WHITEPAPER. Optimizing Results in Automation Projects with Simulation. The Proven Value. July 24, 2006

Transcription

1 July 24, 2006 WHITEPAPER Optimizing Results in Automation Projects with Simulation The Proven Value By Martin Berutti, MYNAH Technologies The use of simulation systems for automation projects and automation system lifecycle management has proven to provide excellent business benefits for process industries. These proven benefits are realized by applying simulation to system testing and operator training. After analyzing the use of simulation systems for automation projects and lifecycle management, industry leaders attest that the business benefits for this investment are compelling. Differentiating Simulation Systems Simulation systems used for plant design are different than simulation systems for testing and training automation systems. Steady-state and dynamic models used for plant design are valuable for designing processing plants, developing economic models of process units, and implementing good process engineering practices like pinch analysis. However, they are typically unusable for automation and lifecycle management. Therefore, plants synthesize simulation in testing, training, and lifecycle management by: Simulating Automation Projects to Maximize Capital Expenditures Simulation should be integrated into the project lifecycle at an early stage. The use of simulation systems is covered in the Front End Engineering Design (FEED) as well as the test plans for the system. As application software is developed, it is thoroughly tested with a simulated IO system and process models in an off-line environment. In addition, the same simulation system is then used for training operations staff on the use of the automation platform and application software. Finally, integration with Manufacturing Execution Systems (MES), Electronic Batch Records (EBR) systems, and other vertical business applications can be tested while the operations staff is trained. Improving Operational Excelllence ence with Simulation in Automation System Lifecycle Management Upgrades and enhancements to the process automation system after the initial capital project can have a great effect on increasing the return on the investment in the automation system. However, many process facilities hesitate to make such changes because they do not have

2 the ability to test or validate upgrades before they are installed in the process. The simulation system becomes an effective tool for testing control system modifications, upgrades, and enhancements in a controlled, offline environment. In addition, plant operations staff and new operators can become qualified on new enhancements and certified on the existing operation. The process automation department for the plant can use the simulation system as a test bed to try new control strategies, build new product recipes, and design new interlocks strategies before proposing the changes to production management. Finally, the simulation system can be an effective tool to mitigate risk to the process or operations staff by providing a means to conduct extensive failure testing in an off-line, safe environment. Reaping Substantial Business Benefits and ROI through Simulation The return on investment in simulation systems has been proven to be effectual and substantial across all process industries from batch to continuous processes. The savings come from two major areas: identifying and correcting automation system errors in a low-cost, offline environment prior to system startup and commissioning, and by identifying sleeping errors or inadequacies in the automation system application software. Identifying and Correcting Errors Offline Saves Times the Cost The cost of investment in office space, simulation hardware and software licenses, and engineering costs for the off-line simulation system is a fraction of the infrastructure cost associated with a process facility. In addition, identifying and correcting automation system errors in an off-line environment allows rapid testing and correction without halting plant operations, disrupting operations support staff, or jeopardizing safety standards. Identification and correction of errors in the off-line simulation environment costs times less than in the online plant environment. Minimizing Risk with Simulation One of the greatest risks of automating a process facility is the quality of the automation system application software. Without using a simulation system, the user has no ability to test the application software thoroughly before actual start-up and production. By testing the automation system with a simulation system for normal, abnormal, and upset conditions, the user can verify that the application software has been designed and implemented to meet the functional needs of the process. 2 Proven BeneB enefits ofo an OfflineO SimuS mulation SystemS stem The benefits for using an off-line simulation system are seen in quicker time to market, better product quality, reduction of unscheduled downtime, and reduced failures and incidents. Quicker Time to Market Using simulation systems has been proven to reduce commissioning and validation time of automation system application software, resulting in savings of $ K / day. Product Quality Extensive testing of automation system application software has been proven to reduce off-spec product, resulting in savings of $50K-$1MM / run or batch. Operating Cost Training plant operations staff with simulation systems has been proven to reduce operationsinduced unscheduled downtime, resulting in savings of $5-100K / hour. Mitigate Risk Simulation systems identify and reduce sleeping errors in the automation system, resulting in savings of $50K - $1MM / incident.

3 Earrl ly Trrai ining Equalss Savingss Offline simulation is the preferred method to train and certify operations staff prior to plant startup and production. Offline simulation is the preferred method to train and certify operations staff prior to plant startup and production. Training operators prior to startup accelerates the learning curve on the new process and automation system. In addition, operators can be trained on upset or emergency conditions that they would normally not encounter during day-to-day operations of the plant. This early, off-line training reduces operator errors in responding to normal and upset process conditions. Requirrementtss fforr Simulatti ion Syssttemss In order to receive the maximum return on investment shown in the previous section, follow these best practices for implementing testing and training simulation for automation systems. Non-IInttrrussi ive Simulatti ion IIntterrffacess Non-intrusive simulation interfaces allow the user to test the control system configuration without making any modifications to the configuration database. By nature a non-intrusive simulation interface will provide a virtual IO interface to the process controller application code that supports IO and process simulation and modeling. It allows the application software to run in a normal mode without any modification during testing so that the testing application software is identical to the production application software. In addition, the non-intrusive interface eliminates the possibility of dead code left in the application software after testing. This type of simulation interface supports complete and thorough testing of the application software and also provides a benchmark of process controller performance, including CPU and memory loading, application software order execution, and timing. Grround- -Up Tesstti ing and Trrai ining Ground-up testing and training is an incremental approach, integrated with the automation project life cycle. This approach to application software testing and training has several benefits. Ground-up testing allows identification and correction of issues early in the project when they can be corrected before being propagated throughout the system. Additionally, ground-up testing allows the end-user and operations staff to gain acceptance and familiarity with the automation system throughout the entire project instead of at one final acceptance testing. Best practices dictate that training and testing are inextricably linked throughout the automation project. Below are some general guidelines for following this best practice: Control Modules are the base-level database elements of the process automation system. These include motors, discrete valves, analog loops, and monitoring points. Testing of these elements can be effectively accomplished with simple tieback simulations and automated test scripts. Operator training on these elements can also bolster buy-in of the automation system and provide a review of usability features.

4 Equipment Modules are the next level of an automation system and generally refer to simple continuous unit operations such as charging paths, valve manifolds, and package equipment. Testing these elements can be effectively accomplished with tieback simulations and limited process dynamics. Operator training on these elements is also valuable. Sequence, Batch Controls, and Continuous Advanced Controls are the next layer of the automation system. Effective testing of these controls generally requires a mass balance simulation with effective temperature and pressure dynamics models. Operator training at this level is necessary due to the complexity of the controls and user interface. MES Applications and Business System Integration is the final layer of most automation systems. Mass and heat balance models are usually required for effective testing of this layer. Training at this level may be extended beyond the operations staff to include quality assurance, information technology and other affected departments. Display Elements for each layer of the automation should be tested with the database elements listed above. In other words, Control Module faceplates are tested with the Control Modules and batch help screens are tested with the Batch Controls. Choosse Syssttem Componenttss Wissel ly The proven best practice is to use actual automation system controllers (or equivalent soft controllers) and application software with a simulation companion system. Simulation systems that use a re-hosted automation system should be eliminated for system testing and avoided for operator training. Use of the actual automation system components with a simulation system allows effective testing and training on HMI use, display access familiarity, process and emergency procedures, response to process upsets, and control system dynamics. This approach builds automation system confidence in operations staff, resulting in more effective use of the automation system and greater benefits. Common on Excuses for not Implementing Simulation Systems The benefits are proven, yet not every automation project uses simulation system for testing and training. The reason that many users fail to embrace this technology is due to perceptions or bad experiences with the wrong product for the application. These perceptions include the following. It s too expensive. My project can t afford it. Simulation systems are easily justified, and the payback is excellent. A few simulation systems are scalable, allowing them to be cost effective for any project. Simulation systems are too difficult to implement or change With some modern simulation systems, integration with the automation system is automatic. Utilities automatically generate a base-level model of the entire automation system. Enhancements and changes to the model can be made quickly and easily by process and automation engineers with little or no simulation experience. I don t have time. I lll think about simulation systems after startup. For maximum benefit, simulation should be incorporated into the project at the FEED and up-front design. If it s not a high-fidelity model, it won t be usable. Studies have shown that medium-fidelity models provide 85% of the functionality for 40% of the cost for automation system testing and training. In fact, high-fidelity models may be cumbersome and not flexible enough for system testing. I lll just use my process design model to train the operators. The cost of enhancing and changing the process model for automation system testing and training may be many times greater than using a medium-fidelity simulation system. Most design models are not the right tool for the job. 4

5 Conssi iderr Validatted IIndussttrry Concerrnss Automation system users and integrators for the validated industries need to be concerned about the GAMP4 Guidelines when applying simulation systems to their automation projects. The GAMP4 Guidelines clearly state that simulation systems are allowable tools for automation system testing. The guideline also makes two requirements for the treatment of the automation system application software. First, it requires that the application software be frozen prior to Software Integration and System Acceptance Testing. Second, it requires the removal of dead code prior to testing. These two requirements dictate the use of non-intrusive simulation interfaces. The GAMP4 Guidelines also states several requirements for the supplier of simulation systems for testing of automation projects. The supplier must have a documented quality and software development program in line with industry best practices. The product used should be designed specifically for process control system testing and operator training. Finally, the product used should be a Commercially-available, Off-The- Shelf (COTS) tool, delivered in validated, tested object code. Additionally, Operator Training Management Modules allow comprehensive development of structured operator training sessions with pre-scripted scenarios and process events. Large or small automation projects can both use a simulation system with a scalable clientserver architecture and stable, repeatable simulation engine. Siimullattiion Soffttwarre The Prroven Solluttiion Using simulation for testing and training for automation systems has proven benefits that maximize Capital Expenditures and Operational Excellence. The key is finding a vendor with a product that is scalable and easy to use. The process of integrating simulation systems with an off-line automation system is quick and can be accomplished through simple networking and PC skills. No custom integration or driver development is required. Auto-generation tools and utilities in simulation products often allow automatic generation of base-level simulations. Simulation interfaces to automation systems are designed to be completely non-intrusive. They have easy-to-use, high-level simulation functions that make unit operations simulations quick and easy. Summarry The use of the simulation systems for testing and training process automation projects has been proven to reduce time-to-market and increase business results. The same systems can be utilized in automation lifecycle management to reduce operational costs and improve product quality. Aboutt tthe Autthorr Martin Berutti is the Director of Business Development at MYNAH Technologies. He helps global customers solve problems in several industries, from refinery to chemical to pharmaceutical plants. His areas of expertise include process simulation, control system and network design, and information integration. Martin has been with MYNAH for over 15 years, holding positions of Systems Engineer, Performance Consultant, Project Manager, and Director, Performance Technology. Previous employers included Fisher Controls, Rosemount, and Applied Automation. He has a B.S. in Chemical Engineering. 5