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1/38 2014 Aspen Technology, Inc. All rights reserved
April 29, 2014
Optimize DCS Testing andOperator Training withAspen HYSYS Dynamics
Webinar with Inprocess
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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
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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/5/21/2018 Inprocess Webinar Slides (1)
4/38 2014 Aspen Technology, Inc. All rights reserved | 4
aspenONE Engineering
EconomicEvaluation
Operationsand Planning
Support
Equipment
Design
BasicEngineering
ConceptualEngineering
SafetyAnalysis
ProcessDevelopment Aspen HYSYS
&Aspen Plus
SafetyAnalysis
Operations
and PlanningSupport
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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
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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
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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.htm5/21/2018 Inprocess Webinar Slides (1)
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OPTIMIZEDCS TESTINGAND
OPERATORTRAININGWITHASPENHYSYS DYNAMICS
JoseMaria Ferrer (inprocess)
Aspentech Webinar 29th-April-2014
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AGENDA
Introduction
Dynamic Simulation
Operator Training Systems (OTS)
Performing DCS FAT Early OTS concept
Inprocess Instructor Station
Training for Field Operator
Economic return
9
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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.pdf5/21/2018 Inprocess Webinar Slides (1)
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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/US54086035/21/2018 Inprocess Webinar Slides (1)
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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/US54086035/21/2018 Inprocess Webinar Slides (1)
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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
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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
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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
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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
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OTHERAREASOFVALUEOFOTSS
17
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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
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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
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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
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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
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DCS FAT WITHFULLVIRTUALPLANTVirtual Control with
DCS Emulator
The I/Os (discrete & analog) are fullysimulated by a process dynamicsimulator of the entire plant
22
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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
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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
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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
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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
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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.
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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
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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)
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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
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SCREENSHOTOFFIELDOPERATORVIEW
31
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SCREENSHOTOFFIELDOPERATORVIEW
32
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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:
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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
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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.html5/21/2018 Inprocess Webinar Slides (1)
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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
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.html5/21/2018 Inprocess Webinar Slides (1)
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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
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.html5/21/2018 Inprocess Webinar Slides (1)
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QUESTIONS, CONTACT
Contact:
JoseMaria FerrerInprocess Technology & Consulting Group, S.L.
Phone: +34 933 308 205
Cell: +34 607 570 685
38
Q&A
Irina Rumyantseva, AspenTech
Ron Beck, AspenTech
b k@ h
mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]