Simulation in the
Water Industry
Doug Johnson
Emerson Process Management
Power & Water Solutions
2012 Annual Ovation
Users’ Group Conference
Emerson Proprietary
Key Messages

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A time of unprecedented challenges
Worker force asked to do more with less
Number of expected retirements is
staggering
– Loss of experience and expertise

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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
2012
2 Annual Ovation
Users’ Group Conference
Emerson Emerson
Process Management
ProprietaryConfidential
From Maintenance Technician to Mayor…
Today’s Water Professionals Face Unprecedented
Challenges
SECURITY
CONCERNS
WEATHER
EMERGENCIES
ENERGY &
“GREEN”
PROGRAMS
WORKFORCE
ISSUES
SUPPLY
CHAIN
PROBLEMS
ESCALATING
COSTS
MEDIA &
PUBLIC
SCRUTINY
VIOLATION
AVOIDANCE
LIMITED
OPERATIONAL
VISIBILITY
CHANGING
REGULATIONS
CAPITAL
EQUIPMENT
PROTECTION
2012
3 Annual Ovation
Users’ Group Conference
Water &
Wastewater
Authorities
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Process Management
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RAPID
TECHNOLOGY
OBSOLESENCE
Workforce Issues – A Growing Concern

Utility Expected Retirements over Next 5 Years
Source: AWWA State of the Industry Report (Mann & Runge)
2012
4 Annual Ovation
Users’ Group Conference
Emerson Emerson
Process Management
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Retirements Bring Challenges
Aging Workforce
How will you capture the wealth of existing
process knowledge to share with new
generations?
Regulations
Will new workers be able to avoid “learning curve”
mistakes that can result in violations, safety issues
and equipment damage?
Abnormal Situations
Is your staff equipped to deal with abnormal events?
How can you help them to prepare?
2012
5 Annual Ovation
Users’ Group Conference
Emerson Emerson
Process Management
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Growing Trend:
Retirees Are Sometimes Not Replaced

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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
2012
6 Annual Ovation
Users’ Group Conference
Emerson Emerson
Process Management
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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
2012
7 Annual Ovation
Users’ Group Conference
Emerson Emerson
Process Management
ProprietaryConfidential
Who Benefits from Simulation?
Operators
Engineers & Technicians

Understand process
fundamentals

Dynamic design
verification

Reinforcing cause &
effect relationships

Pre-evaluate process
equipment changes

Identify and diagnose
fault conditions

Test control change
before implementation

Prepare to handle
emergencies and
abnormal conditions

Develop &
test advanced
control schemes

Improved operational
techniques

Control tuning

Process optimization

Process troubleshooting

Emergency
management
procedures training
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
2012
9 Annual Ovation
Users’ Group Conference
Emerson Emerson
Process Management
ProprietaryConfidential
New Technologies Make Simulation
More Affordable

Automation-based simulation is simpler and costeffective
– Leverages plant control system
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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
2012
10 Annual Ovation
Users’ Group Conference
Regulatory Violations
Equipment Damage
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Flexible Simulation Solutions for
Accurate Decision Making


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
Tie-back
Logic
2012
11 Annual Ovation
Users’ Group Conference
Scalable
Functionality
High-fidelity
Models
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Scalable Solutions Bring Simulation
Within Reach

Functionality
Simulation can be
expanded as needs
change
“What-If”
Abnormal conditions
training
Steady state operations
training
Budget
Startup/Shutdown training
Procedure development &
validation
Ovation navigation
System verification (FAT)
Model Sophistication
2012
12 Annual Ovation
Users’ Group Conference
Emerson Emerson
Process Management
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Flexible Simulation Using Virtual
Technology
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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
2012
13 Annual Ovation
Users’ Group Conference
Emerson Emerson
Process Management
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Actual Plant vs. Simulation:
Key System Components
Plant Process
Controllers & I/O
Operator Interface
Actual
Hard
Station
Control
Plant Modeling System
Simulation
20 Virtual
Controllers
LT
Instructor
Station
2012
14 Annual Ovation
Users’ Group Conference
Emerson Emerson
Process Management
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Optional
Emulated
Hard
Station
Typical Configuration for Tie-back
Simulation Functionality
Domain
Controller
OPERATOR
Stations
Network
ENGINEER Station and
VIRTUAL
Controllers
Each PC can support up to
20 virtual controllers
SM-PPT-XX-100 [2]
2012
15 Annual Ovation
Users’ Group Conference
Emerson Emerson
Process Management
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VIRTUAL
Controllers
Database Server
Tie-Back Simulation
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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
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Creates models using authentic control system
algorithms
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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

2012
16 Annual Ovation
Users’ Group Conference
Emerson Emerson
Process Management
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Typical Configuration for High-fidelity
Simulation Functionality
.........
EngineerDomain Controller
Operator Stations
Database
Server
Network
Virtual Controllers
Hard Panel
Station
Up to 20 virtual
controllers in one PC
Model
Station
Hard Panel Station provides
operator training interface
for non-DCS subsystems
Virtual Controllers run the
actual Ovation DCS
application
2012
17 Annual Ovation
Users’ Group Conference
Instructor
Station
Instructor Station manipulates
the model to change process conditions,
introduce failures, run training scenarios
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/O
Station also includes SimAPI Libraries
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Process Management
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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
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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
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Trains operators in process effectiveness and efficiency, focusing on optimizing
operating procedures
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Demonstrate existing operating procedures
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Validates new procedures
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Demonstrate effect of equipment malfunctions on processes
2012
18 Annual Ovation
Users’ Group Conference
Emerson Emerson
Process Management
ProprietaryConfidential
Simulation Project Implementation
Gather Info /
Plant Walk
Down
Model Design
Implementation
Step 1 – Plant Walk Down
Working 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
2012
19 Annual Ovation
Users’ Group Conference
Emerson Emerson
Process Management
ProprietaryConfidential
Testing
Simulation Project
Implementation
Plant Walk
Down
Model Design
Implementation
Step 2 – Model Design


2012
20 Annual Ovation
Users’ Group Conference
Create design document that details
modeling requirements
Review design ensure modeling
accuracy
– This is done by both the customer
and the simulator team
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Testing
Simulation Project
Implementation
Plant Walk
Down
Model Design
Implementation
Step 3 – Implementation


2012
21 Annual Ovation
Users’ Group Conference
Load simulation models and control
logic into simulation hardware
Test integration of models and logic
to verify proper operation
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Testing
Simulation Project
Implementation
Plant Walk
Down
Model Design
Implementation
Testing
Step 4 – Testing


2012
22 Annual Ovation
Users’ Group Conference
Perform formal factory
acceptance test
Exercise models using a
variety of plant conditions
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Training
Integration
Configuration
Complete
Conversion to
Dynamic
Steady State
Simulation
Design Complete
Process
Modeling
Timelines for Simulation Development
12-14 months
High-Fidelity Simulation
Control System Tie-Back Simulation
Check-out
2012
23 Annual Ovation
Users’ Group Conference
Emerson Emerson
Process Management
ProprietaryConfidential
2-4 weeks
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
2012
24 Annual Ovation
Users’ Group Conference
Emerson Emerson
Process Management
ProprietaryConfidential
Questions?
2012 Annual Ovation
Users’ Group Conference
Emerson Proprietary