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Simulation in the Water Industry

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  1. Simulation in the Water Industry Doug Johnson Emerson Process Management Power & Water Solutions

  2. 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

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

  4. Workforce Issues – A Growing Concern • Utility Expected Retirements over Next 5 Years Source: AWWA State of the Industry Report (Mann & Runge)

  5. 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?

  6. 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

  7. 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

  8. 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

  9. 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

  10. 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 ViolationsEquipment Damage

  11. 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 Scalable Functionality High-fidelity Models

  12. Scalable Solutions Bring Simulation Within Reach Functionality • Simulation can be expanded as needs change Budget Model Sophistication

  13. 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

  14. Actual Plant vs. Simulation:Key System Components Operator Interface Plant Process Controllers & I/O Actual HardStationControl Plant Modeling System 20 Virtual Controllers Simulation LT Optional Emulated HardStation Instructor Station

  15. Typical Configuration for Tie-back Simulation Functionality Domain Controller OPERATORStations Network ENGINEER Station and Database Server OPTIONAL VIRTUAL Controllers VIRTUAL Controllers Each PC can support up to 20 virtual controllers SM-PPT-XX-100 [2]

  16. 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

  17. Typical Configuration for High-fidelity Simulation Functionality . . . . . . . . . Engineer- Domain Controller Operator Stations Database Server Network Virtual Controllers InstructorStation Hard Panel Station Model Station Up to 20 virtual controllers in one PC Hard Panel Station provides operator training interface for non-DCS subsystems Instructor Station manipulates the model to change process conditions, introduce failures, run training scenarios Virtual Controllers run the actual Ovation DCS application • 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 SimAPILibraries

  18. 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

  19. Simulation Project Implementation Step 1 – Plant Walk Down Working closely with plantpersonnel 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 Gather Info / Plant Walk Down Model Design Implementation Testing

  20. Simulation Project Implementation 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 Plant Walk Down Model Design Implementation Testing

  21. Simulation Project Implementation 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

  22. Simulation Project Implementation Step 4 – Testing • Perform formal factory acceptance test • Exercise models using a variety of plant conditions Plant Walk Down Model Design Implementation Testing

  23. Tie-Back Simulation 2-4 weeks Timelines for Simulation Development Process Modeling Steady State Simulation Conversion to Dynamic Design Complete Configuration Complete Integration Training 12-14 months High-Fidelity Simulation Control System Check-out

  24. 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

  25. Questions?