overview agenda for chemical community meeting, hamburg

© Siemens AG 2013. All rights reserved. Unrestricted. siemens.com/answers© Siemens AG 2014. All rights reserved. Unrestricted.

Virtual Commissioning with SIMIT Simulation FrameworkBenefits of Simulation in the Engineering Workflow

Dec 2014 – Simulation Workshop Praha

© Siemens AG 2014. All rights reserved. Unrestricted.

Dec 2014 PD PA AE CHE 4

Engineering FAT Commissioning SAT Operation

FAT = Factory Acceptance TestSAT = Site Acceptance Test

Use Cases Virtual Commissioning (Only)Placement in the Workflow

Virtual Commissioning

No big benefits in engineering Software commissioningreduced max. 20-30%

• Provement of functionality to customer• Easier approval from customer

• (Too) late usage of simulation• Implemented in „time pressure phase“• Experience of early tests not implemented• Model has no time to grow• Danger to implement only a few well known scenarios• Usage of modified/additional code in controller in early phases

(quality problem!)• Often only implemented to pass Factory Acceptance Test• No big advantages in duration, costs and quality



Simulation Aided Engineering



Use Case Simulation Aided EngineeringImplement a Test & Simulation Strategy From the Beginning

Virtual Commissioning

• Easy creation of test functionality from the beginning• Smooth increasing of simulation functionality (signals,

sensors/actuators, process)• No change of automation software. Simulation code is

safely removed by disconneting simulation system.• Less costs than programming of FBs.• Model has time to grow to cover the complete software

and all scenarios.

• Each sub branch of automation engineering can immediately be implemented in simulation.

• Synergies with growing macro, templates and components library.

• Test for FAT and SAT are automatically results of test and simulation strategy.

• High benefits in shorter duration, less costs and high quality.

Software commissioningreduced typically 50-80%

No Non Conformance CostsNo Crisis Projects

Less Guarantee CasesSatisfied Customers

Early and comfortabledetection of software failures

= reduced engineering durationby 10-20%



Simulation Aided Engineering



Use Case Simulation Aided Operator TrainingAdditional Possibilities

Virtual Commissioning Simulation Aided Operator Training

• Easy creation of first operator training systems from simulation based engineering system.

• Training of operators before start of operation.• Training of even critical situations without risk.• Training even in smallest available time slots like e.g.

system maintenance.

• Find out, optimize and train best/reference operation cases.

• Validate and certify operators.• Actively drive, experience and store operator

knowledge management.• Stepwise extension into a „full-blown“ OTS.



Engineering FAT Commissioning ** SAT

High quality softwareEarly detection of failures

Short correction loops

Easy proof of functionalityGetting approval from

customer

Short commissioningEarly production startShort startup phase

Get final approvalCustomer

satisfaction

Qui

ck g

ener

atio

n of

si

gnal

s &

resp

onse

Test

inte

rface

for U

ser F

Bs

Sen

sor &

Act

uato

r Beh

avio

rP

roce

ss B

ehav

ior

Deb

uggi

ng o

f sof

twar

e

Sav

e &

relo

ad a

ny s

ituat

ion

Sav

e/Lo

ad a

ny s

tart

situ

atio

nof

any

sze

nario

Rep

lay

any

sequ

ence

of s

igna

lsC

omm

issi

onin

g su

ppor

tfro

m o

ffice

D

ebbu

ging

and

failu

refix

ing

with

out p

lant

Bas

ic o

pera

tor t

rain

ing

Dev

elop

men

t sys

tem

on s

ite w

ihic

h ne

eds

no s

pace

Pro

of o

f crit

ical

cas

es

Pro

of o

f tot

al fu

nctio

nalit

y

Better supportLess support

Less NCC

Full

supp

ort o

fcu

stom

er c

onfig

urat

ion

Operation **

Offs

ite fa

ilure

fixi

ngC

ontin

uing

eng

inee

ring

FAT = Factory Acceptance TestSAT = Site Acceptance TestNCC = Non conformance Costs

Simulation Aided EngineeringA Lot of Benefits Makes Engineering Easier

** = with Emulation Platform



Bernhard Iffländer

Head of Simulation Center

Siemens AG

Erlangen

PD PA AE CHE 4

Phone: +49 9131-7-23725

E-mail: [email protected]

www.siemens.com/simit

Thank You

siemens.com/answers

overview agenda for chemical community meeting, hamburg

Documents