Barrick simulation with mimic presentation

Implementation of a Simulation-Based Operator Training

System at

Barrick Pueblo Viejo

Implementation of a Simulation-Based Operator Training

System at

Barrick Pueblo Viejo

October, 2011

PresentersPresenters

Paul Yaroshak

Kevin Argudin

AgendaAgenda

Introduction

Project Background

Technology Selection

Project Execution

Benefits & Lessons Learned

Summary

Questions

AgendaAgenda

Introduction

Project Background

Technology Selection

Project Execution

Benefits & Lessons Learned

Summary

Questions

Company BackgroundCompany Background 3 Companies involved in this project

Barrick Gold Corporation Pueblo Viejo Site

Lakeside Process Controls Local Business Partner of Emerson Process Management

Mynah Technologies Simulation Software Developer and System Integrator

Barrick Gold: A Global CompanyBarrick Gold: A Global Company

Pueblo Viejo

Dominican Republic

IntroductionIntroduction Challenges

New processing facility, not yet built. Need to prepare operators as early as possible.

Objectives Safe Startup Efficient Startup

Solution “Ready for Start Up” program (RFSU) Dynamic Simulation is a component of RFSU

IntroductionIntroduction The “Ready for Start Up” Program (RFSU)

Prepares operators for safe and efficient plant startup

3 components: Training on Process Fundamentals using computer-based

interactive training modules (textbook). Simulation-Based Training Field demonstration and practice

AgendaAgenda

Introduction

Project Background

Technology Selection

Project Execution

Benefits & Lessons Learned

Summary

Questions

Project BackgroundProject Background Pueblo Viejo will produce 1 million ounces of gold per year

The plant will process 24,000 tons of ore /day at full production capacity.

DCS platform is DeltaV Version 10.3, approximately 11,000 DST.

Complex plant with many processes, requires a variety of skills and experience.

Pueblo Viejo Processing SitePueblo Viejo Processing Site

Autoclaves

Iron 1 Thickener

CyanideDestruction

Limestone Crushing

Carbon In Leach

CopperRecovery

Acid Wash /

Stripping

Business NeedBusiness Need

Prepare operations team for safe and efficient plant startup (RFSU)

A dynamic process simulator should provide the following benefits: Meet aggressive startup / production deadlines Process understanding and familiarity with control system. Hands on practice of SOP Promote safe production / Mitigate risk of equipment damage Qualify resources for a wide range of roles within the facility Build organization capability to leverage the system for future

training needs

AgendaAgenda

Introduction Project Background Technology Selection

Project Execution

Benefits & Lessons Learned

Summary

Questions

Simulator SelectionSimulator Selection Several alternatives were evaluated.

Low/medium level of fidelity (complexity) is sufficient for training simulation.

The Mimic Dynamic Simulator from Mynah was selected Provides required levels of fidelity (complexity). Integrates seamlessly with DeltaV Project EPCMs already using Mimic Relatively easy to use and change (for implementing model

changes and control system enhancements) Intuitive

Simulation FidelitySimulation Fidelity Select Simulation Fidelity (i.e. complexity) needed to

achieve business results Low Fidelity – Basic I/O tiebacks with simple tuning Medium Fidelity – Engineering first principles, conservation of

energy and mass High Fidelity – Mass / energy transfer equations, differential

equations, empirical models, etc.

Fidelity Breakdown on Pueblo Viejo Simulator Low Fidelity – 70% Medium Fidelity – 20% High Fidelity – 10%

DeltaV Simulate

Simulation EnvironmentSimulation Environment

MiMiC Simulation

Software

Field Devices &Process Dynamics

DeltaV Controllers

Simulated by DeltaV Simulate

Operator &Controller Response

Simulated by Mimic

I/O I/OProcess Dynamics

Real-World Environment Virtual (Simulated) Environment

Project System ArchitectureProject System Architecture

DeltaV Graphic and Trainer ScreenDeltaV Graphic and Trainer Screen

Mimic Trainer ScreenMimic Trainer Screen

AgendaAgenda

Introduction

Project Background

Technology Selection

Project Execution

Benefits & Lessons Learned

Summary

Questions

Project Org ChartProject Org ChartProject Sponsor

Process ManagerProcess Expert

Paul Yaroshak Barrick PM

Hatch Resource

DCS

Kevin ArgudinLakeside PM

Sr. Process Modeling

Consultant

Adisa ShaljaniPM Mynah

Sr. DeltaV Consultant

MiMic Configuration

(3)

DeltaV Configuration (1)

IT Support

Project Support

Hatch ResourceProcess

POX Operations Superintendent

Maintenance Superintendent

POX Operations General Supervisor

Process Systems Engineer

PVDC Resources

PVDC Project Manager

Fluor Resource

Project SponsorProcess ManagerProcess Expert

Paul Yaroshak Barrick PM

Hatch Resource

DCS

Kevin ArgudinLakeside PM

Sr. Process Modeling

Consultant

Adisa ShaljaniPM Mynah

Sr. DeltaV Consultant

MiMic Configuration

(3)

DeltaV Configuration (1)

IT Support

Project Support

Hatch ResourceProcess

POX Operations Superintendent

Maintenance Superintendent

POX Operations General Supervisor

Process Systems Engineer

PVDC Resources

PVDC Project Manager

Fluor Resource

Barrick(Pueblo Viejo) Dominican Republic

Barrick Toronto, Canada

HatchToronto, Canada

MynahSt Louis, MO

Fluor Vancouver, Canada

LakesideToronto, Canada

Geographically Distributed TeamGeographically Distributed Team

Proposed Project Design ProcessProposed Project Design Process Waterfall Model: Sequential Development Process

Feed

DeltaV Configuration

P&IDs

Standard Operating Procedures

Equipment Manuals & Specifications

Execute (Design / Implement)

Review Inputs

Define Simulation Spec

Define Test Plan

Full ModelDeltaV Integration

Low Level ModelOperator Training

Scenario

Operate

FAT / SAT

Deploy / Commishion

SAT

Extend

Training

Simulation Models

Circuit 1

Project RealityProject Reality

Circuit 2

Circuit 3

• Late changes• Control strategy errors• Graphic updates• Missing definitions• Model misalignment

Why an Iterative Development Approach worksWhy an Iterative Development Approach works Lower risk; the waterfall is higher risk

Early risk mitigation and discovery

Accommodates and provokes early change;

Manage complexity

Confidence and satisfaction from early, repeated success

Early partial product

Relevant progress tracking; better predictability

Higher quality; less defects in final product

Final product better matches true client desires

Early and regular process improvement

Communication and engagement required

“I’ll know it when I see it” required

Simulation DevelopmentSimulation Development Develop an Excel model

Provide DeltaV Configuration

DeltaV Simulate: Perform Simulate Conversion

MiMiC: Create I/O Tie-Backs

MiMiC: Implement Medium and High Level Models

MiMiC: Develop Trainer Screens

Initial Review

Incorporate changes

Final review

AgendaAgenda

Introduction

Project Background

Technology Selection

Project Execution

Benefits & Lessons Learned

Summary

Questions

Business Results AchievedBusiness Results Achieved Expected Reduction is Commissioning Time

Early identification of issues Enhanced familiarity with system complexities.

Unanticipated benefits Early identification of usability and logic issues. Circular Interlocks, incorrect alarm limits Identification of HMI errors and issues Sequence development/testing Development of SOPs

Improved training material Trainers have a working system to develop on and not via memory

and documents alone

Lessons LearnedLessons Learned Plan on Low Fidelity simulation of the complete DeltaV

Areas

Alarms need to be managed (to avoid false alarms).

Develop first principle models in Excel.

Consider iterative design process from the start.

Early engagement of the end users (get buy-in)

Distributed Project team can be successful

Develop a plan early with system integrators to implement identified Control Strategy and HMI issues.

Opportunities for ImprovementOpportunities for Improvement

Version control of simulation system (model logic & trainer screens)

Snapshots that better accommodate a changing DeltaV database

Improved support for empirical data in Mimic e.g. data tables

AgendaAgenda

Introduction

Project Background

Technology Selection

Project Execution

Benefits & Lessons Learned

Summary

Questions

SummarySummary The project had unforeseen benefits of helping us

Improve the final production control system Increase general understanding of our process.

Approaching the project in an iterative fashion enabled our team to succeed

Process simulation enabled the business to achieve the desired results Trained Users Developed Operations Documents Early adoption and entrenchment of the Process Control System

Special Thanks ToSpecial Thanks To

Mynah Adisa Shaljani Todd Anstine

Hatch Will McCombe Andy McEwen

Barrick Benoit Bissonette

Lakeside Jorge Jimenez

QuestionsQuestions

Where To Get More InformationWhere To Get More Information Simulation with MiMiC Course 7041

Mynah - www.mynah.com

Lakeside Process Controls www.lakesidecontrols.ca