Today's changing industrial scenario is evolving into a globalization of

economy, where only a well-managed strong technical base can have the
cutting edge over others to maintain a clear superiority. As a pioneer in the
power sector, APGENCO has established its roots in the area of operation and
maintenance of its power stations by adopting most advanced and
sophisticated technology and simultaneously updating the skill of its plant
personnel through training. Power Plant Simulator is the effective tool for
operational training.
In order to build a team of well trained personnel equipped with safety
aspects, it is necessary that the personnel experience a range of operation
and stress situations in an integrated mode, including handling normal and
emergency operations of the power plant. This Simulator Training will ensure
that we have a team of people who are equipped to take better decisions,
reduce power plant trips, ensure trouble free start-ups, optimize usage of
plant auxiliaries, ensure reduced downtime and in the long run help in the
efficient management of the power plant.
Simulators at APGENCO Training Institute :
1) Five customized versions of 210MW/250MW simulators
- 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 500/600 MW simulators
- KWU Turbine, Two pass boiler, Bowl mills, MAX DNA C & I System
- 500MW and 600MW
Simulator System Configuration :
This comprise 2 simulator systems i.e. 210/250MW and 500/600MW.
Both the systems consist of the following major components.
Operator Work Station (OWS) : It is a replica of unit control room desk of the
reference plant. In a simulation environment the trainee operates the control
desk, monitor and control the process parameters and gets a feeling as if one
is involved in real plant operation. There are 5 OWS for each simulator
system.
Instructor Station : It consists of video display, Key board, remote control
devices required to control all aspect of training activities including the
operator work stations.
Large Video Screens (LVS) : Three large video screens of size 67" diagonal
and resolution of 1400 x 1050 pixels for each Simulator system are provided
to display all the operations carried out at the Operator Work Stations and
thereby aiding each trainee operator to observe the activities carried out by
the other trainees on their respective Operator Work Station.
Computer Server Rack : This consists of 4 servers, one server each for
210MW, 250MW, 500MW and 600MW simulation. This is the heart of
Simulator. When a command is given either from Trainees Station i.e.,
Operator Work Stations (OWS) or Instructor Station (IS), the Server receives
it, computes the response and then transfer it back to Instructor Station /
Operator Work Stations on a real time basis to represent the changes in
process parameters / status as happened in the real plant.
Computer Interface : The Interface has the capacity to handle massive high
speed data between the computers and the Rack Server. This helps to
produce a real time response on the control panel.
Scope of Simulator Training
The following features of simulator facilitate effective training :
z Initialization to predefined plant status from where the training session
starts.
z 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.
z 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.
z Snapshot facility initiates any given plant condition from where training
can be commenced providing the flexibility of training.
z Malfunction insertion with variable degree of severity in process
parameters and removal facility encompassing many emergencies in all
systems.
z Slow mode simulation allows a trainee to see certain critical operation
performed in slow mode in order to analyse the sequence of event
taking place in a short span of time clearly.
z 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.
z 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
l Charging of power supply
l Charging of auxiliary system
l Boiler system lineup
l Condensate and feed water system
l Burner management system
l Turbine oil system
l Furnace purge and boiler light-up
l Evacuation system
l HP/LP bypass system
l Automatic turbine run-up system
l Coal firing and load raising
l Boiler & turbine follow modes of operation
l Planned shutdown
l Hot startup
l Emergency handling
l Malfunction handling
l Interactive videos of ash plant, coal handling plant, cooling towers etc.
Simulator Training Programmes
Different types of training modules are available to meet the needs of
various categories of plant personnel.
1. Power Plant Familiarisation (12 days)
Objective : To provide comprehensive training through Systematic
line-up of all the equipments & systems, cold & hot
startups, shutdown procedure malfunctions etc.
Participants : Newly recruited engineers likely to be posted in unit
operation and personnel working in smaller units likely
to switch over to higher unit operation.
Duration : Two weeks (12 days)
2. Operation Familiarization (5 days)
Objective : To provide an overview on unit operations to
maintenance engineers in Unit startup with different
conditions, system lineup, shutdown and few
malfunctions.
Participants : Maintenance engineers from Mechanical, Electrical, C&I
sections, other O&M engineers working in E&P etc.
Duration : One week (5 days)
3. Refresher Training (5 days)
Objective : To refresh knowledge, operation skills and improve
upon interactions of experienced operation engineers.
 Emergency handling, transient operation, malfunction
exercise, performance and efficiency aspects are stressed
upon besides normal panel operation coupled with
lectures on specialized topics and discussion on critical
issues.
Participants : Operation executives working in the level of desk
engineer/unit controller having minimum 5 years
experience in the desk operation.
Duration : One week (5 days)
4. Simulator Appreciation Programme (2 days)
Objective : To demonstrate the capabilities and features available in
the simulator to senior executives and Engineers who are
instrumental in nominating participants for simulator
training.
The course cover system line-up, cold/hot start-ups, shutdown and
demonstration of emergency handling & Instructor station features.
Participants : Senior management executives in the level of GM, Chief
Engineer etc.,
Duration : Two days. (2 days)
Development Activities
In order to meet the specific requirement of various customers, the
institute can also design need based simulator training programme for
working operation and maintenance engineers, newly recruited or posted
power plant engineers.
Location
Around 20km away from Vijayawada Railway station & Vijayawada
APSRTC Bus station.
Nearest Land Mark : Kondapalli

Fee Structure of Simulator Training Programmes (2016-17)

S.No. Name Of the Programme Course Fee** Accomodation Mess Fee
(Excluding Tax) Standard
1. 2 Days Simulator Training Rs. 7400/- Including Single Rs 686/-
Programme Accomodation
2. 5 Days Simulator Training Rs. 13000/- Including Rs. 1715/-
Programme Twin sharing
Accomodation
3. 2 Weeks Simulator Training Rs.30000/- Including Rs. 4459/-
Programme Twin sharing
Accomodation
Note : D For all courses tax is payable as applicable
D AC accommadation hostel charges as per course are included in the course fee.
D Food charge is separate and payable on spot.Provision for Menu changes
(North/South Indian etc.) can be arranged and charges vary accordingly.
For details contact :
Co-Ordinators : T. V.V. Siva Rama Kumar ADE/Simulator, Contact No. 9493120450,
: S. Sukanya ADE/Simulator, Contact No. 9493120576

TRAINING INSTITUTE
APGENCO, IBRAHIMPATNAM - 521 456.
KRISHNA DISTRICT, ANDHRA PRADESH
Phone : 0866 - 2882308, Fax : 2881973
Email : vtps.cetrg.apgenco.gov.in