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DCS Check-Out and Operator Training With HYSYS
DCS Check-Out and Operator Training With HYSYS
DCS Check-Out and Operator Training With HYSYS
Jos Naranjo, Edgar Goitia (Tcnicas Reunidas, Chile) Jos Mara Nougus, Rodolfo Tona, Josep Dav, JosMara Ferrer (inprocess)
AGENDA
Introduction
Dynamic Simulation Operator Training Systems DCS Check-Out
Case of Study
Modelling of an E&P facility DCS Integration and checkout Training scenarios
2006, Sverck et al., A Real Time Approach to Process Control, 2nd Ed.
INTRODUCTION
Consolidated Exploring
1. Equipment sizing and process layout verification:
Compression systems Pipeline networks
Perturbation rejection
Control loops selection
Dynamic Model
networks
Study non-linearities
Test/Tune MPC controller
Emergency scenarios
Knowledge base system
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AOs, DOs
AIs, DIs
DOWNLOAD DATABASE
OPC
AOs, DOs
Operator Console
DOWNLOAD GRAPHICS
Operator Console
Instructor Station
Plant
HYSYS Model
Controls
HYSYS Controls
Operator Console
HYSYS Environment
Simulated
Software emulation
Graphic Interface
Emulated
Real Plant
DCS Hardware
DCS Console
Stimulated
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The I/Os (discrete & analog) are fully simulated by a process dynamic simulator of the entire plant
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Loop testing
Alarm verification SIS verification
No possible
Only non-time dependent Limited, no plant interaction
PROJECT ANTICIPATION
Certain tasks dont need to wait for the physical good to exist, they can start as soon as the dynamic simulation is available
With OTS
Typical Start-up
Less incidents
8 9 Weeks
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DYNAMIC MODEL
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OTS ARCHITECTURE
Operator
Equipments: 68 Isolation valves: 55 Control valves: 38 Relief valves: 55 PID loops: 56 I/O Count: 800
Instructor
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DCS DATABASE
Types of modules:
Control Modules. Associated to controllers and indicators inside the control logic of the plant areas under model scope SIS Modules. Associated to the plant safety logic. Only the ones that affect the modelled areas. Modules grouped by working areas
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Configuration of modules
Control modules configurations generated wrong signals affecting other modules that generate range deviations and could trip ESD.
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OTS BENEFITS
1. 2. 3. 4. Identify unit or process operating constraints at design phase Identify errors in the automation system before commissioning and operation Verify/Improve operating procedures Train operators on safe and optimized procedures for all scenarios
1. 2. 3. 4.
Begin startup sooner Complete startup in less time Improved steady operating rate and product quality Minimize incidents and equipment damages
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RECAP
Uses of Dynamic Simulation What are Operator Training Systems Additional value: DCS Check-Out Case Study: E&P facility Detected DCS problems OTS Benefits
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QUESTIONS, CONTACT
Q&A
Contact:
JoseMaria Ferrer Inprocess Technology & Consulting Group, S.L. Phone: +34 933 308 205 Cell: +34 607 570 685 josemaria.ferrer@inprocessgroup.com
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