egypt adv solu roadshow sim lifecycle may 2012 · • scorm v1 2 interface to 3rdscorm v1.2...
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Roadshow Egypt May 2012Simulation Lifecycle meeting today’s ChallengesGurinder Gill EMEA Simulation Business Development managerGurinder Gill EMEA Simulation Business Development manager
Contact detailsContact details
Gurinder GillAdvanced Solutions Business ConsultantBusiness [email protected]
Direct: +44 1344 655025Mobile: +44 7977 938109
General contact:HPS k i @h [email protected]
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How can Simulation address?How can Simulation address?
Skilled resource shortageIncreasing complex operationsManaging compliance vs managing the bottom lineManaging compliance vs. managing the bottom lineMaking faster, smarter decisions to respond to market variability and speed of changeDoing more with less, and doing it better than everAsset Management
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ChallengesChallengesAutomation - APC Retirements Demographics
Lower entry levels Complexity Environment
Global virtual teamsMentoring
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Engineering Design & SupportEngineering Design & Support
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Competency GapCompetency Gap
Learning PyramidLecture
Reading Average10%
g y Reading
Audiovisual
Demonstration
gStudent
RetentionRates
10%
20%
30%
50%Discussion
50%
75%
90%
Practice doing
Teach others
Cncy
Procedures, tests, techniques to be modeledCompetency
Elements Facts, concepts, principles,theoretical aptitude
Skills
Knowledgeompe
ten modeled
Role expectations, confidence,cultural traits, motivation,values, perceptions, opinionsBehaviors
Co
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Time Source: National Training Laboratories, Bethel, Maine
Engineering EffortEngineering Effort
$ Cost savings through model re-use, standard tools, more efficient use of process knowledge
$$
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People MatterPeople Matter
Errors and inefficiency cost money U.S. process plants lose over $20 billion a year
from abnormal situations. Equipment
40%People• procedure (27%)• Incorrect action (22%)
Abnormal Situation Management ConsortiumPeople40%
Other20%
Incorrect action (22%) • Fail to follow (22%) • work practices (17%)• installation (6%) • recognize problem (6%)20%
2%
2% Operating out ofrange
10%5% 5%
2% rangeImproper design
Impropermaintenance
76%
No defect found
Improper installation
I t i l
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Improper materialHuman Performance Issues Impact 70% or more of Abnormal Events
What is SimulationWhat is Simulation
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The Simulation Lifecycle ApproachPlant Asset Lifecycle
ConceptMain equipment items, P&ID connectivity, control system,
The Simulation Lifecycle Approach
Concept Selection
y ypipeline - process interaction
Extend the course model with vendor data, pipework details, ESD cause & effect functionality
FEED
Detailed
ESD cause & effect functionality, advanced compressor control. APC evaluation & set up
Plant Simulators & Online systems
InitialProcessModel
Detailed Engineering
DetailedProcess
Operator Consoles
Instructor Station
OTS G t
Plant Simulators & Online systems
Construction & Commissioning
Model
Utilit DCS ESD/F&G APC
OTS Gateway
UpdatedProcess Model
OperationsUtility
ModelsDCS ESD/F&G
Control / HardwareAPC
Optimization; Inferential; Shadow models
Model
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Expansion Operations
The Simulation Lifecycle ApproachPlant Asset Lifecycle
ConceptMain equipment items, P&ID connectivity, control system,
The Simulation Lifecycle Approach
Concept Selection
y ypipeline - process interaction
Extend the course model with vendor data, pipework details, ESD cause & effect functionality
FEED
Detailed
ESD cause & effect functionality, advanced compressor control. APC evaluation & set up
Plant Simulators & Online systems
InitialProcessModel
Detailed Engineering
DetailedProcess
Operator Consoles
Instructor Station
OTS G t
Plant Simulators & Online systems
Construction & Commissioning
Model
Utilit DCS ESD/F&G APC
OTS Gateway
UpdatedProcess Model
OperationsUtility
ModelsDCS ESD/F&G
Control / HardwareAPC
Optimization; Inferential; Shadow models
Model
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Expansion Operations
The Simulation Lifecycle ApproachPlant Asset Lifecycle
ConceptMain equipment items, P&ID connectivity, control system,
The Simulation Lifecycle Approach
Concept Selection
y ypipeline - process interaction
Extend the course model with vendor data, pipework details, ESD cause & effect functionality
FEED
Detailed
ESD cause & effect functionality, advanced compressor control. APC evaluation & set up
Plant Simulators & Online systems
InitialProcessModel
Detailed Engineering
DetailedProcess
Operator Consoles
Instructor Station
OTS G t
Plant Simulators & Online systems
Construction & Commissioning
Model
Utilit DCS ESD/F&G APC
OTS Gateway
UpdatedProcess Model
OperationsUtility
ModelsDCS ESD/F&G
Control / HardwareAPC
Optimization; Inferential; Shadow models
Model
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Expansion Operations
USE IT: AnalysisUSE-IT: Analysis
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CSM Tool Scenario SetupCSM Tool Scenario Setup
Topology is checked in all scenarios including Master;
Object is Existing or Absent or in a case
Object Position (Flowsheet), Unit Op Type and Name columns
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Focusing on Results: CSM Tool ResultsFocusing on Results: CSM Tool Results
List of changes detected in each Scenario compared to
Master ScenarioMaster Scenario
Parameter value is identical –Grey background
Difference detected –Yellow highlighted cell
Missing parameter–Red highlighted cell
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The Simulation Lifecycle ApproachPlant Asset Lifecycle
ConceptMain equipment items, P&ID connectivity, control system,
The Simulation Lifecycle Approach
Concept Selection
y ypipeline - process interaction
Extend the course model with vendor data, pipework details, ESD cause & effect functionalityFEED
Detailed
ESD cause & effect functionality, advanced compressor control.
APC evaluation & set upPlant Simulators & Online systems
InitialProcessModel
Detailed Engineering
DetailedProcess
Operator Consoles
Instructor Station
OTS G t
Plant Simulators & Online systems
Construction & Commissioning
Model
Utilit DCS ESD/F&G APC
OTS Gateway
UpdatedProcess Model
OperationsUtility
ModelsDCS ESD/F&G
Control / HardwareAPC
Optimization; Inferential; Shadow models
Model
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Expansion Operations
MVPC (Profit Controller APC) inside UniSimMVPC (Profit Controller – APC) inside UniSim
$ Specification Limit
9 to 12 months
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Process & controller set upProcess & controller set up
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Step test & Response matrixStep test & Response matrix
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Profit Controller in UniSim & ExportProfit Controller in UniSim & Export
Profit Controller ui. in Unisim
Profit Suite Operator
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Station
Controller PerformanceController Performance
Splitter reboiler hot oil use HDS hot oil use Fuel gas consumption
HDS H2 consumtion
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LCN S content HCN S content (after HDS and Stabilizer)LCN + HCN S content
DCS & ESD CheckoutDCS & ESD Checkout
DCSDCSFC
FC
FI
FC
ProcessProcessModel
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UOP Training SimulatorsUOP Training Simulators
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UOP PackagesUOP - Packages
imul
ator
Con
trol
s
–ES
D
APC
arm
Man
oced
ures
pete
ncy
Man
UO
P –
Si
UO
P –
C
UO
P –
UO
P –
UO
P –
Ala
UO
P –
Pro
UO
P –
Com
p
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USO R400 Simulation Server & SCORM LMS InterfaceUSO R400 – Simulation Server & SCORM LMS Interface
• Simulation Server – Centralizes
• UniSim License Manager for Networks
• SCORM V1 2 interface to 3rd• SCORM V1.2 interface to 3rd Party Learning Management Systems
• Model Repository and server• Training Record Management
– Supports Classroom Training Modes• UOP, Lambton College, Suncor,
IrvingIrving• Benefits
– Engineers create & maintain broad solutions with better consistency
– Instructors with a better view of trainee performance
– Trainees supported by better instruction through Learning
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Management System courses
Virtualized UniSim Operations SystemVirtualized UniSim Operations System
• UniSim Operations Suite R400• UniSim Operations Suite R400• Experion PKS R400 with T-
NodesQ lifi i P l• Qualification Process only
– VM Ware ESXi Version 4.0i– Recommended System Specs– User Documentation– Training, Support and Rollout
• Benefit– Decreased system footprint– Improved UniSim deployabilityp p y y
• Switching set ups• Older versions UniSim• Older Windows operating
t
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systems Virtual Hardware
Experience the Whole PlantExperience the Whole PlantMarriage of two best in class 1st principle simulators
UniSim (Honeywell) and MindSafe (Virthualis)
Mindsafe 6 years in development, UniSim premier 2D simulator
Precise modelling, inside and outside the equipment for
i i d i i
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engineering and training
Book your session at the registration desk.
P SProcess Sync.
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Production Unit Simulator
SummarySummary
Skilled resource shortageIncreasing complex operationsManaging compliance vs managing the bottom lineManaging compliance vs. managing the bottom lineMaking faster, smarter decisions to respond to market variability and speed of changeDoing more with less, and doing it better than everAsset Management
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Any QuestionsAny Questions
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SummarySummary
“We Improve Your BusinessPerformance & Peace of Mind”
Better
Performance & Peace of Mind”
BetterBetter TechnologyBetter Technology
Better Lifecycle Support Better Delivery
Gl b l t f t Y i l ti
Better DeliveryBetter
Lifecycle Support
U iSi i t t d Global team of experts ensure your project is delivered to meet your needs
Your simulation investment is protected through the lifecycle of your plant
UniSim integrated technology based on proven, world-class solutions needs your plantsolutions
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