The Millmerran Simulator An Innovative Cooperative Venture between Simulator Manufacturer, DCS...

The Millmerran Simulator An Innovative Cooperative Venture between Simulator Manufacturer, DCS Vendor and Power Plant Customer

Name, department/event, date

Simulator Manufacturer

© Costec Systems & ABB - February 3, 2011 | Slide ‹2›

DCS Vendor


Millmerran Power StationLocation (thanks to Google Maps)

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

Millmerran Power StationOverview


Private venture

No obligation to purchase

No statement of requirements

Support from power station

Support from DCS vendor

Millmerran Simulator ProjectOverview


Scope of simulation

Requirements and expectations

Project stages

End Result

Millmerran Simulator ProjectEvolution


Simulator System ArchitectureSoftware


Simulator System ArchitectureSimulator Management System (SMS)

Executive

Model configuration

Snapshots

Backtrack

Interventions

User management

Diagnostics


Simulator System ArchitectureNetalyser Plant Model

Networks of standard components

Lumped plant component models

Based on physical principles

Fully configurable

Scalable

Performance


Simulator System ArchitecturePseudo HMI & Controls

Operator interface components

Control elements

Fully configurable

Allows DCS-independent model testing


Simulator System ArchitectureInterface – Model side

Transfers data to/from 3rd party DCS

Supports up to 4 OPC servers

Supports custom protocols

Fully configurable


Simulator System ArchitectureABB 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 ArchitectureABB 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 Distributed architecture 130+ Function Codes supported


HTS(Harmony Training Simulator)

HTSManager

OP

C S

erve

r vPCU

vICI

Simulator System ArchitectureABB 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

Simulator System ArchitectureTypical Hardware Configuration


Hosted Simulator

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


User perspective - Pros

Hosted Simulator User perspective - Cons

Not site specific

Constraints on availability

Fixed configuration

Fixed training scenarios


Hosted Simulator Supplier benefits

Market size

Acceptance

Technical support Centralised Updates

Billing options

Usage fees


Hosted SimulatorTechnology

Web-based simulation

Remote Desktop Services

Tightly integrated

Multiple monitors

Obliging DCS & HMI software


Hosted SimulatorSupplier challenges

User expectations


The Millmerran Simulator An Innovative Cooperative Venture between Simulator Manufacturer, DCS...

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