Simulation in the Water Industry

Emerson Proprietary 2012 Annual Ovation Users’ Group Conference

Simulation in the Water IndustryDoug JohnsonEmerson Process ManagementPower & Water Solutions

Emerson Process Management Confidential2 Emerson Proprietary 2012 Annual Ovation Users’ Group Conference

Key Messages A time of unprecedented challenges Worker force asked to do more with less Number of expected retirements is

staggering– Loss of experience and expertise

New, less experienced workers risk mistakes as they learn

Simulators can help accelerate learning– Superb training tool, but have been too costly and

complex New automation technologies bring scalable

simulation within reach


From Maintenance Technician to Mayor…Today’s Water Professionals Face Unprecedented Challenges

Water & Wastewater Authorities

CAPITAL EQUIPMENT

PROTECTION

CHANGING REGULATIONS

MEDIA & PUBLIC

SCRUTINY

ESCALATING COSTS

ENERGY & “GREEN”

PROGRAMS

SECURITY CONCERNS

WEATHER EMERGENCIES

WORKFORCE ISSUES

SUPPLY CHAIN

PROBLEMS

VIOLATION AVOIDANCE

LIMITED OPERATIONAL

VISIBILITY

RAPIDTECHNOLOGY OBSOLESENCE


Workforce Issues – A Growing Concern Utility Expected Retirements over Next 5 Years

Source: AWWA State of the Industry Report (Mann & Runge)


Aging Workforce

How will you capture the wealth of existing process knowledge to share with new generations?

Will new workers be able to avoid “learning curve” mistakes that can result in violations, safety issues and equipment damage?

Regulations

Abnormal Situations

Is your staff equipped to deal with abnormal events?

How can you help them to prepare?

Retirements Bring Challenges


Growing Trend:Retirees Are Sometimes Not Replaced Some authorities plan, as a strategy, to

reduce staff through attrition Politically less controversial than layoffs Can result in critical positions being

compromised as positions are combined Result: Inexperience combined with

reduced focus Help needed to handle both jobs

Position

Canceled


Simulation Can Help Accelerate Learning Operator training and qualification

programs Procedure development and

validation Abnormal situation

– Awareness and response– Post-event analysis and prevention

Control logic development, testing, and verification

Plant engineering test bed for process improvements

Who Benefits from Simulation?Operators Understand process

fundamentals Reinforcing cause &

effect relationships Identify and diagnose

fault conditions Prepare to handle

emergencies and abnormal conditions

Improved operational techniques

Emergency management procedures training

Engineers & Technicians Dynamic design

verification Pre-evaluate process

equipment changes Test control change before

implementation Develop &

test advanced control schemes

Control tuning Process optimization Process troubleshooting

Management Reduces costs Reduces risk of

environmental violation Improves safety Strengthens ability to

handle emergency situations


Why Haven’t Simulators Been More Popular? Expensive – often 10’s of $M

– Typical previous uses in high-risk environments

– Aircraft training and design– Nuclear power operations

Complex model software development Separate equipment required for the

simulator– Duplicate control room plus simulator

computers


New Technologies Make Simulation More Affordable Automation-based simulation is simpler and cost-

effective– Leverages plant control system

Provides scalable, engineered simulation solutions Helps transition personnel and technology during

times of change Aids in understanding of complex operations and

unique plant characteristics Transfers knowledge from current operations

experts to the next generation What is the cost of a mistake?

– Injury Regulatory Violations Equipment Damage


Flexible Simulation Solutions for Accurate Decision Making

Tie-back Logic Scalable

Functionality

High-fidelityModels

Scalable simulators can be tailored to meet the unique operational challenges of your facility

Provides a wide range of engineered simulation solutions to fit needs and budget– From tie-back simulation to high-fidelity simulation


System verification (FAT)

Ovation navigation

Procedure development & validation

Startup/Shutdown training

Steady state operations training

Abnormal conditions training

“What-If”

Scalable Solutions Bring Simulation Within Reach Simulation can be

expanded as needs change

Budget

Model Sophistication

Functionality


Flexible Simulation Using Virtual Technology Replicates control system controllers in a

few desktop workstations Executes control logic, algorithms, and

control timing directly within the workstations Incorporates full functionality of acutal DCS

controllers Model constructed from algorithm library

identical to control system

BENEFITS Minimizes hardware costs Provides smaller system footprint Offers a portable configuration Uses well-known desktop systems


Actual Plant vs. Simulation:Key System Components

Plant Process Controllers & I/O Operator Interface

Simulation

Plant Modeling System

LT

Instructor Station

OptionalEmulated

HardStation

Actual Hard

StationControl

20 Virtual Controllers


Typical Configuration for Tie-back Simulation Functionality

ENGINEER Station and Database Server

OPERATORStations Network

SM-PPT-XX-100 [2]

OPTIONAL

VIRTUALControllers

VIRTUALControllers

Domain Controller

Each PC can support up to 20 virtual controllers


Tie-Back Simulation Most cost-effective Valuable tool for:

– Fundamental operator training– Control system navigation– Process familiarization

Widely applied for control logic checkout – prior to loading on the actual control system

Models specific processes for basic operator training and testing

Creates models using authentic control system algorithms

Interacts with plant’s control strategies through simulated software logic

Presents standard operator and engineer workstation functionality

Provides hands-on training for key processes Additional complexity can be easily added


Operator Stations Engineer-Domain Controller

. . . . . . . . .

Up to 20 virtual controllers in one PC

Virtual Controllers run theactual Ovation DCS

application

Network

Database Server

Hard Panel Station

Hard Panel Station providesoperator training interfacefor non-DCS subsystems

Instructor Station

Instructor Station manipulatesthe model to change process conditions, introduce failures, run training scenarios

Model Station

Model Station is a server that:- Runs first principles high fidelity plant model

and stores configuration- Manages & maps model I/O to plant control I/OStation also includes SimAPI Libraries

Virtual Controllers

Typical Configuration for High-fidelity Simulation Functionality


Simulation with High-fidelity Functionality

Primary uses include: Training control room operators Testing new control strategies Evaluating plant responses when subjected

malfunctions and other abnormal events and conditions

Simulates all plant operating modes process and equipment startup and shutdown normal operation, abnormal and emergency operating conditions

Trains operators on information acquisition and diagnostic skills• Recognition of equipment malfunction and appropriate responses• Isolating failures under emergency conditions

Trains operators in process effectiveness and efficiency, focusing on optimizing operating procedures

Demonstrate existing operating procedures Validates new procedures Demonstrate effect of equipment malfunctions on processes


Simulation Project ImplementationGather Info /Plant Walk

DownModel Design Implementation Testing

Step 1 – Plant Walk DownWorking closely with plant personnel

Simulator simulator specialists perform a plant walk down to:

Confirm the scope of supply Verify project schedule Interview plant staff to investigate plant

processes and operations


Simulation Project Implementation

Plant Walk Down Implementation Testing

Step 2 – Model Design Create design document that details

modeling requirements Review design ensure modeling

accuracy– This is done by both the customer

and the simulator team

Model Design



Plant Walk Down Model Design Implementation Testing

Step 3 – Implementation Load simulation models and control

logic into simulation hardware Test integration of models and logic

to verify proper operation



Plant Walk Down Model Design Implementation Testing

Step 4 – Testing Perform formal factory

acceptance test Exercise models using a

variety of plant conditions


Control System Check-out

Tie-Back Simulation 2-4 weeks

Proc

ess

Mod

elin

g

Des

ign

Com

plet

e

Stea

dy S

tate

Si

mul

atio

n

Con

figur

atio

n C

ompl

ete

Inte

grat

ion

Con

vers

ion

to

Dyn

amic

Trai

ning

12-14 months

High-Fidelity Simulation

Timelines for Simulation Development


Simulation Instructor Training Instructor training is important

to simulation effectiveness Training will help your

instructors learn how to best utilize your simulator

Prepares your simulator instructor to confidently apply simulation to your training program

Emerson Proprietary 2012 Annual Ovation Users’ Group Conference

Questions?

Documents

Simulation in the Water Industry