Dynamic Simulation

in the complete Plant Lifecycle

Peter Both, Invensys Systems GmbH, Invensys SimSci-Esscor
Cal Depew, Invensys Systems Inc., Invensys SimSci-Esscor

Process Systems

Get More from One

Avantis • Foxboro • SimSci-Esscor • Triconex
Agenda
Process Systems

ƒ Experiences
ƒ From Design to Training.
1. Design
2. Control Checkout
3. Initial Training
4. Plant Performance Improvement

ƒ Questions

Company Confidential 2
 Dynsim OTS Projects Process Systems

8/11/05

ƒ Refining ƒ Refining (Cont’d)

– ExxonMobil – Total Leuna
ƒ Integration
ƒ Preferred OTS Services Provider
– Total Dalia
ƒ New projects underway
ƒ Integration
– Husky Energy
ƒ Crude Unit
ƒ Gas Oil Hydrotreater
ƒ Hydrogen Plant ƒ Upstream
ƒ Sulfur Recovery – Shell Bonga
– PDVSA Puerto La Cruz (underway) ƒ FPSO

ƒ Reformer – Shell EA
ƒ Naphtha Hydrotreater ƒ FPSO

ƒ Diesel Hydrotreater – Saudi Aramco Uthmaniyah

ƒ Sulfur Recovery ƒ Reverse Osmosis Plant

– Opti-Canada Long Lake (underway) – ExxonMobil ERHA (underway)

ƒ FPSO
ƒ OrcrudeTM (Crude/Vacuum/Cracking)
– Agip-Petroli Kashagan (underway)
ƒ Gasification
ƒ Offshore platform
ƒ Hydrocracker ƒ Onshore turbo expander gas plant
ƒ Sulfur Recovery ƒ Oil Stabilization
ƒ Air Separation Unit ƒ Sulfur Recovery

– Total Normandy (underway)

ƒ Hydrocracker
ƒ LNG
– Tractebel Reganosa (underway)
ƒ Hydrogen Plant
ƒ LNG Terminal
ƒ Sulfur Recovery Unit
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Dynsim OTS Projects Process Systems

8/11/05

ƒ Power
– Southern Company (13 Systems)
– Wisconsin Energy (3 Systems)
– First Energy (2 Systems)
– TransAlta Centralia Plant
– PPL Montana (2 Systems)
– Intermountain Power
– Public Service New Mexico (2 Units plus environmental
models)
– Deseret
– Mississippi Power
– Puerto Rico Power Authority (PREPA) (2 Systems)
– Iberdrola (Combined Cycle)
– Platte River Rawhide
– Dayton Power and Light (2 Systems)
– Washington Group Mystic River (Combined Cycle)
– Tuscon Electric
– Sceco PP9 (Combined Cycle)
– 50 More

Company Confidential 4
 Dynsim Users Process Systems

8/11/05

ƒ Global ƒ Japan
– ExxonMobil – Chiyoda
ƒ North America – JGC (E&C)
– Bechtel – Kobe Steel (E&C)
– Colt Engineers – Tsukishima Kikai (E&C)
– ABB Lummus – IHI (E&C)
– Conoco Phillips – Shinko Air Water (E&C)
– Koch Glitsch – Mitsubishi Gas Chemical (Chemical)
– Fluor Daniel
– Sumitomo Chemical (Chemical)
– Nova Chemicals
– Toray (Chemical)
ƒ Latin America – Maruzen Chemical (Petrochemical)
– PDVSA – Toyota Motor (Bio Dept)
ƒ Europe – Idemitsu
– Snamprogetti – Mitsubishi Materials
– Eni S.p.A. (Agip) E&P – Air Water
– Technip – National Institute of Advanced Industrial
Science and Technology
– Hyperion
– Kanazawa Univ.
– Polimeri Europa (ENI Chemicals)
– EDL Anlagenbaugesellschaft mbH

Company Confidential 5
 Process Systems

From Design to Training

Company Confidential 6
 Process Systems
Get More from Dynsim SIM4ME

Dynsim/SIM4ME Vs. Other

Dynsim includes Products
Model
Instructor • Multiple
GUI Engines
• Simulation
DCS DYNSIM
Executive
• Instructor
SIM4ME
Interface

PLC Excel
Other products:
• Single Engine
2nd
• Executive not included
DYNSIM
• Instructor features not
included
Company Confidential 7
Combined Engineering/Instructor GUI
Process Systems

Data Historian Scenarios

Thermodynamics Cross Referencing Interactive Control

Model Library

Snapshot
Management

Malfunctions

Trends

Custom Widgets
Company Confidential 8
 Dynamic Simulation Suite
Process Systems

Plant / Validate Checkout Train Improve

Design Controls Personnel Performance

PROCESS DCS INITIAL PLANT

DESIGN CONFIGURATION START OPERATION

1 2 3 4
Company Confidential 9
Project Phase 1:
Plant Design - Validate Design
Process Systems

“Test your plant in the office,

not in the field. Dynamic simulation can verify plant
design before you commit capital to a project.”

Company Confidential 10
Project Phase 1: Plant Design
Dynamic Simulation Benefits
Process Systems

Validate
Design

PROCESS DCS INITIAL PLANT

DESIGN CONFIGURATION START OPERATION

• Reduce equipment cost through reduced overdesign

• Verify safety of relief and flare systems
• Validate controls such as compressor anti-surge
• Analyze operability for highly integrated plants

Company Confidential 11
SIM4ME:
PRO/II to Dynsim Translator
Process Systems

Steady State ƒ Open PRO/II file from

Simulation Dynsim.
S1

S4
ƒ Transfer Thermo data
C1

S2
ƒ Adds additional equipment
S6
ƒ Flowsheet Layout
S3

S5
ƒ Preliminary Equipment Sizing

Dynamic
Simulation

Company Confidential 12
Comprehensive Model Libraries Process Systems

Equipment Controls Electrical Utilities

Company Confidential 13
Integrated Solutions -
DYNSIM™ & Excel
Process Systems

Surge
Controller

Data Export
Trip motor to/from
Microsoft Excel
Engine

Company Confidential 14
 Dynamic Engineering Studies (Dynsim) Process Systems
Column Relief Load Reduction
ƒ Problem
– Conventional methods are very
conservative leading to overly
expensive flare systems and
unnecessary flare or flare header
replacements.

ƒ Solution
– Dynamic simulation provides an
alternative to conventional calculation
methods and provides substantially
lower relief loads. Flare load
reductions up to 50% are possible.
– Dynamic simulation is consistent with
API RP-521 methods.

ƒ Benefits
– Save relief and flare system capital
expenditures up to several million
U.S. dollars.

Company Confidential 15
 Dynamic Engineering Studies (Dynsim) Process Systems
Compressor Surge
ƒ Problem
– Expensive compressors can
be damaged by inadequate
anti-surge control and
equipment design.
ƒ Solution
– Validate controls to keep
compressors out of surge,
especially during startup and
shutdown.
– Evaluate performance using
hot gas bypass vs. cold gas
bypass designs.
ƒ Benefits
– Prevent damage multi-million
dollar machinery.

Company Confidential 16
 Dynamic Engineering Studies (Dynsim) Process Systems
Cryogenic Depressuring
ƒ Problem
– Vessels with light hydrocarbons
become very cold during depressuring
requiring expensive metallurgy.
ƒ Solution
– Calculate the mean metal temperature
as a function of time during
depressurization for gas processing
and LNG applications.
– The mean metal temperature is
substantially less severe than the fluid
temperature and expensive metallurgy
and design choices can be avoided.
ƒ Comments
– Depressuring model is validated with
actual data.
ƒ Benefits
– Avoid use of stainless steel metallurgy
for savings up to several million U.S.
dollars.

Company Confidential 17
Project Phase 2: DCS Configuration
Process Systems

“Checkout of controls in the lab can save

days or weeks of commissioning time and
can get your plant on line sooner.”

Company Confidential 18
Project Phase 2: DCS Configuration Process Systems
Dynamic Simulation Benefits

Validate Checkout
Design Controls

PROCESS DCS INITIAL PLANT

DESIGN CONFIGURATION START OPERATION

• Identify control logic errors

• Identify graphics configuration errors
• Test signal ranges
• Pre-tune control loops
• Test integrated and coordinated controls

Company Confidential 19
Modular Simulation Architecture Available design operate

DCS/PLC Interfaces
Process Systems

ƒDCS
– Foxboro I/A Series FSIM (virtual stimulation)
– ABB/Bailey BALSIM (full em.) GUI
– ABB/Bailey BALTRAN (Partial Stim)
– ABB Industrial IT
– Emerson OVATION
– Emerson DeltaV
Dynsim
– Honeywell (third-party) DCS Engine
– Yokogawa (third-party)

SIM4ME
ƒPLCs
– Triconex TRISIM (virtual stimulation)
– Allen-Bradley PLC-5
– GE Mark IV/V/VI PLC Excel®
– Alstom Funoc Turbine Engine
3rd Party
Requires
– Modicon PLC-984
– Woodward Governor Engine
additional
ƒGeneric
– OPC Interface
Licensing

Company Confidential 20
 Control Checkout Studies (Dynsim/TRISIM Plus) Process Systems
Turbomachinery (TMC) Control Checkout
ƒ Problem
– Complex turbomachinery control
(TMC) can lead to startup delays.
Improperly tuned controls can lead to
damage to multi-million dollar
equipment.
ƒ Ethylene
ƒ LNG
ƒ FCC Wet Gas Compressors

ƒ Solution
– Checkout new TMC controls before
commissioning or poorly behaving
existing controls
ƒ Benefits
– Validate Triconex controls to get
new controls on line sooner.
– Improved reliability
– Prevent equipment damage
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Project Phase 3: Initial Startup
Personnel Training
Process Systems

“Train operator in the safe and efficient operation of

the plant with an emphasis on preventing
catastrophic failure.”

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Project Phase 3: Initial Startup
Operator Training
Process Systems

Validate Checkout Train

Design Controls Personnel

PROCESS DCS INITIAL PLANT

DESIGN CONFIGURATION START OPERATION

• Familiarize operators with new graphics

• Train operators for startup and shutdown
• Improve operator emergency response skills
• Develop technician diagnostic, tuning and
maintenance skills

Company Confidential 23
Objectives
Process Systems

ƒ Improve Control System Response

ƒ Expand Operator Comfort Zone
ƒ Capture Best Practices Procedure
ƒ Increase Startup/Shutdown Training Frequency
ƒ Improve Reliability (Upset, Abnormal Situation,
Malfunctions)

Company Confidential 24
Instructor Overview Background
Process Systems

Company Confidential 25
Project Phase 4: Plant Operation
Improve Plant Performance
Process Systems

“Test both process and control system design

modifications in a risk free environment”

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Project Phase 4: Plant Operation
Improve Plant Performance
Process Systems

Validate Checkout Train Improve

Design Controls Personnel Performance

PROCESS DCS INITIAL PLANT

DESIGN CONFIGURATION START OPERATION

• Experiment with control system modifications

• Evaluate alternative process designs
• Optimize operational procedures
• Test and pre-tune APC systems

Company Confidential 27
Improve Plant Performance
Test Bed Value Proposition
Process Systems

ƒ By understanding an existing process better, small changes in

the arrangement of existing plant equipment, feed point locations,
operating conditions or control strategies can result in tremendous
improvements in safety, yield, process variability, energy utilization,
product quality & waste minimization.

ƒ By understanding the existing controls better, small changes to control

interlock logic and permissives, operator display organization, and
controller tuning can result in tremendous improvements to
emergency condition response and startup and shutdown procedures.
We have a uniquely competitive position w.r.t. Foxboro I/A Series
control systems.

Company Confidential 28
Large Offshore Simulator Architecture Process Systems

InTouch SIM4ME
Instructor
InSQL Station CCCSIM
GUI
Micro I/A
TRISIM

Well Instructor
Locate InControl ABSIM AW

Thorn FSIM
Graph SIM4ME Foxboro I/A
48 cp60s
Executive Instructor
In P WP
3rd Party rog
res
s
Process Model
Utilities
In OLGA2000
Pr
og Wells/Pipelines
re
ss
3rd Party
Process Model Operator
WP
Water Flood OLGA2000
3rd Party (Wells/Pipelines)
Process Model
Production 3rd Party P
Dynsim-P
Process Model
Models
Inlet

* Previous version of Dynsim (Tsunami 6.0.22) Company Confidential 29

Plant Testbed Example Process Systems

FPSO with Integrated Pipeline Modeling

ƒ Required by FPSO (Floating Production
Storage and Offloading) OTS project.

ƒ Predict
operating
procedures to Elevation profile

avoid GUI FLOWLINE

300

E le v a tio n [ m ]
200

Slugging
100
0
-100
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000

ƒ Test process
Horizontal length [m]
OLGA-HYSYS Demo case - Level 1 Cource: Exercise 1
Foxboro IA DYNSIM

improvements
FSIM
SIM4ME

ƒ Test control
improvements
Triconex OLGA
TRISIM 2000

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Complete Lifecycle
Process Systems

“One dynamic model over the complete plant lifecycle.

Company Confidential 31
 SimSci-Esscor Dynamic Simulation Suite:
“From Design to Training!”
Process Systems

Validate Checkout Train Improve

Design Controls Personnel Performance

PROCESS DCS INITIAL PLANT

DESIGN CONFIGURATION START OPERATION

• Reduce cost • Identify control • Familiarize • Experiment with

through reduced logic and graphics operators with new control system
over design errors graphics modifications
• Verify safety of relief • Pre-tune control • Train operators for • Evaluate alternative
and flare systems loops startup and process designs
• Validate controls • Test instrument shutdown, and • Optimize
such as compressor ranges emergencies. procedures
anti-surge • Test integrated • Develop technician • Test and pre-tune
• Analyze operability and coordinated diagnostic, tuning APC systems
for highly heat controls and maintenance
integrated plants skills

Company Confidential 32
 SimSci-Esscor Dynamic Simulation Suite:
“From Design to Training!”
Process Systems

Validate Control OTS Plant

Design Checkout Improvement

PROCESS DCS INITIAL PLANT

DESIGN CONFIG. START OPERATION

SimSci-Esscor
Dynamic YES YES YES YES
Simulation Suite

Need Auxiliary Not an integrated Too difficult to

Engineering YES control emulations environment and modify and maintain
Only Simulators requires add tools

Equation Solvers YES Not used for this Not used for this Not used for this
purpose purpose purpose (e.g. DCS,
Design)
OTS Only Not usually
Simulators used for this YES YES Too difficult to
purpose modify and maintain

Company Confidential 33
Why do Dynamic Engineering?
Process Systems

ƒ Reduce Equipment Costs

– Many design parameters are based on transient operating conditions.

ƒ Evaluate First of a Kind Plant Designs

– These plants may have unforeseen process, control, and relief problems.
– Reveal problems during design to avoid costly modifications after startup.

ƒ Validate Control Strategy

– Test the control strategy as defined on a PFD.
– Avoid costly troubleshooting and tuning efforts in the field.

ƒ Test Heat Integration

– Complex designs with tight heat integration may need supplemental startup
heat.

ƒ Analyze Flare and Relief Systems

– Validate relief system design as a result of a Hazop analysis.

Company Confidential 34
 Dynsim for Process Equipment Design: Process Systems
Results in significant equipment cost savings

Induction motor torque curve

2.5

1.5

Torque factor
1
Series1
0.5

0
0 0.2 0.4 0.6 0.8 1 1.2

-0.5

-1

ƒ Compressor studies avoid equipment

speed - nornalized

ƒ Cryogenic Depressuring Studies

damage and lost production.
save eliminate stainless steel
metallurgy.

ƒ HPU Depressuring Studies can save ƒ Column Relief Load Reduction studies
US$millions by reducing feed/effluent can eliminate unnecessary flare system
heat exchanger design expansions
Company Confidential 35
Dynamic Engineering
Applications
Process Systems

ƒ Fractionation
– Column Relief Studies for unit revamp studies to verify safe design and avoid/reduce flare
system expansion.
– Control validation

ƒ Compressors
– Surge Control
– Startup

ƒ Refinery Flare Systems

– Time dependent pressure profiles

ƒ Upstream/Gas Processing Cryogenic Depressuring

– minimum metal temperature and metallurgy selection
– Valve Sizing

ƒ Hydroprocessing Unit Depressuring

– Feed/Effluent Exchanger design.

ƒ Refinery Steam Generation, Cogen, and Distribution Studies

– Backup steam response requirements
– Control validation

ƒ Boiler Draft Studies

– Boiler implosion risk analysis
Company Confidential 36
 Dynamic Engineering Studies
Benefits Summary
Process Systems

ƒ Improve Project ROI (Process Design Studies)

– $1M for relaxed flare/vessel metallurgy requirements
– $2M for removed requirement for flare system revamp at greater unit
throughput
– $5M to avoid boiler strengthening to FGD retrofit

ƒ Reduce Commissioning Time (Control/Operability Analysis)

– Validate controls for stable operation
– Verify process will behave as expected.
– Checkout startup and shutdown procedures and logic
– Get on line sooner!!

ƒ Improve Operations (Decision Support / OTS)

– Reduce off spec production
– Reduce flaring
– Improve safety
– Protect equipment
– Maintain operator knowledge

Company Confidential 37
 Process Systems

Thank you

Company Confidential 38