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Maximizing Efficiency Using Simulation


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Maximizing Efficiency Using Simulation

  1. 1. Maximizing Efficiency: Using 3 rd -Gen Simulation for Testing & Operator Training © 2008 MYNAH Technologies Jason Covington
  2. 2. Problems Encountered
  3. 3. Operational Needs <ul><li>Integrated Solutions Approach to all projects </li></ul><ul><li>Lifecycle Management of Entire Process, esp. for New Projects </li></ul><ul><li>Offline Training Systems for Safety, Security </li></ul><ul><li>Offline Testing to Keep Plants Productive </li></ul><ul><li>Fast, Comprehensive Implementation </li></ul><ul><li>Meet Validated Requirements </li></ul>
  4. 4. <ul><li>Reduce CapEx Costs </li></ul><ul><ul><li>Testing automation system application software </li></ul></ul><ul><ul><li>Training Operators before startup of new units </li></ul></ul><ul><li>Increase OpEx Results - Maximize Plant Efficiency </li></ul><ul><ul><li>Testing automation system enhancements and additions </li></ul></ul><ul><ul><li>Re-training and qualifying operators on existing operations </li></ul></ul><ul><li>Remove Risk, Increase Safety </li></ul>Simulation is Proven Solution
  5. 5. <ul><li>Time to Market - reduce startup time $100-500K / day </li></ul><ul><li>Product Quality - reduce off-spec product $50K-$1MM / run </li></ul><ul><li>Operating Cost - reduce unscheduled downtime $5-50K / hour </li></ul><ul><li>Reduce Risk – reduce unknown failures and incidents - $50K - $1MM / incident </li></ul>Simulation Measured Results
  6. 6. Simulation in the Past <ul><li>1 st -Gen Simulation: Microcomputer </li></ul><ul><ul><li>Used microcomputers to compile Fortran and C subroutines for process and IO models </li></ul></ul><ul><li>2 nd -Gen Simulation: Most Products Today </li></ul><ul><ul><li>Windows-based, using menus and dialog boxes for configuring process and IO models </li></ul></ul><ul><ul><li>Time consuming, requiring weeks-months to develop simulations </li></ul></ul><ul><ul><li>Too difficult to use, not designed for operator training </li></ul></ul><ul><ul><li>Costly, can be upwards of $1MM USD </li></ul></ul><ul><li>Internal Custom Jobs, Excel Spreadsheets </li></ul><ul><ul><li>Messy, unmanageable </li></ul></ul><ul><ul><li>Unusable later on, impractical </li></ul></ul><ul><ul><li>Waste of man hours, extending projects past deadlines, poor results </li></ul></ul>
  7. 7. <ul><li>Built for SAT and OTS </li></ul><ul><ul><li>Non-intrusive simulation interfaces </li></ul></ul><ul><ul><li>Integrated Operator Training Management System </li></ul></ul><ul><ul><li>Protects control system integrity </li></ul></ul><ul><li>Is Easy to use, Saves Time & $ </li></ul><ul><ul><li>Designed for use by the end-user or integrator </li></ul></ul><ul><ul><li>Automatic integration with control system </li></ul></ul><ul><ul><li>Auto-generation of simulation database </li></ul></ul><ul><li>Is Flexible, Powerful, Dynamic </li></ul><ul><ul><li>Scalable from small to large applications </li></ul></ul><ul><ul><li>Selective application of simulation models </li></ul></ul><ul><ul><li>Dynamic, accurate modeling functions </li></ul></ul>3 rd -Gen Simulation Difference
  8. 8. <ul><li>Seamless integration with control system </li></ul><ul><li>Emulates the plant’s process </li></ul><ul><li>Incorporates Customizable .NET GUIs </li></ul><ul><li>Exchanges XML data </li></ul><ul><li>Uses MS SQL Server Express Database </li></ul><ul><li>Accesses modeling and OTM data via OPC </li></ul><ul><li>Uses IEC function block simulation objects </li></ul><ul><li>Provides Simulation Generation Tools </li></ul>3 rd -Generation Simulation
  9. 9. <ul><li>3 rd -Gen Simulation Fulfills </li></ul><ul><li>GAMP4, Section 9, Requirements! </li></ul><ul><li>Requirements for Process Simulation </li></ul><ul><ul><li>“ Frozen Software” – prior to Software Integration and System Acceptance Testing </li></ul></ul><ul><ul><li>Removal of “dead code” prior to testing </li></ul></ul><ul><li>Simulation Supplier Requirements Appendix 4 </li></ul><ul><ul><li>Documented Quality and Software Development Program in line with industry best practices </li></ul></ul><ul><ul><li>Product should be designed for process control system testing and operator training </li></ul></ul><ul><ul><li>Commercially-available, standard tool (COTS), not highly-customized for use (delivered object code) </li></ul></ul>Reducing Validation Costs
  10. 10. <ul><li>Value of Offline Testing and Training </li></ul>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. 11. <ul><li>3 rd -Generation Simulation Specifications </li></ul><ul><ul><li>High-Performance Simulation Engine </li></ul></ul><ul><ul><li>Simulated IO Drivers for Schneider Unity, OPC, Modbus, others </li></ul></ul><ul><ul><li>Complete Library of Process Modeling Functions </li></ul></ul><ul><ul><li>Graphical User Interfaces </li></ul></ul><ul><ul><li>Operator Training Management Module </li></ul></ul><ul><ul><li>Unit Operation Application Packages </li></ul></ul><ul><ul><li>Modeling Functions </li></ul></ul>3 rd -Generation Specifications
  12. 12. <ul><li>Simulated IO Drivers for Open Modbus TCP/IP </li></ul><ul><ul><li>SIO Bridge multiple register read/writes to large blocks of data </li></ul></ul><ul><ul><li>SIO Tags allow models to use data from any register </li></ul></ul><ul><ul><li>1x, 3x register writes – Simulation is Modbus (write) Master </li></ul></ul><ul><ul><li>32 Runtime Modbus Slaves per Simulation Workstation </li></ul></ul>Simulation for Modbus TCP/IP Control System Workstations Modbus TCP/IP Controllers Modbus TCP/IP Network
  13. 13. <ul><li>Simulated IO Drivers for UnityPro / OFS v3.2 </li></ul><ul><ul><li>SIO OPC Client Bridge reads / writes to data registers </li></ul></ul><ul><ul><li>MiMiC CAPP Interface allows direct writes to input channels </li></ul></ul><ul><ul><li>32 Runtime PLCs / PLC Simulator per MiMiC Workstation </li></ul></ul><ul><ul><li>Unity OFS Utility Generates SIO Tags, IO Models from UnityPro </li></ul></ul>Simulation of UnityPro / OFS HMI Workstations Unity Controllers OFS Simulation Network UnityPro PLC Simulator
  14. 14. <ul><li>Integrated Operator Training Management </li></ul>Integrated Operator Training System
  15. 15. <ul><li>Simulation for End Users & Integrators </li></ul><ul><ul><li>Simulation Models </li></ul></ul><ul><ul><li>Model Library </li></ul></ul><ul><ul><li>Simulated IO (SIO) </li></ul></ul><ul><ul><li>User Views </li></ul></ul><ul><ul><li>Training Scenarios </li></ul></ul><ul><ul><li>Database Control </li></ul></ul><ul><ul><li>Import / Export </li></ul></ul>Manageable Simulation
  16. 16. Generate Models Easily <ul><li>Unity OFS Data Extraction Utility </li></ul><ul><ul><li>Reads Located, Un-located Variables from UnityPro </li></ul></ul><ul><ul><li>User selects mapping of Unity Data Type to Sim Data Type </li></ul></ul><ul><ul><li>Simulation Tags and SIO in Sim database </li></ul></ul>
  17. 17. Automatic Integration <ul><li>Automatic Integration with Control System </li></ul><ul><ul><li>Simple start/stop simulation menu </li></ul></ul><ul><ul><li>Simulated IO (SIO) selected at startup </li></ul></ul>
  18. 18. Configurable Views <ul><li>Configurable User Interface - Views </li></ul><ul><li>MView – Tabular data of Model, IO, or Training data </li></ul><ul><li>Data Monitor – Dynamic trends of Simulation or OPC data </li></ul><ul><li>Component Studio – Dynamic Process Flow Diagrams </li></ul>
  19. 19. <ul><li>Scalable from small to large applications </li></ul><ul><ul><li>Unlimited Simulation Node Definition </li></ul></ul><ul><ul><li>32 Runtime Simulation Nodes </li></ul></ul><ul><ul><li>20,000 Simulated IO per Node </li></ul></ul><ul><ul><li>Unlimited concurrent training sessions </li></ul></ul><ul><ul><li>Unlimited operator training scenarios </li></ul></ul><ul><ul><li>Multiprocessor support </li></ul></ul><ul><ul><li>Dynamic memory allocation support </li></ul></ul><ul><ul><li>Server option for 10 Clients using Windows Terminal Services </li></ul></ul><ul><ul><li>One Second Model Execution can be sped up / slowed down 10x </li></ul></ul><ul><li>Selective application of simulation models </li></ul><ul><li>Dynamic, accurate modeling functions </li></ul>Scalable, Selective, Dynamic
  20. 20. Automatic Unit Conversions <ul><li>Automatic Engineering Unit Conversions </li></ul>Engineering Unit Conversion
  21. 21. <ul><li>Integrated Steam Tables </li></ul><ul><li>Thermodynamic Properties Blocks </li></ul><ul><li>First Principles Modeling Blocks </li></ul><ul><li>IEC1131 Structured Text Calc Model Block </li></ul>Advanced Models & Blocks
  22. 22. <ul><li>Dynamic High-Fidelity Unit Operation Modeling </li></ul><ul><li>Intuitive configuration and data visualization </li></ul>Dynamic & High-Fidelity
  23. 23. <ul><li>Reduce Time to Market - $100K to $1MM/day </li></ul><ul><ul><li>Application software fully tested before startup </li></ul></ul><ul><ul><li>Operators trained before startup of new units </li></ul></ul><ul><li>Increase First Product Quality - $50K to $1MM / batch or run </li></ul><ul><ul><li>Batch, advanced control fully tested </li></ul></ul><ul><ul><li>Operators trained on all process operations </li></ul></ul><ul><li>Reduced Unscheduled Downtime - $50 to $100K per hour </li></ul><ul><ul><li>No hidden issues in application software </li></ul></ul><ul><ul><li>Operator responses trained and measured </li></ul></ul><ul><li>Reduce Risk to Process and Operations Staff – Priceless! </li></ul>The Next Unity or PLC Project
  24. 24. <ul><li>MiMiC Simulation Software </li></ul><ul><li>Over 900 Systems Installed in 60 countries, winning awards from: </li></ul><ul><ul><li>Control Magazine Readers’ Choice Award 2006, 2007, 2008 Exceptional Customer Service </li></ul></ul><ul><ul><li>Control Engineering Editor’s Choice Award 2003 </li></ul></ul><ul><ul><li>Chemical Processing Readers’ Choice Award 2008 </li></ul></ul><ul><li>Getting More Information – </li></ul><ul><ul><li>White Papers, E-Seminars, Podcasts </li></ul></ul><ul><ul><li>MiMiC Users’ Forum – </li></ul></ul><ul><ul><li>MYNAH E-News, RSS Feed – Updates, KBAs, FAQs </li></ul></ul><ul><li>Contact for Questions </li></ul><ul><ul><li>Jason Covington, +1.636.681.1587 </li></ul></ul><ul><ul><li>Skype ID: Jason.Covington </li></ul></ul><ul><ul><li>[email_address] </li></ul></ul>Schneider CAPP Solution