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Maximizing Efficiency Using Simulation
Maximizing Efficiency Using Simulation
Maximizing Efficiency Using Simulation
Maximizing Efficiency Using Simulation
Maximizing Efficiency Using Simulation
Maximizing Efficiency Using Simulation
Maximizing Efficiency Using Simulation
Maximizing Efficiency Using Simulation
Maximizing Efficiency Using Simulation
Maximizing Efficiency Using Simulation
Maximizing Efficiency Using Simulation
Maximizing Efficiency Using Simulation
Maximizing Efficiency Using Simulation
Maximizing Efficiency Using Simulation
Maximizing Efficiency Using Simulation
Maximizing Efficiency Using Simulation
Maximizing Efficiency Using Simulation
Maximizing Efficiency Using Simulation
Maximizing Efficiency Using Simulation
Maximizing Efficiency Using Simulation
Maximizing Efficiency Using Simulation
Maximizing Efficiency Using Simulation
Maximizing Efficiency Using Simulation
Maximizing Efficiency Using Simulation
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Maximizing Efficiency Using Simulation

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  • 1. Maximizing Efficiency: Using 3 rd -Gen Simulation for Testing & Operator Training © 2008 MYNAH Technologies Jason Covington
  • 2. Problems Encountered
  • 3. Operational Needs
    • Integrated Solutions Approach to all projects
    • Lifecycle Management of Entire Process, esp. for New Projects
    • Offline Training Systems for Safety, Security
    • Offline Testing to Keep Plants Productive
    • Fast, Comprehensive Implementation
    • Meet Validated Requirements
  • 4.
    • Reduce CapEx Costs
      • Testing automation system application software
      • Training Operators before startup of new units
    • Increase OpEx Results - Maximize Plant Efficiency
      • Testing automation system enhancements and additions
      • Re-training and qualifying operators on existing operations
    • Remove Risk, Increase Safety
    Simulation is Proven Solution
  • 5.
    • 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
    Simulation Measured Results
  • 6. Simulation in the Past
    • 1 st -Gen Simulation: Microcomputer
      • Used microcomputers to compile Fortran and C subroutines for process and IO models
    • 2 nd -Gen Simulation: Most Products Today
      • Windows-based, using menus and dialog boxes for configuring process and IO models
      • Time consuming, requiring weeks-months to develop simulations
      • Too difficult to use, not designed for operator training
      • Costly, can be upwards of $1MM USD
    • Internal Custom Jobs, Excel Spreadsheets
      • Messy, unmanageable
      • Unusable later on, impractical
      • Waste of man hours, extending projects past deadlines, poor results
  • 7.
    • Built for SAT and OTS
      • Non-intrusive simulation interfaces
      • Integrated Operator Training Management System
      • Protects control system integrity
    • Is Easy to use, Saves Time & $
      • Designed for use by the end-user or integrator
      • Automatic integration with control system
      • Auto-generation of simulation database
    • Is Flexible, Powerful, Dynamic
      • Scalable from small to large applications
      • Selective application of simulation models
      • Dynamic, accurate modeling functions
    3 rd -Gen Simulation Difference
  • 8.
    • Seamless integration with control system
    • Emulates the plant’s process
    • Incorporates Customizable .NET GUIs
    • Exchanges XML data
    • Uses MS SQL Server Express Database
    • Accesses modeling and OTM data via OPC
    • Uses IEC function block simulation objects
    • Provides Simulation Generation Tools
    3 rd -Generation Simulation
  • 9.
    • 3 rd -Gen Simulation Fulfills
    • GAMP4, Section 9, Requirements!
    • Requirements for Process Simulation
      • “ Frozen Software” – prior to Software Integration and System Acceptance Testing
      • Removal of “dead code” prior to testing
    • Simulation Supplier Requirements Appendix 4
      • Documented Quality and Software Development Program in line with industry best practices
      • Product should be designed for process control system testing and operator training
      • Commercially-available, standard tool (COTS), not highly-customized for use (delivered object code)
    Reducing Validation Costs
  • 10.
    • Value of Offline Testing and Training
    Simulation Lifecycle & ROI Value to Plant Operations, ROI Project Timeline Software Testing Begins Commissioning & Startup Testing Value Training Value Controls Upgrade Hazop Review Reduce Capex Costs Increase Opex Benefits Software FAT
  • 11.
    • 3 rd -Generation Simulation Specifications
      • High-Performance Simulation Engine
      • Simulated IO Drivers for Schneider Unity, OPC, Modbus, others
      • Complete Library of Process Modeling Functions
      • Graphical User Interfaces
      • Operator Training Management Module
      • Unit Operation Application Packages
      • Modeling Functions
    3 rd -Generation Specifications
  • 12.
    • Simulated IO Drivers for Open Modbus TCP/IP
      • SIO Bridge multiple register read/writes to large blocks of data
      • SIO Tags allow models to use data from any register
      • 1x, 3x register writes – Simulation is Modbus (write) Master
      • 32 Runtime Modbus Slaves per Simulation Workstation
    Simulation for Modbus TCP/IP Control System Workstations Modbus TCP/IP Controllers Modbus TCP/IP Network
  • 13.
    • Simulated IO Drivers for UnityPro / OFS v3.2
      • SIO OPC Client Bridge reads / writes to data registers
      • MiMiC CAPP Interface allows direct writes to input channels
      • 32 Runtime PLCs / PLC Simulator per MiMiC Workstation
      • Unity OFS Utility Generates SIO Tags, IO Models from UnityPro
    Simulation of UnityPro / OFS HMI Workstations Unity Controllers OFS Simulation Network UnityPro PLC Simulator
  • 14.
    • Integrated Operator Training Management
    Integrated Operator Training System
  • 15.
    • Simulation for End Users & Integrators
      • Simulation Models
      • Model Library
      • Simulated IO (SIO)
      • User Views
      • Training Scenarios
      • Database Control
      • Import / Export
    Manageable Simulation
  • 16. Generate Models Easily
    • Unity OFS Data Extraction Utility
      • Reads Located, Un-located Variables from UnityPro
      • User selects mapping of Unity Data Type to Sim Data Type
      • Simulation Tags and SIO in Sim database
  • 17. Automatic Integration
    • Automatic Integration with Control System
      • Simple start/stop simulation menu
      • Simulated IO (SIO) selected at startup
  • 18. Configurable Views
    • Configurable User Interface - Views
    • MView – Tabular data of Model, IO, or Training data
    • Data Monitor – Dynamic trends of Simulation or OPC data
    • Component Studio – Dynamic Process Flow Diagrams
  • 19.
    • Scalable from small to large applications
      • Unlimited Simulation Node Definition
      • 32 Runtime Simulation Nodes
      • 20,000 Simulated IO per Node
      • Unlimited concurrent training sessions
      • Unlimited operator training scenarios
      • Multiprocessor support
      • Dynamic memory allocation support
      • Server option for 10 Clients using Windows Terminal Services
      • One Second Model Execution can be sped up / slowed down 10x
    • Selective application of simulation models
    • Dynamic, accurate modeling functions
    Scalable, Selective, Dynamic
  • 20. Automatic Unit Conversions
    • Automatic Engineering Unit Conversions
    Engineering Unit Conversion
  • 21.
    • Integrated Steam Tables
    • Thermodynamic Properties Blocks
    • First Principles Modeling Blocks
    • IEC1131 Structured Text Calc Model Block
    Advanced Models & Blocks
  • 22.
    • Dynamic High-Fidelity Unit Operation Modeling
    • Intuitive configuration and data visualization
    Dynamic & High-Fidelity
  • 23.
    • Reduce Time to Market - $100K to $1MM/day
      • Application software fully tested before startup
      • Operators trained before startup of new units
    • Increase First Product Quality - $50K to $1MM / batch or run
      • Batch, advanced control fully tested
      • Operators trained on all process operations
    • Reduced Unscheduled Downtime - $50 to $100K per hour
      • No hidden issues in application software
      • Operator responses trained and measured
    • Reduce Risk to Process and Operations Staff – Priceless!
    The Next Unity or PLC Project
  • 24.
    • MiMiC Simulation Software
    • Over 900 Systems Installed in 60 countries, winning awards from:
      • Control Magazine Readers’ Choice Award 2006, 2007, 2008 Exceptional Customer Service
      • Control Engineering Editor’s Choice Award 2003
      • Chemical Processing Readers’ Choice Award 2008
    • Getting More Information – www.mynah.com
      • White Papers, E-Seminars, Podcasts
      • MiMiC Users’ Forum – www.mynah.com/forum/
      • MYNAH E-News, RSS Feed – Updates, KBAs, FAQs
    • Contact for Questions
      • Jason Covington, +1.636.681.1587
      • Skype ID: Jason.Covington
      • [email_address]
    Schneider CAPP Solution

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