Transcript PPT Template

Slide 1
SSE TSS-4
New Features in DYNSIM 5.0
Bryan C. McAlister, Ph.D.
© 2012 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.
DYNSIM 5.0
DYNSIM® Software version 5.0 is a major release and introduces a
rich set of features and enhancements
The product has been in development for the last 18 months with a
investment of approximately US$3 million
Overarching Goals -
 Ensure DYNSIM remains the Best Available Technology for
Dynamic Simulation and OTS by expanding the existing
product capabilities
 Enable OTS Engineers to be more efficient and competitive
when executing Operator Training Simulator projects
 Improve the long term sustainability /total cost of ownership
of our solutions for both clients and Invensys
Slide 3
Install
1.
New Redesigned, WIX Installers
OLD
NEW
Prerequisites Installer
32 bit DYNSIM Installer (includes
prerequisites)
32 bit DYNSIM +
OTS Engines installer
32 bit OTS Custom Engines Installer
64 bit DYNSIM Engine Installer
Advantage – WiX is script based. Customers could potentially rescript install for internal deployment.
2. The DYNSIM Prerequisites i.e., Windows Installer 4.5 and .NET 3.5
SP 1 are now part of the main setup. The third party installations like
jre 1.6.0._23, SQL Express 2008 etc are also part of the main setup.
Slide 4
Install
3. The Typical Install option installs only the regular DYNSIM and Excel
engines. The Custom option allows the user to add other DYNSIM
engines like DYNSIM–P, DYNSIM-All, OPCServer, OPC-UA, etc.
Slide 5
Install
4. Support for FlexNet11.8 security option (Windows 7, 64 bit
machines)
5. The Custom OTS Engines is now a separate installer and it is no
longer required to install DYNSIM 5.0 for custom OTS engines (just
need the Activation Manager)
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DYNSIM 64-bit Install
1. Starting DYNSIM 5.0, 64-bit version of DYNSIM engines namely
DYNSIM, DYNSIM-All, DYNSIM-P, DYNSIM-Checkout, DYNSIM- Lite
is available as a separate install and can be installed on a 64-bit
machine
2. However, SimExecutive and other components would remain 32-bit
and would be used on both 32-bit and 64-bit machines.
3. The regular DYNSIM 5.0 application is a pre-requisite for installing
the 64-bit DYNSIM engines.
4. 64 bit engines can be selected via “Simulation Configuration” just
like any other engine
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Install
SimExecutive Licensing
1. In DYNSIM 5.0, a new licensing mechanism has been implemented.
The SimExecutive checks for a valid license and returns it after
finding one.
2. This feature has been implemented for all products, which use the
SimExecutive framework i.e., DYNSIM, DYNSIM-P, OTS Engines,
DYNSIM Checkout, FSIM, TRISIM etc.
3. If the SimExecutive finds a valid license, the message window will
display a message “SimExecutive has obtained a runtime license”.
4. If the SimExecutive does not find a valid license, an appropriate
message “SimExecutive could not start successfully” will be
displayed.
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PFR Enhancements Summary
• Compressible Reaction Pass
• Model Catalyst Phase Separately in Energy Balance
• Rigorous Pressure Drop Correlations
 Ergun and Turpin & Huntington
• Model Liquid Hold-up and Liquid Slip
Backward compatible
• Support all existing features. No schema evolution required for
migrating existing simulations
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Holdup Dynamic Calculation
• Holdup Dynamic calculation (Pressure calculation) – Limit to
incompressible holdup dynamic calculation. Unrealistic pressure response
when vapor exists, for example hydrocracker, shift reactor,…, etc.
• Compressible Reaction Pass (CRPass) – Add a new CRPass like
DYNSIM Pipe to support both compressible and incompressible holdup
dynamic calculations.
Solution tab
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Pressure Response
• CO shift reactor – One reaction Pass and One compressible reaction
pass with compressible option, 5 segments
• Pressure response – (a) Pressuring (b) Depressuring
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Catalyst Effect (Energy Balance)
Energy balance on existing PFR
 No separate energy balance on catalyst phase, Require to
combine catalyst to wall
 Unrealistic temperature responses in fluid and catalyst phases
 Energy balance on catalyst phase
 add a separate energy balance on catalyst phase. More realistic
temperature response on fluid and catalyst phases
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Catalyst Effect (Pressure Drop)
• Pressure drop calculation on existing PFR
– Based on simple flow conductance, doesn’t include catalyst effect (void fraction,
catalyst diameter etc.)
– Pressure drop result may be unrealistic
• Rigorous pressure drop calculation
– Including catalyst effect, and fluid physical properties (density, viscosity,
molecular weight, etc.)
– Predictive approach
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13
Catalyst Effect (Pressure Drop)
• Ergun correlation
– Commonly used correlation, can be applied to gas, liquid, and gas-liquid systems.
• Turpin and Huntington (1967)
– Vapor-liquid Two phase system
– Upward and downward flows
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Liquid Holdup and Liquid Slip
• Liquid holdup and Liquid Slip – Relationship among liquid-holdup in
the catalyst bed, liquid, vapor flows, and pressure drop.
Strongly
impact pressure response, pressure drop, and liquid holdup.
• General form – Turpin and Huntington
• DEW – Liquid Slip tab
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More Accurate Trends
 Trend Reactor pressure, liquid saturation, fluid temperature, wall
temperature and catalyst temperature
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Stream Send – Stream Receive
Large
Simulations
Engine 1
SR
Engine 2
SR
Engine 3
SS
SS
Better Performance – Utilize Multi-Cores
Stream Send calculates how sensitive upstream flow is to
downstream pressure.
Stream Receive calculates how sensitive downstream pressure
is to upstream flow
Old Approach –> Local Sensitivity
New Approach –> Network Sensitivity
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Limitations of Local Sensitivity
 Currently, the flow and pressure sensitivities are calculated
locally for the concerned flow devices and pressure nodes.
 Ignores the impact of other network elements on the
sensitivity calculations.
 As a result of this, the sensitivities at times are quite a bit off
compared to the actual sensitivities. At times, this results in
following two issues:
– Mass imbalance and pressure inequalities across the network.
– Flows and pressures quite different compared to single network
in a single engine.
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New Approach – Network Sensitivity
 Takes the entire network into account for the calculation
of the sensitivity
 Much more robust than the local sensitivity but
computationally much more intensive
 Rest of the things regarding the usage of sensitivity and
communication between different engines remain the
same
 Backward Compatible
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Reassignment of Engines
•
User-friendly way to remap simulation from one hardware configuration
to another hardware configuration by using hosts mapping data
•
Easier deployment / transfer of simulations across different hardware
setups
•
Mapping of remote and local host data will be kept in editable text file:
HostsConfig.txt
Existing
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DYNSIM 5.0
Color coding to indicate host resolution
Green –mapped host supports the required engine type and will be used to launch
the engine.
Amber – mapped host was not found and so is being automatically remapped to
the local host
Red – mapped host (or simexec host) doesn’t support the configured engine type
(e.g. TRISIM)
Valid host found.
Valid host not found. Not loaded.
Host not found. Mapped to SimExec host
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HostsConfig.txt
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Additional Messaging
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New Integrator Model
The Utilities library provides a
collection of standalone objects for
various custom calculations.
Integrator provides the integration of
a process variable.
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Data Entry Window
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Overfill Robustness Implementation
• Drum model – DYNSIM 4.5.1
• Tower, Pipe, PFR (CRPass) and Header models – DYNSIM 5.0
• Remaining model - Separator
Holdup
Dynamic
Options
Holdup Calc Type
(Simple, Rigorous,
Global )
Algorithm
Note
Compressible
Rigorous
Overfill robustness
algorithm
Robust, speed
may slow
down
Simple
Legacy compressible
algorithm
Rigorous
Incompressible Volume
Balance
Simple
Legacy incompressible
algorithm
Incompressible
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Overfill Robustness Implementation
•
Global option (default Simple) – Drum, Pipe,
PFR (CRPass), Header
and Tower models
• Global option can be
overwritten by individual
model
 For example: pipe model –
OEV – AdvEdit
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Text based/Editable Ics
• Checkbox option to save ICs in text
• Format  same as states.dat. Default remains “binary”
• Will be managed / handled just like binary ICs (via Snapshot
Summary table)
Existing
DYNSIM 5.0
Option to
save the
IC as text
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Custom Point Description
• Points and parameter names in DYNSIM can be very cryptic and
hard to remember what they are and why they are needed. DYNSIM
5.0 adds a custom description to points and indirectly to point
references
• Users will be able to display custom descriptions for:
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
Trends on screen, printing and exporting to CSV data

Point Monitor

Trainee Performance Monitoring (TPM)

Malfunctions

Miscellaneous Equations
Custom Point Description
In DYNSIM 4.5.4 vs 5.0
•
Points on Trends
Point Monitor
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Custom Point Description
In DYNSIM 4.5.4 versus 5.0
•
Malfunctions & TPM
TPM
Malfunction
Point Monitor
TPM
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Malfunction
Default Trends for Select Unit Operations
DYNSIM 5.0 will include default trends in the
following models:
•
PID Controller
•
Heat Exchanger
•
Utility Exchanger
•
Pump
•
Compressor
Utility Exchanger
Pump
PID
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Mass Fraction in Stream
• Display mass fraction in individual stream (existing
feature) – Select “Component mass fraction” through Stream
“Special Properties” list
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Mass Fraction in Stream
• Display mass fraction in all streams (new feature) – Set
“Calculate stream mass fraction option” to 1 through “Engine
Configuration” window. Default is “0”.
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DYNSIM Power Migration in DYNSIM 5.0
DYNSIM enhancements to support Steam and Gas Turbine modeling:
Enhancements in Compressor model
• Compressor performance curve bases
– Flow basis, Head basis and Speed basis
• Support for performance curves at multiple IGVs
– Performance curves
– Surge point
Enhancements in Expander model
• Efficiency curves
• Leaving losses
• Heat Streams
Metal Casing model
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Compressor performance curve bases
• Current DYNSIM compressor supports performance curve input
as pressure head (Energy/Mass) versus volumetric flow only
• User needs to convert vendor data to equivalent pressure
head versus volumetric flow for using DYNSIM Compressor
model
• In DYNSIM 5.0 new options
have been added to support
different curve formats.
• XY plots display in user
configured curve bases
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Compressor performance curve bases - Options
Flow Basis
• Volumetric
• Mass
• Corrected Mass
Head Basis
• Pressure Head
• Pressure Difference
• Pressure Ratio
• Static Head
Speed Basis:
• Speed
• Corrected speed
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Inlet Guide Vane (IGV) positions
Compressor model already supports performance curves at
multiple speeds.
With IGV implementation
•
Curves at different IGVs can be taken
• User can specify curves at different IGVs at each speed
• In XY plots, 3 radio buttons are added
•
All
• Speed
• IGV
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Inlet Guide Vane (IGV) Curves tab
Current
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New
Inlet Guide Vane (IGV) XY Plot
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Surge point definition at multiple IGV positions
• Surge variation with IGV is considered
• User can provide surge data at different IGVs
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Expander - Efficiency
Constant efficiency
The efficiency is equal to the reference efficiency provided by the user. The
default value of efficiency is 1.0.
Built-in efficiency curve for Steam Turbine
In this method the reference efficiency is compensated for speed and flow
rate using the correlation given below:
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Expander – Leaving Losses
 In typical turbine operations, the losses associated with carry
over velocity are called ‘Leaving Losses’.
 Leaving Losses are associated with last stage in a multi-stage
turbine operation especially in low pressure turbines.
 DYNSIM has two methods to calculate leaving losses:
• Fixed leaving losses
• Fixed value. The losses are considered to be independent of flow
or turbine speed conditions
• Built-in leaving losses curve
• There is a built in curve which is based on a typical GE LP
turbine.
 Used in calculation of Work of Expansion as shown below:
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Expander – Heat Streams
 Heat Stream port is provided to connect Expander model to
Metal Casing.
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Metal Casing model
 Metal casing model is used to predict temperatures of
metal casing and rotors in turbine.
 Casing/Rotor temperatures can be used:
• Calculation of differential axial expansion between rotor
and casing.
• As critical parameter for startup/shut down of turbine
• Monitored for stress and life management.
 Metal casing model needs to be connected to equipment
through heat streams for which metal wall temperature is
required.
 Metal casing / rotor may be subdivided into any number
of axial and radial segments.
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Metal Casing model
 Each metal casing / rotor may be subdivided into any
number of radial divisions representing slices parallel to
the fluid flow.
 Metal casing model as rotor:
•
•
There is no heat loss to ambient.
External heat input is not allowed.
Casing
Radial Seg-1
Radial Seg-2
Rotor
Axial Seg-1
Axial Seg-2
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Compressor Model Demo
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DYNSIM 5.0 Pipe Model Improvements
•Global database
•Beggs-Brill Moody two phase flow correlation
•Elevation profiles
•Kinetic energy effects for high velocity fluids
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Global Database Editor
•
Powerful and flexible way to centralize
common pipeline data (ID, Schedule,
Roughness, etc.).
•
Heat transfer coefficients can also be
stored / specified in the same way.
•
The data can be easily accessed by any pipe
model.
Ease of configuration and maintenance!
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Beggs-Brill Moody Two Phase Flow Correlation
Objective
•
Model multiphase flow more accurately
in DYNSIM.
•
Developed from Air/Water two phase
flow experiments. Its widest application
has been in the area of pipeline
modeling/design.
Key Benefits
•
Well recognized in the upstream
industry.
•
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Applies to pipes of all inclination angles.
Key Output Parameters
• Flow Patterns [parameter name:
FLOWPATTERSEG
– Segregated (Stratified, Wavy,
Annular)
– Intermittent (Plug, Slug)
– Distributed (Bubble, Mist)
– Transition (between Segregated
and Intermittent flow patterns)
• Slip Holdup [parameter name:
HLSSEG]
– Defined as the fraction of an
element of pipe occupied by liquid
at a given time. It accounts for
the ‘slip’ effect.
– Mass Flow Rate
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Pipeline Elevation Profile
Objective
•
More accurate spatial definition of pipe
inlet/outlet elevations.
Key Benefit(s)
•
Long/irregular pipeline profiles descriptions
in one single pipe model.
1800
Pipeline Elevation Profile
1600
1400
1200
1000
800
600
400
200
0
0
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True Pipeline Elevation Profile
100000
200000
300000
400000
Kinetic Energy Effects for High Velocity Fluids
Objective
•
Modify the energy balance equation
to account for high velocity changes
in the pipe model.
Key Benefits
•
Useful for flare systems. Sudden
temperature changes due to high
velocity changes inside the pipe are
accounted for more accurately.
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Pipe Model Demo
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Ejector Model
•
New Model under the Process Equipment
Library.
•
Simplified Ejector design based on performance
curves.
•
Can be used to model steam Ejector.
Suction side flow is determined by the performance curves.
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Design Parameters - DEW
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Quality Improvements
5 year low for
total defects!
#
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Criteria
1
5.0 introduced CRs++ (no new
technical debt allowed)
2
Past Customer Reported Defect
CRs
3
Open Internal Defects from past
releases
Target
Value
End of Beta
Apr 2, 2012
0
57
0
61
76
57
<= 240
289
199
(20%
reduction)
DYNSIM 5.1 in March 2013
To be released in combination with PRO/II and ROMeo in
March 2013 as one common release
All products will share common component versions like
SIM4ME Thermo and SIM4ME Portal
Areas of focus:
 Second Phase of Engineering Productivity Improvements
 New and Enhanced Instructor and Training Capabilities and
Services
 GUI Enrichment for Improved Ease of Use
 Infrastructure Improvements
 Thermodynamic updates and additions
Slide
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Event Logger
• Instructor Capability available under
Tools Menu
• Actions are recorded in chronological
order and stamped with simulation
time
• Actions are stored in log file
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Event Logger
• In DYNSIM GUI
• Instructor actions appear in
Blue
• Operator actions in Dark Grey
• Non-differentiable actions
appear in Green.
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• Captures info in FSIM Plus
• Will support other DCS
emulations in the future
Backtrack Replay Enhancements
Record and replay the actions taken by the operator during a training session
Instructor Capability in Tools Menu
• Start Backtrack Action Recording
• Select Backtrack to Replay Actions
• View Backtrack Action Log
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Backtrack Replay Enhancements
•
Ground zero backtrack saved at the instance of changing to Backtrack
record mode.
•
Backtrack recording in engineering units with units in curly braces
•
Backtrack Action Log – can be saved in DYNSIM Scenario syntax
In User folder
Slide
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Backtrack Replay Enhancement
New column added in backtrack summary table to indicate whether
actions are associated with the backtrack.
Whether back track
Simulation time at which
replays are possible or
backtrack is saved.
not
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Scenario Enhancements
• Existing Scenario Summary Table enhanced to provide more
detail to the engineers.
• Value for the point is now based upon current UOM slate
rather than internal units
• Step number
(current step number which the scenario is executing)
• Current point value (current point value for the WAIT UNTIL command)
• Target point value (Target point value for the WAIT UNTIL command)
• Step Elapse Time (individual step elapsed time for WAIT command)
• Scenario Elapse Time (elapsed time since start of the scenario)
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TPM Enhancements
The instructor monitors and evaluates trainee's performance in operating a
simulated process plant based on a set of pre-defined criteria
TPM exercise saved automatically for a scenario without stop TPM
command
TPM feature is enhanced to include trainee name, ability to allow
multiple TPM’s session
TPM Template ID
New Column Exercise ID
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Trainee Name
TPM Enhancements
Ability to filter by Templates of
Exercises
Browse capability to save TPM
report as excel and PDF.
Option to change trainee name
available in tools menu.
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Opportunities Beyond DYNSIM 5.1
1. Investment in SIM4Me Thermo for new Applications
2. Look Ahead or Online Simulators
3. Complete merge of DYNSIM Power & DYNSIM
4. Auto-model Generation of Dynamic Models from SmartPlant
P&IDs
5. Improved User Added Model Capabilities
6. Improved InTouch Engine for End User Model Deployment
etc.
Many possibilities……….
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