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Virtual Plant Using Mimic For Emerson Process Management DeltaV
By Noelle Weymer
Product: Mimic Simulation

This white paper will cover proven practices for implementing operator training systems for DeltaV using Mimic Simulation Software.

Operator Training Systems are a proven and effective tool for preparing a plant operations staff for effective use of automation systems. However, many users in the process industries are unaware of best practice methods for implementing of these systems. Operator training systems based upon Mimic Simulation Software and the DeltaV Simulate Suite provide a cost-effective and comprehensive solution for meeting Operational Excellence (OpEx) goals by providing:

  • Non-intrusive simulation interfaces for conducting Software Acceptance Testing
  • Off-line systems with realistic process and IO responses for operator training
  • Proven methods for testing new control strategies, recipes, products
  • Effective methods for testing MES integration and electronic batch records

By using Mimic and DeltaV Simulate, the following OpEx goals can be achieved:

  • Automation project schedule is reduced and compressed
  • Quicker unit startup with better product quality
  • Less unscheduled downtime, more effective process operations
  • Compliance with GMP and FDA Regulations
  • Compliance with OSHA, ISO training requirements

This document will cover the following in implementing an Operator Training System using Mimic and DeltaV Simulate:

  • Capabilities and configurations of Mimic and DeltaV Simulate Suite
  • Sample Bill of Materials of Operator Training Systems

Licensing DeltaV Simulate Suite

DeltaV Simulate Suite software licenses allow the user to purchase an off-line DeltaV system, complimentary to the DeltaV system that is used in the production environment and can be used for a number of purposes including software testing, system development, and operator training. DeltaV Simulate Software is licensed in two different configurations: Standalone and Multi-node. DeltaV Simulate is never to be used on a live process and is not a valid software configuration for any operating system. For more information, please refer to the DeltaV Simulate product data sheet, available on http://easydeltav.com.

Licensing DeltaV Simulate Standalone

DeltaV Simulate Standalone is licensed to run on a single PC. In DeltaV Simulate Standalone, DeltaV Control Modules are assigned to the ASSIGNED MODULES folder under the workstation and run in the “virtual controller” function of the workstation.

DeltaV Simulate Standalone is licensed as follows:

  • VE9921, DeltaV Simulate Standalone – provides 16MB of RAM for module execution, giving it the approximate capacity of one MD controller.
  • VE9922, DeltaV SimulatePro Standalone – provides 96MB of RAM for module execution, giving it the approximate capacity of six MD controllers. SimulatePro also has additional capabilities to freeze, restore, and resume module execution and module execution speedup. These features are powerful when combined with Mimic Operator Training Manager (Mimic OTM).

DeltaV Simulate Standalone is a cost-effective solution for a single seat development or training system. It does have the following limitations:

  • DeltaV Simulate Standalone does not support real DeltaV controllers. It does not have an IO system, so it does not support DeltaV configurations using digital busses without modification. Because of this limitation, it does not support non-intrusive simulation interfaces required for software acceptance testing.
  • Simulate Standalone is limited to a single seat. It is not suited for operator training systems that require multiple user stations or more than six controllers.
The DeltaV Experience from a DeltaV Simulate Operator Screen.

Licensing DeltaV Simulate Multi-Node

DeltaV Simulate Multi-Node is licensed per node similar to standard DeltaV systems, without the DST licenses and layered application licenses (such as Batch licenses). All licensed nodes are connected to the DeltaV Area Control Network (ACN) similar to production systems. In DeltaV Simulate Multi-node, DeltaV Control Modules are assigned to the ASSIGNED MODULES folder under the PPN or ASN workstations and run in the “virtual controller” function of those workstations. In addition, actual DeltaV controllers can be connected to the Simulate ACN and used.

DeltaV Simulate Multi-node is licensed as follows:

  • VX2101S01, DeltaV Simulate, Professional Plus Networked (PPN) – functions as the ProPlus node in a standard
  • DeltaV system. Required for the Multi-node system. 16MB of RAM for module execution - Approximate capacity of one MD controller.
  • VX2102S01, DeltaV Simulate, Professional Station Networked (PSN) – functions as the Professional node in a standard DeltaV system.
  • VX2104S01, DeltaV Simulate, Operator Station Networked (OSN) – functions as the Operator node in a standard DeltaV system.
  • VX2201S01, DeltaV Simulate, Application Station Networked (ASN) – functions as the Application node in a standard DeltaV system. Preferred node for “virtual controller” module execution. 16MB of RAM for module execution - approximate capacity of one MD controller.
  • VX2207S01, DeltaV SimulatePro Multi-node – added to each PPN or ASN license required. Increases the memory for module execution to 96MB of RAM - approximate capacity of six MD controllers. Also provides capabilities to freeze, restore, and resume module execution and module execution speedup. These features are optimized when combined with the Mimic Operator Training Manager (Mimic OTM).

DeltaV Simulate Multi-node is a powerful solution for development of training systems. It has the flexibility to be used for almost any development or training system including:

  • Ability to support real DeltaV controllers with IO system, including DeltaV configurations using digital busses without modification. This supports non-intrusive simulation interfaces required for software acceptance testing.

DeltaV Simulate Multi-mode is limited by node number to the same limits as DeltaV.It is well suited for operator training systems that require multiple user stations or more than six controllers.

Using Mimic Simulation Software

DeltaV Simulate provides an excellent environment for setting up the process control functions of a development or training system. In order to complete the operator training system, a simulation of the process must be developed. Using the DeltaV Simulate alone for process simulation has a number of limitations:

Simulation in the control system environment, using the DeltaV function blocks, is intrusive and violates the integrity of the control system configuration. This invalidates this approach for any validated system or process where software reliability is a requirement.

  • The DeltaV function block set is designed for process control, not process simulation. Developing process simulations in process control function blocks is awkward and expensive.
  • DeltaV Simulate has no standard utilities for the generation of base-level process and IO simulation. Any simulation must be developed through systems engineering effort.
  • DeltaV Simulate does not have an operator training system to assist in the development of structured operator training modules.

Mimic Simulation Software complements the DeltaV Simulate product line with a process and IO simulation environment that addresses all the above limitations.

Management of dynamic process simulation in Mimic Explorer.

Mimic is a 3rd-generation simulation software platform proven to save users time and money on process automation capital projects and operational excellence initiatives.

Mimic Simulation Advantages

Mimic was designed for Software Acceptance Testing and Operator Training Systems. Mimic provides:

Unlike other process simulation applications, Mimic is easy to use. It was designed with the end user and integrator in mind. Mimic is a shrink-wrapped configurable product that includes:

  • Auto-generation of simulation database

Mimic v3 is flexible and dynamic, yet extremely powerful with many valuable time-saving features. Mimic advantages include:

Mimic v3 Latest Technology

A third-generation simulation product, Mimic v3 incorporates all of the latest technology for speed, compatibility, and universality:

  • XML data exchange
  • MS Remote Access and Server Support
  • OPC DA (and eventually UA) access and integration for all data
  • IEC function block simulation objects
  • MS SQL Server Open Database
  • Scalable, multiprocessor support

For more information, please refer to the Mimic product bulletin and Mimic OTM product bulletin, available on http://www.mynah.com/mimic.

Mimic Simulation Interfaces for DeltaV Simulate

Mimic support two separate interfaces to DeltaV: a direct interface to the IO bus of the controller and an OPC client interface to the modules running in the workstation’s “virtual controller”.

DeltaV Railbus Simulated IO Driver Uses the DeltaV Virtual IO Module to emulate the complete IO subsystem of the DeltaV controller. The VIM card is installed in a controller slot on a DeltaV Controller carrier connected to the carrier with the DeltaV MD Controller. The 8-wide carriers and all IO modules are removed during when using the direct IO simulation interface. Through the VIM, Mimic emulates all the IO modules and their field signals including the digital buss devices supported by DeltaV. This interface provides completely non-intrusive simulation through the IO system and is the best simulation interface for software acceptance testing or development systems using digital IO busses.

DeltaV Simulate OPC Simulated IO Driver Uses the OPC protocol to read and write data values directly from the modules running in the workstation “virtual controller”. This interface allows the user to take advantage of the efficiency of the DeltaV Simulate “virtual controller” and setup a training system with PC hardware alone. This interface is limited by not having an IO subsystem to communicate to and therefore is not suitable for software acceptance testing of DeltaV systems using digital busses.

Dynamic Process Models in Mimic Simulation Studio

Mimic Software Licensing

Mimic Software Licensing is flexible, scalable, and easy to apply.Sample Bill of Materials of Operator Training Systems Using Mimic and DeltaV Simulate

Following are examples of typical systems. Please contact your Emerson Local Business Partner for your individual needs and a quotation for an operator training system.


Example 1 – Single Seat Operator Training System, One Controller Module Capacity


DeltaV Simulate Bill of Materials

Quantity Model Number Description
1 VE9921 DeltaV Simulate Standalone

Mimic Bill of Materials

Quantity Model Number Description
1 MM3-1101 Mimic 1000 SIO Tag Base License
1 MM3-2102 DeltaV Simulate OPC SIO Driver Pack

Number PC Workstations – 1


Example 2 – Single Seat Operator Training System, Four Controller Module Capacity


DeltaV Simulate Bill of Materials

Quantity Model Number Description
1 VE9922 DeltaV SimulatePro Standalone

Mimic Bill of Materials

Quantity Model Number Description
1 MM3-1103 Mimic 3000 SIO Tag Base License
1 MM3-2102 DeltaV Simulate OPC SIO Driver Pack
1 MM3-3101 Operator Training Manager

Number PC Workstations – 1


Example 3 – Three Seat Operator Training System, Team Training Environment, 8 Controller Module Capacity


DeltaV Simulate Bill of Materials

Quantity Model Number Description
1 VX2102S01 DeltaV SimulateProfessionalPlus Networked (PPN
2 VX2104S01 DeltaV Simulate Operator Station Networked (OSN)
2 VX2201S01 DeltaV Simulate Application Station Networked (ASN)
2 VX2207S01 DeltaV SimulatePro Multi-Node

Mimic Bill of Materials

Quantity Model Number Description
1 MM3-1106 Mimic 6000 SIO Tag Base License
1 MM3-2102 DeltaV Simulate OPC SIO Driver Pack
1 MM3-3101 Operator Training Manager

Number PC Workstations – 10


Example 4 – Five Seat Operator Training System, Individual Training Environment, 4 Controller Module Capacity


DeltaV Simulate Bill of Materials

Quantity Model Number Description
5 VE9922 DeltaV SimulatePro Standalone

Mimic Bill of Materials

Quantity Model Number Description
1 MM3-1115 Mimic 15,000 SIO Tag Base License
1 MM3-2102 DeltaV Simulate OPC SIO Driver Pack
1 MM3-3101 Operator Training Manager

Number PC Workstations – 5


  • NET Graphical User Interfaces
  • Dynamic, accurate modeling functions
  • Easy-to-use high-fidelity application packages
  • Non-intrusive simulation interfaces that require minimal control system changes
  • Integrated Operator Training Management
  • Control system integrity
  • Automatic integration with control system
  • Scalable from small to large applications

Mimic base software - Licenses are available in 1000 through 30,000 Simulated IO(SIO) Tags in 1000 SIO Tag increments. A SIO Tag is an IO signal such as an AI, DI, AO, or DO channel, a serial card register or a digital bus device signal. This base software comes with one driver pack such as the DeltaV Railbus SIO Driver or the DeltaV Simulate OPC SIO Driver. Additional SIO Drivers can be ordered for the same system. SIO Drivers can be used on the same system to drive simulated IO signals to multiple systems. In addition, the first year Mimic Software Support is included in the base software license, starting from date of shipment. Mimic SIO Driver Packs dictates the controller IO systems that can be simulated with the Mimic license. Each simulated Mimic node can run a different IO driver for a different type of controller. One IO driver pack is included in the base software, but it must be specified on the PO. As many other IO driver packs can be specified as required for the simulation system.

Mimic Software Support provides automatic product updates and technical support. Allows users to protect their investment in Mimic.One year of Mimic Technical and Product Support is included with each new base system purchase. The one-year of Mimic Software Support begins upon shipment of the Mimic software and license from MYNAH. Mimic Software Support can be renewed on an annual basis.

Mimic Advanced Modeling Packages

Advanced Modeling Packages allow the user to develop rigorous, dynamic models for a fraction of the time and money of other simulation solutions. Advanced Modeling Applications Packages are available for Distillation and Industrial Boilers.

Simulation Interface Hardware

Interface Hardware is required for the DeltaV Railbus SIO Driver. One Virtual I/O Module is required for each DeltaV Controller in the simulation system (additional hardware required:

  • One DeltaV Power Supply, One 2-Wide Carrier). For DeltaV Simulate OPC SIO Driver the only hardware required is a PC network interface card.