At Emerson Exchange 2009, Martin Berutti presents on the business benefits, requirements, and steps for building a Virtual DeltaV system with a virtual plant and I/O.

1. Building the Virtual Plant for DeltaV

2. Introduction The Business Climate and need for a Virtual Plant Virtual Plant System Architecture Component Selection – DeltaV Simulate and MiMiC Virtual Plant Planning Concerns Process Model Development Operator Training Scenarios Instructor Stations / Graphics / Controls Additional Virtual Plant Features - Snapshots, Speedup / Slowdown

4. Retirement of experienced operators

5. Increased government oversight

6. Fiduciary liability of operations management

8. Half of the current work force will retire (more than 500,000 workers) in 5 to 10 years

9. Irreplaceable knowledge loss

10. Newer generation of workers with less mechanical inclination

11. Petrochemical / energy plants in danger of closing due to lack of qualified operators

13. Automation can handle simple and some complex operational tasks quicker, safer, and at a lower cost than a human operator

15. Operators lose skills to deal with plant upsets or abnormal conditions

16. 7years to achieve operations competence0 20 40 60 80 100 OPERATOR ERROR IS THE HIGHEST CAUSE OF LOSS(average dollar loss in millions of dollars)

18. Operator actions that are inappropriate or insufficient

19. Operating procedures that areincomplete or in error

20. Documentation demands from OSHA National Emphasis Program

21. Finding issues on site can delay startups

22. Not finding issues until too late can endanger the process and operations staff

24. Process design models do not have the real-time performance or range of operations conditions

25. Using an emulated automation system

26. Operator HMI graphics, alarms, controls should be identical to real system

27. Control strategies should be identical

28. Adding simulation to the control system configuration

29. Adds error and risk to automation system

30. Starting too late

32. Training on identical HMI graphics, alarms, controls

33. Testing on identical control strategies

34. Virtual Process – dynamic simulation

35. Selective application of simulation fidelity

36. Easy-to-use, easy-to-change

37. Integrated approach for testing and training

38. Integrated to automation project schedule

40. Virtual Plant / Control system used to test operating procedure and control system

41. Implicit – how it really works

42. Virtual Plant / Control System used to allow new operators to use the operator controls

43. Tacit – how the decision effects the whole plant

44. Virtual Plant / Control System Training Scenarios show the new operator how to work with the real plant / control systemEffective Knowledge Transfer Must Include Hands On Operations of the Plant Source: NTL Institute for Applied Behavioral Science

47. Product Quality - reduce off-spec product – $50K-$1MM / run

48. Operating Cost - reduce unscheduled downtime – $5-50K / hour

49. Reduce Risk – reduce unknown failures and incidents - $50K - $1MM / incident

50. Automation System Application Software

51. Operator Actions and Responses

54. Non-intrusive IO simulation (FF, Digital Bus IO, Serial IO)

55. Validated systems (GAMP4 guidelines)DeltaV Workstations (DV License Pack or DVSim MultiNode) Area Control Network MD Controllers with Virtual IO Module SimulationNetwork

57. Module parameter simulation (simulate value)DeltaV Simulate Multinode PPN, PSN, OSN Workstations Area Control Network DeltaV Simulate ASN with Modules assigned SimulationNetwork

59. Module parameter simulation (simulate value)DeltaV Simulate Standalone Workstations SimulationNetwork

61. Software Acceptance Testing and Operator Training

62. IO channel simulationDeltaV Simulate Multinode PPN, PSN, OSN Workstations Area Control Network DeltaV Simulate Multinode ASN or PPN with DeltaV SIS SimulatePro License DeltaV Simulate Standalone with DeltaV SIS SimulatePro License SimulationNetwork

65. OPC

66. MiMiC SIO TagsDeltaV Simulate Workstations PLC /ESD Simulator MD Controllers w Virtual IO Module PLC /ESD SimulationNetwork

67. Components – DeltaV Simulate DeltaV Simulate - DeltaV licensing scheme for “off-line” simulation systems Exact same graphics, alarms, faceplates, detail display as the operating plant Control modules run in Assigned Modules ofworkstation running same functions as controller Full DeltaV Batch and APC functionality supported Simulate Convert – makes controller configuration Simulate workstation friendly FF Function Blocks converted to standard DeltaV blocks External IO references to Digital Bus, Serial IO modified to OPC read/write parameters DST references removed

68. Components – DeltaV Simulate The DeltaV Simulate Experience

69. Components – DeltaV Simulate DeltaV Simulate - DeltaV licensing scheme for “off-line” simulation systems Standalone – no DeltaV Networking MultiNode – DeltaV networking, controllers PPN, Professional Plus Networked PSN, Professional Station Networked OSN, Operator Station Networked ASN, Application Station Networked SimulatePro option for Standalone or MultiNode Increase module execution memory from 16 MB to 96 MB Supports freeze/snapshot/restore, speedup/slowdown SIS SimulatePro – v10.3, allows 32 logic solvers per workstation

71. Non-intrusive simulation interfaces

72. Integrated Operator Training Management

73. Protects control system integrity

74. Easy to use

75. Designed for use by the end-user or integrator

76. Automatic integration with control system

78. Selective application of simulation models

79. Dynamic, accurate modeling functionsMiMiC is Built for DeltaV!

82. How many operators, availability

83. Span of training – process unit or train, unit operation

84. Team or individual training

85. Model performance requirements – accuracy, dynamics, operating conditions, shutdowns/startups

87. First Principles Modeling – based upon laws of conservation of mass, energy using properties

88. Empirical Modeling - realistic limits to the model using actual or assumed process correlations or dataTypes of Process Models Steady State models - plant and process design. No transitions between process states, time delays or lags Dynamic models – SAT and OTS. Time delays, lags, transport effects are modeled. Model design and math required for Steady State and Dynamic are much different SAT and OTS – we assume the process is designed, models reflect the design dynamically!

89. Choosing Model Complexity Fidelity – Rigorousness or Complexity of the Model Low Fidelity – simple IO signal modeling, device tiebacks, value initialization. Model requires user intervention to respond to automation system actions. Medium Fidelity – mass balance model, heat balance model, streams are single component. Model runs automatically and responds to automation system actions and process changes. High Fidelity – complete mass balance, rigorous heat balance, reaction kinetics, streams model individual component thermodynamic properties. Model runs automatically and responds to automation system actions and process changes in a very similar manner to the designed process. ANSI/ISA - 77.20 - 1993 (R2005) Section 6, 7

93. SIO definition for DeltaV Railbus (VIM), DeltaV Simulate, DeltaV SIS SimulatePro

94. Base level IO, Analog, Discrete Tieback Models

95. MiMiC Modeling Node for each DeltaV device (controller, workstation)Process Model Development

97. DeltaV Railbus (VIM) – SIO Tag to physical IO address

98. DeltaV Simulate – OPC module parameter path

99. DeltaV SIS Simulate – OPC physical IO addressProcess Model Development

101. Easy startup with user selected SIO definitionProcess Model Development

103. Auto-generated Simulation Database

104. IEC Modeling Blocks with WiresEngineering Unit Conversions from Block to Block are calculated by MiMiC Simulation Engine

106. Advanced IEC Objects and Functions with Streams

107. Thermo / Flash / Stream Property Functions

108. Advanced Modeling Core Objects

109. Vessel, Valve, Pump, PRV, HX, DHX, Stream T

110. PF Solver

111. Energy Management Objects

112. Boiler with Furnace, Steam Header, Desuperheater, Fuel, Turbine

113. Distillation Objects

114. Column, Reboiler, Stripper

115. Separator Objects

117. Structured set of malfunctions or process events introduced into running dynamic simulation

118. Process models should be designed to support Scenarios

119. Scenarios can be easily added or changed without chanign process models

120. MiMiC Operator Training Manager Scenarios

121. Malfunctions can be set in MiMiC or DeltaV Simulate

122. MiMiC Simulation functions have malfunction actions built-in

123. Scoring conditions can be defined for each Malfunctions

124. “Ad-Hoc” Instructor driven scenarios with reporting

125. Training sessions use a Scenario definition

127. Familiar user interface

128. DeltaV-centric approach

129. Greater engineering effort

130. MiMiC Component Studio Instructor Station Graphic

131. New user interface to learn

132. Simulator-centric approach

134. Requires DeltaV SimulatePro, MiMiC OTM

135. Integrated Snapshot control of DeltaV modules, MiMiC simulation

136. Does not support Batch Executive Operations

137. MiMiC Process Snapshot also supported with Previse Infi90 simulator, and HIMA Soft PLC

138. Speedup / Slowdown

140. Summary Proven CapEx, Opex Benefits to using Simulation for SAT and OTS Time to Market - reduce startup time – $100-500K / day Product Quality - reduce off-spec product – $50K-$1MM / run Operating Cost - reduce unscheduled downtime – $5-50K / hour Reduce Risk – reduce unknown failures and incidents - $50K - $1MM / incident Questions?

141. Where To Get More Information MYNAH Website – www.mynah.com DeltaV Operator Training Systems with MiMiC DeltaV Software Acceptance Testing with MiMiC Pre-recorded E-Seminars Understanding Simulation Fidelity Paper and Podcast Simulation System Integrity Paper and Podcast Delivering the Virtual Plant Paper and Podcast Simulation Objections Answered Paper and Podcast Using Simulation to Optimize the Results of Automation Projects, Dr. Tom Fiske, ARC MYNAH YouTube Series Martin Berutti, MYNAH Technologiesmartin.berutti@mynah.com, +1.636.681.1567Skype: mberutti