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A Simulator of Sugar Factories for Operator Training
C. de Prada, A. Merino, S. Pelayo, F. Acebes,
R. Alves
CTA (Azucarera Ebro Puleva, S.L.
University of Valladolid) Spain
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1. Beet sugar factories
2. Training simulator
Aims
Architecture
Main Functions
3. A training session
4. Conclusions
INDEX
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•Complex factories, including a wide variety of processes •High degree of automation •Limited number of operators
BEET SUGAR FACTORIES
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BEET SUGAR FACTORY
DIFUSSION
DEPURATION
EVAPORATION
SUGAR HOUSE
PULP DRYER
STEAM BOILERS
TURBOGENERATORS
ALCOHOL House
Waste water treatments
RAW JUICE
JUICE
SYRUP
SUGAR
SLICED BEETS
Vinasses
ALCOHOL
Melasses
Electricity
∼
Dried Pulp
Gas
Fuel/Gas
Steam
Steam
Wet Pulp
Water
Muds
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BEET SUGAR FACTORIES
Process Operation is done by means of a distributed control system (DCS)
– Receives data from tranmiters and Laboratory. – Computes control signals to the actuators – Provides a MMI for supervision of the process
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CONTROL ROOM OPERATORS.
They are in charge of process operation
They must understand how the process and its control system work
They must detect and solve faults and malfunctions
They should provide a smooth and optimal operation
DCS screens
Images of some strategic points
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0 500 1000 1500 2000 2500 3000 3500 4000 4500
0
20
40
60
80
100
Variable manipulada
0 500 1000 1500 2000 2500 3000 3500 4000 450030
40
50
60
70
80
90Varibale controlada: brix de refundidora
Turno 1Turno 2Turno 3Turno 1Turno 2Turno 3Turno 1Turno 2Turno 30 500 1000 1500 2000 2500 3000 3500 4000 4500
0
20
40
60
80
100
Variable manipulada
0 500 1000 1500 2000 2500 3000 3500 4000 450030
40
50
60
70
80
90Varibale controlada: brix de refundidora
Turno 1Turno 2Turno 3Turno 1Turno 2Turno 3Turno 1Turno 2Turno 3Turno 1Turno 2Turno 3Turno 1Turno 2Turno 3Turno 1Turno 2Turno 3
Operation of a sugar melter by several shifts
CONTROL ROOM OPERATORS
Differences in the behaviour of the operators reflect on the process performance
Operators training is a key factor in process performance
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Mimic the environment and functionality of a control room The process is replaced by a real time dynamic simulation
Real process
Simulator
TRAINING SIMULATORS
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TRAINING SIMULATOR AIMS
Facilitate the knowledge of the process and its control system
Achieve uniform operation among shifts Learn how to operate the process in an optimal way Learn how to react in unfrequent but difficult
situations Identify faulty situations and learn how to correct
them
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It allows learning by “experimenting” on the process , What happens if...? What should I do for...?
Experiments on the real process can be dangerous expensive, slow, not always done in the proper conditions,...
Simulation can be performed faster or slower than real time
The efect of a change can be seen in isolation if needed, this is not the case in the real process
Simulation gives access to all variables of the process
Study the best operation estrategies or control estructure
ADVANTAGES OF A TRAINING SIMULATOR
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TRAINING SIMULATORS
Different simulators according to its aims and range:
o Full scope: oPlant wide oReal time
o Specific process units
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CHARACTERISTICS
Mimic the control room environment + DCS Mimic the dynamic behavoiur of the process, both in normal and abnormal operating conditions
Provide a set of predefined operating problems and malfunctions that are adequate for the training
Real time (or acelerated) operation
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ARCHITECTURE OF THE SIMULATOR
• Four main modules: – Dynamic process simulation (EcosimPro) – Distributed Control System (SCADA) – Supervisor console – Real time Comunication system
• PC based under Windows with OPC
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ARCHITECTURE OF THE SIMULATOR
Two versions:
•Full scope
•Single user in a PC
TCP/IPOPC
Operators
Process Simulation
PCs
Instructor Video
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FUNCTIONS
SIMULATION = PROCESS
INSTRUCTOR OPERATOR
SCADA
Acts on the DCS Acts on the process
Manages the simulation
Activates problems and malfunctions
Selects training sessions
Operates the DCS
Reacts to problems and aims
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Training Simulator
INSTRUCTOR
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MODELING
Detailled dynamic process models based on first principles
Include normal behaviour and faults
Different classes:
Concentrate / Distributed parameters
Continuous / Batch
Digital Control functions
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DYNAMIC SIMULATION Simulation Tool: ECOSIMPRO
• Object oriented modelling tool with no predifined computational causality. It allows re-use of the models and hierarchical constructions.
• It generates simulation code after symbolic manipulation of the model equations in order to adapt them to the operating context.
• Good numerical solvers (DASSL sparse) – Models are generated as C++ clases, allowing
them an easy integration with other software components
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LIBRARIES OF MODELS SECTIONS - Destilery - Boilers - Sugar end - Evaporation - Depuration - Difussion - Dryer
GENERIC - Physico-chemical properties - Ports - Control elements - Flow elements - Basic process units
EcosimPro Model
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Compiled Simulation
Includes executables and source files with the C++ classes that contains the
simulation.
Server generator OPC server
OPC client
OPC / DCOM servers
Simulation modules encapsulated as OPC/DCOM servers
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MMI SCADA / EDUSCA.
Information: • Process Schematics • Tables of variables • Alarms • Trends • Historic trends • Bar graphs
Operation: • Change set points / MV • Man / Auto • Tuning • Alarms recognition
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SCADA Configuration
Programs
OPC Server
SCADA Configuration
CI Configuration
SCADA CONFIGURATION.
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OPC Server
Simulation 1OPC Server
Simulation 2OPC Server
Simulation 3
Data Interchange Program(Data Interchange & Synchronization)
Distributed simulation
5 PC under W
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INSTRUCTOR MODULE
On top of the operators console functions, the one of the instructor includes:
• Modifies process variables • Activate/ Deactivate faults • Selects pre-defined training sessions
(changes in production levels, faults...)
• Starts in different operating condictions
• Timing of the simulation
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Operating the Simulator
Navigate in the screens
How to use the operator screens....
.... And the toolbars
DEMOS
Start the simulator
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Operating the Instructor console
Instructor console
DEMO
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Lecturing in the classrooom on the process units, process fundamentals, process operation and control basis.
1
Practical work in the full scope simulator 3
Evaluation 4
A TRAINING SESSION
2 Simulators of process units
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Manuals + Slides
Process
Fundamentals of process units
Process operation
Control system
How to operate the simulator
Lecturing on:
Classroom.
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Friendly user interface
Fast response
Dedicated process units simulators, aimed to allow practicing on the process unit behaviour and operation of its control system
Process units simulators
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Process Units
• Heat exchanger • Evaporator • Filter • Carbonatation tower • Vacuuum pan • Boiler • Dryer • Storage tank • Destillation column
Models:
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OPERATION OF THE SIMULATOR
DEMO How to operate the process
Example: - OPERATION: Change the output brix of the evaporation station - FAULT DETECTION: Non-condensable gases valve closure
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Evaluation.
• Storage / Recovery of system states for:
• Analysis
• Repeat situation
• Supervision by the instructor
• Discusion of alternatives
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Documentation
• Operating the simulator • Operating the different sections of the
factory
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Conclusions Tested at factory director level and undergraduate students
At present is under evaluation at the factories
Key points:
Close links with users
Rapid adaptation, Development times
Degree of accuracy / general
Real time / acelerated time
Advanced control
Predictive simulation
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CENTRO DE TECNOLOGÍA AZUCARERA c/Real de Burgos s/n. Edificio Alfonso VIII
47011 Valladolid ESPAÑA Tfno: +34 983 42 35 63 Fax: +34 983 42 36 16 http://www.cta.uva.es/ [email protected]
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