Simulation
 
   ProSimulator - Operator Training Simulator

Introduction:

Accidents ruin profit and image of process plants and accidents are caused mainly due to mechanical failures or operational errors.

Most of today’s process plants like refineries, gas plants, power plants, fertilizer units and petrochemical plants are large, complex and integrated. The quantum of instrumentation, control logics and interlocks involved in these operations is quite enormous and varies from plant to plant. The various advanced control and optimization techniques that are implemented in many plants automate the critical plant operations and greatly remove routine operator actions. Also the existing plants are being upgraded both technology-wise and capacity-wise to give a boost in their performance.

Hence the operators tend to lose the integrated plant view, troubleshooting, operating capabilities and exposure. These drastic changes in technology & control systems in the existing plants, if not provided with adequate training to the operating personnel, affect safety, plant performance and hence profitability.

A good training is what is required to tackle and eradicate these problems. Classroom training is inadequate and on the job training is costly and risky. These are overcome with the introduction of a good training tool called the Dynamic Process Simulator.

The mathematical model of a process plant is the core of the Dynamic Process Simulator, which also incorporates the control systems, emergency shutdown logics and interlocks, and startup and shutdown procedures. The simulator presents the emulated view of the Distributed Control System (DCS) of the plant and hence provides very realistic environment for the trainee. The simulator training is controlled and monitored by an Instructor for imparting effective training.

The ProSimulator model is based on the first principles (Laws of Physics), Design and Experimental data from the plant. It consists of algebraic / differential equations representing mass balance, heat balance, momentum balance, reaction kinetics and equilibrium phase equations. These equations are solved numerically on every cycle giving all plant parameters. The Simulator model runs in real time with plant parameters getting updated once every 100 milliseconds. The scope of the model includes all equipments (battery limit – battery limit), discrete events (like safety valves), extreme conditions (cold start to design condition), and unlimited number of streams and components. The scope of the simulated model spans right from a simple centrifugal pump operation to complex process plants like a FCC/Hydro cracker/Ammonia/Ethylene Plant.

ProSimulator APPLICATIONS

Primary benefits:
The ProSimulator OTS systems offered are custom developed, high fidelity training systems and will enable the client to provide continuous
training and development of operator and engineers. By using the OTS systems, the client will be able to:

✦   Improve operating experience, confidence and accuracy in normal and abnormal plant operations.
        ✧ Normal operations.
        ✧ Cold and Warm start-up.
        ✧ Normal shutdown and Emergency shutdown.
        ✧ Unit throughput changes.
        ✧ Communication with field operators.
✦  Operator skills developed and sustained in handling emergencies, upsets, alarm management, feedstock changeover & product grade change over .
✦  Communications with field operation via field panel emulation.
✦  Improve understanding of general plant theory and concepts.
✦  Increase knowledge of plant systems and their function and interaction with other systems.
✦  Enhance understanding of plant control theory and operation.
✦  Demonstrate recovery from various upsets and malfunctions.
✦  Evaluate the level of knowledge acquired by a trainee .
✦  Improve Operator confidence .
✦  Faster training of new and replacement staff.
✦  Develop deeper process understanding.

Additional Benefits:

✦  Control and operability studies.
✦  Early identification of design problems & avoid costly corrections.
✦  DCS configuration checkout and validation.
✦  Checkout emergency shutdown systems.
✦  Validation of equipment sizing.
✦  Alarm system validation and assessment.
✦  Rigorous verification of standard operating procedures.
✦  Confirmation of DCS graphics.
✦  Process engineering studies.
✦  Control improvement studies.
✦  De-bottlenecking studies.
✦  Development of improved operating procedures.
✦  Develop Process Hazard Analysis (PHA).
✦  Documented step towards achieving OSHA compliance.

TYPICAL ARCHITECTURE

ProSimulator INSTRUCTOR STATION

ProSimulator Instructor station enables the instructor to control and direct the training sessions. To improve the ease of instructor actions, a graphical user interface with multiple windows, scroll windows, pull down menus, icons, 3D push buttons and dialog boxes are provided. All the actions can be enabled using a mouse pointer or touch screen. Thus an experienced instructor can work efficiently and a novice instructor can learn fast. The PC Windows XP -based ProSimulator instructor station combines the power, compatibility and simplicity with reduced learning time and greatly improves productivity. Thus ProSimulator instructor station groups common functions in a primary window, and lets you access other pertinent information through supplemental window. We have incorporated the “look and feel” feature of the industry - standard GUI user interface to make the instructor station more versatile and powerful.

ProSimulator Instructor Station Features:

Classification

Function

Purpose

Model selection

Model

To select the simulation model for the training session. List of models supplied will be listed and instructor can select any model for the training session.

 

 

 

Mode of operation

Mode selection

To select the model initial condition (Design, Cold condition). If the Design IC is loaded, the simulation database will be populated with base case data. If COLD IC is selected, the simulation database will be populated with shutdown condition data.

 

Run / Hold

Enable to run or freeze the simulation model. This feature will intermediate discussions and analysis.

 

Snapshot

To save / restore database variables on to disk file (permanent). Instructor can at any time save the simulation condition as snapshot and restore this condition at any time in the future. Any number of such snapshots can be taken by the instructor.

 

Backtrack

To Autosave database variables and go back in time (during the training session). This feature is very useful in reducing training duration as well as redo certain operation for better understanding.

 

Replay

To view the past process status for demo & analysis purpose.

 

Simulation speed

Increase / decrease the simulation speed (model cycle time) 0.1, 02, 0.5, 1, 2, 5, 10 x Real-time

 

 

 

Malfunction

Failures

To invoke various predefined failures (with delay) – equipment failures, utility failures, etc.

 

Disturbances

To introduce external disturbances on the simulated model (with delay and ramp time). Fouling, boundary conditions, etc.

 

Instrument failures

To introduce malfunctioning of sensors / transmitters and final control  valves  (fixed value or bias).

 

 

 

Field Operations

Field block valves/switches

To change status of field block valves (Open/Close) and  switches (On/Off)

 

Field glove valves

To change the opening of field globe valves (0-100%)

 

 

 

Automatic Training

Evaluation

To create and run pre created scenarios. This feature can be used for instructorless training.

 

Performance Monitor

To monitor required parameters & produce statistical report for performance.
Both the Excursion and Target evaluation methods are used for performance evaluation.

 

 

 

Reporting

Summary

To list tags along with current & design values

 

Data logging    

To log required tags at specified interval.

 

Alarm logging

To log all alarms

 

Event logging   

To log all operator and instructor actions

 

Summary report

To summarize the simulated plant conditions and produce MIS report.

 

Message

To send text messages to the operator

 

Instructor comments

Instruct can enter any of his comments during the training session and this will be stored in the session log file

 

Session log

All events of a training session is logged in a file which will be time stamped and permanently available for later analysis

 

Trending

Real time & Historical trending of tags

 

Scoring

This feature can be used to evaluate operator performance quantitatively.  The instructor can associate set of tags and target values and weights for every malfunction / disturbance and required time for the solution The system determines the score based on the weighed deviation at the end of the defined time.

Tools

Model view

For model development / tuning  This is the window for process engineer for modifying / developing models.

 

Calculator

Online calculator

 

Notepad

For instructor to edit/create text files

 

Password

To change Instructor password

 

Lock

To lock the instructor station

 

 

 

Online Help

Instructor

Instructor station user guide

 

Operator

Operator station user guide

 

Model

Process models user guide

 

 

 

Configuration

 

This feature is for viewing / modifying the existing network configuration

 

 

 

Training information

 

To maintain Instructor / Trainee database and select the Instructor / Trainees for a training session

Online Quiz

 

Online quiz for trainees. Instructor can set topics, questions/answers and the system pickup random questions and conduct the online test with a time limit.

ProSimulator OPERATOR STATION

The operator station is the heart of any simulation system. It is the window through which an operator or an engineer monitors, controls and manages the process plant. ProSimulator provides emulation for various DCS like Honeywell TDC3000/GUS or Yokogawa CS3000. All functions and features that are essential for training are included.

With ProSimulator, operators learn dynamic process interactions with the same in-depth understanding of your process as with full function direct connect operator-training stations. ProSimulator contains most of the standard features of real DCS console. Using PC keyboard or simulated keyboard (on the screen keyboard) or optionally emulated keyboard, the trainee can operate the simulated plant.

The features of DCS that are available are:

   ✦   Schematic Panel.
   ✦   Overview Panel.
   ✦   Control or Group Panel.
   ✦   Detail Display Panel.
   ✦   Alarm Annunciator Panel.
   ✦   Area Alarm Summary Panel.
   ✦   Unit Alarm Summary Panel.
   ✦   Area Trend Display.
   ✦   Online help.

The OTS will use actual process unit instruments and equipment tag names based on DCS configuration. This will include tag name, type, description, range, loop configuration, graphics, grouping, etc.

In general, all the DCS instrumentation (e.g. indicators, controllers, calculators and switches) that are associated with the agreed model scope are included in the model. All the control loops and the ESD systems shall be identical to the real plant.

All field operated valves and emergency block valves in the model scope are modeled either as Open/Close or as 0-100%.

ESD logic will be functionally simulated in the simulation software, while the events that activate the ESD systems in the plant will also activate the simulated systems. If these events are associated with simulated equipment, then these causes will be generated by the simulation. If the events are associated with non-simulated equipment, custom malfunctions may optionally be added to the scope of simulation to allow the instructor to trigger the events. Activation of the ESD systems will affect only simulated equipment.

The OTS system provided malfunctions of all rotating equipment.

The OTS system through Instrument Malfunction features supports failure of all instruments (transmitters and valves).

PROCESS MODELS

Sim Infosystems offers rigorous hi-fidelity dynamic simulation models for Refinery, Fertilizer, Gas processing and Petrochemical process plants. With our rich experience in Industry, we have already developed standard (generic) simulation models for most of the equipments unit operations and industrial plants.

We also offer to develop custom made simulation models for specific process unit, based on plant data. We have rich experience in developing such rigorous custom simulation models for process & power plants.

TRAINING SERVICES

To achieve operational excellence, companies must consistently improve their team’s knowledge, skills and commitment. Employee training is one of the most important investments a Company can make to maximize return on investment.

We are providing operations training programs to refining, fertilizer, gas plants, petrochemical and power industries. Our courses focus on plant operations and provide necessary theoretical inputs as well as simulator based hands-on-experience. The trainees go through normal plant operations, familiarize with plant configuration and control system, malfunctions, start-up, shutdown and emergency shutdown systems.

We have a panel of experienced instructors, who have rich operations experience. The trainee’s performance are monitored and evaluated by these instructors.

Some of the Standard courses are offered on a regular basis at various cities:

   ✦   Petroleum Chemistry.
   ✦   Basic Refinery operations.
   ✦   Pumps.
   ✦   Compressor operation.
   ✦   Heat Exchangers.
   ✦   Furnace operation.
   ✦   Distillation operation.
   ✦   Boiler operation.
   ✦   Instrumentation & Control.
   ✦   Crude Unit operations.
   ✦   Fluid Catalytic Cracking Unit operations.
   ✦   Hydrocracker unit operations.
   ✦   Hydro Desulphurization unit operations.
   ✦   Ammonia plant operations.

We can also design and provide custom training courses to suit your requirements and training objectives. These custom courses can also be conducted at your site.

Benefits for Industries
✦   Improved Plant Safety.

✦   Faster Recovery from External/Internal Process Disturbances.

✦   Efficient Plant Operations & Optimization Skills.

✦   Smooth Startup & Shutdown.

✦   Evaluation of Operator Proficiency.

✦   Increased familiarity of Controls & Interlock Systems.

✦   Verification of Plant Design & Operation Procedures.

Benefits For Academic
✦   In-depth Process Understanding..

✦   Industrial Exposure for Students.

✦   Hands on Training on DCS Operations.

✦   Manipulation of Controllers & Monitoring their effects.

✦   Tuning the PID values of controllers.

✦   Sound Fundamental Concepts of Process Control.

✦   Knowledge on complex Emergency Shut Down (ESD) System.

✦   Understanding the Intricacy & Complexity Of the real plants.

 

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Sim Infosystems Pvt Ltd.
No.11,1st Cross Street,,
Nehru Nagar,Kottivakkam.
Chennai - 600 041, Tamil Nadu, INDIA.
Tel/Fax: +91-44-2454 2617 / 24541823,
Mobile: +91-9176935805,
Sales: sales@siminfosystems.com.
 





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