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Optimize DCS Testing and Operator Training with Aspen HYSYS® Dynamics® Webinar with Inprocess April 29, 2014 Simulation projects:  Steady state: KPI calculation, soft sensors, optimization  Dynamic simulation: Blow down and relief calculation, flare studies, compressor start up, flow assurance • • Applications:  Operator Training Systems  Instructor Station  Hydrogen Network Optimization  Pressure Swing Adsorption simulation • • • •    Started in 2006 Process Simulation Experts with many years of experience Office in Barcelona, Spain Knowledge transfer/training:  Technology courses: process control, heat transfer, improving refinery operations  Process Simulation  Software Extensibility • • • 01/05/2014 © 2014 by inprocess 2 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 3rd – 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 aspenONE Engineering Conceptual Engineering Process Development Basic Engineering Aspen HYSYS & Aspen Plus Equipment Design Economic Evaluation Safety Safety Analysis Analysis Operations Operations and Planning and Planning Support Support Applications of Dynamic Modeling & Simulation  Operability Engineering Studies – – –  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 –  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 and analysis of emergency shutdown systems, and pressure relief and flare systems Operator Training 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 Comprehensive Training Curriculum Online Training HYSYS HYSYS Dynamics Self-Start Classroom Training Jump Start Guides Recorded Videos Recorded Webinars Sample Models Locations Worldwide OPTIMIZE DCS TESTING AND OPERATOR TRAINING WITH ASPEN HYSYS DYNAMICS JoseMaria Ferrer (inprocess) Aspentech Webinar 29th-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 Can anyone mention a worldwide-spread DCS which is not from ABB, Emerson, Yokogaw Yokogawa, a, 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 MOD5TM, programmed with DOWTRAN TM (a FORTRAN-like language) “With enough idiot lights and  pushbuttons to to satisfy any primate, primate, Dow´s first attempts to automate were complex and wonderful”  In mid 80´s Dow implemented MOD5 globally, globally, as of 2000 there were 1500 systems installed. Source: The MOD Squad: Process automation at Dow. Dow. 10 PROCESS CONTROL WITH DOWTRAN    N    O    I    T    A    T    N    E    M    U    R    T    S    N    I    T    N    A    L    P Analog Inputs (AIs) MOD-5TM COMPUTER (in control room) DOWTRAN CODE (CONTROL) Analog Outputs (AOs) AC(1,200) = AK(1000,100,200) AK(1000,100,200) + AK(1003,5,200) AK(1003,5,200) AC(2,100) = AK(1001) + AK(1004,10,100) AK(1004,10,100) Digital Inputs (DIs) 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) Digital Outputs (DOs) STEP(417) IF STEP(415) OR STEP(416) AND [AI(434) LT AK(417,400,1000) 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)]] DT(3427,5,2)]]    c    t    e  ,    R    O    T    O    M  ,    S    E    V    L    A    V    T    N    A    L    P Thousands of DOWTRAN code lines lines are executed executed in two 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. Source: Patent US 5408603 A. 11 PROCESS CONTROL & SIMULATION WITH DOWTRAN MOD-5TM COMPUTER (in testing room) DOWTRAN CODE (CONTROL) DOWTRAN CODE (SIMULATION) AC(1,200) = AK(1000,100,200) AK(1000,100,200) + AK(1003,5,200) AK(1003,5,200) AC(2,100) = AK(1001) + AK(1004,10,100) AK(1004,10,100) AIs DIs 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) AISIM(100)=AO(100) AISIM(100)=AO(100) AISIM(101)=AI(100)-AI(102) AISIM(101)=AI(100)-AI(102) …. DISIM(100)=DO(100) DISIM(100)=DO(100) DISIM(101)=DO(101) DISIM(101)=DO(101) STEP(417) IF STEP(415) OR STEP(416) AND [AI(434) LT AK(417,400,1000) 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)]] DT(3427,5,2)]] Simulating DIs (like pump ON, or valve CLOSED) was easy, 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 Source: Patent US 5408603 A. 12 Consolidated Exploring WHY DYNAMIC SIMULATION? 4.- Design control layout 1. Equipment sizing and process layout verification: • Scenarios analysis • Compression • Perturbation rejection • Pipeline systems networks networks • Control loops selection 2.- Flare Load calculation and PSV sizing • Design/revamp • Online Analyzers backup • Fault diagnostic • Look-ahead sensors 7.- DCS checkout flare • DCS FAT with virtual plant networks • Operating 3.- Emergency System verification and HAZOP studies support 5.- Prototyping MPC • HIPPS studies • Study non-linearities • Cause • Test/Tune MPC controller & Effect matrixes 6.- Develop virtual sensors • Obtain MPC models procedure test 8.- Operator Training System(OTS) • Operator Training • Emergency scenarios • Knowledge base system 13 Real World Field Operator Process Plant AI, AO DI, DO Control System & SIS • • DCS Hardware & Software OTSs are developed in order to mimic, as close as practical to reality, the Operating Process Plant and its associated Instrumentation Instrumentation and Control System There are two main approaches to achieve such objective:  –  – Human Machine Interface Direct-Connect OTS (also called Stimulated OTS) Emulated OTS DCS Console & Graphics Panel Operator 14 Real World Direct-Connect OTS Field Operator Process Plant Aspen HYSYS Dynamics Model AI, AO DI, DO Control System & SIS AI, AO DI, DO DCS Hardware & Software Human Machine Interface DCS & SIS Emulation Software DCS Console & Graphics Panel Operator Panel Operator Instructor Station & 15 Real World Emulated OTS Field Operator Process Plant Aspen HYSYS Dynamics model AI, AO DI, DO Control System & SIS DCS Hardware & Software Human Machine Interface Controls & SIS also in Aspen HYSYS Dynamic model DCS Console & Graphics Panel Operator Panel Operator Instructor Station & 16 OTHER AREAS OF VALUE OF OTS  OTSS 17 WHAT HAT IS A STANDARD DCS FAT? Factory Acceptance Ac ceptance Test (F ( FAT) involves invol ves of: of : 1. Hardware, such as controllers, controllers, I/O modules, power supplies, terminations, etc. 2. Logic, forcing forcing analog and discrete inputs, then watching the logic to be sure it responds as expected. 3. Oper Operat ator or disp displa lays ys an and d ala alarm rmss, 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 requirements for functional testing before commissioning. • Client/Suppliers Client/Suppliers try t ry to minimize involved involved risks: risks: This includes software testing and early detecting specification errors. • At the real installation: 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: • • • • • • • • • Pre-tune control loops Test control modules implementation Test motor start/stop logic Validate permissive logic for startup/shutdown sequences Verify controls interactions with other modules or against perturbations Check graphics displays operability with real procedures Re-setting Re-setting for certain alarms limits Test ESD timing and logic sequences Evaluate Evaluate procedures for abnormal or emergency operation 20 DCS FAT WITH ONLY EMULATED DCS&SIS Control design and configuration configuration is independent of the hardware, hardware, DCS emulators emulators allows all configuration configuration to run in virtual control with identical functionality Virtual Control with DCS emulator Discrete I/Os are stimulated stimulated by engineer, engineer, Analog I/Os use tie-backs 21 DCS FAT WITH FULL VIRTUAL PLANT Virtual Control with DCS Emulator The I/Os (discrete (discrete & analog) are are fully simulated by a process dynamic simulator of the entire plant 22 STANDARD FAT VS. VIRTUAL PLANT FAT STANDARD STANDARD DCS FA FAT T DCS FA FAT T with VIRTUAL VIRT UAL PLANT PLAN T Software DCS Emulator DCS Emulator, Emulator, HYSYS Dynamics Timing When DCS hardware and I/Os modules are available As soon as DCS logic and configuration is available Testing proceeding proc eeding 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 start-up/shutdown sequences Loop testing and control narrative Simple tie-backs Full, as in real plant Alarm verification verification Only non-time dependent Full, as in real plant SIS verification Limited, no plant interaction interaction Full, as in real plant 23 WORKFLOW FOR DEBUGGING DCS CODE DCS FAT DCS SAT Start-up DCS Vendor Pre-FAT DCS Database v0    t    r    o    p    e    R    s    t    c    e     f    e    D Post-FAT DCS Database v1    t    r    o    p    e    R    s    t    c    e     f    e    D Post-FAT DCS Database v2    t    r    o    p    e    R    s    t    c    e     f    e OTS    D FAT FAT    t    r    o    p    e    R    s    t    c    e     f    e OTS    D DCS SAT Post-SAT DCS Database v3    t    r    o    p    e    R    s    t    c    e     f    e    D Post-Startup DCS Database v4 OTS Vendor OTS OTS update OTS update Customer Important: OTS Vendor acts as an independent auditor of the DCS functionality 24 HYSYS BASED OTS: OPTIONS BY DCS DCS Vendor DCS System DCS vendor Emulator ABB 800xA Siemens Emulated OTS Direct-Connect Direct-Conn ect OTS 800xA Simulator YES YES PCS7 PLCSim/SIMIT YES YES Emerson DeltaV DeltaV Simulate YES YES Yokogawa Centum VP FCS/HIS Simulator Simulato r 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 System 302 YES YES 25 ADDITIONAL EARLY OTS OPTION 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 Delay in DCS FAT shifts OTS delivery DCS Post-FAT Database EARLY OTS OTS 26 INPROCESS INSTRUCTOR STATION Inprocess has developed its Instructor Station software to manage training sessions, but also als o to produce Emulated OTSs, to handle multiplatform communications and to speed up OTS development. 27 ACTIONS OF FIELD OPERATOR IN OTS Field actions in OTS are not available in the control room operator operator consoles. They are usually by the Instructor in the Instructor Station or FOD panel: • • Certain pumps are started/shutdown started/shutdown at field Compressors packages 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 28 TYPICAL OTS ARCHITECTURE WITH FOD 2 Operator Stations Printer DCS & SIS Emulation Server 1 Instructor Station:  Dynamic plant models  Inprocess Instructor Station (IIS) • • Critical Action Panel 1 Field Operator panel:  Inprocess Field Operating Devices (FOD) • 29 TYPICAL OTS ARCHITECTURE WITH FOD-3D 2 Operator Stations Printer DCS & SIS Emulation Server 1 Instructor Station:  Dynamic plant models  Inprocess Instructor Station (IIS) • • Critical Action Panel 1 Field Operator3D:  Inprocess Field Operating Devices in 3D (FOD-3D) and Oculus Rift • 30 SCREENSHOT OF FIELD OPERATOR VIEW 31 SCREENSHOT OF FIELD OPERATOR VIEW 32 WHY THE FOD IN 3D Operating companies have found advantages in: • • • • • Deeper involvement of field staff in understanding understanding the process The full operations team can practice practice critical events such as startups, shutdowns and emergency responses in a fully realistic manner “Best field practices” can be designed and communicated communicated to all staff This type of learning is extremely motivating Reduce travel travel and living li ving costs associated with on-the-job training 33 START-UP WITH OTS Safer Operation 100% With OTS 90% Typical Start-up 80% Less incidents 70% 60% Faster ramp-up 50% 40% 30% 20% 10% 0% 0 1 2 3 4 5 Plant starts weeks earlier 6 7 8 9 Weeks 10 11 12 13 14 15 16 17 34 OTS SURVEY: TIME SAVINGS FROM START-UP The aim of the survey was to quantify the benefits of simulator training in the Norwegian oil and gas industry. 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 Talisman and Sørco 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 35 OTS SURVEY: REDUCTION UNPLANNED SHUTDOWN 3 (average) unplanned shutdowns per year that can be avoided 36 OTS SURVEY: ECONOMIC SAVINGS 15.3 million$ average estimated savings due to training simulator 15 MNOK = 2.6 Million$ 200 MNOK = 38.4 Million$ 37 Q UESTIONS UESTIONS, CONTACT Q&A Contact: JoseMaria Ferrer Inprocess Technology Technology & Consulting Group, S.L. Phone: +34 933 308 205 Cell: +34 607 570 685  [email protected]  josemaria.f [email protected] ocessgroup.com Irina Rumyantseva, AspenTech [email protected] Ron Beck, AspenTech [email protected] 38