Thermal power plant simulator specification

2011-06-07T19:43:00.001+05:30

1) Highly realistic environment:

Simulator should provide highly realistic environment with respect to the reference plant in all respects such as HMI, layout etc.,

a) System Configuration: The system configuration of the simulator should replicate the unit control room HMI(Human Machine Interface) in all respect such as no of operating stations, large size video screens, printers and size of the monitors etc., The layout of the simulator should also replicate the unit control room layout. Instructor station, Remote station and one personal computer with projector for theoretical explanations and presentations should be included in the system configuration itself.

b) DCS emulation: The functions of the reference plant control system, Graphic screens (Plant schematics), operator interface system and information systems should reproduced using the same DCS emulation method.

2) Modeling :

Simulator models should follow the principles of conservation of energy, mass and heat balance, momentum equations and physical laws applicable. The characteristics of the various equipments such as pumps, valves, coolers, motors etc., has to be reproduced as the reference plant with available design data, else to be tuned to meet the reference plant response times and output parameters.

a) Simulation of Process: All the process parameters and respective processes as per the master IO list of the reference plant have to be simulated. All the design parameters will be given as per availability and other should be tuned in simulation modeling to match the reference output parameters at 100% MCR, 60% MCR and 30% MCR. List of the processes which are not covered in the simulator have to be approved during the engineering stage itself.

b) Simulation of controls: All the Analog and Binary controls present in the DCS have to be simulated using the same DCS emulation method. The P&IDS and operation philosophy will be provided.

c) Simulation of electrical system: Electrical systems (switch gear, generator, excitation system, synchronous scope, HT bus system and LT bus system etc.,) in the reference plant have to be simulated in the simulator. All the operations possible from the electrical system in the reference plant should be incorporated in simulator.

d) Stimulation of Front end (graphics): All the graphics /plant schematics, functions of the HMI and information systems such as trends, plots etc to be reproduced as per the reference plant HMI & DCS.

e) Depth and Accuracy of the Simulation models: Simulation models accuracy should be more than 95%. Each and every model has to be evaluated before our engineer and the results to be got approved. After complete assembly of the simulator testing should be done at factory and after getting the proper clearance from us, you should dispatch the simulator. Design data will be provided as per the availability and other data to be assumed and to be tuned to get the desired results.

f) Simulation control: The models should have the control of simulation rate. Slow time ability is provided for fast transients. A rate of about 1/10 slower of real-time (in ten steps) is usually used. Fast time is provided for demonstration of long-term transients and for fast entering of desired plant conditions. Different rates can be used depending on the particular process.

3) Features of the simulator:

a) Stop, freeze, run

The simulator can be stopped, frozen and resumed at any time by the instructor.

b) Slow time

Simulator should have the ability to run at slow rates for demonstrating the faster transients. A rate of about 1/10 slower of real-time in 10 steps is desired. Different rates can be used depending on the particular process.

c) Fast time

Simulator should also have the ability to run at faster rate for demonstration of long-term transients and for fast entering of desired plant conditions without any delay for saving the time. A rate of about 10 times faster of real-time in 10 steps is desired. Different rates can be used depending on the particular process.

d) Step by step mode

In this mode, the process simulation stops at the end of each simulation time step and the user can initiate the next time step at his will. This operating mode is useful for analysis, research and for fine tuning of simulator.

e) Snapshot

Temporary initial conditions can be taken automatically at predefined intervals or on instructor's demand. It should be possible to start the simulator from each snapshot initial condition. A snapshot initial condition can be converted into a new initial condition.

f) Backtrack

The simulator should save initial conditions, automatically, at a user-defined time interval during simulation. Storage space for a high number of backtrack initial conditions should be available. The time interval for recording the backtrack initial conditions can be adjustable between, e.g., 30 s and 600 s. Main plant parameters for identification of the respective plant status should be stored and recallable. The simulator should have the ability to restorable from each backtrack initial condition.

g) Replay

From each backtrack initial condition the simulator should be able to repeat all the trainee's and instructor's actions and plant reactions. The replay process can be, at any time, interrupted and the simulation restarted, from that moment, at normal speed.

h) Initial conditions

A set of initial conditions can be used to initialize the simulator to any arbitrary plant condition. A high number, or even an unlimited number, of initial conditions should be available to the instructors. In the latter case, the maximum number of initial conditions is only limited by the available disk storage space. Any snapshot can be saved as an initial condition. List of arbitrary plant conditions such as cold star up condition, hot star up condition, about to flash, about to rolling etc. should be got approved and these initial conditions shall not be over writable.

i) Malfunctions

Simulator should have the ability to initiate one or more simulated malfunctions/equipment failures through instructor station, triggered at a specified elapsed simulation time, or triggered by a specific event, such as a selected process variable reaching a specified value. The malfunction intensity, when applicable, can occur as either a discrete step, or can be ramped from a minimum value to a specified intensity over a specified period of time. List of non over writable malfunctions are to be approved. Simulator should have the ability to define the malfunctions by instructor at later stages.

j) Influence of External parameters

External parameters such as ambient temperatures, Humidity, etc. should be able to set or changed by the instructor and should reflect the influence of any change of the above parameters in the process.

k) Remote operation station

Separate remote operation station should be provided for selected local in-plant operations such as manual root valve to control valves, Manual I/L ,O/L gates to the dampers etc.,

l) Instructor station

Separate Instructor operation station should be provided for instructor. The instructor station should provide the capability to prepare and initiate training exercises, to control the simulation, and to monitor and evaluate the trainee's performance. The instructor station should also provide the facilities for managing training, maintaining training records, initial conditions, backtrack and malfunctions. To allow the instructor to focus attention on training, rather than on operating the simulator, an intuitive user friendly graphical interface should be employed. Color and animation should be used to emphasize selected items, equipment, status, thresholds, levels, direction of flows and alarms. The instructor station should display schematic diagrams of plant systems and components, menus, and dialogue boxes that are touch sensitive & mouse sensitive.

m) Trainee's performance and evaluation tools

(i) Exercise summary

This is a chronological list of the actions performed by the operator and by the instructor during training sessions. It should be permanently saved, but can be reviewed on-line and reported on hard copy.

(ii) Trainee assessment

An automated trainee assessment function may be specified. The purpose is to assist the instructor in assessing the trainees' performance against specified criteria and in measuring competence in several areas. This function could, for example, record all the trainees' decisions made during the training session and check their correctness against an appropriate procedure. At the end of the exercise, a concise report should be printed out.

(iii)Standard exercises

From the instructor station, standard exercises can be prepared beforehand and activated at any time. These exercises could be, for example, saved as disk files, which could contain simplified commands representing all the available functions including simulation time control. The instructor can activate an exercise file to start a training session with the desired scenario.

(iv) Self - guided exercise

A self-guided exercise mode can be specified. It could be implemented as an expert system, which comprises the rules to be followed, depending on the transient and the trainees' actions. After the analysis the trainee is able, if it is appropriate, to repeat the simulation exercise starting at the point at which he deviated from the correct procedure.

4) Hardware & software:

Latest compatible Hardware should be supplied according to the approved system configuration from approved vendor. Operating system for the simulator computers should be the latest available Windows OS. Firewall and anti-virus software with update manager to be included in the software package. Any up gradations of the simulator with respect to modeling and features should be supplied without any extra cost.

There should be considerable spare computing, memory resources, in the hardware

5) DOCUMENT REQUIREMENTS

a) Training manuals:

Exercise descriptions and lesson plans, with details about learning objectives, time, appropriate graphics to the training subjects, descriptions of possible malfunction variants, descriptions of the time sequence of exercises in short and long versions should be provided. The following documents are absolutely necessary for the instructor.

b) User manuals:

Simulator user manual

Instructor station user manual;

Manuals provided by third-party vendors.

c) Maintenance documentation:

Installation specifications.

Software maintenance manuals.

Software manuals.

Documentation provided by third-party vendors.

6) Design, Quality and Testing:

a) Design :

The design specification (DS) should be submitted and got approved by the customer prior to the start of the construction of the simulator models.

In design specification, system configuration, systems to be simulated, any exceptions, list of design parameters required, P& IDS, Operation philosophies required, list of training exercises, list of malfunctions, list of initial conditions, HMI , features of the simulator etc are to be included.

Where no plant data is available, based on best estimate engineering codes, or evaluation and tuning, the reference plant characteristics should be achieved.

b) Quality:

A Quality assurance Plan to be got approved and should be implemented during building of the simulator.

c) Testing :

A plan for verification and testing of the simulator should be created to enable the customer to check the progress of the simulator. Verification and testing should be conducted during different phases of the project and should be indicated in the project plan.

7) Spares and Support:

Spares and support for the simulator to be provided atleast 15 years from the date of handing over.

8) Upgradations :

Any upgradations in models, which will improve the performance of simulator to be provided free of cost.

Power Plant Simulator

2009-07-30T23:20:00.002+05:30

INTRODUCTION

Simulator training is essential in sectors where safety, reliability and skill are utmost important such as flying aircraft or operating power plants. Person trained on simulator gains confidence and insight and thus handles both normal and emergencies well and avoids negative operations. So, providing training on Simulator to operators are indeed beneficial to the Organization.

What is Power Plant Simulator?

Simulator is a powerful training and analyzing tool which generates the actual characteristics of a power plant, based on mathematical models running on a computer.

Advantage of simulator

Qualified personnel are an important factor for operating power plant safety and reliability. Today, power plant operators are faced with the challenge of training plant operating personnel within as short a time as possible. This can be achieved with the simulator because a wide variety of scenarios can be called up. Every possible malfunction and every plant operating condition can be repeated as often as required until all operator reactions and operating sequences have been perfectly trained.

A well tuned simulator is a laboratory for experts

Trainee quickly gains experience in normal, abnormal and emergency conditions.

A well trained operator runs a plant safely and efficiently.

Provides hands on training in a highly realistic environment and also can not be substituted by any other form of training.

It is basically a training tool for training operators of power plant. It greatly enhances the insight and understanding of the power plant. The knowledge gained by conventional training methods get enhanced and consolidated after being trained on Simulator.

Simulators classification

1. Online Simulators or performance evaluators.

2. Offline Simulators.

Online simulators are used for training and also can be utilized as knowledge management systems (as they can guide or take necessary action on live systems).

Where as offline simulators are used as training tools.

A good simulator should have the following features.

1. A well defined mathematical models.
2. Should run at various speeds as well as with natural response time.
3. Should have Data acquisition system.
4. Play back option.
5. Trainee evaluation system.
6. Predefined fault conditions.
7. Local operation station.
8. Various User levels such as Engineering/trainer/trainee levels.
9. Freeze condition.
10. Should have highly realistic environment.
11. Should run from Dark house to Unit synchronization.

Building Philosophy

I concentrate on building of a coal fired thermal power plant simulator only. Now our task is building a thermal power plant simulator. Let us analyze the task and divide the task into sub-tasks.

1. First we have to choose a programming language for building up a PC based thermal power plant simulator.

2. Data base and network protocols for communication.

3. Good mathematical modeling.

No individual or small group of people dare to think of developing a simulator. It looks like a giant task. Of-course, it is a giant task, no doubt in it. But it is possible. It is a true story. It is my experience and would like to share with the world.

One should select a programming language such as visual basic which is easy to understand, user friendly and having lot of tools for developers.

Selection of database and network protocols are also equally important as the data should be reliable and data flow must be faster.

Mathematical modeling is the brain of simulator. Best models will produce accurate simulator.

While building a thermal power plant simulator one should recognize the importance of steam tables, psychometric chart, air properties, flue gas properties, and evaporation and combustion principles.

CONCLUSION

Improves operation skills in normal, abnormal and emergency scenarios.

Improves overall and system level understanding of the operation characteristics.

Evaluates the emergency operations.

Improves the analytical capabilities of the operator.

Avoids the negative operations

No other tool can replace Simulator.

ALCHEMIST-Au

Thermal power plant simulator specification

Power Plant Simulator