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PROPOSAL FOR SIMULATOR R&M

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ABOUT THE SIMULATOR

COMPUTER : 32 bit GOULD SEL 32/77
SUPPLIER 200 MW SOFTWARE : GOULD/ENCORE COMPUTER USA : MPX-32 Rev. 1.5C

SUPPLIER

: SINGERLINK USA

COMPUTER : 32 bit GOULD SEL 32/67

SUPPLIER
500 MW SOFTWARE SUPPLIER

: GOULD/ENCORE COMP. USA

: MPX-32 Rev. 3.U02 : GOULD USA,SIEMENS GERMANY TEC/TEDS BANGLORE

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SOFTWARE DETAILS
OPERATING SYSTEM MPX 32 PLANT SIMULATION SOFTWARE
PLANT SIMULATION SOFTWARE CONSISTS OF MATH MODELS IN FORTRAN-77 & ASSEMBLY 200 MW PLANT SOFTWARE HAS 32 MATH MODEL IN FORTRAN-77 500 MW PLANT SOFTWARE HAS 85 MATH MODEL IN FORTRAN-77

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LAYOUT OF 200 MW SIMULATOR

SIM. COMPUTER MASTER COMPUTER
SUBCONT-2 Dos/AOs DIs /AIs

PANEL

INSTRUCTOR STATION

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LAYOUT OF 500 MW SIMULATOR

COMPUTER SYSTEM

DOs /AOs

PANEL

SIMTROL
(4 NOS)

DIs / AIs

INSTRUCTOR STATION

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PROPOSED LAYOUT FOR 200 / 500 MW SIMULATOR

INSTRUCTOR STATION HARD

COMPUTER SYSTEM

INTER FACE UNIT-1

INTER FACE UNIT-1 - - -4,3,2 CRT-1

DOs /AOs DIs / AIs

PANEL

SOFT PANEL

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PROBLEM BEING FACED

OBSOLESCENCE CONTROL TECHNOLOGY DEVELOPMENT FREQUENT FAILURES HIGH MAINTENANCE COST

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NEED FOR R&M

As regards 500MW simulator is concerned, the computer and hard panel with instructor station were supplied by M/s Siemens AG .They are no more in the simulator business.I/O interface system were supplied by M/s Tata Power. They are not in a position to give timely supply of I/O cards and reliability is not foolproof. Procurement and proper functioning of these cards have been taking even 2 years.The prices of I/O cards are very high, on the ground that most of the components used are now obsolete & have to be procured at a higher cost. We are facing same problem in 200MW simulator.

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NEED FOR R&M

Views about R&M:

Minutes on the discussion of technical team in NTPC held on 06/08/04-R&M of the existing 200mw & 500MW
simulator are required as advised by D(Opn.) and ED(OS).

Letter ref 01/PMI/Sim.upg/2004-Minutes of meeting ,where D(HR) was present-It was felt that simulator
200MW & 500MW are panel based and new technology (CRT based) simulators have come up in the market,we would immediately go to renovate both the simulator.

M/s RTEDELTEC Corp. ,supplier of UPS system on Korba visits-Your unit have been out of production over
20 years and there are no spares/parts available for them. My suggestion for you to replace your unit with a current model.

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NEED FOR R&M

New NTPC projects & other power utilities are operated from LVS/OWS system and older stations either from a totally hardwired UCB or a mix of both. Thus operators tuned with both types of experience are required over at least ten years from now.Hence, R&M of the simulator by porting of existing software into new hardware platform and augmenting it by adding LVS/OWS based platform is the most feasible solution to the problem. In view of foregoing, it is suggested that R&M both the simulator may please be taken up at the earliest

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R&M ACTIVITIES

The proposed R&M activities includes : Replacement of existing ENCORE/GOULD simulation and DAS computers by latest servers. Replacement of I/O interface system with latest DCS/PLC based system. Replacement of obsolete panel hardware as on required basis. Incorporating the LVS/OWS based operator HMI. Establishing network connectivity to PMI, so that training may be provided at PMI.

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R&M PROCEDURES

As has been done in our DAS R&M cases,the whole R&M activity is proposed to be done in several phases/steps in order to minimize the down time. Most of the software work can be done on the new hardware platform and connectivity to the panel can be done with minimum down time of say 15 days or less. During that time training will be continued with existing configuration.

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R&M PROCEDURE (contd.)

PHASE-1
Replacement of existing ENCORE/GOULD DAS and simulation computers by latest PCs,servers,LAN switches,laser printers etc. Porting of the existing software system on to the new hardware platform. Replacement of I/O interface with latest DCS/PLC based system . Up-gradation of panel hardware like meter, recorders,indicator etc. on as required basis. Replacement of annunciation system with LED based system.

R&M PROCEDURE (contd.)

PHASE-2
Fine tuning of simulation models to the present state of the plant incorporating all modification and up-gradation of plant, that may have been implemented over the years. Up-gradation of instructor station facility like automated trainee exercise,grading functions. One set of LVS/OWS based system may be installed in the existing computer room. Connection will have to be established between the simulator & plant DAS for analyzing plant data.

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R&M PROCEDURE (contd.)

PHASE-3
After the completion of all the R&M activities the network connectivity may be provided to PMI, so that both the simulator operation may be demonstrated at PMI. Connectivity of Sipat simulator with PMI is already envisaged so it can be extended to Korba.

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BENEFITS WITH R&M

TANGIBLE BENEFITS
After R&M we will have 4 panel, that will accommodate more no. of trainees. Simulator training cost (for 2 weeks) with LVS/OWS system is Rs.50,000/- as compared to Rs.30,000/- with conventional system. As on previous available data no. of trainees for 2 weeks program = 1100 (aprox.).,assuming that half of these trainees are for LVS/OWS based system. Approx. cost of simulator training =Rs.4,40,00000/-

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BENEFITS WITH R&M

INTENGIBLE BENEFITS :
The simulator training gives a feeling of operating a real power plant with no fuel cost, no wastage of time,no losses and repairs. It rises the level of proficiency and confidence. Training in emergency handling helps in saving down time of plant. Training in efficient operation helps the operator in improvement of overall efficiency and life expectancy of plant equipment.

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THANK YOU