Engineering and Training Made Easy with a Digital Twin by SIMIT

Transcription

1 Engineering and Training Made Easy with a Digital Twin by SIMIT Leverage big savings in automation engineering by using the potential of digitalization

2 goals of simulation in plant engineering Without simulation Engineering FAT Commissioning SAT Operation A lot of correction loops Long duration especially at back to even basic engineering commissioning Operator knowledge is lost over time Operator knowledge Early identification and correction of design failures With simulation Fast acceptance test and commissioning Increased profitability due to early production start Proof of total functionality to end customer Highest availability due to increased test coverage Cost effective and fast maintenance due to highly available knowledge management -10 to 20% up to -50% up to -50% up to -50% Operation starts much earlier and well prepared Engineering FAT Commissioning SAT Operation SIMIT Simulation Early operator training Simulation of critical situations Periodic refresher training Operator knowledge No risks to implement changes

3 Architecture of the Digital Twin Real Control room computers Controllers Cabinets, racks, cabeling Bus devices, actuators, sensors Process Emulation Simulation Control room computers Virtual SIMIT Virtual Controller SIMIT SF

4 Siemens supports the whole engineering tool chain with a digitalized plant Full integration of real and virtual world COMOS: Engineering of the process (P&I diagrams) Built from specification Control of virtual plant PCS 7 Process control SIMIT Virtual plant & Virtual controllers Control of real plant Walk Inside 3D operator interaction ID: 15030

5 Simulation with SIMIT The Digital Twin Process P&I, objects Actuators/Sensors CMT/PTT *) Signals HW config/tags Model replaces real plant Events via OPC, shared memory *) CMT/PTT = Control Module Types / Process Tag Types SIMIT Simulation Framework & SIMIT Virtual Controller replace real things Process / Plant Actuators / Sensors Controllers, cabinets, racks, cabling, installation

6 Siemens supports the whole engineering workflow with a digitalized plant Workflow step Clarification of automation tasks Without simulation Specification from one sentence to many pages in Microsoft Word Often difficult to understand and incomplete Requires a lot of clarifications Leads to misunderstandings Risk of missing and wrong code Risk of increasing projects costs Many loop backs in clarificationengineering phase Shift clarification problems and risks to commissioning phase Prolonged startup and commissioning time With simulation Build up an early (maybe simplified) process model Clarify behavior with customer with help of a graphical representation of the plant and actuators/sensors (e.g. open a valve, start a motor, ) Demonstrate dynamic behavior Add missing / correct functionality Get an excellent understanding of customer requirements and his plant Create a basis (virtual plant) for excellent automation programming Create confidence between customer and supplier Fast startup after DCS implementation / migration Reduced risks for commissioning

7 Siemens supports the whole engineering workflow with a digitalized plant Workflow step Simulation based engineering & virtual commissioning Without simulation Complete real equipment (hardware environment) cannot be built up in an office environment Real equipment is not available or not setup in an early phase Process details are not available or even not existing (green field) We rely on the knowledge of programmers He needs to know all behavior of actuators/sensors/plant/process He need to know all failure scenarios Prolonged startup and commissioning time With simulation Use already available behavior from SIMIT libraries Build up a knowledge management system for testing and simulation with Lego type blocks (macros, templates, components, libraries) Synergy and reuse of typicals Animate movements and process values (e.g. tank level) for better understanding Create test environment by drag & drop, store/load different test scenarios No need to build up hardware (controllers, cabinets, actuators, sensors, ) Riskless testing and tryout = virtual commissioning

8 Siemens supports the whole engineering workflow with a digitalized plant Workflow step Operator training Without simulation Real plant cannot (or only very limited) be used as a training system Scenarios cannot be stored and loaded (no snapshot functionality) Training with real equipment needs long time to get into a specific state Failure scenarios can in some cases destroy equipment, pollute environment, harm people No training system at all Long ramp-up because of missing knowledge A lot of support needed Wrong reaction in case of a critical plant disturbance Increased risks for equipment and staff With simulation Train and tryout without any risks for people, equipment and environment Store and reload any situation (image of controllers and of process) by a simple double click Prepared operators at ramp-up Start production with full power Training without preparation for various scenarios, just by loading the desired situation via snapshot Fast and correct reaction on any failure situation Increased availability

9 The Digital Twin Controllers Cabinets, racks, cabeling Bus devices, actuators, sensors Process SIMIT Virtual Controller SIMIT SF Test, tryout and train your automation without risks!!!

10 We are happy to answer your questions!