P O W E R P L A N T S I M U L A T O R PROGENSIM POWER PLANT SIMULATOR POWER PLANT SIMULATOR OVERVIEW The PROGENSIM - Power Plant Simulator consists of a comprehensive Model of a fossil- fired (coal, oil, gas) power plant. The simulator can be operated in the full dynamic range, including startup from cold condition, load maneuvering, and shutdown. The fully integrated simulator includes an Instructor Console, and operator Stations. The Operator display software can be selected from a list of DCS emulations. The description of the power plant and the training features are summarized below. CAPACITY / 210 MW FUELS / Coal / Oil / Natural Gas STEAM GENERATOR / Drum type / Natural Circulation FURNACE AIR & EXHAUST SYSTEM / 2 Forced Draft Fans / 2 Induced Draft Fans / 4 Primary Air fans / 1 Igniter Fan / 1 Scanner Fan / Windbox / Steam Air Preheater / Regenerative Air Heater / Soot Blowers / Electro-static Precipitator FUEL AND BURNER SYSTEMS / 4 Coal Feeders / 4 Pulverizers / 2 Ignition Oil Pumps / 2 Fuel Oil Pumps / Fuel Gas Supply Line / Coal, Oil, and Gas Burners at 4 Levels
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POWER
PLANT
SIMULATOR
PROGENSIM
POWER PLANT SIMULATORPOWER PLANT SIMULATOR
OVERVIEW
The PROGENSIM - Power Plant Simulator
consists of a comprehensive Model of a fossil-
fired (coal, oil, gas) power plant. The simulator
can be operated in the full dynamic range,
including startup from cold condition, load
maneuvering, and shutdown. The fully
integrated simulator includes an Instructor
Console, and operator Stations. The Operator
display software can be selected from a list of
DCS emulations. The description of the power
plant and the training features are summarized
below.
CAPACITY
¤ 210 MW
FUELS
¤ Coal
¤ Oil
¤ Natural Gas
STEAM GENERATOR
¤ Drum type
¤ Natural Circulation
FURNACE AIR & EXHAUST SYSTEM
¤ 2 Forced Draft Fans
¤ 2 Induced Draft Fans
¤ 4 Primary Air fans
¤ 1 Igniter Fan
¤ 1 Scanner Fan
¤ Windbox
¤ Steam Air Preheater
¤ Regenerative Air Heater
¤ Soot Blowers
¤ Electro-static Precipitator
FUEL AND BURNER SYSTEMS
¤ 4 Coal Feeders
¤ 4 Pulverizers
¤ 2 Ignition Oil Pumps
¤ 2 Fuel Oil Pumps
¤ Fuel Gas Supply Line
¤ Coal, Oil, and Gas Burners at 4 Levels
POWER
PLANT
SIMULATOR
PROGENSIM
POWER PLANT SIMULATORPOWER PLANT SIMULATOR
BOILER WATER AND STEAM SYSTEM
¤ Economizer
¤ Steam Drum
¤ Downcomer
¤ Waterwalls
¤ Primary Superheater
¤ Secondary Superheater
¤ Reheater
¤ Turbine Bypass line
¤ Attemperators for Superheater, Reheater, and Turbine Bypass
¤ Auxiliary Steam Header
TURBINE AND GENERATOR SYSTEMS
¤ HP/IP/LP Turbines
¤ Main Stop Valve with Bypass
¤ 4 Turbine Control Valves
¤ Reheat Stop/Intercept Valve
¤ Turbine Turning Gear
¤ 2 Turbine Lube Oil Pumps
¤ Turbine Lube Oil Cooler
¤ Turbine Lube Oil Cooling Water Pump
¤ Bearing Vibration Monitors
¤ Rotor Eccentricity Monitor
¤ Differential Expansion Monitor
¤ Generator with Exciter and Automatic Voltage Regulator
¤ Syncroscope
¤ Hydrogen Cooler
¤ Hydrogen Seal Oil Pump
POWER
PLANT
SIMULATOR
PROGENSIM
POWER PLANT SIMULATORPOWER PLANT SIMULATOR
CONDENSATE AND FEEDWATER SYSTEM EQUIPMENT
¤ Condenser
¤ 2 Air Ejectors
¤ 2 Circulating Water Pumps
¤ 2 Condensate Pumps
¤ Condensate Storage Tank
¤ 1 Makeup Pump
¤ Air Ejector Steam Condenser
¤ Gland Seal Steam Condenser with Exhaust Fan
¤ Steam Condenser with Exhaust Fan
¤ Condensate Polisher
¤ 3 Low Pressure Heaters
¤ Deaerator with Storage Tank
¤ 2 High Pressure Heaters
¤ 3 Boiler Feed Pumps (motor driven)
INSTRUMENTATION
¤ 44 Controllers
¤ 10 Auto-Manual Control Stations
¤ 16 Manual Stations
¤ 60 Indicators
¤ 130 Switches
¤ 40 Alarms
¤ Trips and Logic / Interlocks
POWER
PLANT
SIMULATOR
PROGENSIM
POWER PLANT SIMULATORPOWER PLANT SIMULATOR
Major controls
¤ Main Steam Temperature
¤ Condenser Hotwell Level
¤ Deaerator Level
¤ Feedwater Flow
¤ BFW Pump Speed
¤ Pulverizer Exit Temperature
¤ Fuel Master
¤ Air Master
¤ Boiler Master (Main Steam Pressure)
¤ Drum Level (three element control)
¤ Furnace Pressure
¤ Induced Draft Fan Speed
INSTRUCTOR FUNCTIONS
¤ BFW Pump trip
¤ Circulating Water Pump trip
¤ Makeup Water Pump trip
¤ Feeder trip
¤ Turbine trip
¤ Pulveriser trip
¤ Exciter trip
¤ Generator trip
¤ Electrostatic Precipitator malfunction
¤ Lube Oil Pump trip
¤ Main Fuel trip
¤ Tube Leaks
¤ Valve malfunctions
¤ Instrument malfunctions
¤ Heater fouling
¤ Soot accumulation
¤ False alarms
¤ Air Temperature
¤ Low Grade Fuel
¤ External Load Demand
POWER
PLANT
SIMULATOR
PROGENSIM
POWER PLANT SIMULATORPOWER PLANT SIMULATOR
POWER PLANT SIMULATOR BENEFITS:
¤ Savings in Start up time
¤ Reduction in training time to bring new hires up to speed
¤ Increase in plant productivity – reduced energy costs, less downtime
¤ Trainee evaluation for job classification
¤ “What if” Analysis for operating procedures, control and logic modifications
¤ Simulator provides the opportunity of regular rehearsal to maintain operating skills
¤ Validation of training skills
ADVANTAGES OF PROGENSIM - PC BASED DESKTOP SIMULATOR:
¤ PC based simulator, using modern technology plant schematics and DCS emulation, is made available on each trainee’s desk. This becomes a very powerful tool for the trainee to enhance his/her learning process.
¤ Schematics provide much better comprehension of the process.
¤ PC based simulator is available 24 hours / 7 days.
¤ PC based simulator does not require a special room, but can be placed in a classroom setup.
¤ PC based simulator provides high value for training for a very low price.
¤ Custom simulator cost may vary from Rs. 60 lakhs to Rs. 1.50 crore. Whereas, Standard PC based simulator costs a fraction of the Custom simulator.
¤ PC based simulator is virtually maintenance free.