time in which the malfunction will achieve the specified severity level.

• Malfunction deactivation – The instructor has the ability to deactivate a malfunction whenever desired.

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Worldwide Locations

www.GSES.com | info@gses.com

About GSE Systems

GSE Systems, Inc. is a world leader in real-time high-fidelity simulation, providing a wide range of simulation, training and engineering solutions to the power and process industries. Its comprehensive and modular solutions help customers achieve performance excellence in design, training and operations. GSE’s products and services are tailored to meet specific client requirements such as scope, budget and timeline. The Company has over four decades of experience, more than 1,100 installations, and hundreds of customers in over 50 countries spanning the globe.

Information about GSE Systems is available at www.gses.com.

HEadquartErS Maryland, USa

© 2016 GSE Systems, Inc.

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