Cape Software Inc. Houston TX

Transcription

1 The Virtual Process Overview and Applications Cape Software Inc. Houston TX

2 Corporate Overview Founded in 1996 HQs located in Houston Products: VP Link Drivers and database management tools Rigorous modules Scoring engine etc Test Compiler Logic Validation XP TrendCorder High Speed trending for Root cause analysis

3 What is VP Link? A dynamic representation of a chemical process to an offline control system.

4 VP Link components in a client / server architecture VP Link components run seamlessly over the network

5 Virtual Process : Overview Windows based interface: intuitive No Changes to Logic programs: non-invasive I/O Hardware not required (cost advantage) Read value of outputs Eng/Operator Station VPLink Write simulated inputs Calculate Process Variables

6 Some of our customers...

7 Supported Systems ABB 800 xa, Industrial IT ABB Mod300, Advant, Bailey Triconex:Tricon/Trident Honeywell Experion PKS TDC,TPS, FSC Honeywell Plantscape / Rockwell ProcessLogix GE Fanuc series 90 A-B PLC5/SLC500,CLX, Modicon,Siemens-Ti 505 Foxboro I/A,Archestra Siemens APACS, PCS7, S7 Yokogawa CS3000/R3/ ProSafe Etc...

8 Different Architectures for different Applications Logic Testing Setup Parallel Training Setup Engineers test different units, interacting with each other Trainees operate identical units, in parallel

9 The Virtual Process for Legacy ABB Mod300 System VP Link 3.x Server(s) ABB DDE Server with VP3 driver VP Link/ABB Interface Trainer Station DDE over TCP/IP Optional VP Link/SIS Interface ABB Turbo Node SIS Station Mod300 Controllers Operator Station

10 VP Link Specifics : ABB Mod300 Interface TCP-IP based interface Robust DDE based connectivity Non-intrusive ( Set points in Manual ) Interface work in parallel with other simultaneous connections (such as ABB Portal,etc) for vertical integration Full forward integration with 800xA components for seamless simulation migration

11 Does the type of process matter? VP Link is a proven solution for : Batch (recipe / state control based strategy ) Semi-continuous Continuous How? VP Link model is I/O based Hence isolated from control strategy

12 VP Link Applications I - Logic Validation

13 Cost of changes over a typical project development cycle Incre ementa al Cost Minimal to moderate impact Maximal cost impact Time IAT FAT SAT PSSR

14 V-Approach methodology: application to validation Safety Requirement Spec Narrative Pre Start-Up Safety Review Run manual Tests Cause & Develop Effect Scenarios Function Block Design Black Box Testing Deliverable Verification Functional Logic

15 Logic Validation with VP Link VP Link Allows: Graphicsp verification Logic checkout at I/O / block / module / system level Interlock schedule approval Integrated Testing :Mapping to DCS and interaction between DCS/PLC logic ( gateway points tests) How? Automates repetitive testing task (ie resets etc ) Facilitates FAT with customized graphics Collaborative testing framework thru distributed architecture Thoroughly debug prior to online download, ie, Management of Change and periodical testing Test Compiler complies with IEC61508/61511

16 Simulation Screen shots Automated Tag sheet Input/Output sheets per ESD HMI for advanced testing or training

17 VP Link Applications II- Operator Training Simulator (OTS)

18 II- Goals of Operator Training Knowledge Transfer Assess trainees proficiency Refresher Training Re-certification Train Operator s for Emergency Response Faults / Malfunctions / Upsets (Real or Instrumentation) Exercise Startup / Shutdown Procedures Turnaround Run Pre-Startup Familiarize staff with HMI, Overlays, Navigation, FAT Alarm Pages, Trend Displays

19 Operator Training System (OTS) using VP Link Actual control program is solved in native environment for realistic control response Trainees operate the virtual plant using actual consoles, graphics and keyboards ESD (Emergency Shutdown Device) is fully integrated in the process model and OTS HMI graphics are imported in VP Link to offer an intuitive trainer interface High Quality process modeling tools, simulating the most complex chemical processes (Rx,Dist,Compressors ) Scoring Engine for knowledge retention metrics Experienced, in-house Chemical engineers to deliver turnkey, customized training solutions for your process

20 Operator Knowledge Assessment : the Scoring Engine Excel configuration Front End Scenario launched sequences Targets (timing, rate, value, tolerance window) Actions ( I/O activity) Order (logical relationship between steps) Independent trainees logs with: normalized scores relevant actions & timing

21 What kind of process simulation do you need? A closer look at the competition

22 Marginal cost Analysis of process model fidelity ~ 2,000 I/O Oil Refining unit(fcc, HDC etc) $900, $800, $700, $600, $500, $400, $300, $200, $100, $ Simulation Investment Vs level of Fidelity Logic Validation OTS / Engineering VP Link 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

23 Why is Hybrid modeling more cost effective? No compositional (I/O based) = more flexibility All dynamics CAN be captured Rigorous modules available: Distillation modules Heat Exchanger, Compressor & OPEN blocks Reactor module ( catalytic,treating,cracking etc) Liquid Flow Network / HxNGen (and documentation) Sequential and Simultaneous Matrix Solving schemes integrate seamlessly Approximations compensated for by the control outputs Layer Approach minimizes model upkeep costs VP Link allows exactly for desired model fidelity Accuracy: 99% quasi Steady State / 85% full transient

24 A note about Fidelity Fidelity is perceived by Operators ONLY through monitored process variables Fidelity should reflect the overall accuracy of the SYSTEM= process simulator + control environment

25 Conclusion VP Link solves simulation needs from simple to sophisticated, rigorous modeling. OTS node can used as an engineering Test Bed system, for preventive / periodical logic validation Unattended dreal ltime trainee performance logs Modeling environment is flexible, easy to learn and maintain Available New Version Service keeps VP Link components up to date, with free technical support Cost Effective simulation package for OTS,using Off the Shelf components for process model and control or emulated control Cross platform functionalities makes VP Link an evolutive investment

26 Questions???

27 High Level Schedule : OTS Project

28 Methodology and project Schedule for Typical OTS Project Customer Process Model Model Needs Model Fine Acceptance Identification development Tuning And Delivery End User Automation Vendor Gather plant Data PFD & PIDs IO configuration HMI screens (first round) Evaluate : Scope Fidelity SIS comms Scoring Database Extraction Trainer Screens LFN Layout model development Operations Feedback Final IO configuration Final HMI screens On-site connectivity test Dynamics tuning Upset/training i Scenarios Train the trainer Start Operator Training T=0 T=2 weeks T=2.5 month T=3 months