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Introduction

Simulators constitute one of
the most effective instruments for the training and technical qualification
of operations personnel. Thanks to the inherently interactive nature
of these tools, we are able to unite theory with practice and substantially
shorten apprenticeship time. The reduction in the costs of simulators
in the last few years (as a result of using conventional PCs and
commercial software tools for development) significantly improves
the cost-benefit ratio, justifying the use of simulators, preferably
specific to each plant.
Through
the use of a training simulator, operations personnel can acquire
the dexterity and skills necessary for executing common maneuvers
and managing minor situations without compromising the installation's
operations. This helps to improve the operation, availability and
security of the plant. Likewise, the benefit of having a simulator
can be extended to personnel in engineering and the rest of the
plant.
Aside from its use as a training tool, the simulator allows users
to test new operative practices aimed at improving the plant's efficiency,
to test adjustments in the control system and to analyze different
points of operation or settings of equipment or systems without
affecting the plant itself.
Benefits 

Increase in availability and production.
Reduction of the number of unprogrammed stops and of the number
of incidents that cause load reductions.
Optimization of maneuvers like
hot or cold- starting. In this case, the benefit consists of an
increase in the number of hours of operation at full load, considerable
fuel-savings in starting up, and extending the equipment's useful
life.
Availability of a suitable platform for training in case there are
substantial changes in the plant's control system (major changes
in main equipment or repowering, for example). In this case, the
personnel need to learn to manage the plant in a radically different
fashion, making it essential for them to receive training on a simulator
reflecting the new situation.
Fast depreciation of the investment,
given the constantly decreasing price of computer equipment.
Characteristics

A simulator is a configuration of hardware
and software that, by means of calculation algorithms, the
behavior of a selected process or physical system is replicated.
A simulator for a thermal power plant usually consists of the following
components:
A process model:
This is the simulator's motor, where the physical process is simulated.
It models the distinct systems as well as their components: valves,
pipes, electric rods, etc.
A representation of the control
system:
The plant's control system usually consists of a combination of
a distributed control system (DCS),
programmable logical controllers (PLC)
and relay logic.
An interface
with the operator:
It is possible to simulate the physical control panels using graphic
animation in tactile screens (virtual panels). The DCS interface
of the simulator is an exact replica of that in the control room.
A station for the instructor:
This can function as a control center for the simulator. For academic
purposes, it may contain a series of hypothetical actions or situations
such as: stopping/resuming of the simulation, introduction of malfunctions,
repetition of the operation sequences for their subsequent evaluation,
etc.

Applications

The simulators have traditionally been used in various areas, such
as:
1. Training:
The training plans based on simulators are aimed both at the plant's
operations staff and the rest of the plant's personnel. The training
programs can be used to train newly-hired personnel, for giving refresher
courses to operators in service, or for generic or specific courses
targetted at other organizations not directly related to the operation:
Maintenance, Engineering, Management, etc. The range of the training
will depend on the need, from entry-level training in the physical
basic principles of processes and of the control system, to training
in common or special maneuvers, or how to deal with emergency situations.
2. Engineering of operations:
Simulators allow the design and validation of new operation practices
aimed at improving the plant's efficiency or a better use of the equipment
without affecting the installation. Likewise, they can serve as a
testbed for operations support systems, expert systems, efficiency
monitoring, management programs, etc.
3. Engineering Studies:
By means of a simulator it is possible to do advance analysis on modifications
to the control system or on the equipment themselves. In this manner
engineers can anticipate how they will function in reality. |