2014 Aspen Technology, Inc.

All rights reserved

April 29, 2014
Optimize DCS Testing and
Operator Training with
Aspen HYSYS Dynamics


Webinar with Inprocess
01/05/2014 2014 by inprocess 2
Started in 2006
Process Simulation Experts
with many years of
experience
Office in Barcelona, Spain
Applications:
Operator Training Systems
Instructor Station
Hydrogen Network Optimization
Pressure Swing Adsorption simulation
Simulation projects:
Steady state: KPI calculation, soft
sensors, optimization
Dynamic simulation: Blow down and
relief calculation, flare studies, compressor
start up, flow assurance
Knowledge transfer/training:
Technology courses: process control, heat
transfer, improving refinery operations
Process Simulation
Software Extensibility
2014 Aspen Technology, Inc. All rights reserved |

3
Ongoing Series of Technical Webinars
Engineering Webinars for Education and Best Practices
UPCOMING WEBINARS OF INTEREST:
See How Process Ecology Reduce Emissions in Natural Gas Glycol Dehydration Facilities Using Aspen
HYSYS - May 6
th

A Tour of the Latest Innovations in the Aspen Engineering Suite focusing on process safety and
project risk reduction June 3
rd

ON DEMAND WEBINARS
Size Pressure Safety Valves and Design Flare Systems Using Aspen HYSYS and Aspen Flare
System Analyzer
Size & Rate Pressure Safety Valves with Aspen HYSYS and HYSYS Dynamics (Technical)
Upgrade Column Design using Aspen HYSYS Dynamics (Technical)
ADDITIONAL RESOURCES:
Public Website: www.aspentech.com
Aspen HYSYS Product Family Webpage: www.aspentech.com/products/aspen-hysys.aspx
2014 Aspen Technology, Inc. All rights reserved |

4
aspenONE Engineering

Economic
Evaluation
Operations
and Planning
Support
Equipment
Design
Basic
Engineering
Conceptual
Engineering
Safety
Analysis
Process
Development
Aspen HYSYS
&
Aspen Plus
Safety
Analysis
Operations
and Planning
Support
2014 Aspen Technology, Inc. All rights reserved |

5
Applications of Dynamic Modeling & Simulation
Operability Engineering Studies
Understand dynamic plant behavior, including upset propagation
Design and analysis of start-up, shutdown and process transition
strategies
Operability studies of highly-integrated processes
Design / Analysis of Control Schemes
Design the process and control system simultaneously
Analyze and improve basic control strategies
Pre-tune control loops
Evaluate, develop and test APC scenarios
Hazard and Safety Studies
Design and analysis of emergency shutdown systems, and pressure
relief and flare systems
Operator Training
2014 Aspen Technology, Inc. All rights reserved |

6
What Does HYSYS Dynamics Offer?
Seamless transition from steady
state to dynamic model
Dynamics Assistant
Interactive environment
Rich choice between simple and
detailed modeling options
A comprehensive library of
control and logical operations
Aspen Plus users:
Aspen Plus Dynamics performs
most of the same functions
2014 Aspen Technology, Inc. All rights reserved |

7
Comprehensive Training Curriculum
Online Training
HYSYS
HYSYS Dynamics
Self-Start
Jump Start Guides
Recorded Videos
Recorded Webinars
Sample Models
Classroom Training
Locations Worldwide
OPTIMIZE DCS TESTING AND
OPERATOR TRAINING WITH
ASPEN HYSYS DYNAMICS
JoseMaria Ferrer (inprocess)

Aspentech Webinar 29
th
-April-2014
AGENDA
Introduction
Dynamic Simulation
Operator Training Systems (OTS)
Performing DCS FAT
Early OTS concept
Inprocess Instructor Station
Training for Field Operator
Economic return
9
1995: MY FIRST CONTACT WITH CONTROL SYSTEMS
10
Source: The MOD Squad: Process automation at Dow.
http://www.controlglobal.com/assets/knowledge_centers/abb/assets/art_series_mod_squad_pa_dow.pdf
In mid 80s Dow implemented MOD5
globally, as of 2000 there were 1500
systems installed.
Can anyone mention a worldwide-spread DCS which is not from ABB, Emerson, Yokogawa,
Siemens, Honeywell, Schneider, Rockwell, GE Fanuc, Metso, SMAR, Azbil .????
Ill give a clue:
Apart from making good business with petrochemicals, Dow
Chemical also developed his own DCS. It was called MOD5
TM
,
programmed with DOWTRAN
TM
(a FORTRAN-like language)
With enough idiot lights and
pushbuttons to satisfy any primate,
Dows first attempts to automate were
complex and wonderful
MOD-5TM COMPUTER (in control room)
PROCESS CONTROL WITH DOWTRAN
11
Analog
Inputs
(AIs)
DOWTRAN CODE (CONTROL)

AC(1,200) = AK(1000,100,200) + AK(1003,5,200)
AC(2,100) = AK(1001) + AK(1004,10,100)

DO(1) IF STEP(4) OR STEP(1) OR (AI(101) GT AC(2))
DO(2) IF [STEP(2) AND AI(101) GT AK(1005,20,100)
AND AI(100) LT AK(1000)] OR [DO(2) AND AI(100) LT
AC(1)] AND AI(101) LT AK(1001)]
DO(3) IF STEP(2) AND # DO(2) AND AI(101) LT
AK(1001)

STEP(417) IF STEP(415) OR STEP(416) AND [AI(434) LT
AK(417,400,1000) AND AI(435) LT AK(417) AND
AC(430) LT AK(417) OR DM(417) OR [#DI(427) AND
DO(427) FOR DT(3427,5,2)]]

Source: Patent US 5408603 A.
www.google.com/patents/US5408603
P
L
A
N
T

I
N
S
T
R
U
M
E
N
T
A
T
I
O
N

Digital
Inputs
(DIs)
Analog
Outputs
(AOs)
Digital
Outputs
(DOs)
P
L
A
N
T

V
A
L
V
E
S
,

M
O
T
O
R
,

e
t
c

Thousands of DOWTRAN code lines are executed in two redundant Mod-5
computers every second. It allowed to make uploads of new code without
plant shutdown. There were a need to verify all the code before uploads.
MOD-5TM COMPUTER (in testing room)
PROCESS CONTROL & SIMULATION WITH DOWTRAN
12
DOWTRAN CODE (CONTROL)

AC(1,200) = AK(1000,100,200) + AK(1003,5,200)
AC(2,100) = AK(1001) + AK(1004,10,100)

DO(1) IF STEP(4) OR STEP(1) OR (AI(101) GT AC(2))
DO(2) IF [STEP(2) AND AI(101) GT AK(1005,20,100)
AND AI(100) LT AK(1000)] OR [DO(2) AND AI(100) LT
AC(1)] AND AI(101) LT AK(1001)]
DO(3) IF STEP(2) AND # DO(2) AND AI(101) LT
AK(1001)

STEP(417) IF STEP(415) OR STEP(416) AND [AI(434) LT
AK(417,400,1000) AND AI(435) LT AK(417) AND
AC(430) LT AK(417) OR DM(417) OR [#DI(427) AND
DO(427) FOR DT(3427,5,2)]]

Source: Patent US 5408603 A.
www.google.com/patents/US5408603
DOWTRAN CODE
(SIMULATION)

AISIM(100)=AO(100)
AISIM(101)=AI(100)-AI(102)
.
DISIM(100)=DO(100)
DISIM(101)=DO(101)

Simulating DIs (like pump ON, or valve CLOSED) was easy, but simulating a
temperature in a tray or a column top pressure was not possible.
The purpose of the DISIM/AISIM was for basic checkout and training
AIs
DIs
WHY DYNAMIC SIMULATION?
13
1. Equipment sizing and
process layout verification:
Compression systems
Pipeline networks
2.- Flare Load calculation
and PSV sizing
Design/revamp flare
networks
3.- Emergency System
verification and HAZOP
studies support
HIPPS studies
Cause & Effect matrixes
4.- Design control layout
Scenarios analysis
Perturbation rejection
Control loops selection
5.- Prototyping MPC
Obtain MPC models
Study non-linearities
Test/Tune MPC controller
6.- Develop virtual sensors
Online Analyzers backup
Fault diagnostic
Look-ahead sensors
7.- DCS checkout
DCS FAT with virtual plant
Operating procedure test
8.- Operator Training System(OTS)
Operator Training
Emergency scenarios
Knowledge base system
Consolidated
Exploring
14
Real World
DCS Hardware
& Software
DCS Console
& Graphics
Field
Operator
Panel Operator
AI, AO
DI, DO
Control
System
& SIS
Process
Plant
Human
Machine
Interface
OTSs are developed in order to
mimic, as close as practical to
reality, the Operating Process Plant
and its associated Instrumentation
and Control System

There are two main approaches to
achieve such objective:
Direct-Connect OTS (also called
Stimulated OTS)
Emulated OTS
15
DCS & SIS
Emulation
Software
DCS Console as in Control Room
Instructor Station &
Field Operator Devices
Direct-Connect OTS Real World
Aspen HYSYS
Dynamics Model
DCS Hardware
& Software
DCS Console
& Graphics
Field
Operator
Panel Operator
AI, AO
DI, DO
Control
System
& SIS
Process
Plant
Human
Machine
Interface
Panel Operator
AI, AO
DI, DO
16
Emulated Graphics Console
Instructor Station &
Field Operator Devices
Emulated OTS Real World
Aspen HYSYS
Dynamics model
DCS Hardware
& Software
DCS Console
& Graphics
Field
Operator
Panel Operator
AI, AO
DI, DO
Control
System
& SIS
Process
Plant
Human
Machine
Interface
Panel Operator
Controls & SIS also
in Aspen HYSYS
Dynamic model
OTHER AREAS OF VALUE OF OTSS
17
WHAT IS A STANDARD DCS FAT?
Factory Acceptance Test (FAT) involves of:
1. Hardware, such as controllers, I/O modules, power supplies,
terminations, etc.
2. Logic, forcing analog and discrete inputs, then watching the
logic to be sure it responds as expected.
3. Operator displays and alarms, which are tested in
conjunction with the forced logic and signals step above.

18
MOTIVATION FOR BETTER TESTING
Increasing complexity of DCS Tightens the requirements for
functional testing before commissioning.
Client/Suppliers try to minimize involved risks: This includes
software testing and early detecting specification errors.
At the real installation: The available time does not suffice to
achieve the required depth of testing.

Testing environments with a simulated virtual plant can help.

19
WHY USING SIMULATION IN LOGIC DCS FAT?
Some of the DCS testing items made in
OTS projects:
20
Pre-tune control loops
Test control modules implementation
Test motor start/stop logic
Validate permissive logic for start-
up/shutdown sequences
Verify controls interactions with other
modules or against perturbations
Check graphics displays operability with
real procedures
Re-setting for certain alarms limits
Test ESD timing and logic sequences
Evaluate procedures for abnormal or
emergency operation

DCS FAT WITH ONLY EMULATED DCS&SIS
Control design and configuration is independent of the
hardware, DCS emulators allows all configuration to run in
virtual control with identical functionality
Discrete I/Os are stimulated by engineer, Analog I/Os use tie-backs
Virtual Control with
DCS emulator
21
DCS FAT WITH FULL VIRTUAL PLANT
Virtual Control with
DCS Emulator
The I/Os (discrete & analog) are fully
simulated by a process dynamic
simulator of the entire plant
22
STANDARD FAT VS. VIRTUAL PLANT FAT
STANDARD DCS FAT DCS FAT with VIRTUAL PLANT
Software DCS Emulator DCS Emulator, HYSYS Dynamics
Timing When DCS hardware and
I/Os modules are available
As soon as DCS logic and
configuration is available
Testing proceeding Limited to I/O signal forced
by engineer
Same as during commissioning &
start-up with real plant
Procedures testing Limited verification All procedures and start-up/shutdown
sequences
Loop testing and
control narrative
Simple tie-backs Full, as in real plant
Alarm verification Only non-time dependent Full, as in real plant
SIS verification Limited, no plant interaction Full, as in real plant
23
WORKFLOW FOR DEBUGGING DCS CODE
24
DCS Vendor
OTS Vendor
Customer
Pre-FAT
DCS
Database
v0

D
e
f
e
c
t
s

R
e
p
o
r
t

DCS FAT
Post-FAT
DCS
Database
v1
Post-FAT
DCS
Database
v2
OTS FAT OTS SAT
DCS SAT
Post-SAT
DCS
Database
v3
OTS
DCS
OTS
update
Start-up
Post-Startup
DCS
Database
v4

D
e
f
e
c
t
s

R
e
p
o
r
t


D
e
f
e
c
t
s

R
e
p
o
r
t


D
e
f
e
c
t
s

R
e
p
o
r
t


D
e
f
e
c
t
s

R
e
p
o
r
t

OTS
update
Important: OTS Vendor acts as an independent auditor of the DCS functionality
HYSYS BASED OTS: OPTIONS BY DCS
25
DCS
Vendor
DCS System
DCS vendor
Emulator
Emulated OTS Direct-Connect OTS
ABB 800xA 800xA Simulator YES YES
Siemens PCS7 PLCSim/SIMIT YES YES
Emerson DeltaV DeltaV Simulate YES YES
Yokogawa Centum VP FCS/HIS Simulator YES YES
Honeywell Experion PKS C300-Sim YES YES
Schneider Foxboro I/A FSIMplus YES Depend on Schneider
Rockwell RSLogix RSLogix Emulate YES YES
SMAR System 302 System 302 YES YES
Best Choice
ADDITIONAL EARLY OTS OPTION
26
EARLY OTS
In order to provide to the Operators a process
simulator as soon as the dynamic model is
developed, not impacted by delays in DCS
project
DCS
Post-FAT
Database

Delay in DCS FAT shifts OTS delivery

OTS
INPROCESS INSTRUCTOR STATION
27
Inprocess has developed its Instructor Station software to manage training sessions, but also to
produce Emulated OTSs, to handle multiplatform communications and to speed up OTS development.
ACTIONS OF FIELD OPERATOR IN OTS
28
Field actions in OTS are not available in the control room
operator consoles. They are usually by the Instructor
in the Instructor Station or FOD panel:
Certain pumps are started/shutdown at field
Compressors packages use local operation panels to be
operated by field operators
Special operating procedures require manual by-passes
ESD valves/pumps need to be re-armed at field
Inspection of equipments and field instruments reads
Isolation procedures for equipment maintenance


TYPICAL OTS ARCHITECTURE WITH FOD
29
2 Operator Stations
1 Instructor Station:
Dynamic plant models
Inprocess Instructor Station (IIS)
Printer
DCS & SIS Emulation Server
Critical Action
Panel
1 Field Operator panel:
Inprocess Field Operating Devices
(FOD)
TYPICAL OTS ARCHITECTURE WITH FOD-3D
30
2 Operator Stations
1 Instructor Station:
Dynamic plant models
Inprocess Instructor Station (IIS)
Printer
DCS & SIS Emulation Server
Critical Action
Panel
1 Field Operator3D:
Inprocess Field
Operating Devices in
3D (FOD-3D) and
Oculus Rift
SCREENSHOT OF FIELD OPERATOR VIEW
31
SCREENSHOT OF FIELD OPERATOR VIEW
32
WHY THE FOD IN 3D
33
Deeper involvement of field staff in understanding the
process
The full operations team can practice critical events such as
startups, shutdowns and emergency responses in a fully
realistic manner
Best field practices can be designed and communicated to
all staff
This type of learning is extremely motivating
Reduce travel and living costs associated with on-the-job
training


Operating companies have found advantages in:
START-UP WITH OTS
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
With OTS
Typical Start-up
Plant starts weeks earlier
Faster ramp-up
Less incidents
Safer Operation
34
Weeks
OTS SURVEY: TIME SAVINGS FROM START-UP
35
Source: http://www.worldoil.com/December-2012-Economic-benefits-of-training-simulators.html
18 days average time savings
on first commissioning and
start-up

2.2 days average time
savings on commissioning
and start-up after major
turnaround
The aim of the survey was to quantify the benefits of simulator training in the
Norwegian oil and gas industry.

A total of 99 answers was received from 11 different companies, including Statoil,
Shell, AddEnergy, ConocoPhillips, BP, Petrolink, Gaz de France, ExxonMobil,
Marathon, Talisman and Srco
OTS SURVEY: REDUCTION UNPLANNED SHUTDOWN
36
3 (average) unplanned shutdowns per year that can be avoided
Source: http://www.worldoil.com/December-2012-Economic-benefits-of-training-simulators.html
OTS SURVEY: ECONOMIC SAVINGS
37
15.3 million$ average estimated savings due to training simulator
15 MNOK = 2.6 Million$ 200 MNOK = 38.4 Million$
Source: http://www.worldoil.com/December-2012-Economic-benefits-of-training-simulators.html
QUESTIONS, CONTACT
Contact:
JoseMaria Ferrer
Inprocess Technology & Consulting Group, S.L.
Phone: +34 933 308 205
Cell: +34 607 570 685
josemaria.ferrer@inprocessgroup.com

38
Q&A

Irina Rumyantseva, AspenTech
irina.rumyantseva@aspentech.com
Ron Beck, AspenTech
ron.beck@aspentech.com