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SIMULATOR INSTITUTE

CONSUMER NEEDS
* RELIABLE UNINTERRUPTED POWER * QUALITY VOLTAGE & FREQUENCY (VARIATIONS WITHIN SMAL LIMITS)

CHALLENGES
HIGH PLANT AVAILABILITY IMPROVEMENT IN PLANT EFFICIENCY

ENVIRONMENT FRIENDLINESS SAFETY OF PLANT & PERSONNEL


PROFITABILITY OF THE ORGANISATION

NEED FOR SIMULATORS


*
* * * *
PRACTICAL ON JOB TRAINING HIGH RETENTIVITY LEVELS

REAL TIME ENVIRONMENT

REFLEXES OF OPERATORS ARE TUNED CONSIDERABLY


INCREASE IN CONFIDENCE LEVELS

BENEFITS OF SIMULATOR TRG


PLANT DOWN TIME AVOIDED NO WASTAGE OF TIME

NO LOSSESS , NO REPAIRS
INCREASED EFFICIENCY & SAFE WORKING

CONTD. . .

CONTD. . .
NO FUEL COSTS REALISITC ON JOB TRAINING MALFUNCTION TRAINING

NO RISK TRAINING

SIMULATOR
A SIMULATOR IS A DEVICE WHICH CREATES A REALIS- TIC PRESENTATION OF ANY PROCESS IN A INTERACTING MANNER.

TYPICAL TRAINING ACTIVITIES


NORMAL, TRANSIENT AND EMERGENCY PLANT OPERATIONS STARTUP, SHUTDOWN PROCEDURES CONTROL SYSTEMS OPERATIONS

START UP & SHUTDOWN FAULT DIAGNOSIS & TROUBLESHOOTING

FEATURES OF SIMULATOR
ALL THE ENGG SYSTEMS OF POWER PLANT ARE IN THE FORM OF MATH MODELS MATHEMATICAL MODELS ARE PROGRAMMED IN A HIGH SPEED DIGITAL COMPUTER.

THE COMPUTER PROCESSES THE MODELS AT A VERY FAST RATE.

CONTD . . .

CONTD . . .
ALL CHANGES IN THE VARIOUS PROCESSESS OF POWER PLANT BOILER TURBINE GENERATOR DISPLAYED IN THE CONTROL ROOM PANEL INDICATORS PROCESS CHANGES EITHER FROM WITHIN OR IMPOSED FROM OUTSIDE ARE RESPONDED TO DYNAMICALLY BY THE SIMULATOR.

SIMULATION & MODELLING


SIMULATION IS THE PROCESS IN WHICH
A) A MODEL OF REAL SYSTEM IS DESIGNED

B) EXPERIMENTS ARE CONDUCTED


WITH THIS MODEL TO :
I) UNDERSTAND THE BEHAVIOUR OF THE SYSTEM II) EVALUATE THE VARIOUS STRATEGIES FOR OPERATION OF THE SYSTEM

PROCESS OF SIMULATION
PHYSICAL PROCESS MATHEMATICAL MODELS

INTEGRATED MATH MODELS TREATED AS PROGRAMS AND RUN ( ITERATED ) AT FAST RATE BY DIGITAL COMPUTER TO CREATE DESIRED EFFECTS ON UCB

200MW SIMULATOR DETAILS


BASED ON THE DESIGN DATA OF KSTPSSTAGE1
PANEL EXACTLY SIMILAR TO UCB OF KSTPS STAGE1 SUPPLIER - M/S SINGER LINK , U.S.A IN 1984

500MW SIMULATOR
BASED ON DESIGN DATA OF SSTPS UNIT-6
PANEL SIMILAR TO UNIT-6 OF SSTPS

SUPPLIER : M/S SIEMENS AG GERMANY, 1995

SIMULATOR HARDWARE
COMPUTER SYSTEMS ELECTRONIC INTERFACE SYSTEM UCB PANEL UPS AND BATTERY SYSTEM

UPS
DOs /AOs

DIs / AIs

COMPUTER SYSTEM

INTERFACE UNIT

SOFTWARE
SIMULATION COMPUTER SOFTWARE
SYSTEM SOFTWARE
APPLICATION SOFTWARE I/O SOFTWARE

SIMULATION SOFTWARE
INSTRUCTOR STATION SOFWARE

DAS COMPUTER SOFTWARE


SYSTEM SOFTWARE APPLICATION SOFTWARE

UPS system UPS system


Simulation computer System S/W Application S/W 1) I/O S/W 2) Simulation S/W 3) IS S/W Shared Memory

I/O system

DOs /AOs

DIs / AIs

DAS computer System S/W


Application S/W

Instructor Station

SIMULATION & DAS COMPUTER SYSTEM OF 200 MW SIMULATOR

CPU
IPU
MEMORY
REAL TIME CLOCK Programmers Terminal

MTU

MTU

CPU
MEMORY

DD DD Shared Memory

DD

Line Printer
Programmers Terminal
HSDI

Debugger Terminal

DAS Printers

UCB

Instructor Station Printer

Instructor Console

SIMULATION COMPUTER

DAS COMPUTER

FACILITIES OF SIMULATOR
SELECT INITIAL CONDITIONS LIKE :
COLD START BOILER READY TO FIRE TURBINE READY TO ROLL VACCUM PULLED STATE READY TO SYNCHRONIZE PARTIAL/HALF/FULL LOAD

CONTD . . .

CONTD . . .

FREEZE OR RUN THE SIMULATION AT ANY INSTANT OF TIME OPERATE THE SIMULATOR FROM HAND HELD REMOTE CREATE NEW INITIAL CONDITIONS AS PER NEED BACKTRACK TO STEP TO PRIOR CONDITION TAKE A SNAPSHOT AT ANY INSTANT OF TIME SELECT SLOW OR FAST MODES OF OPERATION

CONTD . . .

CONTD . . .
REMOTE FUNCTIONS MALFUNCTION INSERTION OF VARIABLE SEVERITY AND TIME DELAY EXTERNAL PARAMETERS SETTING RECORD/REPLAY FACILITY COMPUTERISED TRAINEE TEST

EXAMPLES OF PROGRAMMED MALFUNCTIONS/EMERGENCIES


ID FAN TRIP FD FAN TRIP CEP TRIP HOTWELL LEVEL HIGH CONDENSER AIR LEAKAGE WATER WALL TUBE LEAK MOP FAILURE

SOFTWARE DETAILS
OPERATING SYSTEM MPX-32 PLANT SIMULATION SOFTWARE
PLANT SIMULATION SOFTWARE CONSISTS OF MATH-MODELS IN FORTRAN77 & ASSEMBLY { 200MW PLANT SOFTWARE HAS 32 MATH-MODELS IN FORTRAN 77 } { 500MW PLANT SOFTWARE HAS 85 MATH-MODELS IN FORTRAN-77 }

DAS SOFTWARE & IS SOFTWARE


DAS SOFTWARE IN FORTRAN77 & AND ASSEMBLY LANGUAGES

PLANT SIMULATION SOFTWARE CONSIST : PROCESS AND CONTROL MODULES FOR CONDENSATE, FEEDWATER AND ELECTRICAL SYSTEMS PROCESS AND CONTROL MODULES FOR BOILER WATER & STEAM AND AIR & FLUE GAS AND FUEL SYSTEM PROCESS AND CONTROL MODULES FOR TURBINE SYSTEM ACS LOOPS INTERLOCKS AND LOGIC MODULES FOR ALL SYSTEMS SPECIAL FUNCTIONS FOR CALCULATION OF ENTHALPY, THERMAL CONDUCTIVITY ETC

SCOPE OF SIMULATION
AIR & FLUE GAS SYSTEM STEAM GENEARATOR SYSTEM TURBINE SYSTEM (INCLUDING ATRS ) CONDENSATE & FEEDWATER SYSTEM WATER CHEMISTRY CW SYSTEM ELECTRICAL UNIT DISTRIBUTION H2 SEAL OIL SYSTEM BURNER MANAGEMENT ( FSSS) INTEGRATED CONTROL (ACS ) MAIN GENERATOR & AUXILLARY SYSTEM FUEL SYSTEM ( OIL , PULVERIZER ETC )

APPLICATIONS OF SIMULATORS
AIR TRAFFIC CONTROL SIMULATORS FLIGHT SIMULATORS FOSSIL FUEL POWER STATION NUCLEAR POWER STATION SIMULATORS RAILWAY SIMULATOR ROAD TRAFFIC & DRIVING

BLOCK DIAGRAM OF DAS


DAS COMPUTER
COMPUTER DATA LINK

UTILITY CRT

OPEARATOR-1 CRT

OPERATOR-2 CRT

ALARM CRT

FACILITIES IN DAS
DISPLAY FUNCTIONS
.. MIMIC DIAGRAMS .. BAR CHARTS .. VIDEO TRENDS .. X-Y PLOTS .. PERIODIC DISPLAY

OTHER DAS FUNCTIONS


ATRS MESSAGES ATT MESSAGES START-UP GUIDANCE MESSAGES OPERATOR GUIDANCE MESSAGES

CONTD . . .

ALARM

ALARM POINTS ARE DISPLAYED ON A SEPARATE CRT WITH SEVERAL PAGES OF ALARM POINTS POINTS IN ALARM CONDITION BLINK TILL THEY ARE ACKNOWLEDGED. PREVIOUS PAGE & NEXT PAGE CAN BE CALLED AT ANY TIME

FUNCTIONS

LOG FUNCTIONS

PERIODIC LOGS (HOURLY , END OF SHIFT ,DAILY LOG ETC ) EVENT TRIGGERED LOGS SEQUENCE OF EVENTS LOG POST TRIP LOG BOILER START -UP LOG TURBINE SHUTDOWN ANALYSIS LOG

BENEFITS OF SIMULATOR (TO VARIOUS DEPTS)


OPERATIONAL PERSONNEL CAN DEVELOP OPERATING PROCEDURES AND EXAMINE CAUSES OF FREQUENT PROBLEMS

CONTROL ENGINEERS CAN DEVELOP CONTROL SYSTEM LOGIC CHANGES AND TEST THE RESULTS AGAINST THE SIMULATOR. TUNING CONTROLS CAN BE PRACTISED AND UPGRADES CAN BE INSTALLED WITHOUT AFFECTING THE PLANT

ENGINEERING STAFF CAN INVESTIGATE THE STABILITY EFFECTS OF PROCESS AND OPERATIONAL CHANGES SUCH AS ADDING A BYPASS OR CHANGING THE STARTUP PROCEDURES. MANAGEMENT CAN QUICKLY UNDERSTAND OPERATIONAL REQUIREMENTS OR PROBLEMS BY DEMONSTRATING THEM ON SIMULATOR

THANK YOU