Best Practices- Simulator Training
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SIMULATORS By
NPTI
Courtesy-
Objectives of Simulators
• Operator Training • Engineering Analysis • Optimizing Control Loops
Purpose 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 bridge between a hard panel operated system and a new advanced plant DCS –Applicable for Renovated Plants
Operator Training
Type & Level of Training
No.
Item
Function Fresh
1
2
3 4 5
Plant dynamics (Abnormal /Failure Plant dynamics (Start-up/Shut down) Start-up/Shut down operation Emergency Operation Complex Operation
Plant dynamics of Plant trip/major Control system failure Function of Control system during start-up/shut down Operation procedure of start-up/shut down Emergency Operation procedure in case of failure Capability for complex and skilled operation
Training Level Experienced
Unit Operator
• Unit Start-up
Major Operator Actions
• Unit Shut down • Emergency Handling • Performance Monitoring
Operator Training
Emergency Handling A simplified Schematic of a Power Plant
Steam
Fuel Coal / Oil / Gas
ESV
Steam Turbine
Air
Boiler FEED CYCLE
GENERATOR
Gen Ckt Bkr
BOILER Electrical Power
Operator Training
Emergency Handling Possible Response of Operator not trained on Siumlator Emergency Condition Turbine Trip actuated
ESV did not close
Turbine Blades broke
Steam
Fuel Coal / Oil / Gas
Steam Turbine
Air
Boiler
GENERATOR
Gen Ckt Bkr Manually OPENED
FEED CYCLE
Electrical Power
Operator Training
Need for Simulator Training
• Automatic plants continue to operate without operator intervention for long periods. • There is little opportunity for new operators to practise operation. • Simulator affords possibility to practise all operations without risk of plant damage due to incorrect operator action.
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 and performance monitoring screens
•
Operator expected to located faulty equipment which might be preventing an automatic sequence from completion
•
Operator expected not only to keep generating power but also to do so with the highest fuel efficiency
Operator Training
Advantages of Simulator Training •
Training on same type of Operator interfaces as in real plant
•
Same type of operating conditions can be repeatedly created to improve operator reaction to a condition
•
Any type of emergency condition can be created to train in emergency handling
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. This permits instructor to explain intermediate condition of plant
•
Facility to take Snap Shots of any plant condition for replay to provide opportunity to learn the best response to a plant condition.
Operator Training
Key Features of Simulator •
Facility to run the model in real time / high speed. Permits speeding up of slow plant processes such as boiler pressure build up. This can be very useful in avoiding tiresome waiting to observe process response to operator actions.
• Malfunctions of plant equipment can be created
to simulate actual plant equipment. For example, Turbine steam inlet valve can be blocked from closing on a turbine trip. Process behaviour and operator response to handle the situation can be repeatedly taught.
•
Historical record of Operator actions can be kept for analysis and evaluation of Operator Performance.
Simulator Training is Effective
Demonstrated Benefits of $1000/Mw/Yr
EPRI Study….
Basic Contents of a Simulator •
Process Model • Can be accurate to within 1-2% of real plant 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 loop controls can be accurately emulated / copied
•
Operator Interface • DCS based screens or hard-panels can be simulated
Types of Simulators
LAN
LAN Serial or SCSI
Emulated DCS Operator Interface
Emulated Panel Operator Interface
1. Fully Emulated Data Highway
Duplicate DCS Operator Interface
Instructor Console with Process & Control Models
LAN
Duplicate Emulated Panel Instructor DCS Operator Console with Processors Interface Process Models
3. Stimulated DCS
Duplicate DCS Operator Interface
Emulated Panel Operator Interface
2. Stimulated MMI
Instructor Console with Process & Control Models
Typical Simulator hardware
Thank You
NPTI
Courtesy-
Objectives of Simulators
• Operator Training • Engineering Analysis • Optimizing Control Loops
Purpose 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 bridge between a hard panel operated system and a new advanced plant DCS –Applicable for Renovated Plants
Operator Training
Type & Level of Training
No.
Item
Function Fresh
1
2
3 4 5
Plant dynamics (Abnormal /Failure Plant dynamics (Start-up/Shut down) Start-up/Shut down operation Emergency Operation Complex Operation
Plant dynamics of Plant trip/major Control system failure Function of Control system during start-up/shut down Operation procedure of start-up/shut down Emergency Operation procedure in case of failure Capability for complex and skilled operation
Training Level Experienced
Unit Operator
• Unit Start-up
Major Operator Actions
• Unit Shut down • Emergency Handling • Performance Monitoring
Operator Training
Emergency Handling A simplified Schematic of a Power Plant
Steam
Fuel Coal / Oil / Gas
ESV
Steam Turbine
Air
Boiler FEED CYCLE
GENERATOR
Gen Ckt Bkr
BOILER Electrical Power
Operator Training
Emergency Handling Possible Response of Operator not trained on Siumlator Emergency Condition Turbine Trip actuated
ESV did not close
Turbine Blades broke
Steam
Fuel Coal / Oil / Gas
Steam Turbine
Air
Boiler
GENERATOR
Gen Ckt Bkr Manually OPENED
FEED CYCLE
Electrical Power
Operator Training
Need for Simulator Training
• Automatic plants continue to operate without operator intervention for long periods. • There is little opportunity for new operators to practise operation. • Simulator affords possibility to practise all operations without risk of plant damage due to incorrect operator action.
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 and performance monitoring screens
•
Operator expected to located faulty equipment which might be preventing an automatic sequence from completion
•
Operator expected not only to keep generating power but also to do so with the highest fuel efficiency
Operator Training
Advantages of Simulator Training •
Training on same type of Operator interfaces as in real plant
•
Same type of operating conditions can be repeatedly created to improve operator reaction to a condition
•
Any type of emergency condition can be created to train in emergency handling
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. This permits instructor to explain intermediate condition of plant
•
Facility to take Snap Shots of any plant condition for replay to provide opportunity to learn the best response to a plant condition.
Operator Training
Key Features of Simulator •
Facility to run the model in real time / high speed. Permits speeding up of slow plant processes such as boiler pressure build up. This can be very useful in avoiding tiresome waiting to observe process response to operator actions.
• Malfunctions of plant equipment can be created
to simulate actual plant equipment. For example, Turbine steam inlet valve can be blocked from closing on a turbine trip. Process behaviour and operator response to handle the situation can be repeatedly taught.
•
Historical record of Operator actions can be kept for analysis and evaluation of Operator Performance.
Simulator Training is Effective
Demonstrated Benefits of $1000/Mw/Yr
EPRI Study….
Basic Contents of a Simulator •
Process Model • Can be accurate to within 1-2% of real plant 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 loop controls can be accurately emulated / copied
•
Operator Interface • DCS based screens or hard-panels can be simulated
Types of Simulators
LAN
LAN Serial or SCSI
Emulated DCS Operator Interface
Emulated Panel Operator Interface
1. Fully Emulated Data Highway
Duplicate DCS Operator Interface
Instructor Console with Process & Control Models
LAN
Duplicate Emulated Panel Instructor DCS Operator Console with Processors Interface Process Models
3. Stimulated DCS
Duplicate DCS Operator Interface
Emulated Panel Operator Interface
2. Stimulated MMI
Instructor Console with Process & Control Models
Typical Simulator hardware
Thank You
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