ANSWERS
SIMULATION FOR TRAINING
Scott Michel, Honeywell
Lifecycle process simulation
Using simulation for plant design, process automation system validation,
and operator training will help optimize plant operations.
D
igital transformation is rapidly influenc-
ing the hydrocarbon processing indus-
try. Up to 60% of refining operations
are spending more on digital technolo-
gies in 2018 and 67% believe a lack of
digital solutions would reduce their competitive edge,
according to a research report by Accenture. While
new software and hardware are being developed to
address this demand, established strategies also stand
to play an important role in the digital revolution. The
change will be in how these tools, such as operator
training simulators, are implemented, deployed, and
used to achieve optimal plant performance.
Process simulation has been a key tool in the
hydrocarbon industry for decades. Simulators have
been used in two key phases of the plant lifecycle.
During the initial design phase, steady-state models
enable engineers to design and size key equipment and
Figure 1: A diagram ensure that heat and material balances are satisfied.
shows a plant life- Later, when the plant is online, the operations staff
cycle’s key phases uses dynamic operator training simulators (OTS) to
and where simula- train new personnel and refresh experienced workers’
tion can be used. skills in phase 3 and part of phase 5 of the Figure 1
All graphics cour- plant lifecycle. This leaves many phases of engineering
tesy: Honeywell and operations without simulator interaction.
18 • December 2018 control engineering
Management can use high-fidelity simulation
throughout the plant lifecycle to yield the greatest
return on investment by treating the simulator as a
digital copy of the physical plant not limited to narrow
use-cases. Advancements in computational technol-
ogy have filled the gap between design and opera-
tions so a full plant model of the highest fidelity can
be used simultaneously for engineering studies and
operator training. In bridging this gap, a much larger
percentage of the plant lifecycle comes into scope and
unlocks the potential of the process simulator as a tool
that covers the plant from design to operation.
Static and dynamic simulation models
Static process simulation software is heavily relied
upon during the front-end engineering and design
(FEED) phase of brownfield and greenfield projects.
Comprehensive plant models provide engineers with
a complete view of heat and material balances for lim-
iting design cases and other operating conditions.
Additionally, simulation software is used to perform
feasibility studies, assess different process configura-
tions, and identify risks. Engineers can leverage this
information to ensure designs are safe, meet environ-
mental regulations, and maximize the operational and
business performance of the asset (see Figure 1).
Generally, static simulation is a tool used most
often during this stage of the plant lifecycle. Howev-
er, dynamic models can be useful for feasibility stud-
ies. Mature simulation software allows the end user to
seamlessly migrate from a static to a dynamic model.
In this case, services required to build the initial model
are performed upfront, during the FEED phase. Simu-
lator benefits can be realized in the downstream life-
cycle phases with minimal services investment.
Simulation for plant design, validation
While static models ensure operation at defined
steady-state conditions, a dynamic simulator allows
engineers to validate that the plant can successfully
operate at every point from black start to full capac-
ity. Once the plant design has been finalized, engi-
neers can use the simulator to ensure the design is fit
for purpose and all equipment can meet the demands
of the startup procedures and operational sequences.
By adhering to process and mechanical datasheets
during the model development phase, end users can
be confident all equipment in the simulation matches
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its physical counterpart in the field. With this knowl-
edge, engineers can scrutinize every piece of equip-
ment in plant from individual piping segments to
complex, multi-pass heat exchangers. With the ability
to pre-program model scenarios, engineers can con-
tinuously run the plant through defined operational
procedures and examine the process responses using
incremental changes in the plant design.
While the benefits of examining the plant process
with a simulator are immense, much of the value is
realized upon integration with the control system.
After the design and testing the controls, the simulator
can provide an additional layer of process automation
insight. Most modern control systems can simu-
late values so rudimentary testing can be performed
on control loops. However, a high-fidelity simulator
provides realistic process responses that are almost
impossible to replicate with empirical correlations.
Sophisticated modeling software is based on
first principles, thus providing meaningful insight
into countless “what if ” scenarios. The controls will
be exposed to more advanced testing that is more
closely aligned with the actual plant response. This
allows engineers to identify potential problems early
in the design phase before they become expensive and
time-consuming to correct.
The safety system’s validation and design is a vital
part in the commissioning of any new facility. All pro-
duction companies aim to minimize the number of
safety incidents that occur onsite. However, safety sys-
tems are exercised so infrequently it may take years for
a flawed design or procedure to be recognized.
A simulator provides real-time process responses
to allow users to scrutinize and dissect safety schemes
during abnormal operating conditions. Using defined
operating scenarios, users can run the plant through
various upset conditions such as: compressor surge,
depressurization/flaring events, and total plant shut-
down. This allows for an iterative process wherein
safety systems are constantly tested and upgraded to
account for all possible outcomes. Once changes have
been proposed, the hazard and operability (HAZOP)
team can use the simulator to support studies and
investigate the integrity of planned designs.
Virtual plant commissioning and startup
While a simulator will not aid in constructing a
new facility, the engineering staff can continue to use
the simulator during this time to ensure commission-
ing and startup (CSU) is as smooth as possible. Many
pieces of the plant, from process equipment to con-
trols and alarming, are being exercised to full func-
tionality for the first time. Many unforeseen issues are
uncovered during this time that require immediate
attention to avoid lengthy and expensive delays.
Issues faced during the CSU can be addressed
much earlier by performing the CSU in a virtual
environment. A virtual commissioning and startup
(vCSU) that involves all key stakeholders will expose
many flaws and allow them to be rectified in a timely
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Figure 2: Screenshot: An operator training simulation environment is
available in Honeywell UniSim Operations.
and controlled manner. For example, vCSU provides
engineers an opportunity to test the detailed startup
procedure, fully exercise the distributed control sys-
tem (DCS) human-machine interface (HMI), validate
alarm suppression, and tune vital control loops. Many
of these activities are often crowded into an already
tight startup schedule leaving little room for error.
This second layer of validation ensures the assets
handed off to operations have been validated and
tested in an environment that mirrors real life.
Plant operation, maintenance
Traditional custom-built plant simulators help
train operators. Many plants implement programs
that require employees to follow extensive, simula-
tor-based training regiments to maintain a certain
level of training. The best practice is to track and
record the performance of board operators using
training scenarios to evaluate key performance indi-
cators (KPIs) against plant standards. Management
can track plant performance and see the
efficacy of the hands-on training program
in real-time (see Figure 2).
Recent improvements to augmented
M More
ANSWERS
reality (AR) and virtual reality (VR) tech- KEYWORDS: Operation training
nologies have extended simulator-based simulators (OTS), augmented
training to field operators. Workers can reality (AR)
practice non-routine tasks in the safety of Enhance personnel and plant
operator training with simulators
a virtualized or mixed reality environment
Extend the plant lifecycle with
with instructors. Hands-on training leads training simulation environments
to a safer and more competent workforce. Support the plant lifecycle with
By viewing a process simulator as a plant’s simulation.
digital clone, users can explore new ave-
COnSiDER thiS
nues to support the plant lifecycle. ce
How can training simulation
software improve the lifecycle?
Scott Michel is senior product mar-
keting specialist, Honeywell. Edited by OnLinE
Emily Guenther, associate content man- Read more online with this
article at www.controleng.com,
ager, Control Engineering, CFE Media, on operations, virtualization, and
eguenther@cfemedia.com. cloud-based project execution.
control engineeering December 2018 • 19