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SS GEN-03DYNSIM and OTS Roadmap

Dr Ian Willetts,Global Practice Director

@InvensysOpsMgmt / #SoftwareRevolution

/InvensysVideos

social.invensys.com

© 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries.All third party trademarks and service marks are the proprietary marks of their respective owners.

Dr Ian Willetts,Global Practice Director

/InvensysOpsMgmt

/DYNSIM Users

Agenda

• Guiding Principles• DYNSIM 5.1 – A look back• Beyond DYNSIM 5.1 – A look forward

• Engineering Studies• Controls Checkout• Operator Training Simulators• Immersive Training Simulators• Training Services

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• Guiding Principles• DYNSIM 5.1 – A look back• Beyond DYNSIM 5.1 – A look forward

• Engineering Studies• Controls Checkout• Operator Training Simulators• Immersive Training Simulators• Training Services

ChemicalsRefining

Over 600 Successful Dynamic Simulationand OTS Projects for more than:

100 Different Clients in over10 Different Industries in over40 Different Countries

Guiding Principles - Clients First

Example Clients & Industries

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MiningPower

LNG Oil and Gas

InvensysFactory

OTS SiteDelivery

ENGINEERINGSTUDIES

TO SUPPORTDESIGN

ENGINEERINGSTUDIES

TO SUPPORTDESIGN

DESIGNDCS & PLC

CONFIGURATION STARTUP OPERATIONS

OPERATOR TRAINING SIMULATORSOPERATOR TRAINING SIMULATORSDCS CONTROLLOGIC CHECKOUT

DCS CONTROLLOGIC CHECKOUT

Guiding Principles – Development toSupport all Applications

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ENGINEERINGSTUDIES

TO SUPPORTDESIGN

OPERATOR TRAINING SIMULATORS

IMMERSIVE FIELD OPERATORTRAINING SIMULATORS

IMMERSIVE FIELD OPERATORTRAINING SIMULATORS

SUPPORT and MAINTENANCE PROGRAMSand LEARNING MANAGEMENT/TRAINING SERVICES

SUPPORT and MAINTENANCE PROGRAMSand LEARNING MANAGEMENT/TRAINING SERVICES

DCS CONTROLLOGIC CHECKOUT

PLC / SIS / TMC LOGIC CHECKOUTPLC / SIS / TMC LOGIC CHECKOUT

Agenda

• Guiding Principles• DYNSIM 5.1 – A look back• Beyond DYNSIM 5.1 – A look forward

• Engineering Studies• Controls Checkout• Operator Training Simulators• Immersive Training Simulators• Training Services

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• Guiding Principles• DYNSIM 5.1 – A look back• Beyond DYNSIM 5.1 – A look forward

• Engineering Studies• Controls Checkout• Operator Training Simulators• Immersive Training Simulators• Training Services

• Improved Overfill Robustness for Separator Model• Simulation Merge Tool• Partial Load Capability for large models (LE)• Point Monitor Updates for Model Tuning• Configurable Default Trends for Base Equipment

Library• Enhanced Search Tool• Additional Best Practice Documentation

DYNSIM 5.1 - Increased EngineeringProductivity (Released April 2013)

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• Improved Overfill Robustness for Separator Model• Simulation Merge Tool• Partial Load Capability for large models (LE)• Point Monitor Updates for Model Tuning• Configurable Default Trends for Base Equipment

Library• Enhanced Search Tool• Additional Best Practice Documentation

• Copy/Paste enhancements• Multiple selection and Protect/Unprotect/Deletion of IC’s

from Summary Table• Prior display short cut key (alt+q)• Cycle through open flowsheets short cut key (ctrl+tab)• Double Click To Open Flowsheet• Snap single port connection to the center• Improved Transmitter & PID connections

DYNSIM 5.1 - GUI Enrichment forImproved Ergonomics & Ease of Use

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• Copy/Paste enhancements• Multiple selection and Protect/Unprotect/Deletion of IC’s

from Summary Table• Prior display short cut key (alt+q)• Cycle through open flowsheets short cut key (ctrl+tab)• Double Click To Open Flowsheet• Snap single port connection to the center• Improved Transmitter & PID connections

• Instructor and Trainee Event Logger• Scenario Enhancements• Backtrack Replay enhancements• TPM Enhancements• Support for Java 7.0 and Win Server 2008• Coexistence of DYNSIM dot versions

DYNSIM 5.1 - Enhanced Instructor andTraining Capabilities & Other Items

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• Instructor and Trainee Event Logger• Scenario Enhancements• Backtrack Replay enhancements• TPM Enhancements• Support for Java 7.0 and Win Server 2008• Coexistence of DYNSIM dot versions

Agenda

• Guiding Principles• DYNSIM 5.1 – A look back• Beyond DYNSIM 5.1 – A look forward

• Engineering Studies• Controls Checkout• Operator Training Simulators• Immersive Training Simulators• Training Services

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• Guiding Principles• DYNSIM 5.1 – A look back• Beyond DYNSIM 5.1 – A look forward

• Engineering Studies• Controls Checkout• Operator Training Simulators• Immersive Training Simulators• Training Services

ENGINEERINGSTUDIES

TO SUPPORTDESIGN

ENGINEERINGSTUDIES

TO SUPPORTDESIGN

DESIGNDCS & PLC

CONFIGURATION STARTUP OPERATIONS

Beyond DYNSIM 5.1- Support for Engineering Applications

• New Compressor Control Algorithm(similar in form to 3rd party system)

• Inclusion of Holdup in Multi-Exchanger• Accelerate to Steady State Option• Three-way valve• Weir in Drum Model• Reboiler/Condensate Pot (Kettle

Reboiler)• Improvements in GUI/Ease of Use• Nitric Acid Database – first moves

toward electrolyte modelingSlide 11

ENGINEERINGSTUDIES

TO SUPPORTDESIGN

• New Compressor Control Algorithm(similar in form to 3rd party system)

• Inclusion of Holdup in Multi-Exchanger• Accelerate to Steady State Option• Three-way valve• Weir in Drum Model• Reboiler/Condensate Pot (Kettle

Reboiler)• Improvements in GUI/Ease of Use• Nitric Acid Database – first moves

toward electrolyte modeling

DESIGNDCS & PLC

CONFIGURATION STARTUP OPERATIONS

Beyond DYNSIM 5.1- Support for Controls Checkout• SCP 270 to replace FSIM Plus – Sept 2013• Logic Validator 2.0• SCP 280 to support CP280 Processor• New engines to Hitachi, Hollysys and

Supercon DCS• MATLAB Engine Link• Generic PLC Emulator/Translator• Foxboro Evo Simulation 1.0• New InTouch Engine with simulation

support

DCS CONTROLLOGIC CHECKOUT

DCS CONTROLLOGIC CHECKOUT

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• SCP 270 to replace FSIM Plus – Sept 2013• Logic Validator 2.0• SCP 280 to support CP280 Processor• New engines to Hitachi, Hollysys and

Supercon DCS• MATLAB Engine Link• Generic PLC Emulator/Translator• Foxboro Evo Simulation 1.0• New InTouch Engine with simulation

support

DCS CONTROLLOGIC CHECKOUT

PLC / SIS / TMC LOGIC CHECKOUTPLC / SIS / TMC LOGIC CHECKOUT

DESIGNDCS & PLC

CONFIGURATION STARTUP OPERATIONS

Beyond DYNSIM 5.1- Support for Operator Training Simulators

OPERATOR TRAINING SIMULATORSOPERATOR TRAINING SIMULATORS

• Eight Generic Simulators for RefiningOperations

• Four Generic Power Plant Simulators• User Productivity Improvements• Model Templates and Auto-naming rulebook• Flash Counter and Tiered VLWE Flash for

Speed• Improved Exception Handling and Flash

Diagnostics• Support for Global Parameters• Transmitter Alarm Limits

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OPERATOR TRAINING SIMULATORS

• Eight Generic Simulators for RefiningOperations

• Four Generic Power Plant Simulators• User Productivity Improvements• Model Templates and Auto-naming rulebook• Flash Counter and Tiered VLWE Flash for

Speed• Improved Exception Handling and Flash

Diagnostics• Support for Global Parameters• Transmitter Alarm Limits

DESIGNDCS & PLC

CONFIGURATION STARTUP OPERATIONS

Beyond DYNSIM 5.1- Support for Immersive Training Simulators

• Dynamic maps for item location andplant orientation

• Item Target Finder• Ambient Occlusion• EYESIM APPs for the Instructor

Interface• Generic Crude Unit OTS & ITS

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IMMERSIVE FIELD OPERATORTRAINING SIMULATORS

IMMERSIVE FIELD OPERATORTRAINING SIMULATORS

• Dynamic maps for item location andplant orientation

• Item Target Finder• Ambient Occlusion• EYESIM APPs for the Instructor

Interface• Generic Crude Unit OTS & ITS

DESIGNDCS & PLC

CONFIGURATION STARTUP OPERATIONS

Beyond DYNSIM 5.1- Training Services and Platforms

• Expansion of Training ServicesTeam to help our clients maximizethe training value of the OTS/ITS

• Integration of DYNSIM withLearning Management Systems –CBT and Certification

• Proof of Concept underway forSubscription Based OTS

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SUPPORT and MAINTENANCE PROGRAMSand LEARNING MANAGEMENT/TRAINING SERVICES

SUPPORT and MAINTENANCE PROGRAMSand LEARNING MANAGEMENT/TRAINING SERVICES

• Expansion of Training ServicesTeam to help our clients maximizethe training value of the OTS/ITS

• Integration of DYNSIM withLearning Management Systems –CBT and Certification

• Proof of Concept underway forSubscription Based OTS

Thank You!

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SUPPORTING INFO

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Acceleration to Steady State• Reduce the drum holdup contents to

get faster composition and energydynamics

• Criteria in calculating scaling factorto reduce holdup contents:

• With reduced contents, residence timeof 10 times of time step should bemaintained

• It shouldn’t enter a condition where holdupprotection would be applied

• Metal mass is reduced by same factor forhandling external heat transfer

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• Reduce the drum holdup contents toget faster composition and energydynamics

• Criteria in calculating scaling factorto reduce holdup contents:

• With reduced contents, residence timeof 10 times of time step should bemaintained

• It shouldn’t enter a condition where holdupprotection would be applied

• Metal mass is reduced by same factor forhandling external heat transfer

Templates – Productivity Enhancement• Productivity enhancement. Templates, in conjunction with

auto-naming rulebook, will provide productivityimprovements.

• Select a group of objects and save as template

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• Productivity enhancement. Templates, in conjunction withauto-naming rulebook, will provide productivityimprovements.

• Select a group of objects and save as template

Multiple objects demo

Stream Send/Receive Enhancements• Split model into multiple flowsheets / engines

• Initially use Source as boundary

• Boundary Mode option is available in Stream Send and Stream Receiveobjects.

• If the STREAMSEND/RECEIVE is in boundary mode it will take its propertiesfrom the boundary specified (composition, temperature, pressure, flow, etc.),and if not, it will take its properties from its pair

• Enables engineers to break the network without breaking SS-SR pair.

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• Split model into multiple flowsheets / engines

• Initially use Source as boundary

• Boundary Mode option is available in Stream Send and Stream Receiveobjects.

• If the STREAMSEND/RECEIVE is in boundary mode it will take its propertiesfrom the boundary specified (composition, temperature, pressure, flow, etc.),and if not, it will take its properties from its pair

• Enables engineers to break the network without breaking SS-SR pair.

Metals & Mining Model Development UpdateModels

ConveyorPrimary CrusherBall MillScreenVibrating screenFluid Bed Roaster & CoolerHydrocycloneFloatation cellFloatation columnAir CycloneMixer, Splitter, Hopper Bin, HeaderAG Mill & SAG MillFlash furnaceSmelting FurnaceAcid Plant ReactorCrusherM3 Stream Send/ReceiveM3 Drum

Particle Size Distribution Sub Totals & PlotUAMs now being converted into DYNSIM Library

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ModelsConveyorPrimary CrusherBall MillScreenVibrating screenFluid Bed Roaster & CoolerHydrocycloneFloatation cellFloatation columnAir CycloneMixer, Splitter, Hopper Bin, HeaderAG Mill & SAG MillFlash furnaceSmelting FurnaceAcid Plant ReactorCrusherM3 Stream Send/ReceiveM3 Drum

Particle Size Distribution Sub Totals & PlotUAMs now being converted into DYNSIM Library

Generic Operator Training Simulators• Off-The-Shelf Operator Training

Simulators of common processes and unitoperations

• CDU/VDU, FCC, Hydrocracker, NHT/CCR,Hydrogen plant (2 designs), DHDS,ARU/SRU/SWS

• Coal fired drum boiler, Natural gas combinedcycle and Super-critical Once through powerplant OTS

• Crude Unit OTS and ITS, IGCC OTS and ITS

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• Off-The-Shelf Operator TrainingSimulators of common processes and unitoperations

• CDU/VDU, FCC, Hydrocracker, NHT/CCR,Hydrogen plant (2 designs), DHDS,ARU/SRU/SWS

• Coal fired drum boiler, Natural gas combinedcycle and Super-critical Once through powerplant OTS

• Crude Unit OTS and ITS, IGCC OTS and ITS

• Product Documentation

• Instructor guide with exercises, PFD and model overview, powerplant generic OTS includes training

Generic OTS Model ProgramGeneric OTS Model Program

•CDU/VDU, FCC, Hydrocracker, NHT/CCR, Hydrogenplant (2 designs), DHDS, ARU/SRU/SWS

•Coal fired drum boiler, Natural gas combined cycleand Super-critical Once through power plant OTS

•Crude Unit OTS and ITS, IGCC OTS and ITS• Product Documentation

•Instructor guide with exercises, PFD and modeloverview, power plant generic OTS includes trainingmaterial

*ARC Global Market Research 2012 – Analysis and Forecast till 2017

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•CDU/VDU, FCC, Hydrocracker, NHT/CCR, Hydrogenplant (2 designs), DHDS, ARU/SRU/SWS

•Coal fired drum boiler, Natural gas combined cycleand Super-critical Once through power plant OTS

•Crude Unit OTS and ITS, IGCC OTS and ITS• Product Documentation

•Instructor guide with exercises, PFD and modeloverview, power plant generic OTS includes trainingmaterial

*ARC Global Market Research 2012 – Analysis and Forecast till 2017

Training as a Service -The Right Tools, Knowledge and Experience

Understand Client’s TrainingRequirements

Understand Trainee Profile andCourse Requirements

Evaluate Different TrainingPlatforms and Customize

Training Program

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Evaluate Different TrainingPlatforms and Customize

Training Program

Define Partnership

Build, Deliver and Sustain