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

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

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

4. 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›

5. 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›

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

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

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

9. 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›

10. 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›

11. 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›

12. © 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

13. 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

14. 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

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

16. © 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›

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

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

19. 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›

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

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