PRESENTATION SIMULATORS

Transcription

1 PRESENTATION ON SIMULATORS S System Technologies Group

2 Objectives of Simulators Operator Training Engineering Analysis Optimizing Control Loops

3 Purpose of Power Plant Training Simulators Train and enhance operator skills for New plants Retrofit of new control systems Assignments in new units Continuous improvement of operator skills Examining alternate power generating strategies Alternate control schemes in existing plants Emergency and complex operations

4 Features of Training Simulator 1. Plant Dynamics (Abnormality) Training Center 5. Complex Operation 2. Plant Dynamics (Start-up/Shutdown) Compact Simulator 4. Emergency Operation 3. Start-up/Shutdownt td

5 Type and Levels of Training Type of Training Plant Dynamics and Control System functions Start-up and Shut Down Procedures Start-up and Shut Down and Abnormal Behaviour Emergency and Abnormal Operations and Failure Handling Complex Operations Level of Experience Fresh Normal Experienced

6 Purpose of Training Simulators Improvement of plant operational skills Familiarity of plant MMI functions Understanding of basic plant dynamics Study of control system functions At Act as a bid bridge between a hard panel operated system and a new advanced plant DCS

7 The Simulator: a Bridge from Hard Panel or Non-Automated to an Automated Environment The Simulator shows you how to use the emulated graphics and faceplates using the computer keyboard and mouse to control the processes realistically modeled after your plant The Simulator allows you to be trained in system operations so you can make a smooth transition to the new plant operator interface

8 Prospective Customers Companies building new plants Retrofit of the control system, especially new operator interfaces Training schools and training departments in different power g g p p utilities

9 Benefits of Simulators EPRI study led to large scale induction of training simulators in USA, starting in 1986 Demonstrated Benefits of $1000/MW/Yr More than 250 simulators in the US today

10 Instructor Man Machine Interface Plant Process Panels TFT / KB Control Sytems Operator 1 Operator 2 Operator 3 Training environment for a Power Plant Training Programme

11 Instructor Instructor Station Man Machine Interface Plant Process Panels TFT / KB Control Sytems Model Server Allways emulated Physical Stimulated t Or Or Emulated Emulated Physical / Virtual / Translated / Emulated Operator 1 Operator 2 Operator 3 Operator Stations Training environment for a Power Plant Training Programme

12 Completely Emulated Instructor Instructor Station Man Machine Interface Plant Process Panels TFT / KB Control Sytems Model Server Allways emulated Physical Stimulated t Or Or Emulated Emulated Physical / Virtual / Translated / Emulated Operator 1 Operator 2 Operator 3 Operator Stations Types of Simulators

13 Completely Stimulated Instructor Instructor Station Man Machine Interface Plant Process Panels TFT / KB Control Sytems Model Server Allways emulated Physical Stimulated t Or Or Emulated Emulated Physical / Virtual / Translated / Emulated Operator 1 Operator 2 Operator 3 Operator Stations Types of Simulators

14 Hybrid Instructor Instructor Station Man Machine Interface Plant Process Panels TFT / KB Control Sytems Model Server Allways emulated Physical Stimulated t Or Or Emulated Emulated Physical / Virtual / Translated / Emulated Operator 1 Operator 2 Operator 3 Operator Stations Types of Simulators

15 Multipliers for options Instructor Instructor Station Man Machine Interface Plant Process Panels TFT / KB Control Sytems Model Server Allways emulated Physical Stimulated t Or Or Emulated Emulated Physical / Virtual / Translated / Emulated Operator 1 Operator 2 Operator 3 Operator Stations Types of Simulators

16 Other ways of classification Low fidelity / High Fidelity Generic / Replica

17 Cit Criteria i for Selection Application of Simulator Training Testing of Control Loops Cost Slow / Fast operation Type of Plant With Panel or about to be renovated

18 Evonik Team s Experience Several projects with Trax toolkits National Power Training Institute (CCPP, India) NPTI Hydro Simulator 500 MW coal fired plant 505 MW CCGT Simulator Simulation for Captive Power of Haldia Petrochem Damieta (CCPP, Egypt) Kureimat (600 MWGas/oil firedl boiler and turbine, Egypt) Zou Xian (conventional boiler and turbine, China) Mohawe (coal slurry plant, USA) Development of proprietary product Detroit (waste water treatment and incineration plant, USA) 8 Simulators Turbine Simulator for Simcon, USA Boiler Simulator for In-house Training

19 Salient features : TRAX Simulators Training fully Integrated with Simulator Development Full Training Services The Leading Supplier of Fossil Simulators Fully Integrated with Several Controls Vendors The Most Tools, The Most Experience Growing to the Future; A Leader in Technological Development

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21 Siemens Teleperm XP

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29 CCGT Simulators Op Screen NPTI CCGT Simulator Op Screen

30 NPTI CCGT S Simulator Simulators

31 NPTI S CCGT Simulator Simulators

32 NPTI CCGT Simulators Model Schematic

33 NPTI CCGT Simulators Model Schematic

34 NPTI CCGT S Simulator Simulators

35 Simulation for Engineering i Analysis Analysis of transients at y Haldia Petrochemicals Ltd.

36 Header Balance of HPL Process Plant

37 BPST TRIP

38 NORMAL CONDITION

39 HRSG AB FLOWS

40 CPP MW

41 FLOWS FROM SHP, HP, MP,LP HEADERS TO NCU HEADERS

42 BPST TRIP Simulators

43 PRDS OPENS DUE TO DISTURBANCE

44 PLANT OVERVIEW HMI SCREEN

45 SHP HEADER SCREEN

46 SlS Sludge Cake Sludge Cake ludge Sluake Ca udge Sludg Cak ke e Cake Sludge Sludge Cake Sludge Cake Cake Drying Zone Burning Zone Cooling Zone Air Main Gas Incinerator Overview

47 Exhaust ID Fan Precooler Impingement Scrubber Venturi Scrubber Pollution Control System

48 Furnace Draft Pr Control Flue Gas Path Cold Air Damper Prim. Air Path Hot Air Damper Sec. Air Path

49 Coal Feeder Coal Mill Boiler Master

50 Spray Control MS Pr Control FW Control Start Up Valve Recirc. Path

51 Simulator Presentation

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56 Instructor Functions Initial Condition Run/Freeze Fast/Slow Time Reset Dynamic Schematic Malfunctions Parameter Changes Snapshots Operator Action Replay Training Scenarios Automated Analyses Teaching Assistant (TA) Coordinated Video Coordinated Sound Trends Plot List Trainee Proficiency

57 Leading Screen

58 Hardpanel Emulation

59 Hardpanel Emulation

60 Instructor Console

61 Instructor Console

62 Dynamic Drawings

63 Dynamic Drawings

64 Quick Malfunctions

65 ProTRAX Teaching Assistant

66 What RTEXEC does Initializes the simulator for training Runs simulation models Tracks and records trainee proficiency Displays local operation screens (LOS) Displays button overlay bar (BOB) Provides tools to build and modify training scenarios Invokes malfunctions Records data

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68 Initial Conditions Instructor Console Initial conditions for the process and control models can be easily saved and then restored at a later time. Run/Freeze Active operator screens begin updating when Run is initiated. The models continue to run until stopped with the Freeze command. Dynamic Schematics The model schematics can be viewed while running RTEXEC. When a flowstream is selected, the current properties for that flowstream are displayed on the screen. The user may view or change parameters, invoke malfunctions, or create malfunctions for the selected component. Parameter Changes This function allows the instructor to change component parameters such as valve characteristics, flow coefficients, heat-transfertransfer coefficients, controller gains and physical dimensions. These changes can be made while the simulator is running or while it is in Freeze mode.

69 ProTRAX Instructor Functions Student Proficiency

70 This is one of the S many model schematics used in the simulation Each component in the plant is represented by individual modules Flowstreams connect the modules and change colors automatically, depending on flow direction

71 Thank You