240-158191826 Generation Operation Training Requirements Specification For Power Plant Simulator

Asset
Specification
Management
Title: Generation Operation Unique Identifier: 240-158191826

Training Requirements
Specification for Power Plant
Simulator Alternative Reference Number: N/A
Area of Applicability: Generation
Documentation Type: Specification
Revision: 1
Total Pages: 27
Next Review Date: October 2025
Disclosure Classification: CONTROLLED

DISCLOSURE
Compiled by Approved by Authorised by
………………………………….. ………………………………….. …………………………………..

W. Hapelt P.A. Goatley M.A.F. Reimers
Technical Training Manager Snr Manager: O&M CoE GM: Gx O&M
Date: ……………………………
2020-09-30 01/10/2020
Date: …………………………… Date: ……………………………
Supported by SCOT/SC/TC
…………………………………..
A. Engelbrecht
SCOT Gx Ops SC Chair
2020-09-30
Date: ……………………………
PCM Reference : 32-1314 (Optimise Operator Training and Maintain Quality of Training)
SCOT Study Committee Number/Name : Generation Operations Study Committee
Generation Operation Training Requirements Unique Identifier: 240-158191826
Specification for Power Plant Simulator Revision: 1
Page: 2 of 27
CONTENTS
Page
1. INTRODUCTION ..................................................................................................................................................... 3
2. SUPPORTING CLAUSES ....................................................................................................................................... 3
2.1 SCOPE ............................................................................................................................................................... 3
2.1.1 Purpose ............................................................................................................................................... 3
2.1.2 Applicability ......................................................................................................................................... 3
2.2 NORMATIVE/INFORMATIVE REFERENCES ................................................................................................... 3
2.2.1 Normative ............................................................................................................................................ 3
2.2.2 Informative .......................................................................................................................................... 3
2.3 DEFINITIONS ..................................................................................................................................................... 4
2.3.1 Disclosure Classification ..................................................................................................................... 4
2.4 ABBREVIATIONS............................................................................................................................................... 4
2.5 ROLES AND RESPONSIBILITIES..................................................................................................................... 5
2.6 PROCESS FOR MONITORING ......................................................................................................................... 5
2.7 RELATED/SUPPORTING DOCUMENTS .......................................................................................................... 5
3. REQUIREMENTS .................................................................................................................................................... 5
3.1 SIMULATOR HARDWARE ................................................................................................................................ 5
3.2 SIMULATOR COMPUTER SYSTEM SOFTWARE ........................................................................................... 6
3.3 REPLICA STATUS ............................................................................................................................................. 6
3.4 TRAINEE ENVIRONMENT ................................................................................................................................ 6
3.4.1 Operator Interfaces ............................................................................................................................. 6
3.4.2 Control Room Environment ................................................................................................................. 7
3.4.3 Engineering Station ............................................................................................................................. 7
3.5 SIMULATOR TRAINING CAPABILITIES ........................................................................................................... 7
3.5.1 Instructor Interface .............................................................................................................................. 7
3.5.2 Instructor Controls/Features ............................................................................................................... 8
3.6 TRAINING ........................................................................................................................................................ 11
3.6.1 Instructor Training ............................................................................................................................. 11
3.6.2 Simulator Maintenance Training ....................................................................................................... 11
3.7 SIMULATOR TESTING .................................................................................................................................... 12
3.8 SIMULATOR MAINTAINABILITY ..................................................................................................................... 12
3.9 DOCUMENTATION .......................................................................................................................................... 12
3.9.1 Instructor Documentation .................................................................................................................. 12
3.9.2 Engineering Documents .................................................................................................................... 13
3.10 SIMULATOR OPERATIONAL LIMITS ................................................................................................... 13
3.11 VERIFICATION AND VALIDATION TOOL ............................................................................................ 13
3.12 SIMULATOR CAPABILITIES ................................................................................................................. 14
3.12.1 Normal Operation .............................................................................................................................. 14
3.12.2 Capability Tests (As Applicable to Reference Plant) ........................................................................ 15
3.12.3 Generic Malfunctions ........................................................................................................................ 18
3.12.4 Remote Functions ............................................................................................................................. 18
3.12.5 Specific Malfunctions ........................................................................................................................ 19
3.12.6 External Factors ................................................................................................................................ 23
3.13 PROCESSES AND SYSTEMS TO BE SIMULATED ............................................................................ 24
3.14 PERFORMANCE CRITERIA ................................................................................................................. 24
3.15 CRITICAL PARAMETERS FOR STEADY STATE LOAD ..................................................................... 24
3.16 TRANSIENT OPERATION..................................................................................................................... 25
4. AUTHORISATION ................................................................................................................................................. 26
5. REVISIONS ........................................................................................................................................................... 27
6. DEVELOPMENT TEAM ........................................................................................................................................ 27
7. ACKNOWLEDGEMENTS ..................................................................................................................................... 27
CONTROLLED DISCLOSURE
When downloaded from the EDMS, this document is uncontrolled and the responsibility rests with the user to ensure it is in line
with the authorised version on the system.
Page: 3 of 27
1. INTRODUCTION
The reliance on power plant simulators to train power plant operators to the required competency level,
ensure enhancement of skills, to perform incident and modification training, and to verify and validate the
control system design has significantly increased over the past years. Power plant simulators do
however vary widely from station to station and therefore the needs of the end-user should be
considered and incorporated by ensuring it is thoroughly defined and documented. This document
serves to provide the minimum requirements for a simulator from the perspective of the end-user
(Generation Operating Training).
2. SUPPORTING CLAUSES
2.1 SCOPE
This document specifies Gx Operating Training requirements for a full scope high realism Operating
Simulator. This document shall therefor be used as the minimum requirements for all power plant
simulators used to determine Unit Controller competency for authorisation to work, perform
refresher/skills enhancement training and initial training to achieve a National Qualification.
2.1.1 Purpose
To capture the minimum Operating requirements for a power plant simulator in a structured approach. In
conjunction with the Technical Requirements for Power Plant Simulators Standard (240-154243686), it
will further guide the user to compile a detailed User Requirement Specification that will accurately
reflect the simulator requirements of a specific reference power plant.
2.1.2 Applicability
This document is based on a Generation fossil fired power station simulator and should be tailored to
suit simulators of other forms of power generation in the Eskom Generation fleet.
2.2 NORMATIVE/INFORMATIVE REFERENCES

Parties using this document shall apply the most recent edition of the documents listed in the following
paragraphs.
2.2.1 Normative
[1] ISO 9001 Quality Management Systems.
[2] ANSI/ISA 77.20.01-2012 Fossil Fuel Power Plant Simulators: Functional Requirements Standard.
[3] 240-154243686: Technical Requirements for Power Plant Simulators Standard.
2.2.2 Informative
[4] 32-1314: Process Control Manual (PCM) for Optimise Operator Training and Maintain Quality of
Training
[5] 240-46315093: Maintaining Training Facilities and Equipment.
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2.3 DEFINITIONS
Definition Description
Approved by The accountability of the Approver of the document is equivalent to the
specified role of Functional Responsible/Owner as identified in 240-
53114186 and 32-6 for Documents and Records Management.
Client A Power Station in the Generation Division.
Client’s Representative The responsible personnel for the simulator as delegated and
appointed in writing by the Client.
Model or Simulation The process of creating and analysing a digital prototype of a physical
Modelling model to predict its performance in the real world.
Full scope high realism A simulator that fully replicates the reference power plant unit,
simulator containing duplicates of the actual operator interface and associated
equipment. The unit responses as simulated by the simulator are
identical in time and response to the actual reference plant time and
responses under similar conditions. Operator training is thus
performed in an environment that is identical to that of the reference
plant.
Reference plant The specific power plant unit of which the simulator control room
configuration, control system configuration and simulator database are
derived from.
Runback Condition initiated by some condition/event, and the unit is
automatically unloaded, usually to some present value/load.
Simulation The mathematical representation and modelling of physical process
and control systems.
Simulation modelling Is a modelling process used to help designers and engineers
understand whether, under what conditions, and in which ways a part
could fail and what loads it can withstand.
2.3.1 Disclosure Classification

Controlled Disclosure: Controlled Disclosure to external parties (either enforced by law, or
discretionary).
2.4 ABBREVIATIONS
Abbreviation Description
BFPT Boiler Feed Pump Turbine
BU Business Unit
DCS Distributed Control System
EL1 Emergency Level 1 (Operating condition on national grid)
EFP Electric Feed Pump
FLIP Flexi Log and Intelli-Permit
HMI Human Machine Interface
IT Information Technology
MC & I Measurement Control and Instrumentation
MCR Maximum Continuous Rating
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Abbreviation Description
OEM Original Equipment Manufacturer
PC Personal Computer
P&ID Piping and Instrumentation Diagrams
2.5 ROLES AND RESPONSIBILITIES

The Engineering section on each power station is responsible to ensure that the Operating Training
Requirements for Power Plant Simulators as stipulated are included in aspects when upgraded,
updating, replacing a simulator or when obtaining a new simulator for refurbished plant.
The Operating training section is responsible to ensure that this document is adjusted according to the
power station specific requirements. Engineering, Operating and Operating training sections of each
power stations co-responsible to ensure that the requirements of this document is adhered to.
2.6 PROCESS FOR MONITORING

Simulator performance and accuracy testing shall be performed on the simulator at least on a two yearly
basis to ensure that the compliance to the approved performance and testing procedure and any
identified inconsistencies/deviations must be addressed in a two yearly update.
For this purpose, reviews will be performed to evaluate the status of simulators as per the requirements
stipulated in this document. These reviews will be performed in conjunction with Operating Training PCM
Reviews and/or Operating Effectiveness Assessments.
2.7 RELATED/SUPPORTING DOCUMENTS

Generation User Requirement Specification for Power Plant Simulators: 36-1422
3. REQUIREMENTS
Power plant simulators shall be delivered as full scope, high realism simulators based on a specific
reference plant.
Generic plant training simulators, should it be required, shall be based on the same functional
requirements as defined herein.
3.1 SIMULATOR HARDWARE
The following minimum requirements;

 Dedicated computer hardware capable of handling the simulation and emulation processes.
 Dedicated backup power supply equipment as per Eskom standards. Replica HMI workstations as
per the reference plant in quantity and configuration.
 Dedicated data recording system.
 Dedicated audio and visual recording system.
 Colour Printing facility.
 Control room and interface equipment.
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3.2 SIMULATOR COMPUTER SYSTEM SOFTWARE
The following minimum requirements;

 Supportability for the duration of the life span of the simulator.
 Cyber-security and physical access control to computers.
 Latest software versions as available and applicable.
 Recovery and back-up systems.
 A user management system is used to ensure that alterations to the simulator and its configuration
are performed by authorised users with the correct user rights.
 Efficiency – Changes of models parameters can be done while the simulator is running.
 Simulation and model stability – proven to be highly stable.
 Assets management as per the current and approved ESKOM relevant procedure.
 Full set of simulation and emulation tools.
3.3 REPLICA STATUS
The replica status of the simulator must be maintained according to the Eskom Engineering Change
Management process. Similarly, any changes to the reference plant’s design base and affecting the
behaviour and response must be implemented on the simulator following the ECM process.
The following list makes up the major simulator design baseline elements, and any changes to it should
follow the ECM process.
 High-fidelity process and control logic models.
 User interfaces.
 Instructor tools.
 Trainee environments.
 Simulator platform.
 Simulator configuration documentation.
 Training documentation (presentations and learner guides)
 Minimum levels of documentation.
3.4 TRAINEE ENVIRONMENT
The operator interface should be a full replica in terms of size, shape, colour, configuration and
functionality of the hardware and displays in the reference plant. It should thus provide all the controls,
indicators and displays, alarms and other interfaces that are necessary to perform normal and abnormal
plant operation.
3.4.1 Operator Interfaces

Provision should be made for controls and displays other than those provided for the operator interface
that would function during normal and abnormal operations. These controls and displays should closely
resemble the visual appearance and location as found in the reference plant and should be functionally
identical to it. The following refers to some of these interfaces, but not limited to it:
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 Tube leak detection.

 Emissions Monitoring and control.
 Dust handling system.
 Bottom ashing systems.
 Relevant outside plant indications and controls.
 FLIP & PTW System.
3.4.2 Control Room Environment

The reference plant control room environment should as far as possible be identical to that of the
reference plant, in appearance and functionally. The following environmental factors should be
considered or adhered to;
 Replica of the control room in terms of dimension and furnishings.

 Replica and location of control desk, operator interface, auxiliary equipment and furniture in the
control room.
 Location and availability of communication equipment.
 Location and intensity of control room lighting.
 Availability of noise/vibration from plant equipment if applicable.
The operational requirements as specified in Standard 240-46315093 – Maintaining Training Facilities,
shall be complied with.
3.4.3 Engineering Station

Provision shall be made for an engineering station on the Simulator and should be a replica of the
reference plant’s engineering interface module. It shall ideally have its own HMI interfaces and modules
to ensure user access and control.
3.5 SIMULATOR TRAINING CAPABILITIES
3.5.1 Instructor Interface

The user shall interface with the simulator via an instructor station, which is independent from the control
room and the operator interface. The instructor interface shall support the following functions and
features;
 Minimum of two monitors shall be provided for the instruction station.
 Activation of all specific malfunctions.
 Activation of all generic malfunctions.
 Activation of all remote functions.
 Activation of external parameters.
 The same naming convention as per the reference plant names and codes should be applied.
 The simulator HMI must be a replica of the reference unit.
 Provision of one operating station with a minimum of two monitors.
 Supporting full control functionality of operator screens.
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 Supporting slave operation on operator screens.

 Provision of one monitor for training surveillance.
 Provision of audio/visual recording system.
 Provision of full functional mounted zoom cameras to cover different angles on operating desk and
interface.
 Provision of a dedicated colour printing facility.
 System engineering or simulator configuration/development station shall be in close proximity of the
instructor station.
3.5.2 Instructor Controls/Features

The simulator shall be capable of freezing the progression of all dynamic simulations at any time,
initializing the simulator at predefined states, inserting/initiating malfunctions at any time, and
manipulating external parameters and remote functions.
In addition, the following features shall be provided;
a) Snapshot
The ability to store the particular conditions existing at any instant during a training session, without
interrupting any dynamic simulation that may be in progress, in order that the specific condition may be
recalled in the future as an initialisation point.
b) Freeze/Run
The ability to control (freeze/run) all dynamic simulations.
c) Record/Replay
The capability to activate a record/replay feature. The replay feature shall allow for the exact repeat in a
semi-dynamic mode (replay of each backtrack) all of the indications in the same sequence for the most
recent actions of the instructor as well as the actions of the operators.
d) Backtrack
The ability to, on demand, periodically record the condition of the Simulator during a training exercise,
while not in freeze mode, enabling the instructor to initialize the Simulator at a previous point in the
simulation exercise.
e) Slow Time
The ability to slow down the entire simulation, providing the capability to observe the action of the
simulation model and controls to specific conditions that are characterised by short time constants.
f) Fast Time
The ability to speed up some lengthy plant evolutions, which represent little or no training value, to move
quickly to another point in the plant operation while retaining the continuity of the training exercise. (E.g.
faster turbine warm up or cool down, faster boiler warm-up etc.)
g) Training Monitoring/Tracking
A student tracking feature shall be installed on the instructor station that allows tracking of student time
and performance on the simulator. The instructor station shall be password protected and the student
tracking feature shall keep records of the log on and off date and time of students and initial conditions
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used during their use of the simulator. This feature shall also support the automatic storing of the data for
the Trainee Performance Review and Computer-Aided Exercises, under the student's name.
h) Trainee Performance Review

A Trainee Performance Review (TPR) program shall be provided, which will simultaneously monitor a
minimum of twelve plant parameters and capable of recording the data.
A full audit trail capability shall be enabled where the trainee has to perform a complex plant operation
(e.g. Unit start-up) on the simulator. It should have the ability to capture the baseline (“ideal”) set of
actions to be undertaken, allowable timeframe for actions and correct execution sequence for the set of
tasks; and then be able to monitor the trainee actions on the simulator against this baseline to identify
and capture instances where the correct action, sequence or limited timeframe for the task was not
achieved. This will enable training facilitators to institute remedial training to address deviations from
expected baseline.
Performance Reviews and the audit trail capability of the simulator shall have reporting functionality
enabled in order to generate the required training assessment and competency declaration reports that
can be stored as evidence artefacts within the trainee’s development program (IDP).
i) Plant Efficiency Monitoring

The simulator shall have the ability to calculate and display both the unit heat rate and the effect of
operationally controllable parameters on plant performance
j) Stopwatch Function
The simulator will be enabled with a stopwatch function that will allow the simulation to freeze when
certain time/plant criteria are met.
k) Event Logging
Logging of all simulation events including trainee and instructor actions.
l) Search help function

The instructor shall have the support of a search and help function that will cover all the required aspects
of simulator configuration, operation and how to deal with potential fault conditions related to the
simulator and its associated hardware/software.
m) Master alarm on/off

The instructor shall have the ability to silence the audible alarms installed on the simulator.
n) Simulator is in the freeze state

Each backtrack record captured shall be saved against the training exercise time and date and shall be
made available and displayed on a Backtrack Index Table. The instructor shall be able to access and
initialise any of the available Backtrack records from the instructor's station, either by entering the time of
the desired record or by manually or automatically stepping in either direction (forward or reverse).
o) Displays of simulated plant and parameters

The instructor shall be capable of monitoring and trending all simulated plant parameters on the
instructor station.
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p) Trending
The instructor shall be capable of trending a minimum of twenty variables on the instructor station with at
least six of those variables present on the instructor screen at any one time. All plant variables shall be
available for selection.
q) Computer-Aided Exercise
The instructor shall be capable of creating and initiating (running) scenarios or computer-aided
exercises. A computer-aided exercise function allows the instructor to predefine and permanently store
a series of scenarios or operational problems.
Each scenario shall be represented as a time-sequenced list of expert commands. This functionality
shall provide the instructor the ability to provide the same training for different operator trainees or to let
the simulation run automatically.
3.5.3 Initial Conditions

The simulator shall be capable of storing initializing conditions to support the specific user defined
training objectives. The selection of these conditions shall be initiated from the instructor station and the
simulator shall be capable of adding, modifying, or deleting initializing conditions as required.
Typical initialising conditions are;

 0% Plant conditions. All auxiliaries out of commission, with zero pressure and ambient temperature.
 Cold start (As per station cold start up criteria requirements).
 Warm start (As per station warm start up criteria requirements).
 Hot start (As per station hot start up criteria requirements).
 Hot start up, after unit trip
 Hot turbine – ready for synchronization.
 Draughts on load and ready for purge.
 Purge complete and ready for first fires in.
 Turbine ready to turn on steam.
 Boiler steam conditions ready – cold turbine on barring/turning gear.
 Boiler steam conditions ready – turbine at various station/design run up speeds.
 Turbine at 3000 rpm, ready to synchronise.
 Boiler and turbine hot condition – ready for turbine over speed trip testing.
 1 X EFP in service, BFPT ready for run up
 Two Boiler feed pumps in service and 1 Boiler feed pump on standby
 Full load –with SFP in service where applicable
 Full load – with EFP`s on load
 Boiler conditions ready for safety valve floating
 Unit start up loading conditions 25%, 50% and 75% of MCR.
 Boiler and turbine ready for Simulation/interlock trip testing procedure.
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Typical initialising conditions for Gas Power Plant:

 Test run after outage 0MW.
 Start up to min loading of 80 MW.
 Start up to max loading of 148 MW.
It should be possible to link the standard operating procedures for these scenarios to the simulator
stored initial conditions configuration to allow the instructor and/or trainee quick reference to the
document.
3.6 TRAINING
3.6.1 Instructor Training

Instructor training for the Simulator platform shall be provided, in the simulator upgrade/replacement
project execution phase to ensure the required training personnel competency in order to provide
effective simulator training.
This training shall include, but not be limited to:

 Instructor platform navigation.
 Engineering station platform training.
 HMI training (designed HMI’s as well as how to create additional training HMI’s).
 Interface software training – knowledge required to be able to manipulate or enhance the simulation
software.
 Basic training on power station model and simulator model functionality.
 Backup and recovery procedure.
Training documentation shall be provided to the OPS training and document centre departments, both in
electronic and hard copy format.
Instructors will be declared competent in writing by the Simulator Platform contractor, confirming that
instructors are able to operate and manage all aspects of the simulator before being authorised to use
the simulator for training or any other purpose.
3.6.2 Simulator Maintenance Training

Simulator Platform maintenance training shall be provided, which shall include, but not be limited to;
 Navigation training.
 Platform training.
 Functional training.
 Simulator configuration training, including testing and debugging of new/modified HMI’s or simulation
sequences.
 System administration training.
 Maintenance tools and diagnostic tools training.
 Fault finding training and error handling.
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 Hardware and software training.

 Backup and recovery procedure.
Training documentation shall be provided to the BU Training Department, the BU IT/C&I Departments
and the BU document centre departments, and shall be delivered in electronic and hard copy format.
Simulator maintenance training shall be conducted in the Simulator upgrade/replacement project

execution phase to ensure that identified maintenance personnel have the required competencies to
provide effective day to day maintenance support to the Simulator Facilitators and users.
Provision will be made for Simulator maintenance staff to be involved during the design processes and
set-up/ configuration of the simulator, FAT and SAT stages of the simulator replacement/upgrade, as
well as be involved in operational testing with other simulator users to become competent on the
maintenance aspects of the simulator.
3.7 SIMULATOR TESTING

Simulator Performance Testing in accordance with the Technical Requirements for Power Plant
Simulators Standard
3.8 SIMULATOR MAINTAINABILITY

The system shall include online diagnostics that indicates all failures within the simulator. All failures in
the system shall be recorded in an auditable log, with date and time of stamp of when failure occurred.
If standard error codes are deployed, the meaning of such error codes must be documented and
supplied to the Client, and the fault finding and remedial action guidelines for such errors shall form part
of the documentation supplied with the simulator.
3.9 DOCUMENTATION
Simulator documentation shall be provided to allow the simulator staff to install, operate, and maintain
the simulator over its life cycle.
All documentation requirements will be specified in detail in the Simulator Standard, but the following
documents will be provided as minimum requirements from an Operating Training perspective:
 Simulator start up procedure.
 Simulator Shut down procedure.
 Simulator Back up procedure.
 Simulator back up restore procedure.
 Simulator yearly/two yearly testing procedure.
 Simulator Software specification and description manuals.
 Simulator Equipment description, specification and layout.
 Diagnostics and Fault-finding Procedure.
3.9.1 Instructor Documentation

The instructor documentation should provide the simulator instructors with sufficiently detailed
information to start up, shut down, and operate the simulator during a training session.
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The documentation should include an overview of the BU process plant and of the plant systems
simulated. It should provide the instructor with a clear understanding of the plant model simulation
capabilities and limitations, as well as the simulated operating procedures.
It should also include the information necessary for the instructor to fully understand the simulator
training features and to effectively apply them in a training exercise.
As a minimum, the instructor documentation should include the following:

1) Simulator operating manual.
2) Instructor manual.
3.9.2 Engineering Documents

The following documents will also be provided and will adhere to requirements as set in the Technical
Requirements for Power Plant Simulators Standard:
 Engineering manuals.
 All system software and hardware.
 Site documentation, including the fully completed and accepted site acceptance testing
documentation package.
3.10 SIMULATOR OPERATIONAL LIMITS

The Simulator shall operate within realistic normal operating limits. If the simulation goes beyond these
limits, misleading training may result in Generation process plant being put at high risk.
The system must therefore be equipped with administrative controls or other means that alert the
instructor when parameters approach values that are indicative of events beyond the behaviour and
acceptable design base limits of the applicable reference plant.
3.11 VERIFICATION AND VALIDATION TOOL

The simulator shall be capable of being used as a verification and validation tool. The following refers to
the minimum functional requirements of this capability;
 Perform human factor engineering and assist with development of optimal operator interface (HMI)
design.
 Perform preliminary failure, incident and safety analysis.
 Perform component sizing and capacity specification.
 Perform scenario (“what if”) simulations.
 Perform DCS functional testing and tuning.
 Verification and development of operating procedures.
 Verify response to failures and faults.
 Verify alarm response and identify alarm overload conditions.
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3.12 SIMULATOR CAPABILITIES
3.12.1 Normal Operation

The Simulator shall be capable of simulating in real time, operating conditions as per the applicable
reference plant.
The Simulator shall calculate plant system parameters that correspond to particular operating conditions,
displaying these parameters on the appropriate instrumentation and simulator HMI’s, and shall provide
proper alarm or protective system actions, or both.
The minimum operations that the simulator shall be capable of performing, using only operator action
that is normal to the reference plant(s), are as follows: (These conditions must be adapted for Hydro and
Gas Power Plant Simulators).
a) Plant Start-Up
 Start-up from cold to 100% load. (Starting conditions must be cold shutdown conditions of
temperature, and pressure for all systems)
 Start-up from warm standby to 100% load.
 Start-up from hot standby to 100% load.
 Boiler, Turbine, Unit Trip followed by recovery to rated load.
b) Shutdown
 Shutdown from 100% load to hot standby conditions.
 Shutdown from 100% load to hot standby and cool-down to cold shutdown conditions.
c) Steady Load
 Steady load at Max Load (EL1).
 Steady load at full load (MCR).
 Steady load at incremental mill load limits. (1 Mill, 2 Mill, 3 Mill etc. Operation).
 Steady load at minimum load without oil support. (38% MCR).
d) Load Variance
 Boiler start-up to match required steam conditions for turbine run-up.
 Turbine start-up and generator synchronisation.
 Generator load to increase according to reference plant load requirements after synchronisation.
 From 0 MW unit must be loaded to full automatic control as per the reference plant requirements.
 Steady full load operation, decrease load to 0 MW.
 Steady load at 50% with one draught group in service, increase load to 100%.
 Steady load at 100%, reduce load to 50% and shut down one draught group.
 Steady load at 50% with one feed pump in service, increase load to 100%.
 Steady load at 100%, reduce load to 50% and shut down one feed pump
 Mill changes and sequences to control pressure and temperature of boiler.
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 On load and off load testing of equipment, including but not limited to turbine over-speed trip tests,
turbine valves, pyro’s, AC lube oil pumps, DC lube oil pumps and auxiliary plant change-overs.
3.12.2 Capability Tests (As Applicable to Reference Plant)

1. All capability tests shall be done by the appointed site Operating representative in the presence of
the Simulator OEM representative, the relevant appointed site system engineers and the project
Manager.
2. Capability tests passed by the reference Unit must be passed on the simulator as well. Where
capability tests failed or was not performed on the reference Unit, the Simulator should still be tested
for records purposes, but it is not required to pass.
3. The relevant site shall provide a data set of approved critical and non-critical parameters as per heat
balance, against which the simulator performance and accuracy shall be tested.
4. All test results shall be captured and compared to the approved data set from the relevant site and
shall be within the approved acceptable steady state of critical parameter range.
5. No capability acceptance test shall be signed off unless all parameters on the simulator as per
approved data set is within the specified and approved critical parameters range.
6. Capability Tests shall include but not be limited to the following:
a) Unit Start-Up
 Cold Start
 Warm Start
 Hot Start
 Miss match in steam temperatures to cause stress or diff expansions on turbine during
 light up conditions (to match unit conditions)
b) Load Increase
 EL 1 capability of the Unit
 Load increase from 40% to 60% as per reference plant designed loading rate
 Load increase from 50% to 75%TMCR as per reference plant designed loading rate
 Load increase from 75% to 100%TMCR as per reference plant designed loading rate
c) Load decrease
 From 100% to 75%
 From 75% to 50%
 From 60% to 40%
d) Load runback
 ID Fan Runback
 FD Fan Runback
 PA Fan Runback
Page: 16 of 27
 Unit Mill Runback - designed number of mills in service for 100% MCR (Trip top mill)
 Unit Mill Runback - designed number of mills in service for 100% MCR (Trip bottom mill)
 Unit Mill Runback - designed number of mills in service for 100% MCR (Trip centre mill)
 Unit Mill Runback - designed number of mills in service for 100% MCR (Trip two Mills)
 HP Heater “Load Limiting Runback” (Trip/bypassing of one HP Heater Bank)
 Vacuum De-loading
 Pressure de-loading
e) High and low Frequency response tests at different frequencies, according to site design
specifications and in line with the requirements set in the Engineering Standard.
f) Load decrease request:
 100% loading down to 40% loading at plant design loading rate – 45 minute stabilisation
 40% loading up to 100% loading at plant design loading rate – 45 minute stabilisation time at 100%.
 40% to 100% loading at plant design loading rate and immediate ramp down once 100% loading
achieved to 40% loading
 1 hour stabilisation check at 40%.
g) Boiler:
 100% MCR – Electrical Feedwater pumps on load – electrical Feedwater pump capability – 50%
Feedwater pump capability. (Where applicable)
 100% MCR with SFP on load – SFP capability/runback – electrical Feedwater pumps cut in
 100% MCR with SFP on load – SFP capability/runback – 50% electrical Feedwater pumps cut in.
 Feedwater regulating valves change-over
 Condensate Extraction Pump (CEP) trip with standby at 100% TMCR load
 Pyrometer testing
 ACCCT control valves change-over
 Oil burner flame scanner testing
h) Turbine
 Control oil pump change-over

 Jacking oil pump change-over
 Stator cooling water pump change-over
 Generator seal oil pump- change over
 Governor valve step tests
 Valve gear exercise tests (full load)
 Cooling water pumps change over
Page: 17 of 27
 Turbine over speed trip testing

 Vacuum decay testing
 Unit demineralised water consumption test
i) Generator
 Over excitation limiter functionality

 Max Field Current Limiter functionality test
 Under Excitation Limiter functionality test
 Minimum Field Current Limiter functionality test
 Stator Current Limiter functionality test
 V/Hz Limiter functionality test
 Leading capability test
 Lagging capability test
 Stator earth fault testing
 Rotor earth fault testing
j) All Unit capability tests as per Unit capability acceptance testing procedure and approved criteria.
All tests to be in line with the plant response – detailed plant parameters for the various tests to be
available and the Simulator performance test results to be in line with the critical parameters
responses/measurements.
3.13 Plant Malfunctions

The simulator shall be capable of simulating abnormal and transient conditions in real time, including
malfunctions and equipment failure to demonstrate inherent plant response and automatic plant control
functions.
It shall be possible to:

 Conveniently insert and monitor remote plant functions, external parameters and malfunctions
through instructor action or pre-programming.
 Insert multiple malfunctions at the same time and also have the ability to create and execute macro
functions where several grouped malfunctions can be inserted with one action.
 Link the Alarm Response Procedure (ARP) for each of the malfunction conditions possible for a
specific reference plant within the simulator, to allow instructor and trainee to call up the ARP for
reference purposes.
Apart from all the standard malfunctions the following must be included.
 Individual LV Boards failing
 Individual 6.6kV Boards failing
 Individual 3.3kV Boards failing
 Individual 11kV Boards failing
 275/400kv HV Yard breaker failing
Page: 18 of 27
3.12.3 Generic Malfunctions

Component Malfunction Description
Motor Operated Valve/damper Fail Open/Close/As is/ Specified value

Solenoid Operated Valve/damper Fail Open/Close/As is/ Specified value
Air Operated Valve/damper Fail Open/Close/As is/ Specified value
Mechanically operated safety, bypass & leak-off valves Fail Open/Close/As is/ Specified value
Pump/Fan/Motor Trip / Fail to Trip / Fail to Start after Trip
Breaker Trip / Fail to Trip / Fail to Start after Trip
Transmitter Fail to Low / high /given limit
Transmitter Increase Noise
When any item is switched to local on the
Valve/Actuator/Motor Breaker/Damper/Solenoid plant, there must a “local” indication on the
HMI
Switchgear or electrical fault must be
Valve/Actuator/Motor Breaker/Damper/Solenoid
indicated on HMI
3.12.4 Remote Functions

Control and operating functions that are performed outside the control room or provide some input to the
simulation models and are necessary to perform the reference plant’s normal and abnormal operations
shall be simulated.
Remote functions Range

Racked in/out/earth
1 Breakers on all unit plant (in/out/earthed)
applied/open/close
Field operated devices (Manual/throttling/isolating
2 valves and bypass valves, drains, filter change over On/off; open/close; variable
etc.
3 All vents Open/close
4 All Pyrometers individual In/out/on/off
5 Turbine and BFPT Manual Turning Gear Engaged/Disengaged
6 Precipitator or FFP In/Out of Service
7 Oil Purifiers & FRF Conditioners On/off
8 All filters and strainers individual Blocked
9 All individual coolers Leaking, blocking
10 Fuel oil isolation, propane gas, fuel oil recirc. etc. Open/closed
rd
11 All 3 party/black box systems Open/closed On/off In/Out of Service
12 All unloaders and resetting devices In/out/on/off
13 All associated key switches/field switches On/off
Page: 19 of 27
3.12.5 Specific Malfunctions

Note: This table must be treated as a guide to develop the simulator requirement for a specific reference
plant configuration and must not be seen as a prescriptive requirement.
A. Boiler Range
1 Boiler Drum/Collecting vessel control failure Variable
2 Boiler pyrometer protection operates Discrete
3 Loss of boiler ash hopper seal /Air ingress into furnace Variable
4 Economizer tube leak Variable
5 Water-wall tube leak Variable
6 Superheater tube leak on different sides and areas of the superheater Variable
7 Reheater tube leak Variable
8 Water-wall slagging / fouling Variable
9 Superheater slagging / fouling (On each individual SH – different sides) Variable
10 Reheater slagging / Fouling (On each individual RH - different sides) Variable
11 Super heater thermal excursions (On each individual SH) Variable
12 Re-heater thermal excursions (On each individual RH) Variable
13 Spurious opening of safety valves Variable
14 High or low furnace pressure Variable
15 Flame failure (flame scanners) Variable
16 Oil burner flame failure Variable
B. Fuel Oil Range
1 Oil burner flame failure Variable
2 Main propane gas pressure low Discrete
3 Fuel oil pressure failure Discrete
4 Fuel oil temperature low/high Discrete
5 Burner control air pressure low Variable
6 Core air failure Variable
7 Fuel oil burner poor performance Variable
C. Draught Range
1 Furnace pressure oscillation Variable
Page: 20 of 27
2 Air heater bearing failure Variable
3 Air heater fouling Variable
4 Air heater leakage Variable
5 Air heater fire Variable
6 FFP fire Variable
7 Secondary air heater axial seal rubbing Variable
8 Sec Air heater bearing temperature high Variable
9 Low / High oxygen Variable
10 High / Low Carbon monoxide (inducing clinker formation) Variable
11 FD/ ID /PA Fan vanes stuck in selected position Variable
12 FD/ ID /PA Fan bearing temperature high Variable
13 FD/ ID /PA Fan motor bearing temperature high Variable
14 LH or RH FFP blockage Variable
15 Air heater soot blower stuck Discreet
16 Dew point on gas air heater Variable
17 Air heater fire Variable
18 Air heater stationary Discreet
19 FD/ ID /PA Fan oil pump fail Variable
20 Hoppers conveying system failure Variable
21 Precipitator / FFP gas inlet temperature high Variable
22 FD/ ID /PA Fan bearing vibration high Variable
23 FD/ ID /PA Fan lube oil pressure low Variable
D. Mills Range
1 Mill lube oil pressure low Variable
2 Mill fire Variable
3 Mill feeder fire Variable
4 Mill running out of coal (level measurement faulty) Variable
5 Mill chokes (mill differential pressure high) Variable
6 Mill motor high bearing temperature Variable
Page: 21 of 27
7 Wet coal to mill Variable
8 Pulverised fuel pipe blockage Variable
9 Poor performance on an individual mill Variable
10 Low PA flow Variable
11 Mill outlet temperature high / low Variable
12 Low seal air pressure Variable
13 Mill feeder over/under speed Variable
E. Turbine Range
1 Turbine water induction Variable
2 Lube oil cooler oil leak Variable
3 Turbine lube oil pressure low Variable
4 Turbine lube oil temperature high Variable
5 Turbine bearing temperature high Variable
6 Diff expansions high / turbine stress high Variable
7 Turbine bearing vibration high Variable
8 Gland steam pressure low Variable
9 One and/or multiple Governor or Emergency Stop valves failing close/open Variable
10 Turbine gland steam temp malfunction Variable
11 HP / IP turbine wet steam Variable
12 Turbine exhaust steam temperature high Variable
F. Feed Heaters Range
1 HP heater level control valve fails Variable
2 HP heater tube leak on each individual heater Variable
3 LP Heater level control valve fails Variable
4 LP heater tube leak on each individual heater Variable
Page: 22 of 27
G. Generator Range
1 AVR failure / Loss of excitation Variable
2 Stator cooling water conductivity high Variable
3 Seal oil/H2 gas differential pressure low/high Variable
4 Unit Islanding Discreet
5 H2 temperature high Variable
6 H2 pressure low/leak Variable
7 H2/air contamination Variable
8 Generator trip Discrete
9 Generator pole slip Variable
10 Stator coolant flow low Discrete
11 Generator bearing vibrations high Variable
12 Reverse power trip Variable
13 Gen fail to synchronise Variable
14 Export and import of MVAR Discrete
H. Unit Controls Range
1 Mill sequential trip fail Discrete
2 Feed water control fail Discrete
3 Fuel master fail Discrete
4 Capability computer fail Discrete
5 Reheat temperature control failure Discrete
6 Superheat temperature control failure Discrete
I. Electrical Range
1 Main transformer loss of cooling Variable
2 Station service transformer loss of cooling Variable
3 Unit transformer winding temperature high Variable
4 Loss of essential board Discrete
5 Loss of HV individual unit board Discrete
Page: 23 of 27
6 Loss of LV unit board individuals boards Discrete
7 Under voltage due to leading Power Factor Variable
J. Gas Turbine Power Plant Range
1 Gas burner flame failure Variable
2 Fire on combustion chamber Variable
3 Compressor wash Variable
4 Prepare unit to resynchronise and close 400kV Breaker Variable
5 Generator Air temperature high Variable
6 Generator Air pressure low/leak Variable
7 Generator Air contamination Variable
8 Fuel forwarding sequential trip fail Variable
9 Fuel forwarding control fail Variable
3.12.6 External Factors

Factors such as ambient temperature that exist outside the control room that affect the operation of the
plant shall be controllable from the instructor’s station and realistically affect plant operations in
response.
External Parameters Range
1. Ambient Temperature 0 – 50°C
2. Ambient air pressure 0-1.2 (bar)
3. FD fan suction temperature 0 – 50°C
4. Circulating Water Inlet Temperature 0 – 50°C
5. Wind speed and direction Variable
6. Coal Calorific Value. Variable
7. Coal bunker levels 0 – 100%

Coal Ultimate Analysis (carbon, hydrogen, oxygen, nitrogen,
8. Variable
sulphur, moisture, volatiles, and ash content)
9. Diesel Ultimate Analysis (Gas Turbine) Variable
10. Electrical System Grid Frequency Variable
11. Electrical System Grid Voltage Variable
Page: 24 of 27
12. Control air pressure Variable
13. System frequency Low / High Variable
14. Emissions Variable
3.13 PROCESSES AND SYSTEMS TO BE SIMULATED

For processes and systems to be simulated, refer to the Technical Requirements for Power Plant
Simulators Standard.
3.14 PERFORMANCE CRITERIA

Steady State Operation:
Steady state measurement of the critical parameters on the simulator platform against the reference Unit
approved steady state parameters on a variety of loading conditions will be performed, while the
simulator maintains the steady load condition as follows:
 At 40 % load for at least two hours
 At 60% load for at least 4 hours
 At 80% for at least 4 hours
 At 100% load for at least 8 hours
The simulator-computed values of critical parameters shall be within 2% of the reference plant
parameters explicitly stated in process units at greater than 25% load.
The calculated values of non-critical parameters agree with the reference plant’s provided values within
a tolerance of 5% of normal or full load values and do not detract from training.
3.15 CRITICAL PARAMETERS FOR STEADY STATE LOAD

Steady State Variation
Parameter (% Difference between
Critical Parameter Simulator and Reference
No. Unit/ Approved heat
balance)
1 Main Steam Pressure 1%
2 Main Steam Temperature 1%
3 Reheat Steam Pressure 1%
4 Reheat Steam Temperature 1%
5 Main Steam Flow 1%
6 Turbine Control Valve Position 2%
7 Generator Megawatts 1%
8 Feedwater Flow 1%
9 Hot Reheat Steam Flow 1%
10 Condenser Vacuum 1%
12 Furnace Pressure 2%
Page: 25 of 27
13 Feedwater Temperature 1%
14 Superheater and Reheat Attemporatoring spray-water 1%
flow
15 Fuel Flow 1%
16 Combustion air flow 1%
17 Boiler oxygen levels 5%
18 CO levels 1%
19 Air heater gas outlet temperatures 1%
20 Deaerator storage tank pressure and temperature 1%
21 Turbine Vane Control Valve Position (Gas turbine power 2%
plant)
22 Fuel forwarding Flow (Gas turbine power plant) 1%
23 Combustion oxygen levels (Gas turbine power plant) 5%
24 Turbine gas outlet temperatures (Gas turbine power 1%
plant)
Note: The abovementioned values must be achieved as far as possible and any deviations from these
values must be agreed on and formally approved by the Eskom Operating and Engineering
representatives.
3.16 TRANSIENT OPERATION

Simulator performance under transient conditions shall meet the following conditions:
 The observable change in parameters shall correspond in time and direction to those expected from
the best estimate for the simulated transient and will not violate the physical laws of nature.
 The simulator shall initiate an alarm or an automatic action only if the reference plant would have
caused an alarm or an automatic action.
 The simulator shall demonstrate a realistic response to operator action.
 The shape of any plant performance curve shall be similar to that of the reference operational power
plant. The transient response of the displayed variables shall have slopes and trends that are
characteristic of the actual power plant and shall have the proper time-dependants relationship to the
related parameter.
 In addition to specified tolerances, the shape of any plant curve shall be similar to that of the
operational power plant. The transient response of the displayed variables shall have slopes and
trends that are characteristic of the actual power plant and shall have the proper dependant
relationship to the related parameters.
Page: 26 of 27
4. AUTHORISATION
This document has been seen and accepted by:
Name Designation
Andre De Villiers Officer Education & Training
Moses Motaung Officer Education & Training
Abram Makua Officer Education & Training
Lindie Van Der Merwe Simulator Instructor
Vusi Thomo Officer Education & Training
Shameth Hurrichand Officer Education & Training
Sakkie Smuts Officer Education & Training
Phumla Zulu Officer Education & Training
Nozee Mavimbela Officer Education & Training
Morne Du Plessis Officer Education & Training
Koos Bester Shift Supervisor Units
Joshua Tshimole Senior Supervisor Tech Operating
Jeffrey Rolfe Senior Supervisor Tech Operating
James Geldenhuys Officer Education & Training
Gert Putter Controller Units
Gary Roos Controller Units
Frans Palm Senior Shift Supervisor Operating
Francois Hanekom Senior Controller Units
Elias Maila Senior Shift Supervisor Operating
Dave Child Officer Education & Training
Charlie Marais Senior Shift Supervisor Operating
Aubrey Nel Officer Education & Training
Maditaba Kubheka LLI Manager
Jaco Smit Snr Advisor HRD
Christoph Kohlmeyer Chief Engineer
Michael du Toit Snr Engineer
Page: 27 of 27
5. REVISIONS
Date Rev. Compiler Remarks
June 2020 0.1 R Odendaal New First Draft document based on Simulator URS with
major changes to content and format.
August 2020 0.2 R Odendaal Final Draft for Comments Review Process
Sept 2020 0.9 R Odendaal Final Document after Comments Review Process
Sept 2020 1 R Odendaal Final Document for Authorisation and Publication
6. DEVELOPMENT TEAM
The following people were involved in the development of this document:
 Jaco Smit
 Rossouw Odendaal
 Frans Palm
 Wayne Hapelt
 Aubrey Nel
 Christoph Kohlmeyer
 Michael du Toit
 Jeff Rolfe
7. ACKNOWLEDGEMENTS
N/A.

240-158191826 Generation Operation Training Requirements Specification For Power Plant Simulator

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240-158191826 Generation Operation Training Requirements Specification For Power Plant Simulator

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Title: Generation Operation Unique Identifier: 240-158191826

Area of Applicability: Generation

Documentation Type: Specification

Next Review Date: October 2025

Disclosure Classification: CONTROLLED

Compiled by Approved by Authorised by

………………………………….. ………………………………….. …………………………………..

2.2 NORMATIVE/INFORMATIVE REFERENCES

2.3.1 Disclosure Classification

2.5 ROLES AND RESPONSIBILITIES

2.6 PROCESS FOR MONITORING

2.7 RELATED/SUPPORTING DOCUMENTS

3.1 SIMULATOR HARDWARE

The following minimum requirements;

3.2 SIMULATOR COMPUTER SYSTEM SOFTWARE

The following minimum requirements;

3.3 REPLICA STATUS

3.4 TRAINEE ENVIRONMENT

3.4.1 Operator Interfaces

 Tube leak detection.

3.4.2 Control Room Environment

 Replica of the control room in terms of dimension and furnishings.

3.4.3 Engineering Station

3.5 SIMULATOR TRAINING CAPABILITIES

3.5.1 Instructor Interface

 Supporting slave operation on operator screens.

3.5.2 Instructor Controls/Features

In addition, the following features shall be provided;

h) Trainee Performance Review

i) Plant Efficiency Monitoring

l) Search help function

m) Master alarm on/off

n) Simulator is in the freeze state

o) Displays of simulated plant and parameters

3.5.3 Initial Conditions

Typical initialising conditions are;

Typical initialising conditions for Gas Power Plant:

3.6.1 Instructor Training

This training shall include, but not be limited to:

3.6.2 Simulator Maintenance Training

 Hardware and software training.

Simulator maintenance training shall be conducted in the Simulator upgrade/replacement project

3.7 SIMULATOR TESTING

3.8 SIMULATOR MAINTAINABILITY

3.9.1 Instructor Documentation

As a minimum, the instructor documentation should include the following:

3.9.2 Engineering Documents

3.10 SIMULATOR OPERATIONAL LIMITS

3.11 VERIFICATION AND VALIDATION TOOL

3.12 SIMULATOR CAPABILITIES

3.12.1 Normal Operation

3.12.2 Capability Tests (As Applicable to Reference Plant)

f) Load decrease request:

 Control oil pump change-over

 Turbine over speed trip testing

 Over excitation limiter functionality

3.13 Plant Malfunctions

It shall be possible to:

3.12.3 Generic Malfunctions

Motor Operated Valve/damper Fail Open/Close/As is/ Specified value

3.12.4 Remote Functions