Simulation in the Water Industry Doug Johnson Emerson Process Management Power & Water Solutions 2012 Annual Ovation Users’ Group Conference Emerson Proprietary 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 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 Emerson Emerson Process Management ProprietaryConfidential 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 ProprietaryConfidential 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 ProprietaryConfidential 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 2012 6 Annual Ovation Users’ Group Conference Emerson Emerson Process Management ProprietaryConfidential 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 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 Emerson Emerson Process Management ProprietaryConfidential 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 Emerson Emerson Process Management ProprietaryConfidential 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 ProprietaryConfidential 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 2012 13 Annual Ovation Users’ Group Conference Emerson Emerson Process Management ProprietaryConfidential 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 ProprietaryConfidential 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 ProprietaryConfidential VIRTUAL Controllers Database Server 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 2012 16 Annual Ovation Users’ Group Conference Emerson Emerson Process Management ProprietaryConfidential 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 Emerson Emerson Process Management ProprietaryConfidential 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 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 Emerson Emerson Process Management ProprietaryConfidential 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 Emerson Emerson Process Management ProprietaryConfidential 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 Emerson Emerson Process Management ProprietaryConfidential 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