VPLink & PCS7 Case Study

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Kristopher Copeland
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1 User Conference Philadelphia,PA VPLink & PCS7 Case Study Stephen V. Smith Eastman Chemical Company

2 Outline Simulation Overview Project Overview VPLink Overview VPLink / PCS7 Interface Options & Components VPLink Database Configuration Project Simulation Highlights & Details Simulator Considerations Q & A 2

3 Simulation Overview Engineering System Checkout Database Configuration Logic Programs Graphics Communication Operator Training User Configuration Process/control basics Low/Medium Fidelity Process Engineering + Operator Training Process/control details Process Design Medium/High Fidelity 3

4 Project Overview PAS Retrofit Honeywell TPS Siemens ICC6000 Justification ICC6000 Removal Labor Reduction Batch Management / Control PAS Alignment Process Esterification (36 Mixers) Hydrolysis (138 Turbos) 2 Train Types 5 Products AI 550, AO 75, DI 1600, DO

5 5 VPLink Overview Features 3 rd party Cape Software Multi-vendor Interface Capability Model Fidelity Low/Medium (Ideal) High (Doable) Field / Process Simulation Only Interfaces w/ Actual System & Configuration Extraction & Configuration Utilities Simulation Loop Toolbook Application Trainer / Tester GUI Tag-based Interpretive vs. Compiled Logic / Algorithm Library High-level Language Support

6 VPLink Overview Components Environment Toolbook v4.0 Application Same for all PAS I/O Driver Environment PAS Unique for each PAS Requirements Toolbook v4.0 Environment I/O Driver Windows 95/98/NT/2000/XP PC 6

7 PCS7 / VPLink Architecture OS Dev & Testing ES Dev & Testing Environment I/O Driver OS Server 7 OS Operator Training

8 VPLink / PCS7 Interface Options Simatic Net OPC AS Required (No PLCSim) Manual OPC Tag Synchronization WinAC OPC Limited OB Support WinCC OPC Supports AS or PLCSim Automatic OPC Tag Synchronization 8

9 VPLink Database Configuration Symbol Table Extraction Export to <*.sdf> format Getioss7 Utility (Cape) Extracts I, Q, IW, QW tags Adds OPC Server to address Analog EU Ranges Manual Tag Configurator / Excel Auto - TAKEFLDS Utility 9

10 VPLink Database Configuration Bulk Configurator Quick method of defining simulation for a group of tags with similar naming conventions and behavior. 10

11 VPLink Database Configuration ASCII Editor Database can be exported/imported as a tab-delimited ASCII file. 11

12 VPLink Database Configuration Tag Definition Page Creates new tags, modifies data for existing tags, deletes existing tags. 12

13 VPLink HMI Audience Developers PAS VPLink Trainers Options Tag Definition Page Tag Parameters Tag Values Graphic Pages Tag List Animated Schematics 13

14 VPLink HMI Mixer / Turbo Graphic Page One graphic for the entire system. 14

15 Simulation Design Initial Mixer/Turbo Set Exported Symbol Table (*.sdf) Executed Getioss7 utility Built simulation for one turbo using Tag Definition Page Tested graphic & tags Exported database to ASCII Replicated turbo tags for others in set (Excel) Imported ASCII into database Modified graphic scripting for new turbos Tested graphic & tags 15

16 Simulation Design Mixer/Turbo Set Tag Replication Toolbook Export VPLink database to ASCII file Excel Sort listing on Description & Tagname Copy Mixer xxx tags Copy Turbo xxx(a,b,c,etc.) tags Rename xxx yyy in copy group Add logic to service paths for Turbos yyy Toolbook Import ASCII file Modify Mixer/Turbo graphic page script Test graphic & tags 16

Time-base Design Warp Factor Adjusts time-based calculations to speed process dynamics. Adjustments are global (all time-based tags affected equally).

17 Time-base Design Warp Factor Adjusts time-based calculations to speed process dynamics. Adjustments are global (all time-based tags affected equally). Ideal for speeding the entire simulation for purposes of testing and training. Based time constants, rates, and durations on event realtime estimates from Operations. 17

18 Time-based Design Algorithm Gains Gain knobs can be, and were, incorporated into algorithm parameters to allow time adjustments on a tag basis. 18

19 Failure Scenarios Scenario Manager Executes a sequence of events. Beneficial for pre-defined training and testing scenarios. Will be used for next round of operator training and possibly cgmp validation. 19

20 Failure Scenarios Algorithm Inclusion Failure modes may be, and were, incorporated into the parameters of a tag. 20

21 Configuration/Program Checkout Device definition/logic I/O assignments Custom objects/blocks Interlocks Alarms Phase logic Batch control Replication verification 21

22 Operator Training Initial (Brief) Platform Graphic layout / conventions Object control / interfacing Devices Phases Batch management Future (Extensive) Object control / /interfacing Batch management Problem intervention (Scenarios) 22

23 Simulation Benefits Operator Training Batch Logic Testing Replication Verification Quicker Start-ups Parallel, Independent Development Contract Labor Savings??? 23

24 Simulator Considerations Multi-platform Capability PAS Simulator Interface User Interface Database Design Tools Model Development Options Algorithm Library Scripting Higher Generation Languages Model Fidelity Vendor Support 24

Cape Software Inc. Houston TX

The Virtual Process Overview and Applications Cape Software Inc. Houston TX Corporate Overview Founded in 1996 HQs located in Houston Products: VP Link Drivers and database management tools Rigorous modules