© 2014 Aspen Technology, Inc.All rights reserved April 29, 2014 Optimize DCS Testing and Operator Training with Aspen HYSYS® Dynamics ® Webinar with Inprocess 01/05/2014 © 2014 by inprocess 2 Started in 2006 Process Simulation Experts with many years of experience Office in Barcelona, Spain Applications: • Operator Training Systems • Instructor Station • Hydrogen Network Optimization • Pressure Swing Adsorption simulation Simulation projects: • Steady state: KPI calculation, soft sensors, optimization • Dynamic simulation: Blow down and relief calculation, flare studies, compressor start up, flow assurance Knowledge transfer/training: • Technology courses: process control, heat transfer, improving refinery operations • Process Simulation • Software Extensibility © 2014 Aspen Technology, Inc. All rights reserved | 3 Ongoing Series of Technical Webinars Engineering Webinars for Education and Best Practices UPCOMING WEBINARS OF INTEREST: See How Process Ecology Reduce Emissions in Natural Gas Glycol Dehydration Facilities Using Aspen HYSYS® - May 6 th A Tour of the Latest Innovations in the Aspen Engineering Suite focusing on process safety and project risk reduction – June 3 rd ON DEMAND WEBINARS Size Pressure Safety Valves and Design Flare Systems Using Aspen HYSYS® and Aspen Flare System Analyzer Size & Rate Pressure Safety Valves with Aspen HYSYS and HYSYS Dynamics (Technical) Upgrade Column Design using Aspen HYSYS Dynamics (Technical) ADDITIONAL RESOURCES: Public Website: www.aspentech.com Aspen HYSYS Product Family Webpage: www.aspentech.com/products/aspen-hysys.aspx © 2014 Aspen Technology, Inc. All rights reserved | 4 aspenONE Engineering Economic Evaluation Operations and Planning Support Equipment Design Basic Engineering Conceptual Engineering Safety Analysis Process Development Aspen HYSYS & Aspen Plus Safety Analysis Operations and Planning Support © 2014 Aspen Technology, Inc. All rights reserved | 5 Applications of Dynamic Modeling & Simulation Operability Engineering Studies – Understand dynamic plant behavior, including upset propagation – Design and analysis of start-up, shutdown and process transition strategies – Operability studies of highly-integrated processes Design / Analysis of Control Schemes – Design the process and control system simultaneously – Analyze and improve basic control strategies – Pre-tune control loops – Evaluate, develop and test APC scenarios Hazard and Safety Studies – Design and analysis of emergency shutdown systems, and pressure relief and flare systems Operator Training © 2014 Aspen Technology, Inc. All rights reserved | 6 What Does HYSYS Dynamics Offer? Seamless transition from steady state to dynamic model – Dynamics Assistant Interactive environment Rich choice between simple and detailed modeling options A comprehensive library of control and logical operations Aspen Plus users: Aspen Plus Dynamics performs most of the same functions © 2014 Aspen Technology, Inc. All rights reserved | 7 Comprehensive Training Curriculum Online Training HYSYS HYSYS Dynamics Self-Start Jump Start Guides Recorded Videos Recorded Webinars Sample Models Classroom Training Locations Worldwide OPTIMIZE DCS TESTING AND OPERATOR TRAINING WITH ASPEN HYSYS DYNAMICS JoseMaria Ferrer (inprocess) Aspentech Webinar 29 th -April-2014 AGENDA • Introduction – Dynamic Simulation – Operator Training Systems (OTS) • Performing DCS FAT • “Early OTS” concept • Inprocess Instructor Station • Training for Field Operator • Economic return 9 1995: MY FIRST CONTACT WITH CONTROL SYSTEMS 10 Source: The MOD Squad: Process automation at Dow. http://www.controlglobal.com/assets/knowledge_centers/abb/assets/art_series_mod_squad_pa_dow.pdf In mid 80´s Dow implemented MOD5 globally, as of 2000 there were 1500 systems installed. Can anyone mention a worldwide-spread DCS which is not from ABB, Emerson, Yokogawa, Siemens, Honeywell, Schneider, Rockwell, GE Fanuc, Metso, SMAR, Azbil ….???? I´ll give a clue: Apart from making good business with petrochemicals, Dow Chemical also developed his own DCS. It was called MOD5 TM , programmed with DOWTRAN TM (a FORTRAN-like language) “With enough idiot lights and pushbuttons to satisfy any primate, Dow´s first attempts to automate were complex and wonderful” MOD-5TM COMPUTER (in control room) PROCESS CONTROL WITH DOWTRAN 11 Analog Inputs (AIs) DOWTRAN CODE (CONTROL) AC(1,200) = AK(1000,100,200) + AK(1003,5,200) AC(2,100) = AK(1001) + AK(1004,10,100) DO(1) IF STEP(4) OR STEP(1) OR (AI(101) GT AC(2)) DO(2) IF [STEP(2) AND AI(101) GT AK(1005,20,100) AND AI(100) LT AK(1000)] OR [DO(2) AND AI(100) LT AC(1)] AND AI(101) LT AK(1001)] DO(3) IF STEP(2) AND # DO(2) AND AI(101) LT AK(1001) STEP(417) IF STEP(415) OR STEP(416) AND [AI(434) LT AK(417,400,1000) AND AI(435) LT AK(417) AND AC(430) LT AK(417) OR DM(417) OR [#DI(427) AND DO(427) FOR DT(3427,5,2)]] Source: Patent US 5408603 A. www.google.com/patents/US5408603 P L A N T I N S T R U M E N T A T I O N Digital Inputs (DIs) Analog Outputs (AOs) Digital Outputs (DOs) P L A N T V A L V E S , M O T O R , e t c Thousands of DOWTRAN code lines are executed in two redundant Mod-5 computers every second. It allowed to make uploads of new code without plant shutdown. There were a need to verify all the code before uploads. MOD-5TM COMPUTER (in testing room) PROCESS CONTROL & SIMULATION WITH DOWTRAN 12 DOWTRAN CODE (CONTROL) AC(1,200) = AK(1000,100,200) + AK(1003,5,200) AC(2,100) = AK(1001) + AK(1004,10,100) DO(1) IF STEP(4) OR STEP(1) OR (AI(101) GT AC(2)) DO(2) IF [STEP(2) AND AI(101) GT AK(1005,20,100) AND AI(100) LT AK(1000)] OR [DO(2) AND AI(100) LT AC(1)] AND AI(101) LT AK(1001)] DO(3) IF STEP(2) AND # DO(2) AND AI(101) LT AK(1001) STEP(417) IF STEP(415) OR STEP(416) AND [AI(434) LT AK(417,400,1000) AND AI(435) LT AK(417) AND AC(430) LT AK(417) OR DM(417) OR [#DI(427) AND DO(427) FOR DT(3427,5,2)]] Source: Patent US 5408603 A. www.google.com/patents/US5408603 DOWTRAN CODE (SIMULATION) AISIM(100)=AO(100) AISIM(101)=AI(100)-AI(102) …. DISIM(100)=DO(100) DISIM(101)=DO(101) Simulating DIs (like pump ON, or valve CLOSED) was easy, but simulating a temperature in a tray or a column top pressure was not possible. The purpose of the DISIM/AISIM was for basic checkout and training AIs DIs WHY DYNAMIC SIMULATION? 13 1. Equipment sizing and process layout verification: • Compression systems • Pipeline networks 2.- Flare Load calculation and PSV sizing • Design/revamp flare networks 3.- Emergency System verification and HAZOP studies support • HIPPS studies • Cause & Effect matrixes 4.- Design control layout • Scenarios analysis • Perturbation rejection • Control loops selection 5.- Prototyping MPC • Obtain MPC models • Study non-linearities • Test/Tune MPC controller 6.- Develop virtual sensors • Online Analyzers backup • Fault diagnostic • Look-ahead sensors 7.- DCS checkout • DCS FAT with virtual plant • Operating procedure test 8.- Operator Training System(OTS) • Operator Training • Emergency scenarios • Knowledge base system Consolidated Exploring 14 Real World DCS Hardware & Software DCS Console & Graphics Field Operator Panel Operator AI, AO DI, DO Control System & SIS Process Plant Human Machine Interface • OTSs are developed in order to mimic, as close as practical to reality, the Operating Process Plant and its associated Instrumentation and Control System • There are two main approaches to achieve such objective: – Direct-Connect OTS (also called Stimulated OTS) – Emulated OTS 15 DCS & SIS Emulation Software DCS Console as in Control Room Instructor Station & Field Operator Devices Direct-Connect OTS Real World Aspen HYSYS Dynamics Model DCS Hardware & Software DCS Console & Graphics Field Operator Panel Operator AI, AO DI, DO Control System & SIS Process Plant Human Machine Interface Panel Operator AI, AO DI, DO 16 Emulated Graphics Console Instructor Station & Field Operator Devices Emulated OTS Real World Aspen HYSYS Dynamics model DCS Hardware & Software DCS Console & Graphics Field Operator Panel Operator AI, AO DI, DO Control System & SIS Process Plant Human Machine Interface Panel Operator Controls & SIS also in Aspen HYSYS Dynamic model OTHER AREAS OF VALUE OF OTSS 17 WHAT IS A STANDARD DCS FAT? Factory Acceptance Test (FAT) involves of: 1. Hardware, such as controllers, I/O modules, power supplies, terminations, etc. 2. Logic, forcing analog and discrete inputs, then watching the logic to be sure it responds as expected. 3. Operator displays and alarms, which are tested in conjunction with the forced logic and signals step above. 18 MOTIVATION FOR BETTER TESTING • Increasing complexity of DCS Tightens the requirements for functional testing before commissioning. • Client/Suppliers try to minimize involved risks: This includes software testing and early detecting specification errors. • At the real installation: The available time does not suffice to achieve the required depth of testing. Testing environments with a simulated virtual plant can help. 19 WHY USING SIMULATION IN LOGIC DCS FAT? Some of the DCS testing items made in OTS projects: 20 • Pre-tune control loops • Test control modules implementation • Test motor start/stop logic • Validate permissive logic for start- up/shutdown sequences • Verify controls interactions with other modules or against perturbations • Check graphics displays operability with real procedures • Re-setting for certain alarms limits • Test ESD timing and logic sequences • Evaluate procedures for abnormal or emergency operation DCS FAT WITH ONLY EMULATED DCS&SIS Control design and configuration is independent of the hardware, DCS emulators allows all configuration to run in virtual control with identical functionality Discrete I/Os are stimulated by engineer, Analog I/Os use tie-backs Virtual Control with DCS emulator 21 DCS FAT WITH FULL VIRTUAL PLANT Virtual Control with DCS Emulator The I/Os (discrete & analog) are fully simulated by a process dynamic simulator of the entire plant 22 STANDARD FAT VS. VIRTUAL PLANT FAT STANDARD DCS FAT DCS FAT with VIRTUAL PLANT Software DCS Emulator DCS Emulator, HYSYS Dynamics Timing When DCS hardware and I/Os modules are available As soon as DCS logic and configuration is available Testing proceeding Limited to I/O signal forced by engineer Same as during commissioning & start-up with real plant Procedures testing Limited verification All procedures and start-up/shutdown sequences Loop testing and control narrative Simple tie-backs Full, as in real plant Alarm verification Only non-time dependent Full, as in real plant SIS verification Limited, no plant interaction Full, as in real plant 23 WORKFLOW FOR DEBUGGING DCS CODE 24 DCS Vendor OTS Vendor Customer Pre-FAT DCS Database v0 D e f e c t s R e p o r t DCS FAT Post-FAT DCS Database v1 Post-FAT DCS Database v2 OTS FAT OTS SAT DCS SAT Post-SAT DCS Database v3 OTS DCS OTS update Start-up Post-Startup DCS Database v4 D e f e c t s R e p o r t D e f e c t s R e p o r t D e f e c t s R e p o r t D e f e c t s R e p o r t OTS update Important: OTS Vendor acts as an independent auditor of the DCS functionality HYSYS BASED OTS: OPTIONS BY DCS 25 DCS Vendor DCS System DCS vendor Emulator Emulated OTS Direct-Connect OTS ABB 800xA 800xA Simulator YES YES Siemens PCS7 PLCSim/SIMIT YES YES Emerson DeltaV DeltaV Simulate YES YES Yokogawa Centum VP FCS/HIS Simulator YES YES Honeywell Experion PKS C300-Sim YES YES Schneider Foxboro I/A FSIMplus YES Depend on Schneider Rockwell RSLogix RSLogix Emulate YES YES SMAR System 302 System 302 YES YES Best Choice ADDITIONAL EARLY OTS OPTION 26 EARLY OTS In order to provide to the Operators a process simulator as soon as the dynamic model is developed, not impacted by delays in DCS project DCS Post-FAT Database Delay in DCS FAT shifts OTS delivery OTS INPROCESS INSTRUCTOR STATION 27 Inprocess has developed its Instructor Station software to manage training sessions, but also to produce Emulated OTSs, to handle multiplatform communications and to speed up OTS development. ACTIONS OF FIELD OPERATOR IN OTS 28 Field actions in OTS are not available in the control room operator consoles. They are usually by the Instructor in the Instructor Station or FOD panel: • Certain pumps are started/shutdown at field • Compressors packages use local operation panels to be operated by field operators • Special operating procedures require manual by-passes • ESD valves/pumps need to be re-armed at field • Inspection of equipments and field instruments reads • Isolation procedures for equipment maintenance TYPICAL OTS ARCHITECTURE WITH FOD 29 2 Operator Stations 1 Instructor Station: • Dynamic plant models • Inprocess Instructor Station (IIS) Printer DCS & SIS Emulation Server Critical Action Panel 1 Field Operator panel: • Inprocess Field Operating Devices (FOD) TYPICAL OTS ARCHITECTURE WITH FOD-3D 30 2 Operator Stations 1 Instructor Station: • Dynamic plant models • Inprocess Instructor Station (IIS) Printer DCS & SIS Emulation Server Critical Action Panel 1 Field Operator3D: • Inprocess Field Operating Devices in 3D (FOD-3D) and Oculus Rift SCREENSHOT OF FIELD OPERATOR VIEW 31 SCREENSHOT OF FIELD OPERATOR VIEW 32 WHY THE FOD IN 3D 33 • Deeper involvement of field staff in understanding the process • The full operations team can practice critical events such as startups, shutdowns and emergency responses in a fully realistic manner • “Best field practices” can be designed and communicated to all staff • This type of learning is extremely motivating • Reduce travel and living costs associated with on-the-job training Operating companies have found advantages in: START-UP WITH OTS 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 With OTS Typical Start-up Plant starts weeks earlier Faster ramp-up Less incidents Safer Operation 34 Weeks OTS SURVEY: TIME SAVINGS FROM START-UP 35 Source: http://www.worldoil.com/December-2012-Economic-benefits-of-training-simulators.html 18 days average time savings on first commissioning and start-up 2.2 days average time savings on commissioning and start-up after major turnaround The aim of the survey was to quantify the benefits of simulator training in the Norwegian oil and gas industry. A total of 99 answers was received from 11 different companies, including Statoil, Shell, AddEnergy, ConocoPhillips, BP, Petrolink, Gaz de France, ExxonMobil, Marathon, Talisman and Sørco OTS SURVEY: REDUCTION UNPLANNED SHUTDOWN 36 3 (average) unplanned shutdowns per year that can be avoided Source: http://www.worldoil.com/December-2012-Economic-benefits-of-training-simulators.html OTS SURVEY: ECONOMIC SAVINGS 37 15.3 million$ average estimated savings due to training simulator 15 MNOK = 2.6 Million$ 200 MNOK = 38.4 Million$ Source: http://www.worldoil.com/December-2012-Economic-benefits-of-training-simulators.html QUESTIONS, CONTACT Contact: JoseMaria Ferrer Inprocess Technology & Consulting Group, S.L. Phone: +34 933 308 205 Cell: +34 607 570 685
[email protected] 38 Q&A Irina Rumyantseva, AspenTech
[email protected] Ron Beck, AspenTech
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