Successful Use of the OTS for SRP Coronado DCS Checkout

2. Successful Use of the OTS for SRP Coronado DCS Checkout Session Name: Simsci-Esscor Operate Session Session ID #: PBSS212 Presented by Ron Cisco 11/08/11 Invensys proprietary & confidential

3. SRP Coronado Generating Station – 435 MW plant preparing for DCS upgrade/migration to Foxboro I/A 8.5 for unit controls and new Flue Gas Desulphurization (FGD) project. • IOM Dynamic Simulator • Dynsim process model of unit and FGD • I/A DCS controls emulated in FSIM • Triconex turbine controls emulated in TRISIM.

4. Benefits and Accomplishments • Identification of Control Logic and Configuration Errors. • Development of HMI including Graphics and Secure User Environments. • Alarm Management Studies and Development of Our Alarm Interface. • Testing and Development of control logic and advisory programs. • Operations training and familiarization of the new control schemes and HMI. • Training a new generation of operators. • Testing and training on the new environmental FGD controls. • Familiarization of I/A for engineering and maintenance.

5. CGS Simulator

6. The Simulator FAT was after the FAT for the main controls. 62 control issues were identified in the BCS, BMS and Auxiliary systems during simulator testing. 82 control issues were discovered in the new FGD controls. This does not include graphics related items. Many of the issues were caused by equipment dynamics that loopback model testing simply cannot reveal. i.e. valve/equipment timing, system pressures and flow dynamics Control Logic and Configuration

7. Issues Resolved Several control errors could have lead to equipment damage and/or personnel injury. • Hard to enumerate actual numbers on cost savings. • Obviously paid for itself several times over with DCS issues found alone.

8. Graphics and Secure User Environments.

9. Platform for Graphics/Environment Development • Included operations in the HMI development • Their feedback led to a more efficient interface. • Revealed protection classes that needed to be set.

10. Graphics Overdevelopment

11. Block Detail Protections Supervisor Environment – Inhibit Alarms Engineer Environment – All others disabled

12. Alarm Management and a New CAD.

13. Alarm Studies and Management • Recognition of alarm flood events before they happened in the real world. • Identified many nuisance alarms before suffering the wrath of operations. “…….I don’t know maybe it got too hot?”

15. Development of control logic and advisory programs. ATS – Many Repairs Major overhaul – It works now. The benefit of being able to realistically test control logic and programs without risk to running processes or looking like an idiot are self evident………

16. Turbine Startup Program Accuracy of turbine model allowed trial and error testing of blocks and HLBL. Repaired logic and stress calcs Saved many hours of startup delays…….

17. Trisim Emulation • Triconex turbine controls were emulated with new standards and applications. • Provided our first look of the new turbine control interface to be installed next year.

18. Generator Monitoring Development to bring more visibility to generator limits.

19. Operations training and familiarization of the new control schemes and HMI.

20. Operations Training We are all resistant to change in one way or another. Especially if you have been performing the same job tasks with the same looking equipment for 20 years. It was a grueling process with a lot of words spoken I cannot mention here….. • We ran all the existing control room operators and shift supervisors through 4 days of training. • This added the benefit of familiarization with something different and brushing off the rust . • An extra benefit was more logic checkout and graphics fixes.

21. Dynsim • Model sufficiently dynamic to seem real. • Local devices such as manual valves and controllers controlled from Instructor Station

22. Cool Features Performance Monitoring adds stress to trainees providing realism. Anything can malfunction in almost anyway you can imagine.

23. More Features Save IC files and return To any load point. Rewind to review or try again….

24. No startup Delays Operations first training experience was tragic on new controls. • Experienced operators were experiencing vapor lock on the controls with the simulator. • After initial 4 days of training they had their bearings • Saved costly mistakes and downtime.

25. Aging Workforce Many of us face the same issues with an aging workforce. People are retiring with 30+ years of experience and we have little time to make sure their skills get passed on. • There has been an increase in confidence and knowledge levels of trainees. • Procedures for startups • Experience taking action during excursions.

26. New Processes Staring at P&ID’s and memorizing facts can only go so far to teaching a new process or piece of equipment. • We trained 5 Operations Specialists procedures for performing loop checks before the checks started. • All of operations was trained to operate the new FGD controls. • The O.S.’s were trained on the new draft system and other process changes. • The simulator has become a part of out process change process for the future.

27. Familiarization of I/A for engineering and maintenance.

28. Learning without risk. • Simulation enabled learning of ICC configuration. • Basics of HLBL and ICCDRVR scripting tasks • System Manager tasks. • General system navigation. • Troubleshooting.

29. Conclusion • Millions saved in logic error fixes that may have caused damage to equipment or worse. • Operations familiarization continues to save costly downtime and delays. • Development opportunities have made our controls more secure and user friendly. • Testing abilities provide feasibility studies and logic/program development. • Large contributor to making a difficult migration successful.