best practices of simulator training
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IGEN PROGRAM
Best Practices
SIMULATOR TrainingSurender Kumar
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IGEN PROGRAM
Objectives of Simulators
Operator Training
Engineering Analysis
Optimizing Control Loops
Simulation Training is an exercise where a direct On-JobHands-on skill is developed and te Operators responsesand reflexes are fine-tuned to react to the urgent ofnecessities.
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IGEN PROGRAM
Operator TrainingPurpose of Training Simulator
Improvement of plant operational skills
Familiarity of plant MMI functions
Understanding of basic plant dynamics
Study of control system functions
Act as a bridgebetween a hard panel operated system and a newadvanced plant DCSApplicable for Renovated Plants
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IGEN PROGRAM
Benefits and functions ofsimulators
Recent studies indicated that simulator training reduce operator-
training time by a factor of five. Not only operators are trained
faster, but they are more confident and skilled.
Optimum procedures, minimizing the potential for costly accidents.
When used to test and tune new control logic prior to plant
commissioning,
Start-up problems and start-up time are reduced.
Control system logic changes can be tested on the simulator prior to
implementation in the plant.
Simulators increase the proficiency levels and raise the skills to
handle the emergencies in actual practice.
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Operator TrainingNeed for Simulator Training
Automatic plants continue to operate without operatorintervention for long periods.
Little opportunity for new operators to practiceoperation.
Simulator affords possibility to practice all operations
without risk of plant damage due to incorrect operatoraction.
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Typical Operation features
Modern Power plants are complex
Operation from Operator Workstations using Monitor / Keyboard
Large amount of information available
Operator expected to handle vast number of operating andperformance monitoring screens
Operator expected to locate faulty equipment which might bepreventing an automatic sequence from completion
Operator expected not only to keep generating power but also to do so
with the highest fuel efficiency
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pera or n er aces as n reaplant
Same type of operating conditions can berepeatedly created to improve operator reactionto a condition
Any type of emergency condition can be createdto train in emergency handling
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Type & Level of Training
No. Item Function Training LevelFresh Experienced
1 Plantdynamics
(Abnormal/Failure
Plant dynamics of Planttrip/major Control system
failure
2 Plantdynamics(Start-up/Shutdown)
Function ofControl system duringstart-up/shut down
3 Start-up/Shut
downoperation
Operation procedure of
start-up/shut down
4 EmergencyOperation
EmergencyOperation procedure incase of failure
5 ComplexOperation
Capability for complexand skilled operation
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Unit Operator
Major
OperatorActions
Unit Start-up
Unit Shut down
Emergency Handling
Performance Monitoring
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Operator Training
Emergency Handling
Steam
Turbine
FEED CYCLE
BOILER
Fuel
Coal / Oil / Gas
Air
Steam
GENERATOR
Electrical
Power
BoilerGen Ckt
Bkr
ESV
A simplified Schematic of a Power Plant
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Operator Training
Key Features of Simulator
Fairly accurate model of real plant. Model will
respond to operator actions exactly as the real
plant would
Facility to Freeze /Start simulator at will. Thispermits instructor to explain intermediate
condition of plant
Facility to take Snap Shots of any plant
condition for replay to provide opportunity to learnthe best response to a plant condition.
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Simulator
Facility to run the model in real time /high speed. Permitsspeeding up of slow plant processes such as boiler pressurebuild up. This can be very useful in avoiding tiresomewaiting to observe process response to operator actions
Replay of frames
Remote functions
Back track
Computer aided Excercices
Malfunctions of plant equipment can be created tosimulate actual plant equipment.
Historical record of operator actions can be kept for analysisand evaluation of operator performance
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Simulator Training is Effective
Demonstrated Benefits
of
$1000/Mw/Yr
EPRI Study.
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Basic Contents
Process model
Can be accurate to within 1-2% of realplant for critical parameters
Can simulate process behaviour even
in transient condition to within 10-20% of real plant
Control model
All real plant closed and open loopcontrols can be accurately emulated /copied
Operator interface
DCS based screens or hard-panelscan be simulated
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Man Machine Interface
Conventional PanelMode of operation
Soft Paneloperation
Video ProcessConsole
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System Models
Air and Flue Gas system
Boiler System
Fuel System
Condensate and Feed Water
System
Electrical Generation System
Main Steam System
Turbine system
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Control Panels
Fuel firing & FSSS
Air & Flue Gas System
Steam System
Feed Water System
Regenerative Feed Heating System
Turbine
Generator
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Initial Conditions
Electrical supply failure
Cold start up
Purge ready Ready to roll turbine
Ready to synchronise generator grid
System at 50/100/150MW.
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Logic Controls
Furnace safeguard supervisory system
Run up Run back
Boiler follow mode Turbine follow mode
Coordinated mode of control (CMC)
Sliding and fix pressure mode of operation
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Logic Control
Automatic turbine run up system
Automatic turbine tester (ATT)
Turbine stress evaluator (TSE)
All auto/manual control of operatingparameters
Starting permissive/interlocks andprotections
Functional group/sub groupcontrol/sub loop control mode ofcontrol for safe starting and stoppingof equipments
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Data Acquisition System
Data Acquisition System
Bar Charts
Plant Mimics
Trends Curves (X-t, X-Y )
Schedule of Alarms and
Logs
Operator Guidance mode
Performance Calculation
Excess Air Control
Boiler Efficiency
Turbine Efficiency
Unit/Turbine Heat rate
TTD of different heaters
Cycle Efficiency
Specific Coal/oil consumption
M lf i d
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Malfunctions andEmergencies
Pre simulated malfunctions/emergency situations:
Wet Coal/No coal/Chocking in milling System
Water walls/ Super heater/Re-heater tube failure
Emergency tripping of major auxilliaries viz. ID
Fans, FD fans, PA fans, CEP,BFP etc.
Turbo-visory parameters
Grid Frequency influence (Free governing modeof operation)
Vacuum/lub oil/Bearing temperatures/ Motorwindings temperature/electrical problems
Failure of control system, False Alarms
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Combine Cycle Gas Turbine
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Combine Cycle Gas TurbineSimulator
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Combine Cycle Gas TurbineSimulator
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Thank YouTHANK YOU