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© Invensys 00/00/00 Invensys proprietary & confidential Slide 2

Simulations for Mining/Oil & Gas

ANZ OpsManage 2013

Perth, 8th of May 2013

Gregor Fernholz

Global Business Development Manger

Operator Training Simulators

Agenda

1. Motivation

2. Case studies

3. Technology Overview

4. Training beyond the control room

5. Demo

6. Summary

Slide 3

1 Motivation

Slide 4

anbei

0

10

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70

80

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2002 2004 2006 2008 2010

$ b

illio

ns

Year

Production by value

Fuel minerals

Metallic minerals

Australian Bureau of Statistics

Slide 5

Strong growth of Oil/Gas, coal and metallic minerals

Australian Bureau of Statistics

Slide 6

50

100

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300

350

2000 2002 2004 2006 2008 2010

Em

plo

ym

en

t in

dex.

Year 2

00

0=

10

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Year

Employment growth in Australia

Mining

Total

Mining: +250% in 11 years

50

70

90

110

130

150

170

190

210

230

250

2000 2002 2004 2006 2008 2010

Em

plo

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t in

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Year

Employment growth in Australia

Australian Bureau of Statistics

Slide 7

35,000 new jobs every year

PLUS retirement replacements

US Mine injuries and operator experience

Slide 8

MSHA, 2002, “Quarterly employment and coal production, accidents/injuries/illnesses reported to MSHA under 30 CFR Part 50, 1991–2000,” U.S. Department of Labor, Mine Safety and Health Administration, Offi ce of Injury and Employment Information – Denver, Colorado.

Are these good questions?

I need to train many young, new operators. What’s the most effective and cost efficient way?

My facility is in a remote location. How can I provide training prior to sending someone to site? How can I improve cooperation between the remote and central control room teams?

How do I train my operators prior to the start-up of the plant on the operation of the control system and the plant?

Is the design of my plant safe, optimal (CAPEX/OPEX) and supports all modes of operation?

My project is tight in time and overrunning the schedule. How can I recover time?

How can I minimize the risk of costly start-up delays?

I need to enhance plant efficiency with fewer people. How?

Slide 9

2 Case studies

Slide 10

SHELL Bonga (Nigeria) Floating Production Storage & Offloading

The ‘process’ is a floating platform with storage and offloading facilities; sea trials and proof of controls at sea are very expensive – 200 people at sea to be able test systems

Changes to the DCS and safety system were done quickly in the simulator (hours/days instead of weeks) and tested.

The need is to improve the quality of the ICSS system to reduce commissioning time and ensure quality of subsequent ICSS updates. On-site safety certification (Lloyds) took 3 months instead of 1 year.

The system was delivered successfully with reduced start up time. Start-up recognized as “best in class”.

Saipem FPSO Fast-track Project GIMBOA

Slide 12

Business challenge for Saipem

High demand for FPSO vessels.

Time to deliver critical for winning projects: Schedule of 16-24 months

Solution

Decoupling the hardware from the application in the DCS (Foxboro I/A) project

Use FSIM Plus for configuring and testing the application

Results

Successful project execution.

DCS Project schedule shortened by 3.5 months.

Improved quality of the application through better testing.

Aker Yards LNG Carriers – Control Testing and Training

Slide 13

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.

Bug-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 €1mio

Sonatrach LNG Terminal Refrigerator TMC replacement

Slide 14

Objective

Replace Woodward with

Triconex controls in minimum

turnaround time.

Simulation Benefits

Improved controller behaviour

Completed turnaround in 3 normal working days instead of 8-9 long days .

Online sooner for 6 more days of LNG production valued at 100 times the project cost for the simulation

OTS Opportunity Success Story

• Business Drivers: Safety, Operational Improvement and

Retiring Personnel

• Solution: OTS for Hydrocracker/Hydrotreater & Hydrogen

Plant, Two Reformers, Delayed Coker and SRU/Amines Unit

• Value

– Site declared value of $10m - $30m based on one decision

support study for the Hydrocracker OTS

– OTS provided process and training knowledge prior to Coker

startup that minimizes startup risk

– Able to recreate abnormal operating issues in OTS and implement

improved control strategy on Reformer

Optimal Design of Flare Headers – Benefits of €20 million for Technip

Slide 16

PetroCanada Tail gas compressor Design and control validation

Slide 17

Increased recycle Cv from 63 to 101.

Added hot gas recycle line avoiding surge

Added feed-forward Anti Surge valve pre-arming to prevent surge during suction or discharge blockage.

Added decoupling between anti-surge and suction pressure controller

Added stonewall controller

Recommended/Confirmed Valve Sizes, Trim and Actuation Times

Accident / Incident free commissioning !

Operator Training Simulator Success Story

Essential component in the safe and successful commissioning of the world’s most complex state of the art upgrading facility

Operators training on the simulator one year before Gasifier startup Benefits Summary: Reduced commissioning time Identification of control issues during

design phase Corrective actions taken prior to start

up

BG Group Gas Platform

Operator competency assessment

Slide 19

(C) BG Group. Used with kind permission of BG Group

Operator competencies are assessed by a competency assessment manager (CAM) prior to starting work on the off-shore platform.

Off-shore training on the platform is costly and bed-room space is limited. Scheduling of the equipment for the training is challenging.

Solution: Use a 3D Virtual Environment on-shore.

Status: pilot completed and next steps under discussion.

Cape Lambert, Australia Port Expansion Project

• SKM/Rio Tinto using Wonderware for HMI on

top of Schneider PLC/SCADA Controls

• Introduced SimSci-Esscor into the account

• Solution – use dynamic models of Cape

Lambert iron ore handling to allow engineers

to validate Schneider control logic before

deployment to site

• Order size so far in excess of $1 million

Cape Lambert, Australia Port Expansion Project

• SKM/Rio Tinto using Wonderware for HMI on

top of Schneider PLC/SCADA Controls

• Introduced SimSci-Esscor into the account

• Solution – use dynamic models of Cape

Lambert iron ore handling to allow engineers

to validate Schneider control logic before

deployment to site

• Order size so far in excess of $1 million

“fantastic achievement”

“brilliant outcome”

Agrium JV Vault Potash OTS Project

Slide 22

Process

Agrium Vanscoy process model includes:

• Raw ore handling

• Flotation

• Compaction

• Crushing/Desliming

Project VAnscoy ULTimate Expansion (VAULT) - potash mine expansion including an additional new processing train

Purpose The simulator will be a tool for initial training and retraining of operators in:

● Plant systems, their function and interaction with other systems

● Development of operating experience, confidence and accuracy in normal and abnormal plant operations

● Tool to aid in developing and conducting engineering and control system analysis

Teck Zinc Roaster Operator Training Simulator

Slide 23

Acid Plant process flow includes:

• Zinc Roaster (Fluidized bed roaster)

• Draft from the roaster all the way to the stack

• Calcine ball mill

• Waste heat boiler, Gas cooling, Mercury removal, Acid plant

Acid Plant OTS completed and in operation since Jan ‘13:

Second OTS project for a new acid plant ongoing

More OTS projects in the pipeline.

“…starting the plant up on the simulator was real … the simulator behaved just like the real plant … I actually

started to sweat like I do with the real plant … my body thought it was the real thing … It was great to be able to

push the plant, I mean, Simulator as I have always wanted and was afraid to do with the real plant …”

Codelco Sulphuric Acid Plant for Solvent

Extraction in Copper Production

Slide 24

Process

Acid Plant process flow includes:

• SO2 Tank Reactors

• Gas Conditioning System

• Cooling Tower System

Purpose

• PLCs and old DCS are being migrated to Foxboro I/A DCS –

model will be used for controls checkout and pre-tuning of controls

• Model will be used for operator training when complete

Estimated savings of 4 days of commissioning time worth $1.8

million for a $500k investment

Case studies - Summary

Reducing DCS project execution schedule.

Flawless and faster plant start-ups.

CAPEX reduction by $$$ millions by design studies.

Preventing costly start-up delays caused by design or control faults saving $$$ millions.

Reducing $$$ millions of training costs for off-shore/remote plants.

… these projects simply pay for themselves – easily!

… and there are even more benefits (increased safety…)

Slide 25

3 Technology overview

Slide 26

What’s an Operator Training Simulator?

Slide 27

PLANT CONTROLS HMI

Dynamic

Simulation

DCS MARSHALLING

CABINET

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ESD CABINET

DCS ESD

Software

Emulation

Same / Similar

HMI Hardware Simulation

Real

A typical OTS architecture

Slide 28

FSIM Plus

TRISIM Plus

GUI

Trip Station

DYNSIM Model

FOD Station

Instructor Station

SIM4ME

FOXBORO

I/A DCS

Triconex

ESD

CONTROLS

CONTROLS

HMI

HMI

PLANT

PLANT

OTS Infrastructure

OTS Infrastructure

DYNSIM – for the process simulation

Slide 29

Malfunctions

Trends

Initial Conditions and Backtracks

Interactive Control

Custom Widgets

Model Library

Cross Referencing

Data Historian

Thermodynamics

Scenarios

Trainee Performance Monitoring (TPM)

Engineering/Model Building

OTS Instructor Station

Both Engineering and OTS

Slide 29

… special focus Upstream OLGA integration for multi-phase flow

Slide 30

“Since the ’90s, Chevron and Texaco have separately adopted the OLGA technology as the main tool for solving flow assurance challenges. Today OLGA is an integral part of the work flow in Chevron Texaco and continues to be used in the design of major fields.” Michael R. Barret ChevronTexaco

“The Snøhvit field would not have been realized without the results from OLGA” Terje Overvik- Executive Vice President Head of Exploration & Production, Statoil

…for minerals, metals and mining! The DYNSIM 3M library

Slide 31

Particle size distribution

Mills (Ball, SAG,…)

Crushers

Cyclones & hydro cyclones

Conveyor

Roaster

Screens

Floatation cells

Converters

…

Solids

Slid

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4 Training beyond the control room

Training beyond the control room EYESIM – Immersive Virtual Reality Plant

IMMERSIVE VIRTUAL REALITY PLANT

is a comprehensive solution linking

Control Room Operators..…

.... by means of high fedelity Process

Simulation and a Virtual Walkthrough

Plant Environment for a complete:

PLANT CREW TRAINING

...to Field Operators ..

...to Maintenance Operators ..

3D Modelling – Source data

3D CAD models All major CAD vendor files Microstation, SmartPlant, PDMS, Autodesk and more................

3D Laser Scanning “Point Cloud” All file major file formats Leica Systems, *.pts, *.igs, *.sab, *.emb, *.bin and more

BG Group – video from the pilot

Slide 35

…on-shore training and competency assessment of off-shore operators in the EYESIM 3D immersive training environment.

5 Demo

Slide 36

DYNSIM demo: Mining application

Slide 37

6 Summary

Slide 38

Is my design right before I purchase my equipment?

DESIGN DCS & PLC

CONFIGURATION STARTUP OPERATIONS

Dynamic Simulation Suite – One Solution,

Many Applications, High Value

DCS Control logic configured

correctly the first time

PLC/SIS/TMC logic Configured Correctly the First Time

World Class Operator Training Simulators

Coordinated Training of Control Room and Field Operators

Support and Maintenance Programs and Learning Management System Consulting Services

Summary

Reducing DCS project execution schedule.

Flawless and faster plant start-ups.

CAPEX reduction by $$$ millions by design studies.

Preventing costly start-up delays caused by design or control faults saving $$$ millions.

Reducing $$$ millions of training costs for off-shore/remote plants.

… these projects simply pay for themselves – easily!

… and there are even more benefits (increased safety…)

Invensys has got the technology, people and know-how!

Slide 40