Wayne Stefancin, Magnus Hammar, 2017-02-15

Simulation
ABB offering
Agenda

 Simulation purpose
 Test platform for additional functions, simple manual
process feedback simulation
 800xA Simulator for complete 800xA operator training
and full automatic process feedback
 800xA Simulation portfolio
 Simulation with Harmony
ABB 800xA Simple Simulation with AC800M
No process model feedback
 System 800xA has soft controllers available. Up to
10 AC800M controllers can be simulated in the
same PC.
 Could be used for very simple training
purposes, i.e. get acquainted with Graphic
Displays/Faceplates etc.
 Uses the same control logic and HMI as in
active plant
 No Connection to any process model
 Library Modules can be set in Sim mode, Single node for engineering
automatic simulation of discrete process and test simulation
feedback, for valves motors etc.
 Analog process feedback must be done
manually from faceplate or via excel OPC
interface
 Main purpose: Test environment for new application
code.
ABB 800xA Simple Simulation with AC800M
Topology

Single node for MS sharepoint server Production System

engineering and with ACM (Application
simple test simulation change management)

Manual transfer of
application code via
Import/Export tools
ABB 800xA Simulator
Product introduction
 System 800xA Simulator is the control system part of a
simulator:
 System 800xA runs in simulator mode for training
scenarios
 Uses the same control logic and HMI as in active plant
 Connects to model for process dynamics and
instrumentation
 System 800xA Simulator provides a safe and realistic
environment where operators can learn to master the
process, thereby reducing risks and number of unplanned
shutdowns
 System 800xA Simulator is a powerful tool for optimization
and engineering studies to improve productivity and energy
savings
ABB 800xA Simulator
Concept
ABB 800xA Simulator
Features
 Solution is based on System 800xA with
additional simulator functionality for
testing and training scenarios:
 Start, stop, freeze and resume
 Speed up/down
 Snapshots
 Initial conditions
 Step execution
 Record and replay
 Soft controllers
ABB 800xA Simulator
Features
 Direct reuse of control code from real
plant control system
 SoftController for AC 800M,
Advant Master, Melody, Harmony,
Freelance

 Direct reuse of real plant HMI

 System 800xA, Advant Station 500

 I/O redirected from HW I/O to

high-speed communication with
dynamic model representing process
ABB 800xA Simulator
Features
 Links control system to third-party process model
 GSE (Power plants and nuclear power plants)
 SimSci (Schneider/Invensys) (Power plants)
 Trax (Power plants)
 Samahnzi (Power plants)
 Westinghouse (Nuclear power plants)
 KSU (Nuclear power plants)
 AspenTech (project specific: nuclear waste treatment)
 Cape Software (Chemical and petrochemical)
 Andritz Ideas (Pulp and paper)
 Metso (Pulp and paper)
 Kongsberg O&G Technologies (Oil and gas)
System 800xA Simulator is independent of business areas  RSI (Oil and gas)
Process models are more related to business area  Honeywell UniSim (Oil and gas)

ABB is independent of process model vendor  Optimation (Minerals and mining)

 …
ABB 800xA Simulator
Typical topology
Agenda

 Simulation purpose
 Test platform for additional functions, simple manual
process feedback simulation
 800xA Simulator for complete 800xA operator training
and full automatic process feedback
 800xA Simulation portfolio
 Simulation with Harmony
Simulator Solutions
ABB Virtual Controller Provides the Core
• ABB provides a Virtual Controller for Harmony (HTS)
• Executes the plant control logic true to physical controllers
• Supports simulation commands (run, freeze, step, snapshot etc.)

Production Simulation environment Production

Virtual environment for:

Control communications
Control applications
Control I/O

SD Series Virtual Controller HR Series

© ABB Group
Month DD, Year | Slide 17
Simulator Solutions
Types of Models

• High Fidelity Model simulator solutions

• 3rd party high fidelity models drive I/O via HTS OPC interface
• 3rd party instructor station manages the simulation scenarios, fault
insertion & sends simulation commands to HTS via OPC interface

• Function Code Model simulator solutions

• Tie-back and/or function models (low/medium fidelity) are done in
function code logic and drive I/O via an inter-controller mapping
• Scenarios & simulation commands driven from HTS user interface
• Fault insertion done from an Operator Workstation via faceplates
• Option for 3rd party instructor station exists

© ABB Group
Month DD, Year | Slide 18
Simulator Solutions
Lining up with the Plant’s Goals
Check-out Concept Basic Op Extended Engineer
Functionality Training Training Training Grade
Graphic Verification (drive I/O & values) X X X X X
Device Verification (w/permissive) Option X X X X
Normal Operations (start-up/shut-down etc.) Limited X X X
Scenarios w/in plant systems Limited X X
Scenarios between plant systems Limited X X
Virtual Commissioning Limited X

Standard Component Failures Limited X X X X

Specific Equipment Malfunctions X X X
Complex Malfunctions between plant systems Limited X X
Malfunctions for extreme plant conditions X

Pipe empty startup (optional) Limited Option

Black start Lim Opt Option
Picture Realistic Panel Support Lim Opt Option

© ABB Group
Month DD, Year | Slide 19
Integrated Instructor Station
State-of-the-art training platform w/lower cost models

 Supports both instructor lead and self-paced training

 Initializes the simulator for training
 Tracks and records trainee proficiency
 Provides tools to build and modify training scenarios
 Invokes malfunctions
 Records data
 Supporting the Panel Emulation solutions
 Displays locally operated control screens (LOS)
 Displays hard panel emulation screens
 Supports a mix of Function Code and High Fidelity models
 Allows future expansion/evolution
 Supports integration of 3rd part virtual controls/HMI

© ABB Group
Month DD, Year | Slide 20
Integrated Instructor Station
Tracking and recording student proficiency
Data Recorded on Lesson Results
 Instructor and student name
 Files loaded to initialize the lesson
 Date and time at start and end of training lesson
 Duration of lesson
 Duration score – This score indicates if the session was completed within a defined time limit
 Constraint score – This is an average score that indicates how well all critical system parameters
were maintained within defined limits. Additional data recorded for each critical parameter includes:
 Number of times defined limits are exceeded
 Minimum and Maximum value of parameter that exceeded limits
 Total violation time
 Procedure score – This score indicates how well the student followed a defined procedure
(available when using the Teaching Assistant)
 TA Test Score – This score indicates the student’s performance on a multiple choice test (available
when using the Teaching Assistant)
 Line and bar graphs of critical system parameters

© ABB Group
Month DD, Year | Slide 21
Integrated Instructor Station
Tracking and recording student proficiency

Trend Showing Constraint Violations

© ABB Group
Month DD, Year | Slide 22
Integrated Instructor Station
Curriculum Development services

© ABB Group
Month DD, Year | Slide 23
Integrated Instructor Station
Teaching Assistant - self paced learning examples

Operator help can exist while learning but be hidden during testing
© ABB Group
Month DD, Year | Slide 24
Integrated Instructor Station
Teaching Assistant - self paced learning examples

Good self paced examples limited to 20 or less steps

 Condenser Circulating Water System Startup
 Closed Cooling Water System Startup
 Steam Turbine Prestart
 Boiler Prestart
 Combustion Air and Gas System Startup
 Boiler Lightoff and Warmup
 Condenser Air Evacuation
 Steam Turbine Startup
 Ramp the Unit to Minimum Load
 Ramp the Unit to Full Load
 Pulverizer Startup
 DCS Screen Familiarization
 Generator Synchronization
 Tying the HRSGs together (CCPP 2-on-1)

© ABB Group
Month DD, Year | Slide 25
Integrated Instructor Station
ABB provides supporting workshop

© ABB Group
Month DD, Year | Slide 26
Product Update
Scaled Licensing for More Options

• Harmony Training Simulator Licensing:

• HTS Tags (Virtual ICI sizing)
• HTS OPC server points (simulated Hard/Soft I/O)
• Base HTS Server
• 5,000 HTS Tags,
• 250 OPC Server Points
• up to 100 Virtual Controllers
• 2 virtual ICIs (concurrent connections)

• Standalone Simulate and Test Package

• Soft Controller: For Engineering Test Bench
• 2,500 HTS Tags,
• No OPC Server Points
• 1 Virtual Controllers
• 2 virtual ICIs (concurrent connections)
© ABB Group
Month DD, Year | Slide 27