Emerson Proprietary 2012 Annual Ovation Users’ Group Conference Simulation in the Water Industry Doug Johnson Emerson Process Management Power & Water Solutions
Feb 24, 2016
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
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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
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Workforce Issues – A Growing Concern Utility Expected Retirements over Next 5 Years
Source: AWWA State of the Industry Report (Mann & Runge)
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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Simulation Project Implementation
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
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Simulation Project Implementation
Plant Walk Down Model Design Implementation Testing
Step 4 – Testing Perform formal factory
acceptance test Exercise models using a
variety of plant conditions
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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
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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?