PPT Template - iom.invensys.comiom.invensys.com/EN/userGroupsPresentationsDallas2013/SimSci/SS...

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© 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries.All third party trademarks and service marks are the proprietary marks of their respective owners.

SS GEN-02 - Business Justification forDynamic Simulation and OperatorTraining Simulator Solutions

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Alastair Fraser,VP Simulation and Training

Dr Ian Willetts,Global Practice Director

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Alastair Fraser,VP Simulation and Training

Dr Ian Willetts,Global Practice Director

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SS GEN-02 - Business Justification forDynamic Simulation and OperatorTraining Simulator Solutions

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© 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries.All third party trademarks and service marks are the proprietary marks of their respective owners.Slide 2


Agenda

• Industry Trends & Challenges

• Enabling Design and OperationalExcellence

• Benefits Assessment

• Can I Be Confident This Will Work?

• Conclusions

IndustryIndustryChallengesChallenges

& Trends& Trends

Design &Design &OperationalOperationalExcellenceExcellence


Can I beCan I beConfidentConfidentThis willThis will

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ConclusionsConclusionsConclusionsConclusions

BenefitsBenefitsAssessmentAssessment


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Agenda





• Conclusions


& Trends& Trends




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Agenda





• Conclusions


& Trends& Trends




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Agenda





• Conclusions


& Trends& Trends




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Agenda





• Conclusions


& Trends& Trends




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Agenda





• Conclusions


& Trends& Trends




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Trends Challenges

Industry Trends & ChallengesCapital Expenditure Minimization

• Large Investment in new Plantsaround the globe, including manynew plants in the USA to capitalizeon the Shale Gas Boom

• Very competitive bidding for newprojects by all EPCs

• Resource constraints to execute thework are a challenge


& Trends& Trends




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Trends Challenges

Industry Trends & Challenges





& Trends& Trends




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Industry Trends & ChallengesIndustryIndustryChallengesChallenges

& Trends& Trends




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Trends Challenges

Industry Trends & ChallengesCapital Expenditure Minimization

• How do I verify the sizing of anti-surge valves and hot/cold bypassvalves before committing mycapital?

• How do I know my compressorcan handle all process conditionse.g. gas MW, pressures, turn-down etc?

• My new flare header is muchmore expensive than weanticipated. Is it sized correctly?

• How do I balance over-designversus under-design for todayand the future?





& Trends& Trends




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Trends Challenges










& Trends& Trends




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Trends Challenges

Industry Trends & ChallengesComplex Process Integration in Large Facilities

• Economies of scale and supply chainintegration is driving theconstruction of larger integratedprocess facilities

• Designs often involve tight process,heat and utility integration

• Utilities, for example could becomethe bottleneck


& Trends& Trends




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Trends Challenges






& Trends& Trends




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Trends Challenges

Industry Trends & ChallengesComplex Process Integration in Large Facilities

• Do I have all the start-up lines andequipment I will need to get on-linesooner?

• How do I train my staff to operatesuch a large, integrated facility?

• What steam loading shedding strategyshould I use to maintain my criticalprocesses during abnormalconditions?

• How do I avoid domino trips acrossmy facility?





& Trends& Trends




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Trends Challenges










& Trends& Trends




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& Trends& Trends




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Trends Challenges

Industry Trends & ChallengesOperability and Commissioning

• Highly integrated plant design isimpacting start-up and operability

• Control logic or configuration errorscan dramatically impact time to on-line

• Drive to shorten commissioningtimes?


& Trends& Trends




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Trends Challenges






& Trends& Trends




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CEP April 2010

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& Trends& Trends




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Trends Challenges

Industry Trends & ChallengesOperability and Commissioning





& Trends& Trends




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• How do I know the plant will operateas designed?

• How do I minimize equipment andcontrols commissioning times?

• How do I verify my standardoperating procedures are detailedand accurate?

• How do I eliminate control logicmistakes before we go live in theplant?

• How do I check-out my compressorcontrol logic before starting up mycritical equipment?

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Trends Challenges






& Trends& Trends




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Trends Challenges

Industry Trends & ChallengesAging Workforce


& Trends& Trends




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Trends Challenges

Industry Trends & ChallengesIndustryIndustryChallengesChallenges

& Trends& Trends




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Strong need for a formal mechanism totrain operators and facilitate knowledgetransfer to the next generation of workers

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10,000 Boomerswill retire, onaverage, everyday for the next19 years


& Trends& Trends




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Trends Challenges

Industry Trends & ChallengesAging Workforce

• How do I capture and transfer theknowledge of my most experiencedoperators to the rest of the team?

• What hiring and training plan do Ineed for the next 5 years?

• How do I prepare the operators tohandle abnormal situations only themost experienced staff have seen?


& Trends& Trends




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Trends Challenges






& Trends& Trends




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Trends Challenges

Drive For High Availability and Operational Excellence

Ever Increasing Control RoomComplexity and Leaner Staff

Drive for revenue and profitabilityis directly impacted by unplannedshutdowns


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Trends ChallengesEver Increasing Control RoomComplexity and Leaner Staff

Drive for revenue and profitabilityis directly impacted by unplannedshutdownsA 2010 ARC Reportindicates thatoperator error is thecause of 42 percent ofunscheduled plantshutdowns


& Trends& Trends




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Drive for revenue and profitabilityis directly impacted by unplannedshutdownsA 2010 ARC Reportindicates thatoperator error is thecause of 42 percent ofunscheduled plantshutdowns


& Trends& Trends




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Trends Challenges

Drive For High Availability and Operational Excellence

• How do I increase the effectiveness ofall my operational resources in orderto meet my company’s OperationalExcellence goals?

• How do I shorten the time for myoperator to reach the highest levels ofoperator competence?

• What was the cause of the mostrecent unplanned outage and whatwas the cost?

• How do I teach my staff to avoidmaking the same mistakes again?




& Trends& Trends




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Trends Challenges• How do I increase the effectiveness of

all my operational resources in orderto meet my company’s OperationalExcellence goals?







& Trends& Trends




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• How do I increase the effectiveness ofall my operational resources in orderto meet my company’s OperationalExcellence goals?







& Trends& Trends




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Trends Challenges

Industry Trends & ChallengesGrowing Awareness of the Importance of Safety

Arson/Sabotage

• Major accidents and incidents around theglobe have raised awareness of theimportance of safety

• Recent regulations such as 49CFR haverecommended greater levels of training


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Trends Challenges


Arson/Sabotage

Mechanical Failure 38

ACCIDENT (Incident) PERCENTAGESUS Health and Safety Executive




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West Virginia GasPipeline Explosion

Dec 2012

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Arson/Sabotage

Design Error

Natural Hazard

Process Upsets

Unknown Causes

Operational Error

Mechanical Failure

34

71012

2638


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26% of accidentsdue to operationalerror

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Trends Challenges

Industry Trends & ChallengesGrowing Awareness of the Importance of Safety

• How do I prepare Operators to bebetter prepared to respond toabnormal conditions

• What tools are available to help theHAZOP team be more effective andinformed?

• How do I know my staff are welltrained and the best that they can be?

• How do I test the EmergencyShutdown Logic in a safe environmentad at minimum cost?

Arson/Sabotage




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Trends Challenges






Arson/Sabotage

US Health and Safety Executive




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West Virginia GasPipeline Explosion

Dec 2012

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Arson/Sabotage


& Trends& Trends




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26% of accidentsdue to operationalerror

Agenda





• Conclusions


& Trends& Trends




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• Conclusions


& Trends& Trends




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Agenda





• Conclusions


& Trends& Trends




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• Conclusions


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• Conclusions


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• Conclusions


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Heat & MaterialBalance


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Enabling Design Excellence

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EngineeringProcessDesign

InstrumentationControl



Heat & MaterialBalance

DepressuringAnalysis

Load SheddingStrategy


& Trends& Trends




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Load SheddingStrategy

Master ControlStrategies


& Trends& Trends




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Heat ExchangerRating

ColumnRating


& Trends& Trends




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Valve Sizing

Heat ExchangerRating

ColumnRating

Flare ReliefAnalysis


& Trends& Trends




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Valve Sizing

Master ControlStrategies


& Trends& Trends




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Enabling Operational Excellence byEmpowering Better Decisions

MobileSolutions

PerformanceMonitoring, APC &

Optimization


& Trends& Trends




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OperationsSupervisors

Lead OperatorsOperators

Field Operators



Field Operators

MobileSolutions

AlarmManagement

Board OperatorTraining


Optimization


& Trends& Trends




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Field OperatorsBoard Operator

TrainingWorkflow

Management


& Trends& Trends




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Enabling Operational Excellence byEmpowering Better Decisions

LoopManagement


Optimization


& Trends& Trends




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Field Operators



Field OperatorsField Operator

Training

ConditionMonitoring

LoopManagement


Optimization


& Trends& Trends




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Field OperatorsField Operator

TrainingWorkflow

Management


& Trends& Trends




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ENGINEERINGSTUDIES

TO SUPPORTDESIGN

ENGINEERINGSTUDIES

TO SUPPORTDESIGN

DESIGNDCS & PLC

CONFIGURATION

Dynamic Simulation Suite – One Platform,Multiple Solutions, High Value

DCS CONTROLLOGIC

CHECKOUT

DCS CONTROLLOGIC

CHECKOUT


& Trends& Trends




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ENGINEERINGSTUDIES

TO SUPPORTDESIGN

ENGINEERINGSTUDIES

TO SUPPORTDESIGN

DCS CONTROLLOGIC

CHECKOUT

DCS CONTROLLOGIC

CHECKOUT

PLC / SIS / TMC LOGICCHECKOUT



& Trends& Trends




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SUPPORT and MAINTENANCE PROGRAMSand LEARNING MANAGEMENT/TRAINING SERVICES



& Trends& Trends




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DCS & PLCCONFIGURATION STARTUP OPERATIONS

Dynamic Simulation Suite – One Platform,Multiple Solutions, High Value

DCS CONTROLLOGIC

CHECKOUT

DCS CONTROLLOGIC

CHECKOUT

OPERATOR TRAININGSIMULATORS



& Trends& Trends




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DCS CONTROLLOGIC

CHECKOUT

DCS CONTROLLOGIC

CHECKOUT




IMMERSIVE FIELD OPERATORTRAINING SIMULATORS



& Trends& Trends




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& Trends& Trends




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Agenda





• Conclusions


& Trends& Trends




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Agenda





• Conclusions


& Trends& Trends




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Agenda





• Conclusions


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Agenda





• Conclusions


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• Conclusions


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• Conclusions


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Benefits Overview - Design

Optimal Design

Capital Cost Savings Incident Free Start-up per the design


& Trends& Trends




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Capital Cost Savings Incident Free Start-up per the design

Correct selectionand configuration ofstart-up lines and

equipment

More detailed andcomprehensiveHAZOP analysis

Design errorsidentified and

eliminated duringthe FEED

Identification ofcorrect combinationof hot and cold gas

bypasses


& Trends& Trends




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Design errorsidentified and

eliminated duringthe FEED


bypasses


& Trends& Trends




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Benefits Overview - Design

Optimal DesignIncident Free Start-up per the design

Equipment sizeverified before

capital commitmentsmade


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Incident Free Start-up per the design

Equipment sizeverified before

capital commitmentsmade

More detailed andcomprehensiveHAZOP analysis

Better ProcessUnderstanding


bypasses


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bypasses


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Benefits Overview – Controls Checkout

Correct Control The First TimeIncrease availabilityfrom shorter start-up

times

ShorterCommissioning

Times


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Increase availabilityfrom shorter start-up

times


TimesControl logic check-

out in a safeenvironment

Training performedprior to plant start-

upDefect Free Anti-Surge Controls –

correct sequencingand permissives

Defect Free ESD/SISControls– correctsequencing and

permissives


& Trends& Trends




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Defect Free Anti-Surge Controls –

correct sequencingand permissives


permissives


& Trends& Trends




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Benefits Overview – Controls Checkout

Correct Control The First TimeShorter

CommissioningTimes

On-Line ProducingSooner


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Times

On-Line ProducingSooner

Training performedprior to plant start-

up

Optimal design ofoperators screens


permissives

Defect Free PLCControls – correctsequencing and

permissives


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permissives

Defect Free PLCControls – correctsequencing and

permissives


& Trends& Trends




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Benefits Overview – Training

Highly Competent OperatorsFormal certification

and auditing tosatisfy regulators

Knowledge Transferfrom Experienced

Staff to others


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Formal certificationand auditing to

satisfy regulators


Staff to others

Improved Safety Fewer UnplannedShutdowns

Permit to Operatemaintained Increased Production


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Improved ProcessUnderstanding

Lower operatingcosts from

consistent operations


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Benefits Overview – Training

Highly Competent OperatorsKnowledge Transferfrom Experienced

Staff to others

Operations Trained &Ready at Start-up


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Staff to others

Operations Trained &Ready at Start-up

Fewer UnplannedShutdowns

Higher Availability,Higher Revenues and

Profit

Increased ProductionReduce time tocompetency for

operators


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Reduce time tocompetency for

operatorsLower operating

costs fromconsistent operations

Fewer EnvironmentalExcursions/ Flares


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Phased Approach to Realizing Value Across the Enterprise

DC

S, P

LC, T

MC

and

SIS

Logi

c C

heck

out

Cor

pora

teO

TS

Ope

rato

rTr

aini

ngSi

mul

ator

FEEDFEEDPulsePulse

Enterprise

PlantPlantPulsePulse

Fundamental Proactive Collaborative

Slide 18

Phased Approach to Realizing Value Across the EnterpriseEn

gine

erin

gSt

udie

s

DC

S, P

LC, T

MC

and

SIS

Logi

c C

heck

out

Cor

pora

teO

TS

Ope

rato

rTr

aini

ngSi

mul

ator

Gen

eric

Tra

inin

gSi

mul

ator

FEEDFEEDPulsePulse

Enterprise


Slide 18

Phased Approach to Realizing Value Across the EnterpriseEn

gine

erin

gSt

udie

s

Cor

pora

teO

TS

Gen

eric

Tra

inin

gSi

mul

ator

FEEDFEEDPulsePulse

Enterprise


ControlRoomEngineering C&I

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Fiel

dO

pera

tor T

rain

ing

Cor

pora

teO

TS

Ope

rato

rTr

aini

ngSi

mul

ator

FEEDFEEDPulsePulse

Enterprise


Lear

ning

Man

agem

ent

Syst

ems

Collaborative Assessable

Slide 18


Fiel

dO

pera

tor T

rain

ing

Cor

pora

teO

TS

Ope

rato

rTr

aini

ngSi

mul

ator

FEEDFEEDPulsePulse

Enterprise


Lear

ning

Man

agem

ent

Syst

ems

Slide 18


Cor

pora

teO

TS

FEEDFEEDPulsePulse

Site Enterprise


Field

ControlRoom

FEED PULSE

Initially 1-2 days

Objective is Process Design ValidationBenefits Assessment

Meeting with Senior Management tohighlight typical benefits of dynamicsimulation and other tools

Identifies potential application areasand value

Interviews with Engineering teams

• Typically 45-60 minutes per group

Identifies opportunities & value

Output is a summary presentation andreport to engineering management

Recommended Interviews

• Utilities, Rotating Equipment,Safety, HAZOP, Piping, Equipmentand other groups

Pulse Value AssessmentsIndustryIndustry

ChallengesChallenges& Trends& Trends




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FEED PULSE

Initially 1-2 days















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FEED PULSE

Initially 1-2 days















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FEED PULSE

Initially 1-2 days










Pulse Value AssessmentsPLANT PULSE

Initially 1-2 days

Objective is to site wide assessment ofpotential benefits of Training Solutions

Interviews with site team/otherstakeholders


Identifies site objectives, needs,opportunities & value

• Benefit assessments, identifyimmediate focus areas

Output is a summary presentation andreport to site/stakeholders


• Operations Management, Operators(experienced and new), ProcessEngineering, Process Controls, Learningand Development


& Trends& Trends




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FEED PULSE

Initially 1-2 days











Initially 1-2 days










& Trends& Trends




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FEED PULSE

Initially 1-2 days











Initially 1-2 days










& Trends& Trends




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Invensys Refining Industry BenefitsCalculator


& Trends& Trends




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& Trends& Trends




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& Trends& Trends




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Invensys Refining Industry BenefitsCalculator


& Trends& Trends




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& Trends& Trends




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& Trends& Trends




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Costs and Benefits of Implementing APC &OTS for all major units at a 100,000 bpdrefinery (in Northern California)


& Trends& Trends




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Costs and Benefits of Implementing APC &OTS for all major units at a 100,000 bpdrefinery (in Northern California)


& Trends& Trends




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Agenda





• Conclusions


& Trends& Trends




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Agenda





• Conclusions


& Trends& Trends




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Agenda





• Conclusions


& Trends& Trends




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• Conclusions


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Agenda





• Conclusions


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Agenda





• Conclusions


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Benefits for Technip in FranceIndustryIndustryChallengesChallenges

& Trends& Trends




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& Trends& Trends




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OTS on State-of-the-ArtOil Sands UpgraderEssential component in the safeand successful commissioning ofthe world’s most complex state-of-the-art upgrading facility

Operators training on thesimulator one year before Gasifierstartup

Benefits Summary:• Reduced commissioning time• Identification of control

issues during design phase• Corrective actions taken prior

to start up


& Trends& Trends




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Essential component in the safeand successful commissioning ofthe world’s most complex state-of-the-art upgrading facility




to start up


& Trends& Trends




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Accident / Incident free commissioning !





to start up


& Trends& Trends




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OTS on State-of-the-ArtOil Sands UpgraderEssential component in the safeand successful commissioning ofthe world’s most complex state-of-the-art upgrading facility




to start up


& Trends& Trends




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to start up


& Trends& Trends




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Accident / Incident free commissioning !





to start up


& Trends& Trends




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Aker Yards LNG Carriers – Control Testing andTraining

Slide 25

Objective• Reduce DCS delivery time and improve DCS test procedures.• Reduce on-board training time for crew

Solution• Aker Yards selected Foxboro I/A as the DCS• Decided to go for FSIM Plus for improved testing and training

Results/benefits• Saved 5-6 man-months for dock trials of the system.• Defect-free DCS application delivered to the carrier.• Sea trial campaign for an LNG carrier is 15 days for 150 people on

board.• Cost per sea trial is €150k per day.• Project savings on seal trial: 1 week worth $1.3 million


& Trends& Trends




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Aker Yards LNG Carriers – Control Testing andTraining

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SSE Keadby Power Station Automation Projectincluding DCS, Optimization and OTS

“Not only did the simulatorplay an important role in theDCS migration project, it isnow proving particularlybeneficial both for stafftraining and as a rigoroustest-bed for control andprocess changes”

Hugh Ferguson, C&IEngineer & DCS UpgradeProject Manager

The equipment upgrade was completed in less than 13 days,compared with the 18 days that was scheduled


& Trends& Trends




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& Trends& Trends




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SSE Keadby Power Station Automation Projectincluding DCS, Optimization and OTS



The equipment upgrade was completed in less than 13 days,compared with the 18 days that was scheduled


& Trends& Trends




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& Trends& Trends




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& Trends& Trends




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Long-Term Sustainability Ensures Benefitsand High Return On Investment

Common Platformacross all

Applications


& Trends& Trends




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ExecutiveSponsorship –Client andInvensys


& Trends& Trends




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Long TermMaintenance Contract


& Trends& Trends




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Invensys is ready and willing to help identify the opportunity,deliver value and maintain the benefits

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Long-Term Sustainability Ensures Benefitsand High Return On Investment

Remote Access(VPN) for

Maintenance


& Trends& Trends




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Continuous Visualization,Quantification and

Reporting of Benefits


& Trends& Trends




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Long TermMaintenance Contract

Focus on Benefits notCost


& Trends& Trends




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Invensys is ready and willing to help identify the opportunity,deliver value and maintain the benefits

Agenda





• Conclusions


& Trends& Trends




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Agenda





• Conclusions


& Trends& Trends




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Agenda





• Conclusions


& Trends& Trends




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Agenda





• Conclusions


& Trends& Trends




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Agenda





• Conclusions


& Trends& Trends




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Agenda





• Conclusions


& Trends& Trends




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• Optimal design for CAPITAL COST AVOIDANCE

• Continuous improvements and PRODUCTIVITY INCREASES

• Increased throughput yields increased PROFITABILITY

• Increased SAFETY of the operations and improve theQUALITY OF LIFE of the workers.

• Increase in production through improved AUTOMATION

• Enable cultural change to manage the KNOWLEDGE and tosupport continuous INNOVATION.

• SUSTAIN and develop clean/environmentally friendlyoperations

Industry Goals Enabled by DynamicSimulation


& Trends& Trends




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& Trends& Trends




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& Trends& Trends




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Industry Goals Enabled by DynamicSimulation


& Trends& Trends




WorkWork


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& Trends& Trends




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& Trends& Trends




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Thank You&

AnyQuestions?


& Trends& Trends




WorkWork


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Slide 30

Thank You&

AnyQuestions?


& Trends& Trends




WorkWork


WorkWork




Slide 30


& Trends& Trends




WorkWork


WorkWork




Slide 30

Thank You&

AnyQuestions?


& Trends& Trends




WorkWork


WorkWork




Slide 30

Thank You&

AnyQuestions?


& Trends& Trends




WorkWork


WorkWork




Slide 30


& Trends& Trends




WorkWork


WorkWork




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