Simulations for Mining/Oil & Gas ANZ OpsManage 2013 Perth, 8th of May 2013
Gregor Fernholz Global Business Development Manger Operator Training Simulators
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Agenda 1. Motivation 2. Case studies 3. Technology Overview 4. Training beyond the control room 5. Demo 6. Summary
1 Motivation anbei
Australian Bureau of Statistics Production by value 100 90
Strong growth of Oil/Gas, coal and metallic minerals
70 60 50 40
20 10 0 2002
Australian Bureau of Statistics Employment index. Year 2000=100
Employment growth in Australia Mining: +250% in 11 years
Australian Bureau of Statistics Employment growth in Australia 250
Employment in mining in '000
35,000 new jobs every year PLUS retirement replacements
150 130 110 90 70 50 2000
US Mine injuries and operator experience 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?
2 Case studies
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 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 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 Objective Replace Woodward with Triconex controls in minimum
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 Slide 14
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
PetroCanada Tail gas compressor Design and control validation 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 antisurge and suction pressure controller Added stonewall controller Recommended/Confirmed Valve Sizes, Trim and Actuation Times Slide 17
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
Accident / Incident free commissioning !
BG Group Gas Platform Operator competency assessment 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.
(C) BG Group. Used with kind permission of BG Group
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 “fantastic achievement” top of Schneider PLC/SCADA Controls • Introduced SimSci-Esscor into the account • Solution – use dynamic models of Cape “brilliant outcome” 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
Agrium JV Vault Potash OTS Project Project VAnscoy ULTimate Expansion (VAULT) - potash mine expansion including an additional new processing train Process Agrium Vanscoy process model includes: • Raw ore handling • Flotation • Compaction • Crushing/Desliming
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 Slide 22
Teck Zinc Roaster Operator Training Simulator Acid Plant process flow includes: • Zinc Roaster (Fluidized bed roaster)
• Draft from the roaster all the way to the stack •“…starting Calcine ballthe millplant up on the simulator was real … the
simulator behaved just like the real plant … I actually • Waste heat boiler, Gas cooling, Mercury removal, Acid plant 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 Acid Plant OTS completed and in operation since Jan ‘13: push the plant, I mean, Simulator as I have always wanted and was doplant withongoing the real plant …” Second OTS project for afraid a new to acid More OTS projects in the pipeline.
Codelco Sulphuric Acid Plant for Solvent Extraction in Copper Production 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…)
3 Technology overview
What’s an Operator Training Simulator? PLANT
CONTROLS F C P
F C P
I/ I/ I/ I/ I/ I/ I/ I/ O O O O O O O O
I/ I/ I/ I/ I/ I/ I/ I/ O O O O O O O O
DCS MARSHALLING CABINET
Simulation Slide 27
Same / Similar HMI Hardware
A typical OTS architecture OTS Infrastructure
FOXBORO I/A DCS
GUI Instructor Station
CONTROLS FSIM Plus
DYNSIM PLANT Model
CONTROLS Triconex ESD
HMI Station FOD Station
DYNSIM – for the process simulation Engineering/Model Building OTS Instructor Station Both Engineering and OTS Thermodynamics
Model Library Interactive Control
Custom Widgets Initial Conditions and Backtracks Malfunctions Trainee Performance Monitoring (TPM) Scenarios Cross Referencing Data Historian Slide 29
Trends Slide 29
… special focus Upstream OLGA integration for multi-phase flow “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 Solids Particle size distribution Mills (Ball, SAG,…)
Crushers Cyclones & hydro cyclones
Conveyor Roaster Screens
Floatation cells Converters … Slide 31
Training beyond the control room
Slid e 32
Training beyond the control room EYESIM – Immersive Virtual Reality Plant IMMERSIVE VIRTUAL REALITY PLANT is a comprehensive solution linking Control Room Operators..…
...to Field Operators .. ...to Maintenance Operators .. .... by means of high fedelity Process Simulation and a Virtual Walkthrough Plant Environment for a complete:
PLANT CREW TRAINING
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
…on-shore training and competency assessment of off-shore operators in the EYESIM 3D immersive training environment.
DYNSIM demo: Mining application
Dynamic Simulation Suite – One Solution, Many Applications, High Value DESIGN
Is my design right before I purchase my equipment?
DCS & PLC CONFIGURATION 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