Aug 11, 2005 - Experiences. â« From Design to Training. 1. Design .... Comprehensive Model Libraries. Equipment .... Develop technician diagnostic, tuning and.
Dynamic Simulation in the complete Plant Lifecycle
Peter Both, Invensys Systems GmbH, Invensys SimSci-Esscor Cal Depew, Invensys Systems Inc., Invensys SimSci-Esscor
Process Systems Get More from One Avantis • Foxboro • SimSci-Esscor • Triconex
Agenda
Process Systems
Experiences From Design to Training. 1. 2. 3. 4.
Design Control Checkout Initial Training Plant Performance Improvement
Questions
Company Confidential
2
Dynsim OTS Projects
Process Systems
8/11/05
Refining
Refining (Cont’d) – Total Leuna
– ExxonMobil
Preferred OTS Services Provider New projects underway
– Total Dalia
– Husky Energy
Crude Unit Gas Oil Hydrotreater Hydrogen Plant Sulfur Recovery Reformer Naphtha Hydrotreater Diesel Hydrotreater Sulfur Recovery OrcrudeTM (Crude/Vacuum/Cracking) Gasification Hydrocracker Sulfur Recovery Air Separation Unit
– Total Normandy (underway)
Hydrocracker Hydrogen Plant Sulfur Recovery Unit
– Shell Bonga
FPSO
– Shell EA
FPSO
– Saudi Aramco Uthmaniyah
– Opti-Canada Long Lake (underway)
Integration
Upstream
– PDVSA Puerto La Cruz (underway)
Integration
Reverse Osmosis Plant
– ExxonMobil ERHA (underway)
FPSO
– Agip-Petroli Kashagan (underway)
Offshore platform Onshore turbo expander gas plant Oil Stabilization Sulfur Recovery
LNG – Tractebel Reganosa (underway) Company Confidential
LNG Terminal 3
Dynsim OTS Projects
Process Systems
8/11/05
Power – – – – – – – – – – – – – – – – –
Southern Company (13 Systems) Wisconsin Energy (3 Systems) First Energy (2 Systems) TransAlta Centralia Plant PPL Montana (2 Systems) Intermountain Power Public Service New Mexico (2 Units plus environmental models) Deseret Mississippi Power Puerto Rico Power Authority (PREPA) (2 Systems) Iberdrola (Combined Cycle) Platte River Rawhide Dayton Power and Light (2 Systems) Washington Group Mystic River (Combined Cycle) Tuscon Electric Sceco PP9 (Combined Cycle) 50 More
Company Confidential
4
Dynsim Users
Process Systems
8/11/05
Japan
Global
– ExxonMobil
North America – – – – – – –
Bechtel Colt Engineers ABB Lummus Conoco Phillips Koch Glitsch Fluor Daniel Nova Chemicals
Latin America – PDVSA
Europe – – – – – –
Snamprogetti Eni S.p.A. (Agip) E&P Technip Hyperion Polimeri Europa (ENI Chemicals) EDL Anlagenbaugesellschaft mbH
Chiyoda JGC (E&C) Kobe Steel (E&C) Tsukishima Kikai (E&C) IHI (E&C) Shinko Air Water (E&C) Mitsubishi Gas Chemical (Chemical) Sumitomo Chemical (Chemical) Toray (Chemical) Maruzen Chemical (Petrochemical) Toyota Motor (Bio Dept) Idemitsu Mitsubishi Materials Air Water National Institute of Advanced Industrial Science and Technology – Kanazawa Univ. – – – – – – – – – – – – – – –
Company Confidential
5
Process Systems
From Design to Training
Company Confidential
6
Process Systems
Get More from Dynsim SIM4ME Dynsim/SIM4ME Dynsim includes Model Instructor GUI DCS
• Multiple Engines DYNSIM
• Simulation Executive • Instructor Interface
SIM4ME
PLC
Vs. Other Products
Excel
Other products: • Single Engine
2nd
• Executive not included
DYNSIM
• Instructor features not included Company Confidential
7
Combined Engineering/Instructor GUI Data Historian Thermodynamics Cross Referencing
Process Systems
Scenarios Interactive Control Model Library
Snapshot Management
Malfunctions
Trends
Custom Widgets Company Confidential
8
Dynamic Simulation Suite
Plant / Validate Design PROCESS DESIGN
1
Process Systems
Checkout Controls
Train Personnel
Improve Performance
DCS CONFIGURATION
INITIAL START
PLANT OPERATION
2
3 Company Confidential
4 9
Project Phase 1: Plant Design - Validate Design
Process Systems
“Test your plant in the office, not in the field. Dynamic simulation can verify plant design before you commit capital to a project.”
Company Confidential
10
Project Phase 1: Plant Design Dynamic Simulation Benefits
Process Systems
Validate Design
PROCESS DESIGN
DCS CONFIGURATION
INITIAL START
PLANT OPERATION
• Reduce equipment cost through reduced overdesign • Verify safety of relief and flare systems • Validate controls such as compressor anti-surge • Analyze operability for highly integrated plants
Company Confidential
11
SIM4ME: PRO/II to Dynsim Translator
Process Systems
Open PRO/II file from Dynsim.
Steady State Simulation S1
Transfer Thermo data
S4
C1
Adds additional equipment
S2
Flowsheet Layout
S6 S3
Preliminary Equipment Sizing
S5
Dynamic Simulation
Company Confidential
12
Comprehensive Model Libraries Equipment
Controls
Electrical
Company Confidential
Process Systems
Utilities
13
Integrated Solutions DYNSIM™ & Excel
Process Systems
Surge Controller
Trip motor
Company Confidential
Data Export to/from Microsoft Excel Engine
14
Dynamic Engineering Studies (Dynsim) Column Relief Load Reduction
Process Systems
Problem – Conventional methods are very conservative leading to overly expensive flare systems and unnecessary flare or flare header replacements.
Solution – Dynamic simulation provides an alternative to conventional calculation methods and provides substantially lower relief loads. Flare load reductions up to 50% are possible. – Dynamic simulation is consistent with API RP-521 methods.
Benefits – Save relief and flare system capital expenditures up to several million U.S. dollars.
Company Confidential
15
Dynamic Engineering Studies (Dynsim) Compressor Surge
Process Systems
Problem – Expensive compressors can be damaged by inadequate anti-surge control and equipment design.
Solution – Validate controls to keep compressors out of surge, especially during startup and shutdown. – Evaluate performance using hot gas bypass vs. cold gas bypass designs.
Benefits – Prevent damage multi-million dollar machinery.
Company Confidential
16
Dynamic Engineering Studies (Dynsim) Cryogenic Depressuring
Process Systems
Problem
– Vessels with light hydrocarbons become very cold during depressuring requiring expensive metallurgy.
Solution
– Calculate the mean metal temperature as a function of time during depressurization for gas processing and LNG applications. – The mean metal temperature is substantially less severe than the fluid temperature and expensive metallurgy and design choices can be avoided.
Comments
– Depressuring model is validated with actual data.
Benefits
– Avoid use of stainless steel metallurgy for savings up to several million U.S. dollars. Company Confidential
17
Project Phase 2: DCS Configuration
Process Systems
“Checkout of controls in the lab can save days or weeks of commissioning time and can get your plant on line sooner.”
Company Confidential
18
Project Phase 2: DCS Configuration Dynamic Simulation Benefits
Validate Design
PROCESS DESIGN
Process Systems
Checkout Controls DCS CONFIGURATION
INITIAL START
PLANT OPERATION
• Identify control logic errors • Identify graphics configuration errors • Test signal ranges • Pre-tune control loops • Test integrated and coordinated controls
Company Confidential
19
Modular Simulation Architecture Available DCS/PLC Interfaces
design operate Process Systems
DCS –
Foxboro I/A Series FSIM (virtual stimulation)
–
ABB/Bailey BALSIM (full em.)
–
ABB/Bailey BALTRAN (Partial Stim)
–
ABB Industrial IT
–
Emerson OVATION
–
Emerson DeltaV
–
Honeywell (third-party)
–
Yokogawa (third-party)
GUI
SIM4ME
PLCs –
Triconex TRISIM (virtual stimulation)
–
Allen-Bradley PLC-5
–
GE Mark IV/V/VI
–
Alstom Funoc Turbine
–
Modicon PLC-984
–
Woodward Governor
Generic –
OPC Interface
Dynsim Engine
DCS
Excel® Engine
PLC
Requires additional Licensing Company Confidential
3rd Party Engine
20
Control Checkout Studies (Dynsim/TRISIM Plus) Turbomachinery (TMC) Control Checkout
Process Systems
Problem – Complex turbomachinery control (TMC) can lead to startup delays. Improperly tuned controls can lead to damage to multi-million dollar equipment. Ethylene LNG FCC Wet Gas Compressors
Solution – Checkout new TMC controls before commissioning or poorly behaving existing controls
Benefits – Validate Triconex controls to get new controls on line sooner. – Improved reliability – Prevent equipment damage Company Confidential
21
Project Phase 3: Initial Startup Personnel Training
Process Systems
“Train operator in the safe and efficient operation of the plant with an emphasis on preventing catastrophic failure.”
Company Confidential
22
Project Phase 3: Initial Startup Operator Training
Validate Design
PROCESS DESIGN
Checkout Controls
Train Personnel
DCS CONFIGURATION
INITIAL START
Process Systems
PLANT OPERATION
• Familiarize operators with new graphics • Train operators for startup and shutdown • Improve operator emergency response skills • Develop technician diagnostic, tuning and maintenance skills
Company Confidential
23
Objectives
Process Systems
Improve Control System Response Expand Operator Comfort Zone Capture Best Practices Procedure Increase Startup/Shutdown Training Frequency Improve Reliability (Upset, Abnormal Situation, Malfunctions)
Company Confidential
24
Instructor Overview Background
Company Confidential
Process Systems
25
Project Phase 4: Plant Operation Improve Plant Performance
Process Systems
“Test both process and control system design modifications in a risk free environment”
Company Confidential
26
Project Phase 4: Plant Operation Improve Plant Performance
Validate Design
PROCESS DESIGN
Checkout Controls
Train Personnel
DCS CONFIGURATION
INITIAL START
Process Systems
Improve Performance
PLANT OPERATION
• Experiment with control system modifications • Evaluate alternative process designs • Optimize operational procedures • Test and pre-tune APC systems
Company Confidential
27
Improve Plant Performance Test Bed Value Proposition
Process Systems
By understanding an existing process better, small changes in the arrangement of existing plant equipment, feed point locations, operating conditions or control strategies can result in tremendous improvements in safety, yield, process variability, energy utilization, product quality & waste minimization. By understanding the existing controls better, small changes to control interlock logic and permissives, operator display organization, and controller tuning can result in tremendous improvements to emergency condition response and startup and shutdown procedures. We have a uniquely competitive position w.r.t. Foxboro I/A Series control systems.
Company Confidential
28
Large Offshore Simulator Architecture InTouch InSQL
SIM4ME Instructor Station GUI
Process Systems
CCCSIM Micro I/A
TRISIM Well Locate
InControl
Thorn Graph
ABSIM
In P
3rd Party Process Model Utilities
In
3rd Party Process Model Water Flood 3rd Party Process Model 3rd Party P Production Process Model Inlet
* Previous version of Dynsim (Tsunami 6.0.22)
FSIM Foxboro I/A 48 cp60s
SIM4ME Executive
Pr
Instructor AW
Instructor WP
rog res s
OLGA2000 og re ss
Wells/Pipelines
OLGA2000
Operator WP
(Wells/Pipelines)
Dynsim-P Models
Company Confidential
29
Plant Testbed Example FPSO with Integrated Pipeline Modeling
Process Systems
Required by FPSO (Floating Production Storage and Offloading) OTS project. Predict operating procedures to avoid Slugging Test process improvements Test control improvements
Elevation profile
GUI
FLOWLINE
E le v a tio n [ m ]
300 200 100 0 -100
DYNSIM
Foxboro IA FSIM
0
500
1000 1500 2000 2500 3000 3500 4000 4500 5000 Horizontal length [m]
OLGA-HYSYS Demo case - Level 1 Cource: Exercise 1
SIM4ME
Triconex TRISIM
OLGA 2000
Company Confidential
30
Complete Lifecycle
Process Systems
“One dynamic model over the complete plant lifecycle.
Company Confidential
31
SimSci-Esscor Dynamic Simulation Suite: “From Design to Training!” Validate Design
PROCESS DESIGN
• Reduce cost through reduced over design • Verify safety of relief and flare systems • Validate controls such as compressor anti-surge • Analyze operability for highly heat integrated plants
Checkout Controls
Train Personnel
DCS CONFIGURATION
INITIAL START
• Identify control logic and graphics errors • Pre-tune control loops • Test instrument ranges • Test integrated and coordinated controls
• Familiarize operators with new graphics • Train operators for startup and shutdown, and emergencies. • Develop technician diagnostic, tuning and maintenance skills
Company Confidential
Process Systems
Improve Performance
PLANT OPERATION
• Experiment with control system modifications • Evaluate alternative process designs • Optimize procedures • Test and pre-tune APC systems
32
SimSci-Esscor Dynamic Simulation Suite: “From Design to Training!” Validate Design
PROCESS DESIGN
SimSci-Esscor Dynamic Simulation Suite
Process Systems
Control Checkout
OTS
Plant Improvement
DCS CONFIG.
INITIAL START
PLANT OPERATION
YES
YES
YES
Engineering Only Simulators
YES
Need Auxiliary control emulations
Not an integrated environment and requires add tools
Too difficult to modify and maintain
Equation Solvers
YES
Not used for this purpose
Not used for this purpose
OTS Only Simulators
Not usually used for this purpose
Not used for this purpose (e.g. DCS, Design)
YES
Company Confidential
YES
YES
Too difficult to modify and maintain
33
Why do Dynamic Engineering?
Process Systems
Reduce Equipment Costs – Many design parameters are based on transient operating conditions.
Evaluate First of a Kind Plant Designs – These plants may have unforeseen process, control, and relief problems. – Reveal problems during design to avoid costly modifications after startup.
Validate Control Strategy – Test the control strategy as defined on a PFD. – Avoid costly troubleshooting and tuning efforts in the field.
Test Heat Integration – Complex designs with tight heat integration may need supplemental startup heat.
Analyze Flare and Relief Systems – Validate relief system design as a result of a Hazop analysis. Company Confidential
34
Dynsim for Process Equipment Design:
Process Systems
Results in significant equipment cost savings
Induction motor torque curve 2.5
2
Torque factor
1.5
1 Series1 0.5
0 0
0.2
0.4
0.6
0.8
1
1.2
-0.5
-1
Compressor studies avoid equipment damage and lost production. speed - nornalized
Cryogenic Depressuring Studies save eliminate stainless steel metallurgy.
HPU Depressuring Studies can save US$millions by reducing feed/effluent heat exchanger design
Column Relief Load Reduction studies can eliminate unnecessary flare system expansions
Company Confidential
35
Dynamic Engineering Applications
Process Systems
Fractionation – Column Relief Studies for unit revamp studies to verify safe design and avoid/reduce flare system expansion. – Control validation
Compressors – Surge Control – Startup
Refinery Flare Systems – Time dependent pressure profiles
Upstream/Gas Processing Cryogenic Depressuring – minimum metal temperature and metallurgy selection – Valve Sizing
Hydroprocessing Unit Depressuring – Feed/Effluent Exchanger design.
Refinery Steam Generation, Cogen, and Distribution Studies – Backup steam response requirements – Control validation
Boiler Draft Studies – Boiler implosion risk analysis Company Confidential
36
Dynamic Engineering Studies Benefits Summary
Process Systems
Improve Project ROI (Process Design Studies)
– $1M for relaxed flare/vessel metallurgy requirements – $2M for removed requirement for flare system revamp at greater unit throughput – $5M to avoid boiler strengthening to FGD retrofit
Reduce Commissioning Time (Control/Operability Analysis) – – – –
Validate controls for stable operation Verify process will behave as expected. Checkout startup and shutdown procedures and logic Get on line sooner!!
Improve Operations (Decision Support / OTS) – – – – –
Reduce off spec production Reduce flaring Improve safety Protect equipment Maintain operator knowledge
Company Confidential
37
Process Systems
Thank you
Company Confidential
38
