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© Invensys 00/00/00 Invensys proprietary & confidential Slide 2
Simulations for Mining/Oil & Gas
ANZ OpsManage 2013
Perth, 8th of May 2013
Gregor Fernholz
Global Business Development Manger
Operator Training Simulators
Agenda
1. Motivation
2. Case studies
3. Technology Overview
4. Training beyond the control room
5. Demo
6. Summary
Slide 3
1 Motivation
Slide 4
anbei
0
10
20
30
40
50
60
70
80
90
100
2002 2004 2006 2008 2010
$ b
illio
ns
Year
Production by value
Fuel minerals
Metallic minerals
Australian Bureau of Statistics
Slide 5
Strong growth of Oil/Gas, coal and metallic minerals
Australian Bureau of Statistics
Slide 6
50
100
150
200
250
300
350
2000 2002 2004 2006 2008 2010
Em
plo
ym
en
t in
dex.
Year 2
00
0=
10
0
Year
Employment growth in Australia
Mining
Total
Mining: +250% in 11 years
50
70
90
110
130
150
170
190
210
230
250
2000 2002 2004 2006 2008 2010
Em
plo
ym
en
t in
min
ing
in
'0
00
Year
Employment growth in Australia
Australian Bureau of Statistics
Slide 7
35,000 new jobs every year
PLUS retirement replacements
US Mine injuries and operator experience
Slide 8
MSHA, 2002, “Quarterly employment and coal production, accidents/injuries/illnesses reported to MSHA under 30 CFR Part 50, 1991–2000,” U.S. Department of Labor, Mine Safety and Health Administration, Offi ce of Injury and Employment Information – Denver, Colorado.
Are these good questions?
I need to train many young, new operators. What’s the most effective and cost efficient way?
My facility is in a remote location. How can I provide training prior to sending someone to site? How can I improve cooperation between the remote and central control room teams?
How do I train my operators prior to the start-up of the plant on the operation of the control system and the plant?
Is the design of my plant safe, optimal (CAPEX/OPEX) and supports all modes of operation?
My project is tight in time and overrunning the schedule. How can I recover time?
How can I minimize the risk of costly start-up delays?
I need to enhance plant efficiency with fewer people. How?
Slide 9
2 Case studies
Slide 10
SHELL Bonga (Nigeria) Floating Production Storage & Offloading
The ‘process’ is a floating platform with storage and offloading facilities; sea trials and proof of controls at sea are very expensive – 200 people at sea to be able test systems
Changes to the DCS and safety system were done quickly in the simulator (hours/days instead of weeks) and tested.
The need is to improve the quality of the ICSS system to reduce commissioning time and ensure quality of subsequent ICSS updates. On-site safety certification (Lloyds) took 3 months instead of 1 year.
The system was delivered successfully with reduced start up time. Start-up recognized as “best in class”.
Saipem FPSO Fast-track Project GIMBOA
Slide 12
Business challenge for Saipem
High demand for FPSO vessels.
Time to deliver critical for winning projects: Schedule of 16-24 months
Solution
Decoupling the hardware from the application in the DCS (Foxboro I/A) project
Use FSIM Plus for configuring and testing the application
Results
Successful project execution.
DCS Project schedule shortened by 3.5 months.
Improved quality of the application through better testing.
Aker Yards LNG Carriers – Control Testing and Training
Slide 13
Objective
Reduce DCS delivery time and improve DCS test procedures.
Reduce on-board training time for crew
Solution
Aker Yards selected Foxboro I/A as the DCS
Decided to go for FSIM Plus for improved testing and training
Results/benefits
Saved 5-6 man-months for dock trials of the system.
Bug-free DCS application delivered to the carrier.
Sea trial campaign for an LNG carrier is 15 days for 150 people on board.
Cost per sea trial is €150k per day.
Project savings on seal trial: 1 week worth €1mio
Sonatrach LNG Terminal Refrigerator TMC replacement
Slide 14
Objective
Replace Woodward with
Triconex controls in minimum
turnaround time.
Simulation Benefits
Improved controller behaviour
Completed turnaround in 3 normal working days instead of 8-9 long days .
Online sooner for 6 more days of LNG production valued at 100 times the project cost for the simulation
OTS Opportunity Success Story
• Business Drivers: Safety, Operational Improvement and
Retiring Personnel
• Solution: OTS for Hydrocracker/Hydrotreater & Hydrogen
Plant, Two Reformers, Delayed Coker and SRU/Amines Unit
• Value
– Site declared value of $10m - $30m based on one decision
support study for the Hydrocracker OTS
– OTS provided process and training knowledge prior to Coker
startup that minimizes startup risk
– Able to recreate abnormal operating issues in OTS and implement
improved control strategy on Reformer
Optimal Design of Flare Headers – Benefits of €20 million for Technip
Slide 16
PetroCanada Tail gas compressor Design and control validation
Slide 17
Increased recycle Cv from 63 to 101.
Added hot gas recycle line avoiding surge
Added feed-forward Anti Surge valve pre-arming to prevent surge during suction or discharge blockage.
Added decoupling between anti-surge and suction pressure controller
Added stonewall controller
Recommended/Confirmed Valve Sizes, Trim and Actuation Times
Accident / Incident free commissioning !
Operator Training Simulator Success Story
Essential component in the safe and successful commissioning of the world’s most complex state of the art upgrading facility
Operators training on the simulator one year before Gasifier startup Benefits Summary: Reduced commissioning time Identification of control issues during
design phase Corrective actions taken prior to start
up
BG Group Gas Platform
Operator competency assessment
Slide 19
(C) BG Group. Used with kind permission of BG Group
Operator competencies are assessed by a competency assessment manager (CAM) prior to starting work on the off-shore platform.
Off-shore training on the platform is costly and bed-room space is limited. Scheduling of the equipment for the training is challenging.
Solution: Use a 3D Virtual Environment on-shore.
Status: pilot completed and next steps under discussion.
Cape Lambert, Australia Port Expansion Project
• SKM/Rio Tinto using Wonderware for HMI on
top of Schneider PLC/SCADA Controls
• Introduced SimSci-Esscor into the account
• Solution – use dynamic models of Cape
Lambert iron ore handling to allow engineers
to validate Schneider control logic before
deployment to site
• Order size so far in excess of $1 million
Cape Lambert, Australia Port Expansion Project
• SKM/Rio Tinto using Wonderware for HMI on
top of Schneider PLC/SCADA Controls
• Introduced SimSci-Esscor into the account
• Solution – use dynamic models of Cape
Lambert iron ore handling to allow engineers
to validate Schneider control logic before
deployment to site
• Order size so far in excess of $1 million
“fantastic achievement”
“brilliant outcome”
Agrium JV Vault Potash OTS Project
Slide 22
Process
Agrium Vanscoy process model includes:
• Raw ore handling
• Flotation
• Compaction
• Crushing/Desliming
Project VAnscoy ULTimate Expansion (VAULT) - potash mine expansion including an additional new processing train
Purpose The simulator will be a tool for initial training and retraining of operators in:
● Plant systems, their function and interaction with other systems
● Development of operating experience, confidence and accuracy in normal and abnormal plant operations
● Tool to aid in developing and conducting engineering and control system analysis
Teck Zinc Roaster Operator Training Simulator
Slide 23
Acid Plant process flow includes:
• Zinc Roaster (Fluidized bed roaster)
• Draft from the roaster all the way to the stack
• Calcine ball mill
• Waste heat boiler, Gas cooling, Mercury removal, Acid plant
Acid Plant OTS completed and in operation since Jan ‘13:
Second OTS project for a new acid plant ongoing
More OTS projects in the pipeline.
“…starting the plant up on the simulator was real … the simulator behaved just like the real plant … I actually
started to sweat like I do with the real plant … my body thought it was the real thing … It was great to be able to
push the plant, I mean, Simulator as I have always wanted and was afraid to do with the real plant …”
Codelco Sulphuric Acid Plant for Solvent
Extraction in Copper Production
Slide 24
Process
Acid Plant process flow includes:
• SO2 Tank Reactors
• Gas Conditioning System
• Cooling Tower System
Purpose
• PLCs and old DCS are being migrated to Foxboro I/A DCS –
model will be used for controls checkout and pre-tuning of controls
• Model will be used for operator training when complete
Estimated savings of 4 days of commissioning time worth $1.8
million for a $500k investment
Case studies - Summary
Reducing DCS project execution schedule.
Flawless and faster plant start-ups.
CAPEX reduction by $$$ millions by design studies.
Preventing costly start-up delays caused by design or control faults saving $$$ millions.
Reducing $$$ millions of training costs for off-shore/remote plants.
… these projects simply pay for themselves – easily!
… and there are even more benefits (increased safety…)
Slide 25
3 Technology overview
Slide 26
What’s an Operator Training Simulator?
Slide 27
PLANT CONTROLS HMI
Dynamic
Simulation
DCS MARSHALLING
CABINET
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F
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ESD CABINET
DCS ESD
Software
Emulation
Same / Similar
HMI Hardware Simulation
Real
A typical OTS architecture
Slide 28
FSIM Plus
TRISIM Plus
GUI
Trip Station
DYNSIM Model
FOD Station
Instructor Station
SIM4ME
FOXBORO
I/A DCS
Triconex
ESD
CONTROLS
CONTROLS
HMI
HMI
PLANT
PLANT
OTS Infrastructure
OTS Infrastructure
DYNSIM – for the process simulation
Slide 29
Malfunctions
Trends
Initial Conditions and Backtracks
Interactive Control
Custom Widgets
Model Library
Cross Referencing
Data Historian
Thermodynamics
Scenarios
Trainee Performance Monitoring (TPM)
Engineering/Model Building
OTS Instructor Station
Both Engineering and OTS
Slide 29
… special focus Upstream OLGA integration for multi-phase flow
Slide 30
“Since the ’90s, Chevron and Texaco have separately adopted the OLGA technology as the main tool for solving flow assurance challenges. Today OLGA is an integral part of the work flow in Chevron Texaco and continues to be used in the design of major fields.” Michael R. Barret ChevronTexaco
“The Snøhvit field would not have been realized without the results from OLGA” Terje Overvik- Executive Vice President Head of Exploration & Production, Statoil
…for minerals, metals and mining! The DYNSIM 3M library
Slide 31
Particle size distribution
Mills (Ball, SAG,…)
Crushers
Cyclones & hydro cyclones
Conveyor
Roaster
Screens
Floatation cells
Converters
…
Solids
Slid
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4 Training beyond the control room
Training beyond the control room EYESIM – Immersive Virtual Reality Plant
IMMERSIVE VIRTUAL REALITY PLANT
is a comprehensive solution linking
Control Room Operators..…
.... by means of high fedelity Process
Simulation and a Virtual Walkthrough
Plant Environment for a complete:
PLANT CREW TRAINING
...to Field Operators ..
...to Maintenance Operators ..
3D Modelling – Source data
3D CAD models All major CAD vendor files Microstation, SmartPlant, PDMS, Autodesk and more................
3D Laser Scanning “Point Cloud” All file major file formats Leica Systems, *.pts, *.igs, *.sab, *.emb, *.bin and more
BG Group – video from the pilot
Slide 35
…on-shore training and competency assessment of off-shore operators in the EYESIM 3D immersive training environment.
5 Demo
Slide 36
DYNSIM demo: Mining application
Slide 37
6 Summary
Slide 38
Is my design right before I purchase my equipment?
DESIGN DCS & PLC
CONFIGURATION STARTUP OPERATIONS
Dynamic Simulation Suite – One Solution,
Many Applications, High Value
DCS Control logic configured
correctly the first time
PLC/SIS/TMC logic Configured Correctly the First Time
World Class Operator Training Simulators
Coordinated Training of Control Room and Field Operators
Support and Maintenance Programs and Learning Management System Consulting Services
Summary
Reducing DCS project execution schedule.
Flawless and faster plant start-ups.
CAPEX reduction by $$$ millions by design studies.
Preventing costly start-up delays caused by design or control faults saving $$$ millions.
Reducing $$$ millions of training costs for off-shore/remote plants.
… these projects simply pay for themselves – easily!
… and there are even more benefits (increased safety…)
Invensys has got the technology, people and know-how!
Slide 40