ABB Ability™ System 800xA Simulator

Reduce the risks and the number of unplanned shutdowns, improve safety, productivity and energy savings thanks to realistic DCS simulation.

The control system in a simulator is disconnected from the physical process, and is instead simulated by a dynamic process model. By seamlessly extending your DCS it provides the same look and feel as the core functional areas.

A great number of large, medium and small 800xA Simulator systems have been installed in the Oil & Gas, Nuclear, Power Generation, Petrochemical, Chemical, Pulp & Paper and Mining industries, and a large number of process model vendors within these areas have interfaced this ABB simulator.

ABB Ability System 800xA Simulator is a scalable solution in system size, functionality and control system connectivity. It is available in three editions: Basic, Premium and Professional.

ABB also provides training, support, service and software upgrade agreements.

Did you know you can use simulator in every project phase?

Are you looking for support or purchase information?

Simulation support for all phases of the plant lifecycle

Engineering and Testing

Use standard engineering tools for design and configuration data transfer between simulator and real system. Verify / tune control logic before commissioning

Operator Training

Make operators familiar with the plant operation, start-up, shutdown, response on malfunction, emergencies and safety procedures prior to production start / modifications

Plant Optimization

Test software and application library updates, run "what if" engineering studies and verify control logic / process design modifications to improve productivity

Evolution

Migrate from 3rd party DCS system to ABB 800xA via offline simulation to test and verify changes, design the process, train operators on the new HMI and get their feedback

Simulation capabilities

Benefits
Functionalities
Process models
Tools
Supported systems
  • 100% realistic and correct behavior as the real system
  • 100% transferable operation, control and engineering skills
  • Cost and space efficient simulator platform
  • Exact copy of engineering data from plant system
  • Identical engineering environment
  • Automated reconfiguration reduces maintenance costs
  • Assures reuse through plant system’s lifecycle
Microsite
ABB Ability™ Collaborative Operations

Connect to ABB experts anytime, anywhere to make the best data-driven decisions possible
  • I/O exchange with process model
  • Interface for activation of simulation functions
  • Run and freeze the control system
  • Run faster or slower than real time
  • Run the control system in steps
  • Save and load of different initial process conditions (100% production, cold start, etc.)
  • Automated or manual snapshot of current process condition
  • Recreate alarm/event lists and trends when restoring process conditions
  • Simulated I/O and protocol inputs
  • Simulated fieldbus communication between control systems
  • Record and Replay of operator actions
  • Hardware malfunction simulation
  • Physical I/O support
  • Configuration tools for System 800xA and the different control systems
  • Supervision tool for the system status
In a simulator system, the control system’s process I/O is stimulated by a dynamic process model. These process models can range from high-fidelity third party models to low-end models giving stimulation through control logic.

An external process model environment stimulates I/O through OPC Data Access interface of 800xA Simulator. A model vendor also typically supplies an instructor station from where training and test session are administrated (start, stop, scenarios, snapshot, etc), and it interfaces and activates simulation functions in the control system through the Link interface of 800xA Simulator.

The simulator product is provided with several tools:
  • Simulator configuration tools for System 800xA and the different controller families. The process model extent specifies the process units and sections that shall be simulated, and the controller configuration tools are used to select the controllers and applications that are relevant for simulation.
  • Supervision tool for the system status
  • Upgrade of initial conditions

800xA Simulator supports simulation of several control system in ABB’s portfolio:

  • AC 800M including High Integrity
  • Advant OCS with Master software
  • Symphony Melody (AC 870P and CMC50/60/70)
  • Symphony Harmony
  • PLC Connect for third party integration

The controllers run as Soft Controllers in a more cost and space saving computer hardware with Microsoft Windows, which enables you to utilize the full CPU and memory capacity in a computer.

Industry

Solution

Topic

Country

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URLImageTitleDescriptionIndustrySolutionTopicCountry
https://new.abb.com/control-systems/industry-specific-solutions/pulp-and-paper/system-800xa-for-pulp-mill-to-become-major-energy-supplier800xA for Södra Cell pulp mill becoming energy supplierThe world’s first pulp mill to be independent of fossil fuels for its day-to-day operation and to supply neighboring town with electricity, district heating and biofuelsPulp and PaperABB 800xASimulationSweden
https://new.abb.com/control-systems/industry-specific-solutions/mining/system-800xa-simulator-for-lkab800xA Simulator for LKAB minerals processing plant in Sweden (by Optimation AB)Simulator shortens the new plant start-up period, helps train operators and test changes to control systems and processes, free of interferenceMiningABB 800xAABB Partners SimulationSweden
https://new.abb.com/control-systems/industry-specific-solutions/pulp-and-paper/800xa-simulator-for-recovery-boiler-control-pulp-mill800xA Simulator for recovery boiler control at SCA pulp millSkilled operators from day one, lower risk potential and cost savings thanks to realistic process simulationsPulp and PaperABB 800xASimulationSweden
https://new.abb.com/control-systems/industry-specific-solutions/pulp-and-paper/system-800xa-simulator-for-swedish-paper-pulp-mill800xA Simulator for Södra Cell paper pulp millSystem simulator provides operator training and enables test runs to reduce time and effort for commissioningPulp and PaperABB 800xASimulationArgentina
https://new.abb.com/control-systems/industry-specific-solutions/oil-gas-and-petrochemicals/800xa-simulator-for-statoil-peregrino800xA Simulator for Statoil PeregrinoTwo System 800xA Simulators have helped Statoil overcome the challenges of recovering and processing some of the heaviest and most challenging crude oil on the planet.Oil, Gas and PetrochemicalABB 800xASimulationBrazil
https://new.abb.com/pulp-paper/abb-in-pulp-and-paper/articles/previous-2/sca-ostrand-to-increase-pulp-mill-efficiency-with-integrated-digitalized-automation-solutionIntegrated operation with single control room at SCA pulp mill in SwedenFirst time ever an integrated automation to manage end-to-end production from woodyard to baling line Pulp and PaperABB 800xASimulationSweden
https://new.abb.com/metals/abb-in-metals/references/Optimize-steel-hot-flat-millsProcess model optimizes operation at Sandvik steel hot flat millsHighly precise and quick control system to enable the strip products to be rolled thinly, less scrap to melt and lower energy consumptionMetalsABB 800xASimulationSweden
https://new.abb.com/control-systems/industry-specific-solutions/oil-gas-and-petrochemicals/system-800xa-for-trans-anatolian-natural-gas-pipelineSystem 800xA for Trans-Anatolian Natural Gas Pipeline TANAPDelivering integrated software solutions for telecoms and control systems to monitor, secure and control 1,850 km gas pipelineOil, Gas and PetrochemicalABB 800xA ABB Control Room SolutionsOperator Effectiveness SimulationBulgaria
https://new.abb.com/mining/digital-applications/advanced-process-control/abb-ability-ventilation-optimizer/underground-mine-ventilation-how-to-improve-safety-and-half-energy-costsVIDEO: Digital optimization of the ventilation systemApplying a more model-based algorithm to control all the fans underground. This creates a digital twin of the ventilation system able to control all fans in an optimized way.MiningABB 800xASimulationCanada
https://new.abb.com/mining/grinding/artificial-intelligence-in-mining-what-can-grinding-learn-from-gamingAI study at Boliden SwedenUsing AI to optimize concentration processesMiningABB 800xASimulationSweden
https://new.abb.com/control-systems/industry-specific-solutions/oil-gas-and-petrochemicals/integrated-process-control-and-safety-system-for-statoil-gullfaks-a-platformIntegrated Process, Electrical Control and Safety System for Statoil GullfaksThe very first integrated MP200 based safety systems evolution to 800xA, Fire & Gas system, HVAC, sequence, subsea, wellhead control, power managementOil, Gas and PetrochemicalABB 800xASimulationNorway
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