Name, department/event, date The Millmerran Simulator An Innovative Cooperative Venture between Simulator Manufacturer, DCS Vendor and Power Plant Customer

Simulator Manufacturer DCS Vendor © Costec Systems & ABB - February 3, 2011 | Slide ‹2›

Millmerran Power Station Location (thanks to Google Maps) © Costec Systems & ABB - February 3, 2011 | Slide ‹3›

Millmerran Power Station Overview Owners Intergen Inc (USA) China Huaneng Corporation (PRC) 2x430MW coal-fired supercritical units Babcock & Wilcox boiler Ansaldo turbine Air-cooled condenser ABB Harmony DCS ABB 800xA Process Portal © Costec Systems & ABB - February 3, 2011 | Slide ‹4›

Millmerran Simulator Project Overview Private venture No obligation to purchase No statement of requirements Support from power station Support from DCS vendor © Costec Systems & ABB - February 3, 2011 | Slide ‹5›

Millmerran Simulator Project Evolution Scope of simulation Requirements and expectations Project stages End Result © Costec Systems & ABB - February 3, 2011 | Slide ‹6›

Simulator System Architecture Software © Costec Systems & ABB - February 3, 2011 | Slide ‹7›

Simulator System Architecture Simulator Management System (SMS) Executive Model configuration Snapshots Backtrack Interventions User management Diagnostics © Costec Systems & ABB - February 3, 2011 | Slide ‹8›

Simulator System Architecture Netalyser Plant Model Networks of standard components Lumped plant component models Based on physical principles Fully configurable Scalable Performance © Costec Systems & ABB - February 3, 2011 | Slide ‹9›

Simulator System Architecture Pseudo HMI & Controls Operator interface components Control elements Fully configurable Allows DCS-independent model testing © Costec Systems & ABB - February 3, 2011 | Slide ‹10›

Simulator System Architecture Interface – Model side Transfers data to/from 3rd party DCS Supports up to 4 OPC servers Supports custom protocols Fully configurable © Costec Systems & ABB - February 3, 2011 | Slide ‹11›

© Costec Systems & ABB – February 14, 2011 | Slide 12 Simulator System Architecture ABB DCS – Harmony Training Simulator (HTS) Re-hosted control execution environment Windows application Based on Harmony Controller (MFP/BRC) Behavior faithful to physical controller Establishes virtual Loop Communication Emulates MFP/BRC segment control and Control Way Distributable across multiple PC’s Direct reuse of plant control configurations Executes the composer config file. (.cfg’s) Monitor\Tune from Engineering Workstation Supports a comprehensive set of runtime simulator functions Vendor Independent Model Interface Switch between multiple simulation projects © Costec Systems & ABB – February 14, 2011 | Slide 12

Simulator System Architecture ABB Harmony Training Simulator (HTS) HTS Manager Data exchange and communication coordination Simulation command execution Built-in OPC Server for model interface Virtual ICI (vICI) Virtual Connection to ABB Consoles Self-building database Unlimited Connections Distributed architecture Virtual PCU (vPCU) Unlimited # of vPCU’s and Controllers Executes Controller CFG’s 130+ Function Codes supported HTS (Harmony Training Simulator) OPC Server HTSManager vPCU vICI © Costec Systems & ABB – February 14, 2011 | Slide 13

Simulator System Architecture ABB 800xA Process Portal HMI Reuse of Plant displays and configurations Operator Faceplates, dialogs and displays are reused without modifications Configuration of event/alarm lists, history loggings and trends are reused Provides identical Operator environment in the simulator system and real control room Connected to Virtual Controls via a virtual ICI and network. All fidelity type simulators use the same operator configuration and graphics. Identical operator environment © Costec Systems & ABB – February 14, 2011 | Slide 14

Simulator System Architecture Typical Hardware Configuration © Costec Systems & ABB - February 3, 2011 | Slide ‹15›

© Costec Systems & ABB - February 3, 2011 | Slide ‹16› Hosted Simulator User perspective - Pros High fidelity Accessibility Minimal delay Any time Guaranteed System support Minimal Automatic updates Customised training Minimal simulator footprint Financial No capital outlay Reliable budgeting Try before you buy © Costec Systems & ABB - February 3, 2011 | Slide ‹16›

Hosted Simulator User perspective - Cons Not site specific Constraints on availability Fixed configuration Fixed training scenarios © Costec Systems & ABB - February 3, 2011 | Slide ‹17›

Hosted Simulator Supplier benefits Market size Acceptance Technical support Centralised Updates Billing options Usage fees © Costec Systems & ABB - February 3, 2011 | Slide ‹18›

Hosted Simulator Technology Web-based simulation Remote Desktop Services Tightly integrated Multiple monitors Obliging DCS & HMI software © Costec Systems & ABB - February 3, 2011 | Slide ‹19›

Hosted Simulator Supplier challenges User expectations © Costec Systems & ABB - February 3, 2011 | Slide ‹20›

© Costec Systems & ABB - February 3, 2011 | Slide ‹21›