Conventional on job Training & Globally Acknowledged Simulator training

Keeping pace with the fast developing technology of today and considering the technical superiority and economical benefits we have opted for the construction of higher capacity fossil power plants with most advanced state of art control devices. For reliable, sustainable & efficient operation and safety of these power plants we need a team of properly trained and skilled human resources.

Conventional on the job training does have some constraints and found deficient to develop the true skill of an operator, whereas simulator have proved as an effective training tool since it gives a feeling of operating a real power plant with no fuel cost, no wastage of time, no losses or repairs. The operators gain quickly hands-on-experience both for normal and abnormal/emergency operation of the plant. A simulator-trained operator reduces the downtime significantly and runs the plant safely and efficiently.

Power Plant training simulator at Bakreswar Thermal Power Station of WBPDCL is supplied by GSE Power System Inc., USA. Its main features are :


• Full size replica of control room of BkTPP unit 1# (210 MW)
• Workstation computers (8 nos.) as soft panel.
• Conventional hard panel.
• PLC for interfacing between soft panel & hard panel

• Instructor Station.
• Field Device Terminal (FDT).

In real plant, Boiler & Generator are supplied by Bharat Heavy Electricals Limited who imported Ball & Race Coal Mills from Mitsui Babcock ltd., U.K. Turbine is supplied by Fuji Electric Co., Japan.

In real plant we have individual equipments like Boiler, Turbine and Generator etc., whereas in Simulator,

there is no Boiler, no Turbine and no Generator etc. but there are software model (dynamic), which is created on the basis of the data of this individual equipments. The integrated software form of mathematical dynamic model of all the individual equipment of real plant is stored in the memory of thecomputer, which is called a SIM-SERVER. Simulator Server is the brain of the Simulator Plant. The Real Time Executive of the Sim-Server runs the above cited models and the effect of model execution comes in such a manner as if a real plant is running in practice. The effect of model execution is displayed in the mimic diagram of Plant Management System (PMS) as well as in the hard panel. At the same time, the real time executive is scanning the status of different operating tools i.e. ON-OFF, OPEN-CLOSE, AUTO-MAN etc of PMS as well as Hard Panels and updates the model accordingly. The Sim-Server communicates with the Hard Panel via PLC, which acts as an interpreter between Sim-Server and Hard Panel.

It is a UNIX base Alpha Deck Server the memory of which is enriched with software form of all plant dynamics.

Motif Instructor Station (MIS) is the interface between the instructor and the simulator. Instructor Station is provided with Instructor related functions to conduct & control training programme. Insertion of Malfunction, Taking Snapshots, Monitoring Parameters, Remote function operation, Freeze, Backtrack, Override, Replay, Daily Operational Readiness Test (DORT), Reset the Simulator to any one of the 200 Initial Condition, Run the Simulator in REAL TIME, SLOW TIME and FAST TIME, Creation of Training Scenario etc. are the main available feature of Instructor Station Server. Moreover, from Instructor Station the External Parameters e.g. Ambient Temperature, Grid Frequency etc. may be modified to show the corresponding effects on other parameters. Monitoring the Performance of the Trainees as well as Performance of the Trainer is also possible from Instructor Station. Insertion of 292 numbers Emergency Condition (Malfunction), which help the Trainee to tackle the hazardous operating condition and save the man & machine in real world, is one of the great features of Instructor Station. REPLAY is one of the prideful tools of the Instructor and by using this tool the Instructor can teach the trainee regarding correct operation by pointing out the area of wrong operation, which the trainee has performed in the previous course of training session.

It is a dual redundant PLC system, which consists of both analogue and digital Input / Output (I/O) cards, BUS Interface Unit (BIU), BUS controller, Module expander and equipped with dual redundant LAN system. The system is also equipped with one PC for diagnosis and I/O mapping etc. It works as an interpreter between hard panel and SIMSERVER.

It is the conventional remote Control Panel of the plant. In case of failure of DCS or PMS system, Operation Engineers can control / run the plant through this panel. Moreover parallel operation of the plant can be executed both from DCS workstation and hard panel. Thus, Simulator Training can also be extended to the operation engineers, who are familiar with only hard panels.

BkTPP Power Plant Training Simulator Includes The following training features :

Library

BkTPP simulator training institute is provided with unique library facilities. The Library is equipped with various Technical Manuals and Books related to Thermal Power Plant. Trainees may study and take notes in the STUDY ROOM adjacent to Library

Model Room
Various comprehensive models of plant equipments and systems have been placed in the Model Room e.g. :