Indonesia OBI Nickel Iron Project and Supporting Power Plant Simulation Project

Overview

The Indonesian OBI Nickel Iron Project processes nearly 10 million tons of low-grade nickel ore and 12 million tons of high-grade nickel ore annually, with an annual production output of 350,000 tons of nickel metal. Given the scale of this project, flawless operation of the supporting power plant is important. To guarantee stable power supply and safe production, precise operator training with an advanced simulation system is indispensable.

Solutions

With advanced virtual DPU technology, HollySys seamlessly integrated the actual DCS software and virtual master control software (VDPU) into the simulation system. The VDPU software boasts the same control logic computation and communication functions  with actual master control, ensuring effortless integration between  simulation system and DCS. Due to the identical DCS system structure and global database, each point in the virtual DPU aligned perfectly with its counterpart in the actual DCS. It allowed for direct import of DCS configuration files from the onsite engineer station to the simulation machine, ensuring high simulation accuracy, short development cycles, and excellent simulation results.

Furthermore, adopting the same DCS system and engineering with actual units, we ensured accurate replication of real unit control schemes and functionalities. This included control logic, sequencing logic, interlock protection, thermal configuration, alarms, points lists, trends, PID tuning, forced listings and more. Our systems also facilitate control logic verification, system design analysis, and simulation debugging.

Results

We're thrilled to announce the successful commissioning of our 1:1 customized subcritical 150MW thermal power simulation machine for the OBI project. The outcomes have exceeded expectations, with outstanding on-site training results and good reviews from our clients.