Woudagemaal simulator

In 1920 the Ir. D.F. Woudagemaal pumping station in Lemmer was built. The largest, still-functioning steam pumping station in the world, has been on UNESCO's World Heritage List since 1998. This monumental steam giant is still used by Wetterskip Fryslân to ensure dry feet in Friesland when water levels are too high. With the changing climate and more often periods of heavy rain, the role of the pumping station is important. Therefore, it is of essential to maintain a good level of education and training for the employees and as such, a request was done to produce a 3D real time simulator of the steam pumping station. 

Motivation

Currently two training weeks per year are organized to train the employees of Wetterskip Fryslân to run the Woudagemaal pumping station. More training is required, while it is not desired to increase the number of running weeks due to fuel costs and emissions. Therefore a realistic time domain simulator of the pumping station is a serious tool to be able to educate and train the employees of Wetterskip Fryslân.

What problem does it solve?

Training with the simulator leads to an improved education level and a sustainable and quicker option to educate employees.

Project team

The simulator was developed by the Maritime Research Group of NHL Stenden. Ralph Schaafsma, Arjan van Vliet and Jan de Jonge developed the simulator under guidance of team leader Marcel Krijnen and with assistance of prof. Herbert Koelman. Many thanks to the employees of the Ir. D.F. Wouda pumping station for the extensive tours and information shared to be able to make the project successful.

Approach

An extensive time domain class-based calculation model was set up with Python. The model uses the XSteam library to calculate the properties of boiling water, saturated steam and superheated steam. The simulator was divided into several components like:

• Boilers
• Superheaters
• Pipeloop system
• Steam Machines 
• Pumps
• Condensors
• Support steam machines
• Condensate and Filter tanks
• Valves

Each time step the calculated values of mass, flow, temperatures, pressures, enthalpy et cetera are shared with the visual model. Within the visual model the calculated parameters are shown. The user of the simulator can thus see the actual situation of the pumping station and can actively adjust valves, handles, heaters et cetera to operate the pumping station.

The visual model is a fully real-time 3D modelled representation of the real station. Built with the Unity engine’s High-Definition Pipeline, the virtual environment features high visual fidelity with the latest in graphic technologies. Tightly coupled with the calculation model, it offers a highly realistic and interactive training environment.

What are the main results?  

NHL Stenden contributed to the Wetterskip training program of the Ir. D.F. Wouda pumping station. The training program is herewith extended while avoiding additional running of the pumping station. By giving the employees the opportunity to operate the pump station from a laptop environment the training possibilities are endless. In addition simulator training is a very good way to work in a safe environment without risk of damaging precious equipment. 

• A physically correct time domain simulator was built by NHL Stenden
• Improves education of Wetterskip employees
• Sustainable alternative for training by avoiding use of additional fuel

Project partners

• Wetterskip Fryslân