APGENCO Training Institute
simulator lab
Power Plant Simulator is an advanced hands–on –training tool, used mainly for the plant operation staff training in areas such as Unit start up, Shut down, load operation, emergency handling etc. In addition, a simulator can also be used as a powerful tool to verify process and control strategies to start up of a plant as well as investigation and testing of operational problems that are normally not allowable under real plant operating conditions.

Simulator consists of a set of programmes that computes the mathematical equations which govern the dynamic behaviour of the simulated plant in real time.

Simulator gives the feeling of operating a real power plant without incurring any generation loss or damaging any plant equipment. It raises the level of proficiency of the operator and builds up confidence required to handle emergencies in an actual plant operation. Simulator training enhances the retention level of the operators to handle various operational emergencies of the plant.

The main purpose of the Thermal Power Plant simulator is to train and assess operators in general plant operation, including training in plant start-up and shut-down, supervision, monitoring and control during normal, emergency situations and in safety procedures.

Simulators at APGENCO Training Institute:
1) Five customized versions of 210MW/250MW simulator

- LMZ Turbine, Two pass boiler, Bowl Mills, MAX DNA C&I System
- KWU Turbine, Tower Type Boiler, Ball Mills, MAX DNA C&I System
- KWU Turbine, Tower type Boiler, Ball mills, YBL C&I System
- KWU Turbine, Two pass Boiler, Bowl mills, MAX DNA C&I System
- KWU Turbine, Tower type Boiler, Ball mills, EC PC Pose system 250 MW

2) Two customized versions of 500/600MW simulator
- KWU Turbine, Two pass boiler, Bowl mills, MAX DNA C&I System
- 500MW and 600MW
Advantages of the Simulator Training :
1. By operating the equipment with own hands the trainee gains confidence and expertise in a very short period which otherwise could not be possible in a real plant.
2. No fuel wastage cost on account of learning
3. No wastage of equipment time
4. Risk free training.
5. High retention level of handling emergencies due to real time visualization.
6. Improved sharpness of the operator in handling the plant due to the knowledge and experience gained on the Simulator.

Scope of Simulator Training:
The following features of simulator facilitate effective training:
• Initialization to predefined plant status from where the training session starts.
• Freezing of the dynamic simulation programmes at any plant status to facilitate detailed explanation to the trainee at that particular stage of operation and subsequently resuming from there.
• Back tracking enables simulation status to traverse all events of operation for past sixty minutes and scans back to any status from there for repeat of operation.
• Snapshot facility initiates any given plant condition from where training can be commenced providing the flexibility of training..
• Malfunction insertion with variable degree of severity in process parameters and removal facility encompassing many emergencies in all systems.
• Slow mode simulation allows a trainee to see certain critical operation performed in slow mode in order to analyses the sequence of event taking place in a short span of time clearly.
• Fast mode simulation saves valuable panel time operation under certain plant status e.g. cold soaking of turbine can be achieved in six minutes instead of one hour.
• Remote function facilitates the instructor to perform any manual operation like opening, closing of valves which are not possible from control panel.

In addition to all the above facilities normal start-up / shut-down, run-back, Automatic Turbine Run-up System, Trend Monitoring of Parameters etc. provide trainee a feeling of working in real plant situation.

Simulator Training Profile:
• Charging of Power supply
• Charging of auxiliary system
• Boiler system lineup
• Condensate and feed water system
• Burner Management System(FSSS)
• Turbine oil system
• Furnace Purge and Boiler light-up
• Evacuation system
• HP/LP bypass system
• Automatic Turbine Run-up system
• Coal firing and load raising
• Boiler & turbine follow modes of operation
• Planned Shutdown
• Emergency handling
• Malfunction handling