Inprocess Webinar Slides (1)

5/21/2018 Inprocess Webinar Slides (1)

1/38 2014 Aspen Technology, Inc. All rights reserved

April 29, 2014

Optimize DCS Testing andOperator Training withAspen HYSYS Dynamics

Webinar with Inprocess


2/3801/05/2014 2014 by inprocess 2

Started in 2006

Process Simulation Expertswith many years ofexperience

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, optimizationDynamic 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


3/38 2014 Aspen Technology, Inc. All rights reserved | 3

Ongoing Series of Technical WebinarsEngineering Webinars for Education and Best Practices

UPCOMING WEBINARS OF INTEREST:

See How Process Ecology Reduce Emissions in Natural Gas Glycol Dehydration Facilities Using AspenHYSYS - May 6th

A Tour of the Latest Innovations in the Aspen Engineering Suite focusing on process safety andproject risk reduction June 3rd

ON DEMAND WEBINARS

Size Pressure Safety Valves and Design Flare Systems Using Aspen HYSYS and Aspen FlareSystem 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
http://www.aspentech.com/http://www.aspentech.com/products/aspen-hysys.aspxhttp://www.aspentech.com/products/aspen-hysys.aspxhttp://www.aspentech.com/products/aspen-hysys.aspxhttp://www.aspentech.com/products/aspen-hysys.aspxhttp://www.aspentech.com/



aspenONE Engineering

EconomicEvaluation

Operationsand Planning

Support

Equipment

Design

BasicEngineering

ConceptualEngineering

SafetyAnalysis

ProcessDevelopment Aspen HYSYS

&Aspen Plus

SafetyAnalysis

Operations

and PlanningSupport



Applications of Dynamic Modeling & Simulation

Operability Engineering Studies Understand dynamic plant behavior, including upset propagation

Design and analysis of start-up, shutdown and process transitionstrategies

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 pressurerelief and flare systems

Operator Training



What Does HYSYS Dynamics Offer?

Seamless transition from steadystate to dynamic model

Dynamics Assistant

Interactive environment

Rich choice between simple anddetailed modeling options

A comprehensive library ofcontrol 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

Jump Start Guides

Recorded VideosRecorded Webinars

Sample Models

Classroom Training

Locations Worldwide
http://support.aspentech.com/supportpublictrain/TrainHome.htmhttp://support.aspentech.com/supportpublictrain/TrainHome.htm


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OPTIMIZEDCS TESTINGAND

OPERATORTRAININGWITHASPENHYSYS DYNAMICS

JoseMaria Ferrer (inprocess)

Aspentech Webinar 29th-April-2014


9/38

AGENDA

Introduction

Dynamic Simulation

Operator Training Systems (OTS)

Performing DCS FAT Early OTS concept

Inprocess Instructor Station

Training for Field Operator

Economic return

9


10/38

1995: MYFIRSTCONTACTWITHCONTROLSYSTEMS

10Source: 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 80s 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 .????

Ill give a clue:

Apart from making good business with petrochemicals, Dow

Chemical also developed his own DCS. It was called MOD5TM,

programmed with DOWTRANTM(a FORTRAN-like language)

With enough idiot lights and

pushbuttons to satisfy any primate,

Dows first attempts to automate were

complex and wonderful
http://www.controlglobal.com/assets/knowledge_centers/abb/assets/art_series_mod_squad_pa_dow.pdfhttp://www.controlglobal.com/assets/knowledge_centers/abb/assets/art_series_mod_squad_pa_dow.pdf


11/38

MOD-5TMCOMPUTER (in control room)

PROCESSCONTROLWITHDOWTRAN

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

PLANTINSTR

UMENTATION

Digital

Inputs(DIs)

Analog

Outputs

(AOs)

Digital

Outputs(DOs)

PLANTVALVE

S,MOTOR,etc

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.
http://www.google.com/patents/US5408603http://www.google.com/patents/US5408603


12/38

MOD-5TMCOMPUTER (in testing room)

PROCESSCONTROL& SIMULATIONWITHDOWTRAN

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
http://www.google.com/patents/US5408603http://www.google.com/patents/US5408603


13/38

WHYDYNAMICSIMULATION?

13

1. Equipment sizing andprocess layout verification:

Compression systems

Pipeline networks

2.- Flare Load calculationand PSV sizing

Design/revamp flarenetworks

3.- Emergency Systemverification and HAZOPstudies 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


14/38

14

Real World

DCS Hardware

& Software

DCS Console

& Graphics

Field

Operator

Panel Operator

AI, AO

DI, DO

Control

System

& SIS

ProcessPlant

Human

Machine

Interface

OTSs are developed in order to

mimic, as close as practical toreality, the Operating Process Plant

and its associated Instrumentation

and Control System

There are two main approaches toachieve such objective:

Direct-Connect OTS (also called

Stimulated OTS)

Emulated OTS


15/38

15

DCS & SIS

Emulation

Software

DCS Console as in Control RoomInstructor Station &Field Operator Devices

Direct-Connect OTSReal World

Aspen HYSYS

Dynamics Model

DCS Hardware

& Software

DCS Console

& Graphics

Field

Operator

Panel Operator

AI, AO

DI, DO

Control

System

& SIS

ProcessPlant

Human

Machine

Interface

Panel Operator

AI, AO

DI, DO


16/38

16Emulated Graphics Console

Instructor Station &Field Operator Devices

Emulated OTSReal World

Aspen HYSYS

Dynamics model

DCS Hardware

& Software

DCS Console

& Graphics

Field

Operator

Panel Operator

AI, AO

DI, DO

Control

System

& SIS

ProcessPlant

Human

Machine

Interface

Panel Operator

Controls & SIS also

in Aspen HYSYS

Dynamic model


17/38

OTHERAREASOFVALUEOFOTSS

17


18/38

WHATISASTANDARDDCS 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


19/38

MOTIVATIONFORBETTERTESTING

Increasing complexity of DCSTightens 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


20/38

WHYUSINGSIMULATIONINLOGICDCS FAT?

Some of the DCS testing items made inOTS 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 othermodules 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 oremergency operation


21/38

DCS FAT WITHONLYEMULATEDDCS&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


22/38

DCS FAT WITHFULLVIRTUALPLANTVirtual Control with

DCS Emulator

The I/Os (discrete & analog) are fullysimulated by a process dynamicsimulator of the entire plant

22


23/38

STANDARDFAT VS. VIRTUALPLANTFAT

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


24/38

WORKFLOWFORDEBUGGINGDCS CODE

24

DCS Vendor

OTS Vendor

Customer

Pre-FAT

DCS

Database

v0

Defects

Report

DCS FAT

Post-FAT

DCS

Database

v1

Post-FAT

DCS

Database

v2OTS FAT OTS SAT

DCS SAT

Post-SAT

DCS

Database

v3

OTS

DCS

OTS

update

Start-up

Post-Startup

DCS

Database

v4

Defects

Report

Defects

Report

Defects

Report

Defects

Report

OTS

update

Important: OTS Vendor acts as an independent auditor of the DCS functionality


25/38

HYSYS BASEDOTS: OPTIONSBYDCS

25

DCSVendor

DCS System DCS vendorEmulator

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


26/38

ADDITIONALEARLYOTS OPTION

26

EARLY OTS

In order to provide to the Operators a processsimulator 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


27/38

INPROCESSINSTRUCTORSTATION

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.


28/38

ACTIONSOFFIELDOPERATORINOTS

28

Field actions in OTS are not available in the control roomoperator 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


29/38

TYPICALOTS ARCHITECTUREWITHFOD

29

2 Operator Stations

1 Instructor Station:Dynamic plant modelsInprocess Instructor Station (IIS)

Printer

DCS & SIS Emulation Server

Critical Action

Panel

1 Field Operator panel:Inprocess Field Operating Devices(FOD)


30/38

TYPICALOTS ARCHITECTUREWITHFOD-3D

30

2 Operator Stations

1 Instructor Station:Dynamic plant modelsInprocess Instructor Station (IIS)

Printer

DCS & SIS Emulation Server

Critical Action

Panel

1 Field Operator3D:Inprocess FieldOperating Devices in3D (FOD-3D) andOculus Rift


31/38

SCREENSHOTOFFIELDOPERATORVIEW

31


32/38

SCREENSHOTOFFIELDOPERATORVIEW

32


33/38

WHYTHEFOD IN3D

33

Deeper involvement of field staff in understanding theprocess

The full operations team can practice critical events such as

startups, shutdowns and emergency responses in a fullyrealistic manner

Best field practices can be designed and communicated toall staff

This type of learning is extremely motivating

Reduce travel and living costs associated with on-the-jobtraining

Operating companies have found advantages in:


34/38

START-UPWITHOTS

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

34Weeks


35/38

OTS SURVEY: TIMESAVINGSFROMSTART-UP

35Source: 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 theNorwegian 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 Srco
http://www.worldoil.com/December-2012-Economic-benefits-of-training-simulators.htmlhttp://www.worldoil.com/December-2012-Economic-benefits-of-training-simulators.htmlhttp://www.worldoil.com/December-2012-Economic-benefits-of-training-simulators.htmlhttp://www.worldoil.com/December-2012-Economic-benefits-of-training-simulators.htmlhttp://www.worldoil.com/December-2012-Economic-benefits-of-training-simulators.htmlhttp://www.worldoil.com/December-2012-Economic-benefits-of-training-simulators.htmlhttp://www.worldoil.com/December-2012-Economic-benefits-of-training-simulators.htmlhttp://www.worldoil.com/December-2012-Economic-benefits-of-training-simulators.htmlhttp://www.worldoil.com/December-2012-Economic-benefits-of-training-simulators.htmlhttp://www.worldoil.com/December-2012-Economic-benefits-of-training-simulators.htmlhttp://www.worldoil.com/December-2012-Economic-benefits-of-training-simulators.htmlhttp://www.worldoil.com/December-2012-Economic-benefits-of-training-simulators.htmlhttp://www.worldoil.com/December-2012-Economic-benefits-of-training-simulators.htmlhttp://www.worldoil.com/December-2012-Economic-benefits-of-training-simulators.html


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OTS SURVEY: REDUCTIONUNPLANNEDSHUTDOWN

36

3 (average) unplanned shutdowns per year that can be avoided

Source: http://www.worldoil.com/December-2012-Economic-benefits-of-training-simulators.html


37/38

OTS SURVEY: ECONOMICSAVINGS

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


38/38

QUESTIONS, CONTACT

Contact:

JoseMaria FerrerInprocess 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

b k@ h
mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]

Inprocess Webinar Slides (1)

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