Transcript PPT Template

Slide 1
SSE-09
Dynamic Simulation
From Checkout to Optimization
Howard Jemison
© 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.
Agenda
“A computer lets you make more mistakes
faster than any other invention in human
history, with the possible exceptions of
handguns and tequila.”
– Mitch Ratcliffe
● Operator Training Simulator Overview
● Control System Checkout with Simulation
● Advanced Process Control with Simulation
Slide 3
Industry Pressures - The “Perfect Storm”
Environmental
Regulations
Utilization Down
High Energy Costs
Supply > Demand
Margins Down
Loss or Lack
of Experience
Slide 4
Population
in ME and
NA between
ages 15-24
Operator Training Simulator
Plant
Control system
DCS
+ ESD
Mechanical Failure
Dynamic Process Model
ACCIDENT PERCENTAGES
Software Emulation
38
26
Operational Error
Operator
consoles
Unknown Caus es
HMI
Proces s Ups ets
12
10
7
Natural Hazard
Des ign Error
Ars on/Sabotage
Slide 5
4
3
Same or similar
The Current Human Resource Crisis
• Industrial companies in a human resource crisis
• Fewer people entering the industrial workforce
• 10,000 retiring per day for the next 19 years
• Large inexperienced youth population
Slide 6
New Approach to Training
• This comes from a combination of training approaches geared
to minimizing time to efficiency, then driving new levels of
operational and financial performance
Slide 7
New Approach to Training
• This comes from a combination of training approaches geared
to minimizing time to efficiency, then driving new levels of
operational and financial performance
Slide 8
Dynamic Simulation Suite – Applications
across the Process Lifecycle
DESIGN
Slide 9
DCS & PLC
CONFIGURATION
STARTUP
OPERATIONS
Control System Checkout
World Class Operator Training
Simulators
SIS, TMC and PLC Controls
Logic Testing/Verification
Coordinated Training of Control
Room and Field Operators
Operator Training Simulators
Slide 10
“EMRE estimates the training can
reduce the time taken for the
operator to progress to the top
level of operator competency by
30 to 50%”
“Operators train for emergency
preparedness under real-world
conditions”
“The operators understand how
to avoid upsets and shutdowns
and improve efficiency, safety and
reliability”
“….improves employees abilities
to respond to potential
emergencies”
Slide 12
Well Trained Staff Improve Safety & Plant
Availability Operations
An ARC Report (2010)
reports that operator error
results in 42 percent of
unscheduled plant shutdowns
US Health and Safety Executive
reports 26% of accidents occur
due to operational
error
ACCIDENT (Incident)
PERCENTAGES
38
Mechanical Failure
26
Operational Error
12
Unknown Causes
10
Process Upsets
7
Natural Hazard
Design Error
Arson/Sabotage
Slide 13
4
3
How Much Money Will We Save?
• Average cost per major incident related to operator error exceeds
$80M.
• Findings by the Chemical Safety Topical Committee (funded by DOE)
reveal an average of one chemical incident/day.
• Average cost to comply with ORPS process is estimated at $2M per
incident *
Slide 14
Deethanizer Process Diagram
Reflux drum
Propane in overhead target 1.5%
Reflux
Ethane in bottoms target 4%
Top product
Reboiler steam
Bottom product
Slide 15
Forcing Inputs
TAG
DESCRIPTION
TYPE
AI101
PROPANE IN OVERHEAD
AIN
AI102
ETHANE IN BOTTOMS
AIN
AC101
PROPANE IN OVERHEAD
CONTROL
PIDX
AC102
ETHANE IN BOTTOMS CONTROL
PIDX
LC101
CONDENSER TANK LEVEL
PIDX
TT102
TOP COLUMN TEMPERATURE
AIN
TT103
BOTTOM COLUMN
TEMPERATURE
AIN
FC101
FEED FLOW
PIDX
FC102
BOTTOM PRODUCT FLOW
PIDX
LC102
REBOILER TANK LEVEL
PIDX
PC101
COLUMN PRESSURE
PIDX
FC103
REBOILER STEAM FLOW
PIDX
FC104
TOP PRODUCT FLOW
PIDX
FC105
REFLUX FLOW
PIDX
Slide 16
•
Create a simulation
•
Deploy the controls
•
Create an I/O cross
reference list
•
Force an input
Automatic Loop Validation
TAG
DESCRIPTION
TYPE
AI101
PROPANE IN OVERHEAD
AIN
AI102
ETHANE IN BOTTOMS
AIN
AC101
PROPANE IN OVERHEAD
CONTROL
PIDX
AC102
ETHANE IN BOTTOMS CONTROL
PIDX
LC101
CONDENSER TANK LEVEL
PIDX
TT102
TOP COLUMN TEMPERATURE
AIN
TT103
BOTTOM COLUMN
TEMPERATURE
AIN
FC101
FEED FLOW
PIDX
FC102
BOTTOM PRODUCT FLOW
PIDX
LC102
REBOILER TANK LEVEL
PIDX
PC101
COLUMN PRESSURE
PIDX
FC103
REBOILER STEAM FLOW
PIDX
FC104
TOP PRODUCT FLOW
PIDX
FC105
REFLUX FLOW
PIDX
Slide 17
•
Create an Excel input file
•
Automatically force inputs
•
Automatically validate
loop output
Demo: Automatic Loop Validation
Slide 18
Bulk Configuring Tieback
TAG
DESCRIPTION
TYPE
AI101
PROPANE IN OVERHEAD
AIN
AI102
ETHANE IN BOTTOMS
AIN
AC101
PROPANE IN OVERHEAD
CONTROL
PIDX
AC102
ETHANE IN BOTTOMS CONTROL
PIDX
LC101
CONDENSER TANK LEVEL
PIDX
TT102
TOP COLUMN TEMPERATURE
AIN
TT103
BOTTOM COLUMN
TEMPERATURE
AIN
FC101
FEED FLOW
PIDX
FC102
BOTTOM PRODUCT FLOW
PIDX
LC102
REBOILER TANK LEVEL
PIDX
PC101
COLUMN PRESSURE
PIDX
FC103
REBOILER STEAM FLOW
PIDX
FC104
TOP PRODUCT FLOW
PIDX
FC105
REFLUX FLOW
PIDX
Slide 19
•
Create a simulation
•
Deploy the controls
•
Create an I/O cross
reference list
•
Start Bulk Configurator
•
Create tieback based on
the I/O tag names
Bulk Configuring Tieback
Control System
Tag or I/O name
Create a model object
to match the physical
plant or use Lead/Lag
or point objects
DEETHANIZER:FT105.POINT
Give the object a name
that correlates to the
Tag or I/O
Valve: FV105
PID: FC105
Slide 20
Deethanizer Process Diagram
Manipulated Variables
Controlled Variables
Propane in overhead target 1.5%
Reflux drum level ~ 0.5 m
Overhead pressure ~ 3050 kPa
Top column temperature range 260 – 300 K
Reflux flow rate
~ 12000 kg/hr
Ethane in bottoms target 4%
Bottom column temperature
range 360 – 400 K
Slide 21
Top product flow ~ 6700 kg/hr
Reboiler steam flow ~ 2200 kg/hr
Deethanizer Optimization
Slide 22
Demo: Deethanizer Optimization
Slide 23