Operator training simulator

A training simulator shall be supplied covering all the equipment supplied for the power plant which is controlled and monitored by the DCS. The training simulator shall be installed in a training simulator room in the Central Control Building. The desk, furniture, panels, etc shall be a replica of the control desks for one unit and the common services desk complete with printers, etc. The simulator shall replicate the actual look of a single power block including all large screen displays. The simulator supplied shall be capable of realistic simulation of a power block and associated common services. The system shall have the following requirements: Item
Replication of the system to the reference plant

Requirements The simulator system shall replicate the reference power block (one unit) and common systems. The tolerance limit of the simulated data against the reference plant data for steady state and transient power conditions shall meet the relevant ISA standard ANSI/ISA77.201993. It should be exact replica, Hifidelity simulator of the actual plant process and equipment.

System model software

Simulator system shall provide a realistic training environment for operator. The plant model (one unit and common services) shall be exact replica, Hi-fidelity type. I&C simulation shall be identical to DCS used in the plant. The same DCS environment as in the main plant shall be provided. The actual DCS in the main plant shall be stimulated in the Simulator using virtual controller of the DCS. Turbine control system and all important 3rd. party control systems (based on control systems: DCS or PLC ) of the plant shall be emulated using virtual controller environment of the plant DCS. Degree of fidelity of I&C shall not be less than the degree of fidelity required for the associated process model. Each model shall have a design report. Model execution rates shall accurately replicate the interface and process response rates. Software system shall have easy portability and expandable. High fidelity replica shall be adopted for important process lines, equipment and devices. Simplified dynamic replica shall be adopted for electrical and auxiliary system. Functional replica shall be adopted for other processes.

Fidelity for process modeling

Item Scope of simulation

Requirements All processes, auxiliary and electrical systems for a single unit shall be modelled. Normal control room operations, transients and malfunctions shall be included. Field operator actions are to be included / provided for actions required to support normal operation from field.

Instructor station (IS)

The IS shall have the following functionalities: Operation of the simulator including start/end the simulation, run/pause, slow/fast time, initial conditions sets, snapshot, simple malfunctions, complex malfunctions, manual/automatic simulation control, student performance recording and evaluation, record/replay, alarm functions set up, user selection, trending, real and simulation clocks, environmental conditions, event logging display, dynamic messaging, video display, help facility/manuals and others. Full replication of the electrical system shall be provided. The system shall provide 100% replication of the functions and features of the common services console. The FAT and SAT procedures shall comprise of the following as a minimum:
a. b. c. d.

Electrical system (ES) Common services Factory and Site Acceptance Tests

Structured hardware tests Software functionality tests User defined tests System availability test.

Operational availability test

No functional abnormality in the hardware or software system performance shall be observed. The test period shall not be less than 1 month of continuous operation. All manuals and design basis shall be included. 1. Online download upon change in engineering in OTS shall be possible in the same way in main plant DCS 2. Full Stimulation of actual plant DCS and emulation of all 3rd party control systems where stimulation is not available shall be provided 3. Accuracy :1 % static on critical parameters and 3% on noncritical and 10% dynamic fidelity/ accuracy for critical 20% for

Documentation system Technical specification

Item

Requirements non-critical 4. A min of 50 nos of preconfigured malfunctions shall be provided with the option of creating more 5. Snapshot capability shall be provided 6. Possibility of downloading actual DCS control algorithms to the simulator any time in future upon modifications in main plant DCS shall be possible. It shall be possible to keep the OTS logics/ control schemes exactly at par by copying the main plants DCS control database and putting that in the OTS any time.