Samahnzi Simulation and Training

SamahnziSimulation and Training Presentation to 16 May 2012

Overview • Company • Products • Full-scope simulators • Unit process simulators • FSE advances simulation software • 3D Plant visualization • FSE (Flownex Simulation Environment) • Nuclear Library • Petro-chemical options • Demonstrations

Company History: Samahnzi (Pty.) Ltd. was founded in 2007 through a merger of existing companies and divisions, to provide engineering and training simulators to the power and process industries in Africa. The founding members of Samahnzi contain a wealth of experience in the power and process simulation and control industries and have executed several high-value projects with great success. Shareholding: • Black Shareholding: 12.6% • B-BBEE Level 4 (100% recognition level)

Company Vision : Samahnzi’s vision is to become the most trusted and respected provider of engineering and training simulators to the power and process industries in Africa. • Mission: • Samahnzi will create and build training software product brands that facilitate technical education in new and revolutionary ways by using the latest hardware and software technologies available. • We envision for each of our brands to become the best known and most respected in its area of application through having: • Superior production and education value, • High accuracy, • Superior speed of execution while being • Cost effective

Company • Personnel: • Full-time engineers: 16 • Part-time consulting engineers: 3 • Administration: 2 Turn-over:

Products and Services Samahnzi provides solutions and services to design, control, operate and optimize the following: Full-scope simulators We offer High Fidelity, Full Scope Training Simulators, that are custom-built for all types of fossil and nuclear power plants. • Our full-scope simulators support Simulated, Emulated and Virtual DCS/HMI integration with all major I&C vendors. • Part of our offering includes full scope simulators for the outside plants: • Condensate polishing plant (CPP) • Station electrical and HV yard • Raw water treatment • Ash and coal conveying

Products and Services Reduced scope simulators The target market of these products is the same as for Full-Scope Training Simulators, the only difference being that it is stripped of most secondary elements and only focus on the primary processes and engineering principles involved. This results in a lower cost product with much of the advantages of the Full-Scope product.

Products and Services Unit process simulators Unit processes are focused training modules used to teach specific power plant principles, operating philosophies and control fundamentals. These focused, modular packages are ideal for teaching plant principles of operation to new or inexperienced technical staff and provide hands-on experience at the same time. Modules included, are: - Rankine Cycle - Boiler Operation - Boiler Control - Mill and Burner Operation - Draught Group Operation - Tank with Turbine Driven Pump - Condenser Operation

Products and Services 3D Visualization 3D PACT is a revolutionary suite of real time 3D Training and Production Support Tools. It is based on video gaming technology and adds the ability to create or use existing 3D CAD models of industrial facilities and integrate them with 3rd party software tools such as Plant Information Databases, ERP systems, or existing Training Simulators. The flexibility and technology in 3D PACT provides plant instructors, operators, engineers and maintenance staff with unrivalled abilities and intuitive, easy to use interfaces for training, monitoring and planning purposes.

Products and Services 3D Visualization (Cont.) 3D PACT’s primary application areas: System Identification Training and Evaluation: Trace and ‘walk’ plant systems quickly and efficiently on the training PC and view interconnections and interdependencies between processes first hand. System Operations Training and Evaluation: Perform operating sequences on plant systems, such as start-ups, shutdowns and emergency operations to ensure a trainee knows his/her way around the plant under normal and abnormal conditions. Equipment Operations Training: Trainees can view and navigate the internals of equipment and go to areas and spaces which is impossible to access under normal conditions on the actual plant.

Products and Services 3D Visualization (Cont.) Inspection Training: In most plants, to access certain inspection points for condition monitoring require scaffolding, harnesses and other safety equipment. With 3D PACT, planning and providing direction for inspections can be performed efficiently in the office prior to executing it on the plant. Maintenance Planning: Plan complex and time critical maintenance tasks to perform them as quickly as possible to limit production loss to a minimum. Legislative and Procedural Training: Equipment isolation procedures to obtain a permit to work and to ensure equipment is safe to enter can be efficiently trained, reviewed and evaluated

Flownex Simulation Environment FSE is an Advanced Simulation Software Suite that was developed by M-Tech Industrial and Samahnzi through the Innovation Fund, a business unit of the Department of Science and Technology of South Africa. FSE Two phase flow First release of Flownex Gas mixtures and heat transfer Pebble Bed Reactor Transient simulation capacity Aircraft engine systems Implicit solution algorithm Air-conditioning systems Pipe Network Solver Flownet

Flownex Simulation Environment FSE is an extremely powerful, integrated software platform which enables engineers to develop high fidelity, full-scope power and process plant simulators quicker than ever before. It sports a modern, intuitive graphical user-interface which makes it exciting to develop, analyse and train on. The power of FSE comes from embracing the latest software technologies and engineering strategies. This not only enables quicker development of full-scope plant simulators, but also delivers higher accuracy, which allows engineering analysis and operator training on the same simulation platform, at no extra cost. FSE sports a totally open, customizable architecture. Using any Microsoft .NET capable programming language, engineers can easily develop and integrate their own solvers, libraries, schedulers or even control all simulator functionality from an external application.

Flownex Simulation Environment The following high fidelity, configurable solvers and libraries are by default included within FSE: • Multi-Phase Flow with Incondensable Gases (Based on the Flownex Systems CFD Solver) • Electrical Networks • Logic and Control Networks (Basic and Advanced) • OPC Client (Integration to 3rd Party Control Systems) • Mechanical Solver (Shafts, Gearboxes, Bearings etc.) • Sensors and Actuators • Fossil Power (Drum, Sub- and Super-Critical Benson, Fluidised Bed Boilers. Various types of Coal Mills, Oil/Gas/Coal Burners, etc.) • Nuclear Power (Pressurized Water Reactors, High Temperature Gas-Cooled Reactor, etc.) • Integration library with Aspen Materials Database and Aspen OTS Framework • Seamless Integration with 3D PACT Virtual Training and Production Support Software

Pressurized Water Reactor FSE Library • As part of the validation of the FSE platform, Samahnzi had to proof that FSE is suitable for nuclear simulators. We had two options: • Koeberg Nuclear Power Station • Plant data could not be distributed in public. • Three Mile Island: • Plant data is freely available. • NEA (Nuclear Energy Agency) commissioned a benchmarking exercise in 1999. • 14 companies participated with engineering grade software • The results were published and rendered an excellent benchmark for the FSE results.

Reactor Core: Neutronic Simulation • Three dimensional diffusion model core with: • Nodalization: x-y-z: 17x17 matrix and 24 layers in the z direction (4992 fuel nodes, 1536 boundary nodes) • Two energy group (fast and thermal) diffusion equations implemented in FSE (to be extended to four groups in future) • Six delayed neutron groups.

Reactor Core: Hydraulic Simulation • Three dimensional reactor core thermo-hydraulic model: • Nodalization: r-θ-z: 3 Radial divisions, 6 sectors and 6 layers (108 Nodes) • The Flownex flow solver (which is part of the FSE suite) is used for the thermo-hydraulic simulation.

Reactor Core: Neutronic/Hydraulic Interfacing • Thermal-Hydraulic model: • Receives Power from PWR-Neutronic components • Calculates Fuel Temperature and Moderator Density • PWR-Neutronic Components implemented to solve Diffusion Equations • Receives Fuel Temperature and Moderator Density from Flownex • Calculates Cross-Sections • Solves Diffusion Equations • Calculates Power • Models are coupled within FSE using Data Transfer links between FSE components and PWR Component Ports

PWR: Steam Cycle • The steam cycle is similar to that any fossil power plant and was not part of the NEA data. • Samahnzi used the Koeberg Turbine Cycle. • The Flownex flow solver (part of the FSE suite) is used.

PWR Simulation: Results Coupled Thermal-Hydraulics and Neutronics Steady State Results compared withNEA MSLB Benchmark 0.05% Average Difference 0.03% Average Difference Core Average Moderator Density time History: 20

PWR Simulation: Results Normalized Average Radial Power: 0.12% Average Difference

PWR Simulation: Future Developments • As part of our continuous drive for improvement, it is our intention to extent our Nuclear Library to allow for different client and regulator preferences: • Inclusion of Relap-RT into FSE: • Regulatory authorities prefer the use of qualified code, such as Relap for the thermo-hydraulic simulation of the Nuclear Steam Supply System (NSSS) of a PWR. • The FSE environment is designed to include 3rd party code as libraries – Relap-RT could be integrated with ease. • The configuration of Relap-RT parameters will be intuitive to be similar to the Flownex configuration. (objects instead of input decks). • Extension of the diffusion equations: • The two energy group diffusion equations will be extended to four groups. • Absorption coefficient calculation: • The inclusion of a 3rd party software library (NECSA) for the calculation of Absorption Coefficients will allow the adaptation of the reactor core for different configurations to be done without timeously interactions with reactor physicists.

Petro-chemical options • The following possibilities are available for petro-chemical simulators: • Flownex integration library with Aspen Materials Database and Aspen OTS Framework. • Integration of models from Simulation Solutions (USA). • Integration with SimSuitePro from GSE Systems in the USA. • Generic Distillation. • Generic Oil and Gas. Demonstrations

Thank you!

Samahnzi Simulation and Training