Building The Virtual Plant For DeltaV
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At Emerson Exchange 2009, Martin Berutti presents on the business benefits, requirements, and steps for building a Virtual DeltaV system with a virtual plant and I/O.
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Building The Virtual Plant For DeltaV
- 1. Building the Virtual Plant for DeltaV
- 2. Introduction The Business Climate and need for a Virtual Plant Virtual Plant System Architecture Component Selection – DeltaV Simulate and MiMiC Virtual Plant Planning Concerns Process Model Development Operator Training Scenarios Instructor Stations / Graphics / Controls Additional Virtual Plant Features - Snapshots, Speedup / Slowdown
- 4. Retirement of experienced operators
- 6. Fiduciary liability of operations management
- 8. Half of the current work force will retire (more than 500,000 workers) in 5 to 10 years
- 10. Newer generation of workers with less mechanical inclination
- 11. Petrochemical / energy plants in danger of closing due to lack of qualified operators
- 13. Automation can handle simple and some complex operational tasks quicker, safer, and at a lower cost than a human operator
- 15. Operators lose skills to deal with plant upsets or abnormal conditions
- 16. 7years to achieve operations competence0 20 40 60 80 100 OPERATOR ERROR IS THE HIGHEST CAUSE OF LOSS(average dollar loss in millions of dollars)
- 18. Operator actions that are inappropriate or insufficient
- 19. Operating procedures that areincomplete or in error
- 20. Documentation demands from OSHA National Emphasis Program
- 21. Finding issues on site can delay startups
- 22. Not finding issues until too late can endanger the process and operations staff
- 24. Process design models do not have the real-time performance or range of operations conditions
- 25. Using an emulated automation system
- 26. Operator HMI graphics, alarms, controls should be identical to real system
- 27. Control strategies should be identical
- 28. Adding simulation to the control system configuration
- 29. Adds error and risk to automation system
- 32. Training on identical HMI graphics, alarms, controls
- 33. Testing on identical control strategies
- 34. Virtual Process – dynamic simulation
- 35. Selective application of simulation fidelity
- 37. Integrated approach for testing and training
- 38. Integrated to automation project schedule
- 40. Virtual Plant / Control system used to test operating procedure and control system
- 41. Implicit – how it really works
- 42. Virtual Plant / Control System used to allow new operators to use the operator controls
- 43. Tacit – how the decision effects the whole plant
- 44. Virtual Plant / Control System Training Scenarios show the new operator how to work with the real plant / control systemEffective Knowledge Transfer Must Include Hands On Operations of the Plant Source: NTL Institute for Applied Behavioral Science
- 47. Product Quality - reduce off-spec product – $50K-$1MM / run
- 48. Operating Cost - reduce unscheduled downtime – $5-50K / hour
- 49. Reduce Risk – reduce unknown failures and incidents - $50K - $1MM / incident
- 50. Automation System Application Software
- 51. Operator Actions and Responses
- 54. Non-intrusive IO simulation (FF, Digital Bus IO, Serial IO)
- 55. Validated systems (GAMP4 guidelines)DeltaV Workstations (DV License Pack or DVSim MultiNode) Area Control Network MD Controllers with Virtual IO Module SimulationNetwork
- 57. Module parameter simulation (simulate value)DeltaV Simulate Multinode PPN, PSN, OSN Workstations Area Control Network DeltaV Simulate ASN with Modules assigned SimulationNetwork
- 59. Module parameter simulation (simulate value)DeltaV Simulate Standalone Workstations SimulationNetwork
- 61. Software Acceptance Testing and Operator Training
- 62. IO channel simulationDeltaV Simulate Multinode PPN, PSN, OSN Workstations Area Control Network DeltaV Simulate Multinode ASN or PPN with DeltaV SIS SimulatePro License DeltaV Simulate Standalone with DeltaV SIS SimulatePro License SimulationNetwork
- 65. OPC
- 66. MiMiC SIO TagsDeltaV Simulate Workstations PLC /ESD Simulator MD Controllers w Virtual IO Module PLC /ESD SimulationNetwork
- 67. Components – DeltaV Simulate DeltaV Simulate - DeltaV licensing scheme for “off-line” simulation systems Exact same graphics, alarms, faceplates, detail display as the operating plant Control modules run in Assigned Modules ofworkstation running same functions as controller Full DeltaV Batch and APC functionality supported Simulate Convert – makes controller configuration Simulate workstation friendly FF Function Blocks converted to standard DeltaV blocks External IO references to Digital Bus, Serial IO modified to OPC read/write parameters DST references removed
- 68. Components – DeltaV Simulate The DeltaV Simulate Experience
- 69. Components – DeltaV Simulate DeltaV Simulate - DeltaV licensing scheme for “off-line” simulation systems Standalone – no DeltaV Networking MultiNode – DeltaV networking, controllers PPN, Professional Plus Networked PSN, Professional Station Networked OSN, Operator Station Networked ASN, Application Station Networked SimulatePro option for Standalone or MultiNode Increase module execution memory from 16 MB to 96 MB Supports freeze/snapshot/restore, speedup/slowdown SIS SimulatePro – v10.3, allows 32 logic solvers per workstation
- 72. Integrated Operator Training Management
- 73. Protects control system integrity
- 74. Easy to use
- 75. Designed for use by the end-user or integrator
- 76. Automatic integration with control system
- 78. Selective application of simulation models
- 79. Dynamic, accurate modeling functionsMiMiC is Built for DeltaV!
- 82. How many operators, availability
- 83. Span of training – process unit or train, unit operation
- 84. Team or individual training
- 85. Model performance requirements – accuracy, dynamics, operating conditions, shutdowns/startups
- 87. First Principles Modeling – based upon laws of conservation of mass, energy using properties
- 88. Empirical Modeling - realistic limits to the model using actual or assumed process correlations or dataTypes of Process Models Steady State models - plant and process design. No transitions between process states, time delays or lags Dynamic models – SAT and OTS. Time delays, lags, transport effects are modeled. Model design and math required for Steady State and Dynamic are much different SAT and OTS – we assume the process is designed, models reflect the design dynamically!
- 89. Choosing Model Complexity Fidelity – Rigorousness or Complexity of the Model Low Fidelity – simple IO signal modeling, device tiebacks, value initialization. Model requires user intervention to respond to automation system actions. Medium Fidelity – mass balance model, heat balance model, streams are single component. Model runs automatically and responds to automation system actions and process changes. High Fidelity – complete mass balance, rigorous heat balance, reaction kinetics, streams model individual component thermodynamic properties. Model runs automatically and responds to automation system actions and process changes in a very similar manner to the designed process. ANSI/ISA - 77.20 - 1993 (R2005) Section 6, 7
- 93. SIO definition for DeltaV Railbus (VIM), DeltaV Simulate, DeltaV SIS SimulatePro
- 94. Base level IO, Analog, Discrete Tieback Models
- 95. MiMiC Modeling Node for each DeltaV device (controller, workstation)Process Model Development
- 97. DeltaV Railbus (VIM) – SIO Tag to physical IO address
- 98. DeltaV Simulate – OPC module parameter path
- 99. DeltaV SIS Simulate – OPC physical IO addressProcess Model Development
- 101. Easy startup with user selected SIO definitionProcess Model Development
- 104. IEC Modeling Blocks with WiresEngineering Unit Conversions from Block to Block are calculated by MiMiC Simulation Engine
- 106. Advanced IEC Objects and Functions with Streams
- 107. Thermo / Flash / Stream Property Functions
- 108. Advanced Modeling Core Objects
- 109. Vessel, Valve, Pump, PRV, HX, DHX, Stream T
- 110. PF Solver
- 112. Boiler with Furnace, Steam Header, Desuperheater, Fuel, Turbine
- 113. Distillation Objects
- 115. Separator Objects
- 117. Structured set of malfunctions or process events introduced into running dynamic simulation
- 118. Process models should be designed to support Scenarios
- 119. Scenarios can be easily added or changed without chanign process models
- 120. MiMiC Operator Training Manager Scenarios
- 121. Malfunctions can be set in MiMiC or DeltaV Simulate
- 122. MiMiC Simulation functions have malfunction actions built-in
- 123. Scoring conditions can be defined for each Malfunctions
- 124. “Ad-Hoc” Instructor driven scenarios with reporting
- 125. Training sessions use a Scenario definition
- 130. MiMiC Component Studio Instructor Station Graphic
- 131. New user interface to learn
- 134. Requires DeltaV SimulatePro, MiMiC OTM
- 135. Integrated Snapshot control of DeltaV modules, MiMiC simulation
- 136. Does not support Batch Executive Operations
- 137. MiMiC Process Snapshot also supported with Previse Infi90 simulator, and HIMA Soft PLC
- 138. Speedup / Slowdown
- 140. Summary Proven CapEx, Opex Benefits to using Simulation for SAT and OTS Time to Market - reduce startup time – $100-500K / day Product Quality - reduce off-spec product – $50K-$1MM / run Operating Cost - reduce unscheduled downtime – $5-50K / hour Reduce Risk – reduce unknown failures and incidents - $50K - $1MM / incident Questions?
- 141. Where To Get More Information MYNAH Website – www.mynah.com DeltaV Operator Training Systems with MiMiC DeltaV Software Acceptance Testing with MiMiC Pre-recorded E-Seminars Understanding Simulation Fidelity Paper and Podcast Simulation System Integrity Paper and Podcast Delivering the Virtual Plant Paper and Podcast Simulation Objections Answered Paper and Podcast Using Simulation to Optimize the Results of Automation Projects, Dr. Tom Fiske, ARC MYNAH YouTube Series Martin Berutti, MYNAH Technologiesmartin.berutti@mynah.com, +1.636.681.1567Skype: mberutti
Notas do Editor
- The dynamic, off-line simulator is built to provide a virtual control system and plant equivalent to the on-line control system and process in operation and response.In the real plant we have a unit operation, like this distillation column. In order to operate the column safely and profitably we use a control system like DeltaV with transmitters and final control elements.In the virtual control system we use DeltaV Simulate to emulate the operator stations, engineering station, process controllers and higher level system functions. DeltaV Simulate provides an environment where the control system can run in an identical manner as in the actual plant.The transmitters, final control elements, and the process itself are simulated with MiMiC. MiMiC provide complete IO simulation and an environment where the development of complex, dynamic process models is quick and easy.