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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