WSC has completed the simulation of one the largest IGCC plants in the world. In parallel with the IGCC plant design and commissioning process, WSC completed and made the simulator available for further design and control validations as well as training on the integrated plant of both power and gasification islands for this unique and massive new power plant simulator. Many new design concepts are featured in this technological marvel, so it was critical for the customer to be able to start training operators ahead of plant start-up.
WSC has developed this IGCC simulator that goes beyond the traditional combined cycle power plant. The power plant and simulator are a first of a kind for the customer and implement new low emissions gasification processes as part of the combustion turbine-generator. Rather than burning coal directly to make electricity, gasification first breaks coal down into chemical components. Gases that result from this chemical breakdown can be used to fuel the power plant.
The integrated gasification combined cycle plant is modeled to replicate the Coal Feed System, Gasifier, Process Air Compressors, Extraction Air Compressors, Gas Cleanup Equipment, CT, HRSG, and ST. All balance of plant systems are modeled, including: condensate, feedwater, circulating water, cooling water, sour water, turbine auxiliaries, generator auxiliaries, tempered water, coal drying loop, coal milling loop, syngas coolers, gasifier island steam drums, recuperative heat exchangers and syngas cleaning reactors, columns and equipment.
The WSC 3KEYMASTER™ environment also includes a full-featured Instructor Station which provides a flexible simulator environment with embedded features such as monitored parameters, trending, Validation and Verification, Scenario Based Testing (SBT), and other standard features such as event triggers, scenario creation, and trainee performance tracking. The generic and specific malfunction features extend the capability of the simulator to allow for thousands of malfunctions that may be used by instructors to develop exercises that replicate plant behavior and demonstrate such behaviors to operation staff.