Simulation Applications for Testing and Training

With its Testbed Simulation (TBS), Operator Guidance Simulator (OGS) and Operator Training Simulator (OTS), Siemens has a wide range of simulation products.

The challenge

TBS: The objective of our partners is that the control systems they are supplying are of high quality even before they are commissioned on-site. This results in a shorter commissioning process and a shorter overall project. The fact that the system can be linked up earlier boosts the image of Siemens in the eyes of the customer.

OGS: The shortening of the overall project timescale is a key factor in the end customer's decision to purchase, but also in reducing the partner's costs. Even before the power station is commissioned, the end customer's operators can start to learn how to operate it, or in the case of modernisation familiarise themselves with the new control system.

OTS: The objective of the power station operating company is to achieve maximum availability, and so faults need to be avoided whenever possible. With the OTS, on the one hand training is given to operators on critical situations and how to master them with the aim of avoiding faults, and on the other hand faults that have occurred in the past can be analysed and simulated, and measures implemented to avoid the same fault in the future. It is also possible to validate possible process optimisation measures for the power station on the simulator without any risk. OGS and OTS are likewise ideally suited for training new personnel when existing operators move on.

Our solution

The Siemens Simulation Center possesses in-depth expertise in the following areas:

• Simulation of physical processes
• Emulation of automation systems based on SIMATIC S5 and S7
• Simulation of the original operator control and monitoring system

Combining these areas of expertise enables our customers' requirements to be met, as we can supply simulators in three coordinated and scalable stages.

Testbed Simulator (TBS):

For this stage a plant-specific process model is linked with the original automation system (hardware-in-the-loop). The benefit of this simulator lies in the fact that the automation software is validated during plant testing. It can therefore be seen as a pre-commissioning tool. This provides our partner with a guarantee that the software supplied is of high quality. This results in a shorter commissioning process and a shorter overall project. The fact that the plant can be connected to the grid sooner boosts our image in the eyes of the customer. The TBC can also be carried out with the help of emulation and emulated PCs (if the original hardware has already been despatched).

Operator Guidance Simulator (OGS):

The OGS takes place immediately after the TBS, but before a power station goes into actual operation. Here, the provisional plant-specific process model is linked with the emulated automation level. The benefit of this simulator lies in making the operators familiar with dealing with a new power station or, in the case of modernization, with the new control system. By gaining knowledge rapidly of how the plant works, the end customer is in a position to take responsibility for the entire system earlier, which has the effect of reducing the commissioning period and also the overall project timescale for our partner. The end customer has the additional advantage that his operations team becomes highly efficient at an early stage.

Operator Training Simulator (OTS):

At this stage the process model, which is closely related to the actual plant, is linked with the emulated automation system. The automation software corresponds with the current status of the plant. The simulation system is also extended to include plant-specific malfunctions that enable training to be provided for dealing in particular with critical operational states. In this way operators can be trained to the highest possible level to enable them to detect any malfunctions that may occur early and to deal with them appropriately. This guarantees the end customer greater availability of their plant and avoids penalties being imposed by the operators of connected electrical grids.

Good reasons for the simulation applications TBS, OGS and OTS:

• Your control software is of high quality because errors are detected at an early stage
• Shorter overall project timescale due to shorter commissioning period
• Mechanical components avoid wear, and the testing of process optimization measures using the simulator is risk-free
• Operators trained quicker
• Increased system availability thanks to highly-trained operators