KORBA SIMULATORS

S.No. DETAILS 1 2 3 4 5 REFERENCE SUPPLIER CONTR.AWARD Dt CONTRT. VALUE TRAINING INAUGURATION 200 MW SIMULATOR KORBA, UNIT -1 M/s. SINGER LINK,USA 14.02.1981 US $ 4,389,645 Approx Rs.21 Cr. 21.12.1984 500 MW SIMULATOR SINGRAULI UNIT-6 M/s. SIEMENS, AG,GERMANY 14.10.1988 Rs. 24,34,52,000 27.11.1995

TRAINING IMPARTED & REVENUE EARNED YEAR-WISE

YEAR PROG R (No) PARTICIPATION
NTPC EXT

REV. FROM EXT. TOTAL AGENCIES

2003-04

66

343 (ET 149)

206

549

29,84,310/-

2004-05
2005-06 2006-07 2007-08 2008-09

68
66 60 69 67

409 (ET 174)

506 (ET 273) 474 (ET 306) 413 (ET 260) 519 (ET 398)

61
179 58 163 143

470
685 532 576 652

9,25,515/26,04,040/7,47,378/19,46,091/15,96,654/-

EXTERNAL ORGANISATIONS
LANCO AMARKANTAK POWER PVT LTD VISA POWER APGENCO HPGCL KPCL MPGENCO NSPCL

enaTIpIsaI

NTPC

LAYOUT OF SIMULATOR

COMPUTER SYSTEM

DOs /AOs

PANEL

I/OSYSTEM

DIs / AIs

INSTRUCTOR STATION

CHALLANGES
200 MW SIMULATOR
UPS- (PROVIDED BY RTE DEL TEK- 1984)
* SHIFTING TO BATTERY BACK UP ON MINOR VOLTAGE FLUCTUATIONS. * PCB SPARES N/A. VENDOR REPLIED THAT THIS TYPE OF UNIT IS OUT OF PRODUCTION FOR LAST 20 YEARS.

DISC DRIVE* OUT OF REQUIRED TWO DRIVES (MAIN PANNEL + DAS

SYSTEM) ONLY ONE IS HEALTHY SO DAS FACILITY N/A Contd.

 TAPE DRIVE-

* (THIS IS REQUIRED TO RE-LOAD THE SOFTWARE

ON DISC AS DISC MAY GET CORRUPTED OVER A PERIOD DURING SERVICE). * OUT SINCE LONG AS SPARES N/A. * NOW WE DEPEND ON ALREADY LOADED SPARE DISC

COMPUTER PCBs* SPARES N/A DUE TO OBSOLESCENCE

CHALLENGES
500MW SIMULATOR
I/O SYSTEM (SIMTROL) PCBs-(POPULATION 28 MAIN + 60
SUPPORTIVE) * ERRATIC BEHAVIOUR, AS HIGHLY SENSITIVE TO MINOR TEMP FLUCTUATION. (CAUSING FREEZING OF RELATED PANEL) * FOR SPARES OF I/O SYSTEM, VENDOR (M/S TATA POWER Co.Ltd (OEM) ) EXPRESSED DIFFICULTY IN WRITING AS ENGR. FAMILIAR TO THIS OLD SYSTEM HAVE LEFT ORGN.

* DURING PRIVIOUS P. O. , THEY CHARGED AROUND 7 LACS PER PCB AND TOOK MORE THAN 2.5 YEARS TO SUPPLY & COMMISSION THE SAME WITH 95 % ADVANCE PAYMENT. Contd.

 COMPUTER PCBs
* SPARES N/A DUE TO OBSOLESCENCE * ALMOST ALL THE CRITICAL PCBs ARE FEW / NIL IN NO.s

TAPE DRIVE
* 1/3 TAPE DRIVE IS IN RUNNING CONDITION.IT IS ALSO A REPAIRED ONE AND INTERMITTANTLY CAUSES PROBLEM. * AGAINST THE PROPOSAL OF REPAIRING OF FAULTY TAPE DRIVE M/S TATA POWER Co.Ltd , REGRET MESSAGE WAS SENT AS IT IS OBSOLETE.

SHORTCOMING
CRT & LVS/OWS BASED OPRATION, USED IN NEW UNITS COULD NOT BE FACILILATED IN OUR PRESENT SIMULATORS.

R&M OF SIMULATOR
CONSIDERING CHALLENGES IN MAINTAINING SPARES AND SHORTCOMING OF NOT FACILITATING CRT BASED OPERATION,A PROPOSAL FOR R&M WAS MOVED BY DGM(SIMULATOR) THROUGH PMI AND MATTER HANDED OVER TO PE-C&I. A COMITTIE WAS FORMED COMPRISING TWO MEMBERS OF PE,2 MEMBERS OF OS,ONE FROM PMI AND ONE FROM KORBA SIMULATORTO EXPLORE ALTERNATIVE CONFIGRATION & METHODOLOGIES FOR R&M ACTIVITIES. COMITTIE HAD STUDIED THE MATTER AND GIVEN THE FOLLOWING RECOMMANDATIONS ON 05.02.2006 Contd.

* COMPLETE REPLACEMENT OF BASIC COMPUTR SYSTEM, DAS COMPUTER SYSTEM AS WELL AS INSTRUCOR STATION WITH LATEST SERVER BASED SYSTEMAND ASSOCIATED PHERIPHERIAL. * REPLACEMENT OF I/O INTERFACING HARDWARE WITH LATEST DCS/PLC MODULES. * RETAINING THE CONVENTIONAL HARDWIRE BASED PANEL WHILE REPLACING THE FAULTY DEVICES(METERS,RECORDERS,LAMPS) AND ANNOUNCIATION WINDOWS. * PROVIDING ADDITIONAL FACILITY OF OWS/LVS BASED OPERATION. * PORTING THE EXISTING SIMULATION APPLICATION SOFTWARE (210MW/500MW) AND DEVOLOPING ADDITIONAL MODELS FOR LATEST COMMISSIONED (210MW/500MW)PLANTS. * NETWORKING AND CONNECTIVITY WITH SIMULATOR SYSTEM ENVISAGED AT PMI FOR PARRALLEL TRAINING SESSIONS, AS WELL AS HAVING A GLIMPSE OF THE REAL LIFE PLANT.

COST WAS ESTIMATED 26,89,30,000/- BY COST ENGG. C.C. ON 21.08.06.

BASED ON THE RECOMMANDATIONS, FOLLOWING MODEL WAS PROPOSED.