The Virtual Process The Virtual Process Overview and ApplicationsOverview and Applications

Cape Software Inc.

Overview and ApplicationsOverview and Applications

Cape Software Inc.Houston TX

Corporate OverviewCorporate OverviewppFounded in 1996HQs located in HoustonQProducts:

VP Link Drivers and database management toolsDrivers and database management toolsRigorous modulesScoring engine etc…

Test CompilerLogic Validation

XP TrendCorderHigh Speed trending for Root cause analysis

What is VP Link ?What is VP Link ?

A dynamic representation of a chemical y pprocess to an offline control system.

VP Link components in a VP Link components in a client / server architectureclient / server architecture

VP Link components run seamlessly over the network

VVirtualirtual PProcess : Overviewrocess : OverviewVVirtual irtual PProcess : Overviewrocess : Overview

Windows based interface: intuitiveNo Changes to Logic programs: non-invasiveI/O Hardware not required (cost advantage)

Calculate

Read value of outputs

Calculate ProcessVariablesVPLink

Eng/Operator Station Write simulated inputs

Some of our customers...Some of our customers...

Supported SystemsSupported SystemsSupported SystemsSupported Systems

ABB 800 xA, Industrial ITABB 800 xA, Industrial ITABB Mod300, Advant, BaileyTriconex:Tricon/Trident Honeywell Experion PKS TDC,TPS , FSCHoneywell Plantscape / Rockwell ProcessLogixy p gGE Fanuc series 90A-B PLC5/SLC500,CLX, Modicon,Siemens-Ti 505Foxboro I/A,ArchestraSiemens APACS, PCS7, S7Yokogawa CS3000/R3/ ProSafeEtc...

Different Architectures for Different Architectures for ff fff fdifferent Applicationsdifferent Applications

Logic Testing Setup

Parallel Training Setup

Engineers test different units, Trainees operate identical units,g ,interacting with each other

p ,in parallel

TheThe VVirtual irtual PProcess for rocess for Legacy ABB Mod300 SystemLegacy ABB Mod300 System

ABB DDE ServerVP Link 3.x

Legacy ABB Mod300 SystemLegacy ABB Mod300 System

VP Link/ABB Interface

ABB DDE Serverwith VP3 driverServer(s)

DDE over TCP/IPTrainer Station

OptionalOptionalVP Link/SIS

Interface ABB Turbo Node

Operator Station

Mod300 ControllersSIS Station

VP Link Specifics :VP Link Specifics :VP Link Specifics : VP Link Specifics : ABB Mod300 InterfaceABB Mod300 Interface

TCP-IP based interfaceRobust DDE based connectivityRobust DDE based connectivityNon-intrusive ( Set points in Manual )Interface work in parallel with otherInterface work in parallel with other simultaneous connections (such as ABB Portal,etc) for vertical integrationPortal,etc) for vertical integrationFull forward integration with 800xA components for seamless simulation pmigration

Does the Does the type of process matter ?type of process matter ?

VP Link is a proven solution for :Batch (recipe / state control based strategy )Semi-continuousContinuous

How ?VP Link model is I/O based Hence isolated from control strategy

VP Link ApplicationsVP Link Applications

I - Logic Validation

Cost of changes over a typical Cost of changes over a typical project development cycle project development cycle

Incre Minimal to Maximal ementa

moderateimpact

cost impact

al Cost

Time IAT FAT SAT PSSR

VV--Approach methodology:Approach methodology:li ti t lid tili ti t lid tiapplication to validationapplication to validation

Safety R i t

Pre Start-Up S f tRequirement

Spec

Run manual

Safety Review

Narrative

C & D l

Run manualTests

Cause &Effect

Function

DevelopScenarios

Function Block

Design

Black BoxTesting

DeliverableFunctional

Logic

Deliverable

Verification

Logic Validation with VP LinkLogic Validation with VP LinkVP Link Allows:

Graphics verificationpLogic checkout at I/O / block / module / system levelInterlock schedule approval Integrated Testing :Mapping to DCS and interactionIntegrated Testing :Mapping to DCS and interaction between DCS/PLC logic ( gateway points tests)

How ?Automates repetitive testing task (ie resets etc…)Facilitates FAT with customized graphics Collaborative testing framework thru distributed garchitecture

Thoroughly debug prior to online download, ie, Management of Change and periodical testingManagement of Change and periodical testingTest Compiler complies with IEC61508/61511

Simulation Screen shotsSimulation Screen shotsSimulation Screen shotsSimulation Screen shotsAutomated Tag sheet

Input/Output sheets per ESD

HMI for advanced testingHMI for advanced testing or training

VP Link ApplicationsVP Link ApplicationsVP Link ApplicationsVP Link Applications

II- Operator Training Simulator (OTS)

IIII-- Goals of Operator TrainingGoals of Operator TrainingIIII Goals of Operator TrainingGoals of Operator Training

Knowledge Transfer

Assess trainees proficiency

Turnaroundproficiency

Refresher TrainingRe-certification Run

Train Operator’s for Emergency Response Faults / Malfunctions / Upsets (Real or Instrumentation)

Pre-StartupExercise Startup / Shutdown Procedures

Familiarize staff ith HMI O l N i ti FAT

Pre Startup

with HMI, Overlays, Navigation, Alarm Pages, Trend Displays

FAT

OOperator perator TTraining raining SSystem ystem pp gg yy(OTS) using VP Link(OTS) using VP Link

• Actual control program is solved in native environmentActual control program is solved in native environment for realistic control response

• Trainees operate the virtual plant using actual consoles, graphics and keyboardsgraphics and keyboards

• ESD (Emergency Shutdown Device) is fully integrated in the process model and OTS

• HMI graphics are imported in VP Link to offer an intuitive trainer interface

• High Quality process modeling tools, simulating theHigh Quality process modeling tools, simulating the most complex chemical processes (Rx,Dist,Compressors…)

• Scoring Engine for knowledge retention metrics• Scoring Engine for knowledge retention metrics• Experienced , in-house Chemical engineers to deliver

turnkey, customized training solutions for your process

Operator Knowledge Assessment :Operator Knowledge Assessment :Operator Knowledge Assessment :Operator Knowledge Assessment :the Scoring Enginethe Scoring Engine

Excel configuration Front EndScenario launched sequencesScenario launched sequences

Targets (timing, rate, value, tolerance window)Actions ( I/O activity)Actions ( I/O activity)Order (logical relationship between steps)

Independent trainees logs with:Independent trainees logs with:normalized scores relevant actions & timingrelevant actions & timing

What kind of processWhat kind of processWhat kind of process What kind of process simulation do you need ?simulation do you need ?

A closer look at the competition…

Marginal cost Analysis of Marginal cost Analysis of g y fg y fprocess model fidelityprocess model fidelity

• ~ 2,000 I/O• Oil Refining unit(FCC, HDC etc)

Simulation Investment Vs level of Fidelity

$800 000 00

$900,000.00

$400 000 00

$500,000.00

$600,000.00

$700,000.00

$800,000.00

Logic Validation OTS /

$0 00

$100,000.00

$200,000.00

$300,000.00

$400,000.00 EngineeringVP Link

$0.00

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Why is Hybrid modeling Why is Hybrid modeling more cost effective ?more cost effective ?

No compositional (I/O based) = more flexibilityp ( ) yAll dynamics CAN be capturedRigorous modules available:

Distillation modulesHeat Exchanger, Compressor & OPEN blocksReactor module ( catalytic,treating,cracking etc)Reactor module ( catalytic,treating,cracking etc)Liquid Flow Network / HxNGen (and documentation)Sequential and Simultaneous Matrix Solving schemes integrate seamlesslyseamlesslyApproximations compensated for by the control outputs

Layer Approach minimizes model upkeep costsVP Link allows exactly for desired model fidelityAccuracy: 99% quasi Steady State / 85% full transient

A note about “Fidelity”Fidelity is perceived by Operators ONLY through

i d i blmonitored process variables

Fidelity should reflect the overall accuracy of theSYSTEM= process simulator + “control environment”

ConclusionConclusionVP Link solves simulation needs from simple to sophisticated, rigorous modeling.OTS node can used as an engineering Test Bed system, for preventive / periodical logic validationU tt d d R l Ti t i f lUnattended Real Time trainee performance logsModeling environment is flexible, easy to learn and maintainAvailable New Version Service keeps VP Link components up to date, with free technical supportCost Effective simulation package for OTS,using Off the Shelf components for process model and control or emulated controlCross platform functionalities makes VP Link an evolutive investment

Questions ???Q

High Level Schedule :High Level Schedule :OTS ProjectOTS Projectjj

Methodology and project Schedule Methodology and project Schedule for Typical OTS Projectfor Typical OTS Project

Customer Needs Identification

ProcessModeld l

ModelFine

i

ModelAcceptanceA d D liIdentification development Tuning And Delivery

• Gather plant Data• PFD & PIDs

• Operations Feedback• Final IO configuration

End UserPFD & PIDs

• IO configuration• HMI screens (first round)

Evaluate :

•Train the trainer• Start Operator Training

g• Final HMI screensAutomation

VendorEvaluate :•Scope•Fidelity•SIS comms•Scoring

• Database Extraction• Trainer Screens• LFN Layout• model development

• On-site connectivity test• Dynamics tuningU t/t i i S i

T=0 T=2 weeks T=2.5 month T=3 months

•Scoring •Upset/training Scenarios