Day - 2 - 1500 - Dynamic Simulation Technology in Future

Dynamic Simulation
Technology in the future

hiromichi HAMASAKI
Omega Simulation Co., Ltd.
5th July 2007
TECHNOLOGY INNOVATIONS FAIR

& USERS CONFERENCE – 4th-5th July 2007
AGENDA
• Omega’s Company Profile, Mission, Vision and Dream

• Simulation Technology in Plant Lifecycle
• Simulator for Operation Support
Current
Near Future (Vision)
Far Future (Dream)
Page 2
© Omega Simulation Co., Ltd.
1
Company Profile, Mission and Vision
Name Omega Simulation Co.,

Co., Ltd (OSC)
Foundation Date April 1, 1997

Parent Company Yokogawa Electric Corp. (YHQ)
Mitsui Chemicals Inc. (MCI)
< Topics>
1999 Developed Dynamic Simulation Environment
called “ OmegaLand ” running on Windows-PC.
2003 Received “ SCEJ Technology Awards ” to Visual
Modeler.
(SCEJ: Society of Chemical Engineering, Japan)
<Mission>
Develop and sell plant simulator application products for
global spread of plant simulator
<Vision>
Contribute to development of plant operation through
simulation technology
Page 3
Simulation Technology in Plant Life Cycle
Plant
PlantImprovement
Improvement
Cycle of Plant Improvement
Plant Design Trial Run Plant Operation

MVPC
Operation Design Check of Control system
、Operator Training
Optimization、
Operator Training
Plant Plant
PlantSimulator
Simulator
PlantDesign
Design&&Operation
Operation (Dynamic
(DynamicSimulation)
Simulation)
Concept Design Process Design

PFD
R&D
Physical Properties PFD
PJT Evaluation Optimization
Products Data
Cost estimate
Process
ProcessSimulator
Simulator
Process Design & FS
(Steady
(SteadyState
StateSimulation)
Simulation)
Page 4
2
Process Simulator / Plant Simulator
Process Simulator Plant Simulator
Steady-State Simulation Dynamic Simulation

( Static ) Safety Device Condenser System
Control System
PC Q
Line Change
Re-boiler System
Q
Spare Equipment
Covered all units associated
Mainly calculate Mass & Besides Distillation Column, Re-boiler, Condenser,

Heat Balance. Spare Pump, Control Valve, Instruments, safety
Re-boiler and Condenser device, Line, etc are considered.
are included into Distillation Operation of Startup/Shutdown, Transition are
system as One System. considered in addition to Steady-State Condition.
Page 5
Coverage area of Simulator

Plant Simulator
Optimization Verification of
Control Logics
Plant Simulator
Plant Operation Support (guidance, diagnosis, prediction)

Operation Study of Plant Improvement
Operator Training
Process Education
Development and Verification of

Plant rating
Plant Control System,
Process Line design
Design Safety System and
Process Simulator
Construction Operation Procedure

Equipment
Rating Design Basic Design
Process Control Strategy
Design Safety Design
Conceptual Design
Operating Condition
Usage Steady State Simulation
Type Dynamic Simulation
Page 6
3
Operation Support Simulator
Simulator for Operation Support

What is, and what should it be?
Page 7
Classification of Plant Operation
Planned Events Non-Planned Events
Normal Operation Minimum knowledge/skill

Recognition / Decision
Making against Abnormality
Daily Operations Formalized Operation

Malfunctions not Normal
* Load , Set-value change etc.
but Probable to happen
Routine work
Exceptional Experience Complete knowledge of

Operation Plant Operation
Plant Equipment maintenance Emergency Shut-down

Not daily Operations Start-up / Shut-down User Plant Emergency S/D
Experience
Page 8
4
Operation Support by DCS and/or APC
DCS and/or APC


Routine work


Experience
Page 9
Operation Support Package (ExaPilot)


Routine work


Experience
Exapilot
Page 10
5
Safety System (Prosafe-RS)


Routine work


Experience
Prosafe-RS
Page 11
(near) Future Trend of Operation Support
Class room study


Routine work


Experience
Stimulation OTS
Page 12
6
Conventional OTS System
OmegaLand CENTUM
Process Model
PCS
VM Space
Exatif
DCS
View
Exec/DB
Page 13
Application Verification Environment
CENTUM
OmegaLand Prosafe-RS
Process Model PCS

OPC Client
Prosafe-
RS
VM Space
Exatif
DCS
View
Exec/DB
ExaPilot
ExaOPC
Server
APC
Page 14
7
Virtual Test Function
(HIS)
Simulate complete DCS on computers (including actual DCS application)

100% Engineering and operation functionality
Wireless debug to simulate inputs and outputs
Snap shots for evaluations
Page 15
Stimulation versus Emulation
TARGET SYSTEM STIMULATION SOLUTION EMULATION SOLUTION
SIS and F&G DCS Engineering DCS Engineering

Engineering Station Station
Station 100% simulated
Man Machine Interface

Man Machine Interface Emulated by Company X
100% simulated
SIS and F&G DCS controllers

SIS and F&G DCS controllers Emulated DCS controllers Emulated by Emulated by
controllers By Yokogawa 100% simulated Company X Company X
Transmitters, detectors and valves Transmitters, detectors and valves Transmitters, detectors and valves
Plant (Process)
Simulated by
Simulated by
Company X
: Test function : mimic
Page 16
8
Stimulation versus Emulation
TARGET SYSTEM STIMULATION SOLUTION EMULATION SOLUTION
SIS and F&G DCS Engineering DCS Engineering

SIS and F&G
Engineering Station Station
Engineering
Station 100% simulated
Station

Man Machine Interface Emulated by Company X
100% simulated
SIS and F&G DCS controllers

SIS and F&G DCS controllers Emulated DCS controllers Emulated by Emulated by
controllers By Yokogawa 100% simulated Company X Company X
Transmitters, detectors and valves Transmitters, detectors and valves Transmitters, detectors and valves
Plant (Process)
Simulated by
Simulated by
Company X
: Test function : mimic

Dec. 2007
Page 17
Exatif (dedicated DCS-OTS link)
Ethernet Exatif
(Interface between CENTUM CS300
Virtual and Omega plant model) Plant model
Field Control Stations Interface installed on a CS3000 computer OmegaLand
CENTUM CS3000
OPC supports this

Function only
INTERFACE
Data Transferring Functions between Model Computer and FCS simulator(s) of CENTUM CS 3000 system.
RUN/FREEZE Function
This function allows link software to change status of all of the function blocks in FCS simulators at anytime.
SNAPSHOT/STEPBACK FUNCTION
This function allows link software to save snapshot files to keep the situation relating FCS simulators.
TIME SCALE CHANGE FUNCTION

This function allows link software to change time scale of FCS simulator.
CENTUM CS 3000 MESSAGES ACQUIRING FUNCTION

This function allows link software to acquire messages from CENTUM CS 3000.
Page 18
9
(not near) Future of Dynamic Simulator (On Line)
Through real-time utilization of plant modeling

and simulation technologies,
we offer
safer and more efficient operation
and
realize
Transparent Plant Operation
Page 19
Operation in future
The virtual plant simulator is set aside DCS system which
actually controls the plant.
Through real-time utilization of plant modeling and
simulation technologies, operators want to know more
efficient or economical operation and achieves Transparent
Plant Operation.
- Aid for “decision making” Normal Zone
- Aid for “strategic operation”

- What-If study
- Advanced preparation of operations Response
predictio
n
now
Page 20
10
Virtual Plant Simulation Technology
Prediction
Response
Y prediction
I LIT
AG
ITH
now
On-line Plant TW
AC
Simulator mirroring Diagnosis
< Technology >
Data Reconciliation in Normal Zone
KNOW IN ADVANCE
dynamic condition
Parameter estimation of
steady model in dynamic
condition
SE Visualization, Estimation
EC
Basis LEA
RL
Y
Off-line Plant
Simulator for OTS
Page 21
Future Direction of Dynamic Simulation
Multi-
Multi-Purpose Use
As a Virtual PLANT Site Wide
BIG NEEDS Quality Optimization
Tradition
Optimization
Optimization of
Steady State Operation Operation Scheduling
Operation
Operation Prediction Prediction based on
Training
Training
Making Process Market Demand
Process Visible Maintenance
Trouble
Education Prediction
Situation Diagnosis
Process Estimate Equipment
Analysis Parameter
Estimate
Check of
Control Method Design of
& Logic Plant Level
小 TIME
Present Near Future
Page 22
11
Thank you for your attention.
Page 23
12

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Dynamic Simulation

Technology in the future

5th July 2007

TECHNOLOGY INNOVATIONS FAIR

• Omega’s Company Profile, Mission, Vision and Dream

Name Omega Simulation Co.,

Foundation Date April 1, 1997

Simulation Technology in Plant Life Cycle

Cycle of Plant Improvement

Plant Design Trial Run Plant Operation

Concept Design Process Design

Process Simulator Plant Simulator

Steady-State Simulation Dynamic Simulation

Covered all units associated

Mainly calculate Mass & Besides Distillation Column, Re-boiler, Condenser,

Coverage area of Simulator

Plant Operation Support (guidance, diagnosis, prediction)

Development and Verification of

Construction Operation Procedure

Simulator for Operation Support

Classification of Plant Operation

Planned Events Non-Planned Events

Normal Operation Minimum knowledge/skill

Daily Operations Formalized Operation

Exceptional Experience Complete knowledge of

Plant Equipment maintenance Emergency Shut-down

Planned Events Non-Planned Events

Normal Operation Minimum knowledge/skill

Daily Operations Formalized Operation

Exceptional Experience Complete knowledge of

Plant Equipment maintenance Emergency Shut-down

Operation Support Package (ExaPilot)

Planned Events Non-Planned Events

Normal Operation Minimum knowledge/skill

Daily Operations Formalized Operation

Exceptional Experience Complete knowledge of

Plant Equipment maintenance Emergency Shut-down

Planned Events Non-Planned Events

Normal Operation Minimum knowledge/skill

Daily Operations Formalized Operation

Exceptional Experience Complete knowledge of

Plant Equipment maintenance Emergency Shut-down

(near) Future Trend of Operation Support

Class room study

Planned Events Non-Planned Events

Normal Operation Minimum knowledge/skill

Daily Operations Formalized Operation

Exceptional Experience Complete knowledge of

Plant Equipment maintenance Emergency Shut-down

Application Verification Environment

Process Model PCS

Simulate complete DCS on computers (including actual DCS application)

Stimulation versus Emulation

TARGET SYSTEM STIMULATION SOLUTION EMULATION SOLUTION

SIS and F&G DCS Engineering DCS Engineering

Man Machine Interface

SIS and F&G DCS controllers

: Test function : mimic

TARGET SYSTEM STIMULATION SOLUTION EMULATION SOLUTION

SIS and F&G DCS Engineering DCS Engineering

Man Machine Interface

SIS and F&G DCS controllers

: Test function : mimic