best practices- simulator training
TRANSCRIPT
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SIMULATORS
By NPTI
Courtesy-
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Objectives of Simulators
• Operator Training
• Engineering Analysis
• Optimizing Control Loops
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urpose o ra n ngSimulator
• Improvement of plant operational skills
• Familiarity of plant MMI functions
• Understanding of basic plant dynamics
• Study of control system functions
• Act as a bridge between a hard panel operated system and a newadvanced plant DCS –Applicable for Renovated Plants
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Operator Training
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 of Control 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
MajorOperatorActions
• 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
ElectricalPower
Boiler Gen Ckt
Bkr
ESV
A simplified Schematic of a Power Plant
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Operator Training Emergency Handling
Steam
Turbine
FEED CYCLE
FuelCoal / Oil / Gas
Air
Steam
GENERATOR
ElectricalPower
Boiler
TurbineBlades broke
Emergency ConditionTurbine Tripactuated
ESVdidnotclose
Gen Ckt Bkr ManuallyOPENED
Possible Response of Operator not trained on Siumlator
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Operator Training
Need for Simulator Training
• Automatic plants continue to operate without operator intervention for long periods.
• There is little opportunity for new operators topractise operation.
• Simulator affords possibility to practise all operationswithout risk of plant damage due to incorrect operator action.
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Operator Training 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 located 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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Operator Training Advantages of Simulator Training
• Training on same type of Operator interfaces asin real plant
• 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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Operator Training Key Features of Simulator
• Fairly accurate model of real plant. Model willrespond to operator actions exactly as the realplant would
• Facility to Freeze /Start simulator at will. Thispermits instructor to explain intermediatecondition of plant
• Facility to take Snap Shots of any plantcondition for replay to provide opportunity to learnthe best response to a plant condition.
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Operator Training Key Features of Simulator
• Facility to run the model in real time / high speed.Permits speeding up of slow plant processes such asboiler pressure build up. This can be very useful inavoiding tiresome waiting to observe processresponse to operator actions.
• Malfunctions of plant equipment can be createdto simulate actual plant equipment. For example,Turbine steam inlet valve can be blocked from closingon a turbine trip. Process behaviour and operator response to handle the situation can be repeatedlytaught.
• Historical record of Operator actions can be kept for
analysis and evaluation of Operator Performance.
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Simulator Training is Effective
Demonstrated BenefitsDemonstrated Benefits
of of
$1000/Mw/Yr $1000/Mw/Yr
EPRI Study….
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Basic Contents of a Simulator
• Process Model
• Can be accurate to within 1-2% of real plantfor critical parameters
• Can simulate process behaviour even intransient condition to within 10-20 % of real
plant
• Control Model
• All real plant closed and open loop controlscan be accurately emulated / copied
• Operator Interface
• DCS based screens or hard-panels can besimulated
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Types of Simulators
1. Fully Emulated
Emulated DCSOperator
Interface
Instructor Console with
Process &Control
Models
3. Stimulated DCS
2. Stimulated MMI
Instructor Console with
Process Models
Data Highway
DuplicateDCS
Processors
LAN
LAN
Duplicate DCS
Operator
Interface
Instructor
Console withProcess & Control
Models
LAN
Emulated PanelOperator
Interface
Emulated Panel
Operator
Interface
Serialor SCSI
Emulated PanelOperator
Interface
Duplicate DCSOperator
Interface
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Typical Simulator hardware
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Thank You