Barrick simulation with mimic presentation

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Barrick simulation with mimic presentation

  1. 1. Implementation of a Simulation-Based Operator Training System atBarrick Pueblo Viejo October, 2011
  2. 2. Presenters Paul Yaroshak Kevin Argudin
  3. 3. Agenda  Introduction  Project Background  Technology Selection  Project Execution  Benefits & Lessons Learned  Summary  Questions
  4. 4. Agenda  Introduction  Project Background  Technology Selection  Project Execution  Benefits & Lessons Learned  Summary  Questions
  5. 5. Company Background 3 Companies involved in this project  Barrick Gold Corporation  Pueblo Viejo Site  Lakeside Process Controls  Local Business Partner of Emerson Process Management  Mynah Technologies  Simulation Software Developer and System Integrator
  6. 6. Barrick Gold: A Global Company Pueblo Viejo Dominican Republic
  7. 7. Introduction Challenges  New processing facility, not yet built.  Need to prepare operators as early as possible. Objectives  Safe Startup  Efficient Startup Solution  “Ready for Start Up” program (RFSU)  Dynamic Simulation is a component of RFSU
  8. 8. Introduction The “Ready for Start Up” Program (RFSU) Prepares operators for safe and efficient plant startup 3 components:  Training on Process Fundamentals using computer-based interactive training modules (textbook).  Simulation-Based Training  Field demonstration and practice
  9. 9. Agenda  Introduction  Project Background  Technology Selection  Project Execution  Benefits & Lessons Learned  Summary  Questions
  10. 10. Project Background Pueblo Viejo will produce 1 million ounces of gold per year The plant will process 24,000 tons of ore /day at full production capacity. DCS platform is DeltaV Version 10.3, approximately 11,000 DST. Complex plant with many processes, requires a variety of skills and experience.
  11. 11. Pueblo Viejo Processing Site Iron 1 Thickener Autoclaves Acid Wash / Stripping Cyanide Destruction Limestone Copper Carbon In Crushing Recovery Leach
  12. 12. Business Need Prepare operations team for safe and efficient plant startup (RFSU) A dynamic process simulator should provide the following benefits:  Meet aggressive startup / production deadlines  Process understanding and familiarity with control system.  Hands on practice of SOP  Promote safe production / Mitigate risk of equipment damage  Qualify resources for a wide range of roles within the facility  Build organization capability to leverage the system for future training needs
  13. 13. Agenda  Introduction  Project Background  Technology Selection  Project Execution  Benefits & Lessons Learned  Summary  Questions
  14. 14. Simulator Selection Several alternatives were evaluated. Low/medium level of fidelity (complexity) is sufficient for training simulation. The Mimic Dynamic Simulator from Mynah was selected  Provides required levels of fidelity (complexity).  Integrates seamlessly with DeltaV  Project EPCMs already using Mimic  Relatively easy to use and change (for implementing model changes and control system enhancements)  Intuitive
  15. 15. Simulation Fidelity Select Simulation Fidelity (i.e. complexity) needed to achieve business results  Low Fidelity – Basic I/O tiebacks with simple tuning  Medium Fidelity – Engineering first principles, conservation of energy and mass  High Fidelity – Mass / energy transfer equations, differential equations, empirical models, etc. Fidelity Breakdown on Pueblo Viejo Simulator  Low Fidelity – 70%  Medium Fidelity – 20%  High Fidelity – 10%
  16. 16. Simulation Environment Real-World Environment Virtual (Simulated) EnvironmentDeltaV Controllers DeltaV Simulate Simulated by DeltaV Simulate Process Operator & Dynamics I/O I/O Controller ResponseField Devices &Process Dynamics MiMiC Simulation Software Simulated by Mimic
  17. 17. Project System Architecture
  18. 18. DeltaV Graphic and Trainer Screen
  19. 19. Mimic Trainer Screen
  20. 20. Agenda  Introduction  Project Background  Technology Selection  Project Execution  Benefits & Lessons Learned  Summary  Questions
  21. 21. Project Org Chart
  22. 22. Geographically Distributed Team BarrickBarrick Toronto, Canada(Pueblo Viejo)Dominican Republic Hatch Toronto, CanadaFluorVancouver, Canada Lakeside Mynah Toronto, Canada St Louis, MO
  23. 23. Proposed Project Design Process Waterfall Model: Sequential Development Process
  24. 24. Project Reality • Late changes • Control strategy errorsCircuit 1 • Graphic updates • Missing definitions • Model misalignment Circuit 2 Circuit 3
  25. 25. Why an Iterative Development Approachworks Lower risk; the waterfall is higher risk Early risk mitigation and discovery Accommodates and provokes early change; Manage complexity Confidence and satisfaction from early, repeated success Early partial product Relevant progress tracking; better predictability Higher quality; less defects in final product Final product better matches true client desires Early and regular process improvement Communication and engagement required “I’ll know it when I see it” required
  26. 26. Simulation Development Develop an Excel model Provide DeltaV Configuration DeltaV Simulate: Perform Simulate Conversion MiMiC: Create I/O Tie-Backs MiMiC: Implement Medium and High Level Models MiMiC: Develop Trainer Screens Initial Review Incorporate changes Final review
  27. 27. Agenda  Introduction  Project Background  Technology Selection  Project Execution  Benefits & Lessons Learned  Summary  Questions
  28. 28. Business Results Achieved Expected Reduction is Commissioning Time  Early identification of issues  Enhanced familiarity with system complexities. Unanticipated benefits  Early identification of usability and logic issues.  Circular Interlocks, incorrect alarm limits  Identification of HMI errors and issues  Sequence development/testing  Development of SOPs Improved training material  Trainers have a working system to develop on and not via memory and documents alone
  29. 29. Lessons Learned Plan on Low Fidelity simulation of the complete DeltaV Areas Alarms need to be managed (to avoid false alarms). Develop first principle models in Excel. Consider iterative design process from the start. Early engagement of the end users (get buy-in) Distributed Project team can be successful Develop a plan early with system integrators to implement identified Control Strategy and HMI issues.
  30. 30. Opportunities for Improvement Version control of simulation system (model logic & trainer screens) Snapshots that better accommodate a changing DeltaV database Improved support for empirical data in Mimic e.g. data tables
  31. 31. Agenda  Introduction  Project Background  Technology Selection  Project Execution  Benefits & Lessons Learned  Summary Questions
  32. 32. Summary The project had unforeseen benefits of helping us  Improve the final production control system  Increase general understanding of our process. Approaching the project in an iterative fashion enabled our team to succeed Process simulation enabled the business to achieve the desired results  Trained Users  Developed Operations Documents  Early adoption and entrenchment of the Process Control System
  33. 33. Special Thanks To  Mynah  Barrick  Adisa Shaljani  Benoit Bissonette  Todd Anstine  Lakeside  Hatch  Jorge Jimenez  Will McCombe  Andy McEwen
  34. 34. Questions
  35. 35. Where To Get More Information Simulation with MiMiC Course 7041 Mynah - www.mynah.com Lakeside Process Controls www.lakesidecontrols.ca

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