Proceedings of the ASME 2013 International Mechanical Engineering Congress and Exposition

IMECE2013
November 15-21, 2013, San Diego, California, USA

IMECE2013-66570

DEVELOPMENT OF A COMPREHENSIVE VIRTUAL TRAINING PACKAGE FOR POWER

PLANT BOILER

Fan Li, Litao Shen, Guangwu Tang, Bin Wu, and Chenn Q. Zhou
Center for Innovation through Visualization and Simulation (CIVS), Purdue University Calumet
Hammond, IN 46323

Joel E. Heim
Northern Indiana Public Service Company (NIPSCO)
721 Zigler Rd. LaPorte, IN 46350

ABSTRACT Sebastien Caillat. et al [4] studied the flow, combustion, heat

As one of the most important components in coal-fired power
station, the operators and maintenance crews of boiler systems
receive comprehensive training in unit operation procedures
and emergency preparedness. Due to the inaccessibility of the
field environment, the majority of the training sessions take
place in a classroom using 2D presentation materials such as
pictures, drawings, etc. In order to provide a more efficient
training program, a software package for power plant boilers
was developed through the integration of Computational Fluid
Dynamics (CFD) and Virtual Reality (VR) visualization. Using
numerical simulation data, the package creates a computer-
generated boiler in which the users can observe the actual
phenomenon in an easily-understood context. It also allows
instructors and trainees to selectively explore various
components, operating conditions and scenarios using the built-
in Graphic User Interface (GUI). This training package enables
people who are unfamiliar with boiler operations to gain better
understanding in much less time.
Keywords: Virtual training, coal-fired boiler, power plant,
virtual reality, Graphic User Interface (GUI), CFD
INTRODUCTION
Nowadays, coal-fired power stations provide approximately
41% of the global electricity. The competitive price of coal has
made the coal-fired boiler play a dominant role in power
generation and will remain as major component for some time
[1]. In North America, coal-fired boilers are widely used in
power plants. As one of the major components in a power plant,
the boiler‟s operation is a complex process involving many
physical and chemical phenomenon, and full scale
measurements are restricted by high risk and cost [2],
Computational Fluid Dynamics (CFD) simulations have been
successfully used to study the coal combustion and emission
behavior in large scale boilers [3]. For example, Chungen Yin,
transfer and emissions of a 609MW utility tangentially fired
boiler firing pulverized coal by using CFD method and showed
great agreement with design parameters and site operation
records.
While CFD application has become increasingly popular, full
understanding of simulation results by field engineers is critical
to the successful implementation of numerical optimizations.
Furthermore, comprehensive training is an important process to
the new operators and maintenance crews in power plants. All
of these require a good presentation of both fundamental
operation and detailed scientific research findings. However,
due to the inaccessibility of the field environment, the majority
of the training sessions take place in a classroom using 2D
presentation materials such as pictures, drawings, etc. In order
to provide a more efficient training program, a software
package had been developed for power plant boilers through
the integration of Computational Fluid Dynamics (CFD) and
Virtual Reality (VR) visualization.
In previous study [5], the boiler under the typical/normal
operating conditions had been simulated. The present study
focuses on parametric simulation of the boiler under various
operating conditions such as different burner firing duty and
burner failure. This parametric study provides operators a much
better understanding of the effects of different operating
conditions therefore help them to avoid making operational
mistakes. With the integration of VR and CFD, various
combinations of numerical data are presented in a 3D
immersive environment. While it provides comprehensive
access to a simulated boiler unit, the large amount of numerical
and visual data needs to be presented in a well-organized and
efficient way. Therefore, a Graphical User Interface (GUI) was
created to organize all the models by presenting information in
a manner that allows rapid assimilation and manipulation [6].

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 In this study, the GUI was made by using WPF technology, or
more specifically the XAML language which is used to build
components in GUI and arrange the layout. The functions
behind the GUI were realized by using Windows .NET
language C#. For rendering and controlling, the C++ library
OpenSceneGraph® (OSG) is used to render the model and the
VR Juggler suite is used for controlling the model behavior
through user interaction with a wand controller.
By integrating numerical simulation, VR visualization, a
software package had been developed to allow trainees
selectively explore various components, operating conditions
and scenarios using the built-in Graphic User Interface (GUI).
It provides a complete training experience for boiler operators
by offering prompt access to different components of a virtual
boiler from many aspects under various conditions.
METHDOLOGY AND THEORY
Simulation and visualization techniques had been employed for
this application. A numerical model for a power plant coal fired
boiler was developed and simulation results for typical and
optimized operation conditions were achieved. Then the
application of visualization technique is aimed at developing
user-friendly interfaces to provide an effective understanding of
the scientific data. During the development of the GUI, the
OpenSceneGraph® (OSG) and VR Juggler suite were used to
enhance the visual effect for the future Virtual Reality training.
CFD Simulation
The complex flow pattern, coal combustion process, and heat
transfer inside the power plant boiler can be described by
commercialized CFD models and the following governing
equations.
In these two equations, 𝐺𝑘 is the generation of turbulence
kinetic energy due to the mean velocity gradients. 𝐺𝑏 is the
generation of turbulence kinetic energy due to buoyancy. 𝑌𝑀
represents the contribution of the fluctuating dilatation in
compressible turbulence to the overall dissipation rate. 𝑆𝑘
and 𝑆𝜀 are user-defined source terms, which are equal to zero
for this study. The following values for the constants are
used: 𝐶1𝜀 =1.44, 𝐶2𝜀 =1.92, 𝐶𝜇 =0.09, 𝜎𝑘 =1.0, 𝜎𝜀 =1.3.
This model is applied for the fully turbulent flow. The effect of
molecular viscosity is negligible [8].
Non-Premixed Combustion with PDF:
𝜕 𝜇
(𝜌𝑓)̅ + ∇ ∙ (𝜌𝜈̅ 𝑓 ̅) = ∇ ∙ ( ∇𝑓)̅ + 𝑆𝑚 + 𝑆𝑢𝑠𝑒𝑟 (6)
𝜕𝑡 𝜎
where f is a conserved quantity, 𝑆𝑚 is due solely to transfer of
mass into the gas phase from liquid fuel droplets or reacting
particles, and 𝑆𝑢𝑠𝑒𝑟 is any user-defined source term [9].
A Probability Density Function (PDF) is formed and utilized to
calculate the interaction of turbulent flow and chemistry. This
model is used for solving transport equations for one or more
conserved scalars. Species concentrations are obtained by
mixture fractions.
Discrete Phase Model (DPM):
𝑑𝑢 𝑔 (𝜌 −𝜌)
= 𝐹𝐷 (𝑢 − 𝑢𝑝 ) + + 𝐹𝑥 (7)
𝑑𝑡 𝜌
where 𝐹𝑥 is an additional acceleration (force/unit particle
mass) term, 𝐹𝐷 (𝑢 − 𝑢𝑝 ) is the drag force per unit particle
mass, 𝑢 is the fluid phase velocity, and 𝑢𝑝 is the particle
velocity.
This model is used to simulate the discrete phase coal particles.
The trajectories of these discrete phase entities are calculated,
including the mass and heat transfer to/from them [9].

Continuity Equation: Kinetics/Diffusion Limited Combustion:

𝜕𝜌
⃗ ) = 𝑆𝑚
+ ∇ ∙ (𝜌𝑉 (1) The kinetic/diffusion-limited rate model assumes that the
𝜕𝑡
surface reaction rate is determined either by kinetics or by a
The Momentum Conservation Equation: diffusion rate. In this study, the assumption for the particle size
𝜕 is constant but density is changeable.
⃗ ) + ∇ ∙ (𝜌𝑉
(𝜌𝑉 ⃗𝑉⃗ ) = −∇𝑝 + ∇ ∙ (𝜏̿) + 𝜌𝑔̅ + 𝐹̅ (2)
𝜕𝑡 The applied models were chosen due to their applicability as
In this equation, 𝜌𝑔̅ and 𝐹̅ are gravitational body force and determined by previous research and theory.
external body force, and 𝜏̿ is the stress tensor.
Virtual Reality Development
Energy Equation: Virtual Reality (VR) is about displaying the 3D model and
𝜕
⃗ (𝜌𝐸 + 𝑃)] = ∇ ∙ [𝑘𝑒𝑓𝑓 ∇𝑇 − ∑𝑗 𝑕𝑗 𝐽𝑗 + (𝜏̿𝑒𝑓𝑓 ∙
(𝜌𝐸) + ∇ ∙ [𝑉 providing methods to control the 3D model in a 3D
𝜕𝑡
environment. In this project, ParaView® and 3ds Max® are
⃗ ) + 𝑆𝑕 ]
𝑉 (3) adopted to play the key role of generating and extracting the 3D
In this equation, 𝑘𝑒𝑓𝑓 is the effective conductivity, 𝐽𝑗 is the model simulation results into the VR application system which
diffusion flux of species j, and 𝑆𝑕 includes the heat of is an open-source, multi-platform data analysis and
chemical reaction, and any other volumetric heat sources [7]. visualization application [10]. This application can run both on
Standard k-ε turbulence model: regular computer and on a large-scale 3-D virtual reality (VR)
𝜕 𝜕 𝜕 𝜇 𝜕𝑘 system so that multiple users can look at the model. Also, the
(𝜌𝑘) + (𝜌𝑘𝑢𝑖 ) = [(𝜇 + ) ] + 𝐺𝑘 + 𝐺𝑏 − 𝜌𝜀 −
𝜕𝑡 𝜕𝑥 𝜕𝑥 𝜎 𝜕𝑥 virtual reality 3D environment can be controlled by using a
𝑘 wireless wand controller in an immersive way.
𝑌𝑀 + 𝑆𝑘 Where 𝜇𝑡 = 𝜌𝐶𝜇 (4)
𝜀
And
OpenSceneGraph® Open Source Library
𝜕 𝜕 𝜕 𝜇 𝜕𝜀 𝜀
(𝜌𝜀) + (𝜌𝜀𝑢𝑖 ) = [(𝜇 + ) ] + 𝐶1𝜀 (𝐺𝑘 + OpenSceneGraph® (OSG) is an open source C++ library for
𝜕𝑡 𝜕𝑥 𝜕𝑥 𝜎 𝜕𝑥 𝑘
𝜀
visualizing the models. OSG is a computer graphics engine
𝐶3𝜀 𝐺𝑏 ) − 𝐶2𝜀 𝜌 + 𝑆𝜀 (5) based on OpenGL [11]. It is highly abstract and provides
𝑘

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 functions that can let developers remove details of graphical
programming. This library can visualize many types of model
file such as *.ive and *.osg file types and provides some special
effects like particle systems and animation.

GUI Development
As a graphical user interface needs to be built and used in the
Microsoft Windows® operating system for Virtual Reality
training, the newest Windows GUI technology WPF was
applied. The XAML language is used for designing the GUI,
and the functions behind it are realized by using the C#
programming language. This application is designed to provide
the users more than 600 combinations of components, camera
view, working conditions and display parameters. Figure 1: Computational geometry.
In order to reduce the work of coding and improve code Table 1. Boundary conditions
maintenance and additions, the user-interaction procedure is
Case Mass flow rate Operating
divided into three main steps. The first step is to choose the Injection
Number (kg/s) Conditions
building units. The second step is to choose the camera view
and position of the building unit. This step provides some Coal 57.83 All Cyclones
Case 1
shortcuts so that users can go to a position directly and with the Air 502.61 Full Duty
proper view angle to explore the boiler. The final step is to Coal 28.92 All Cyclones
select the working condition and display parameters which Case 2
Air 251.30 Half Duty
include vector, streamline and contour.
Coal 46.27 #6 and #7
Case 3
Air 401.60 Cyclones Off
VR Juggler Suite
VR Juggler suite is another C++ library, and it is used for
providing an interface between hardware and visualization tools.
This application can utilize a wireless wand as a remote RESULTS AND DISCUSSION
controller. The whole system is called Flex, and this system can Simulation and Visualization
provide tracking function for the wand. The tracking system Based on typical operating scenarios in the plant, many cases
can sense the position and button event of the wand. VR had been simulated to provide quantitative information such as
Juggler provides a library for handling these events. By flow temperature, velocity and species concentration, etc. For
combining this suite and OSG functions, this application example, temperature contour inside the cyclone burner is
provides agile control of the model; users can fly into the model shown at the top of Figure 2. By using a Particle System, the
from any direction and, through button combinations, they can flame visualization had been introduced to intuitively present
also accelerate the movement speed when the model is too big the coal combustion inside the burners, as shown in Figure 2.
to explore. This information can be used to achieve full understanding
through detailed analysis.
GEOMETRY AND BOUNDARY CONDITIONS
The computational geometry is shown in Figure 1. The coal and
combustion air were injected through 10 cyclone burners. The
combustion occurred and supplied heat to generate steam
through the whole boiler. After combustion, the flue gas flows
to the outlet.

A parametric study has been conducted with typical operating

conditions and failure scenarios such as different burner duties,
fuel air ratios and fuel composition. These data will be used for
basic operation procedures and emergency preparedness. Some
examples of different operating conditions are listed in Table 1.

Figure 2: Burner flame simulation and visualization.

By coupling the visual effects and simulation data, different

operating conditions can be easily understood. In Figure 3,

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 three typical conditions are presented, namely, 100% duty, 70%
duty and 50% duty. From side by side comparison in Figure 3,
the decrease in wall temperature and gas velocity can be
observed. In this study, different burner duty, fuel composition,
fuel/air ratio, and steam generation rate had been simulated in
parametric study. The results provided a combination of 600
sets of data to achieve full understanding of the unit’s
operation.
Case 1 Case 2 Case 3
Figure 3: Comparison of temperature contour and velocity
streamline.
Continued efforts had been made to integrate simulation data
with visual models to enhance training experience. By using
newly developed Virtual Engineering package at the Center for
Innovation through Visualization and Simulation (CIVS),
Purdue University Calumet [8-10], visual models of boiler
building had been combined with simulation data. Figure 4
shows a picture of the boiler building taken at the plant on left-
hand-side. Many of these pictures had been taken and used as
textures to complete the visual model which is shown on the
right-hand-side of the same Figure. Inside these visual models,
combinations of streamlines, contours, and vectors colored by
different flow data are readily available for detailed
presentation. More details of this integration can be found in
the previous paper.
Figure 4: Boiler unit building visualization.
Similar to the boiler unit, the steam turbine model had been
developed using pictures and simulation data. The detailed
turbine blade configuration is shown in Figure 5. The turbine
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unit and the boiler unit are connected through steam tubes.
These two major units interact to each other through different
steam generation rate.
Figure 5: Turbine unit visualization.
GUI Construction
As described earlier, more than 600 sets of data had been
provided to fully understand the unit operation. However,
during a short training session, typically a week, this amount of
information can be overwhelming to new operators. A better
presentation of these data is required to conduct training more
efficiently. Therefore, a compact interface had been developed
for this training package to provide users 3D simulation data
with different working conditions. For instance, users can see
the geometry of the model and turn on and off the cyclone
burners. Different display modes can also be chosen such as
streamline, vector and contour. Streamline for example, is ideal
for showing the flow pattern.
Considering the fact that learners may just want to take a look
at certain parts of the boiler, this application provide some
shortcuts to access the main components at the proper angle.
The process is shown in the following work flow. As the
software was created using an object oriented language, there
exist many methods for manipulating the data and handling
events. Strings were used to make the logic structure more
clear, and also to reduce a few hundreds lines of code, as there
are no iterative loops. In this project, multiple media are used,
such as images and video. The users can see some images about
the virtual boiler and they can also watch a video for
introduction to the virtual boiler. The working logic behind the
Interface is shown in Figure 6. It can be seen from this working
logic that this GUI interface contains three parts: the main
menu, the boiler unit menu, and the turbine unit menu.
 Figure 6: GUI interface working logic.

Main Menu
To render the models in 3D and also interact with hardware in
the CIVS lab like the wand (controller), the OpenSceneGraph
(OSG) toolkit and VR Juggler libraries were used for this
interface. By using OSG and VR, a program was developed
to render the scene and take multiple arguments so the number
and type of models displayed can be controlled. Figure 7 Figure 7: GUI menu---Main menu.
presents the main menu for the GUI. The central middle screen
plays the virtual movie for the No. 14 plant unit. Under the
video screen are three buttons. They are the boiler unit menu
button, play movie button, and turbine unit menu button. Boiler
unit button, as its name, is connected to the boiler menu. The
arrow button is the movie control button. It controls the status
of play and pause for the VR power unit movie. Same as the
boiler unit button, the turbine unit button connects to the
turbine menu. Clicking any one of those buttons, the following
menu will be shown for detailed combination for showing
results.

No.14 Boiler Unit Menu

The No.14 boiler unit menu has approximately six hundred
combined results selected to be shown. The majority of the
programs require minimal or no user input. From the interface,
operators can choose the initial view of the model, which
directs to ten important regions such as the main view of
cyclone, lower furnace, the specific flow pattern view, etc. The
reason for this is that the virtual boiler is fairly large and it
would be difficult to fly to a certain position when starting from
the same region; and if user wants to change the condition or Figure 8: GUI menu---Boiler initial views.
model, then the user would have to fly again, a frustrating and
redundant process. The initial position page is shown in Figure
8 while Figure 9 shows a zoom-in view. After choosing any one
of ten initial views, operators will be guided to next menu of
combination selections for components.

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 Figure 11: Zoomed-in boundary conditions.
Figure 9: Zoomed-in initial views.
After all components are selected, the result will be shown in
The next menu is for operators who can choose the boundary OSG Viewer. Figure 12 shows one of the combinations of
conditions, which means different burner duties can be chosen results. From the picture, it shows the velocity streamlines
in this menu shown in Figure 10. By this selection the trainees inside the cyclones and lower furnace with inner wall
can fully understand the work load of each burner. The next temperature and flame effect. This illustrates the flow
step is for users to choose whether the flame is displayed or not. development and combustion process after air and coal are
This is done by adding the OSG file of the flame to the model injected into cyclone burners [10].
for enhanced visual effect. Simulation data is also provided for
detailed analysis of temperature, velocity, pressure, etc. This
GUI provides three different ways for the user to perceive how
the boiler is working by using either vector, streamline, or
contour. The software will write related model’s name into a
configuration file then read by the OSG program to launch
specific batch of data accordingly. A zoomed-in view of this
menu is shown in Figure 11 for details.

Figure 12: Combustion zone---temperature contour and

velocity streamlines.

This training package is compatible with both desktop

computer and 3D VR system. By launching this application on
an immersive 3D theater at CIVS research center, the integrated
models can be visualized in full 3D, as shown in Figure 13 to
15. Using this package, plant operators are able to control a
wand to fly in and explore the virtual boiler in detail. Figure 13
shows one of the models from outside of the lower furnace
while burners are running at full duty.

Figure 10: GUI menu---Operating conditions.

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 The flame effect had been introduced according to the
temperature and species concentration from the simulation.

No.14 Turbine Unit Menu

The steam turbine is located in the room next to the boiler unit.
As another major part of the plant, it utilizes high
pressure/temperature steam from the boiler to drive generators
to produce electricity. Figure 15 shows the main turbine menu
which includes three buttons to launch different sections and
presentations of the complex turbines. The two arrow buttons
below are Play and Back buttons in order to make it convenient
for operators to make any changes. Using this menu, users can
selectively enable different components of this turbine unit.
This is specifically illustrated in Figure 16 and 17 showing
detailed 3D turbine blades and casing.
Figure 13: Outside of combustion zone.

Figure 14 demonstrates the user using wand to navigate inside

the model to access to different areas inside the boiler. As the
user flies into the combustion zone, the temperature inside has
increased significantly. The flames have also become much
brighter.

Figure 15: GUI menu---Steam turbine.

Figure 14: Inside combustion zone.

Figure 16: Detailed turbine blades.

Figure 15: Inside cyclone burner.

Figure 15 is a picture taken inside the cyclone burner showing

streamlines and contours colored by the temperature. The
swirling flow pattern is very obvious due to the cyclone
configuration that allows a very good mix of coal particles and Figure 17: Turbine animation without casing.
air which leads to a very rapid combustion inside the burners.

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 CONCLUSIONS
In this project, a training package has been developed for power
plant boiler operators. By using CFD and VR, the numerically
simulated model and visual model have been integrated to
provide quantitative and intuitive presentations of the unit’s
operation. A GUI was introduced to allow trainees to
selectively navigate inside this virtual training model to obtain
a detailed view of the boiler and have a good understanding of
boiler internals and operation. Professional workers can also
use this tool as a reference to analyze the work efficiency of the
boiler under many different scenarios and make optimizations
based on enhanced understanding.
ACKNOWLEDGEMENTS
The authors would like to thank NIPSCO for offering this
research opportunity, providing funding, and for assistance
during the course of this work.
[12]. Guoheng Chen, John Moreland, Daniel Ratko, Li Jin,
Hao Shen, Bin Wu and Chenn Q. Zhou, “Virtual Reality
Development For Engineering Applications”, ASME 2010
World Conference on Innovative Virtual Reality,
WINVR2010-3757.
[13]. Bin Wu, Guoheng Chen, Dong Fu, John Moreland,
Chenn Q.Zhou, 2009, “Integration of Virtual Reality with
Computational Fluid Dynamics for Process Optimization”,
6th International Symposium on Multiphase Flow, Heat
Mass Transfer and Energy Conversion.
[14]. Dong Fu, Bin Wu, John Moreland, Guoheng Chen,
Chenn Q.Zhou, 2009, “CFD Simulations and VR
Visualization for Process Design and Optimization”, In
Proceedings of UECTC-RE ‘09.

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