Presentation CHEMCAD Simulation Software Training Simulator John Edwards, P&I Design Ltd July 2016 www.chemstations.com 1

DYNAMIC TRAINING SIMULATOR FLOWSHEET www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com DYNAMIC TRAINING SIMULATOR FLOWSHEET Case D3.13 Level Model with GUI

DYNAMIC TRAINING SIMULATOR SET INLET FLOW RAMP www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com DYNAMIC TRAINING SIMULATOR SET INLET FLOW RAMP

DYNAMIC TRAINING SIMULATOR CONTROL VALVE & CONTROLLER ACTIONS www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com DYNAMIC TRAINING SIMULATOR CONTROL VALVE & CONTROLLER ACTIONS CHEMCAD Job: Level Model with GUI Must connect vapor line Av = 0.0625 Bv = -0.25 Fail Closed Signal to Open 20 Controller Output (mA) 4 V a l v e Open Closed Level Valve 3

DYNAMIC TRAINING SIMULATOR CONTROL VALVE CHARACTERISTIC www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com DYNAMIC TRAINING SIMULATOR CONTROL VALVE CHARACTERISTIC LINEAR EQUAL PERCENTAGE QUICK OPENING BUTTERFLY VALVE CHARACTERISTIC ANY POSITIONER 10 20 30 40 50 60 70 80 90 100 FLOW % VALVE STROKE (%) VALVE COEFFICIENT (Cv) Equal % for flow control Linear for level and pressure control

DYNAMIC TRAINING SIMULATOR CONTROL VALVE ACTION www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com DYNAMIC TRAINING SIMULATOR CONTROL VALVE ACTION SINGLE CONTROL VALVE OPERATIONS ACTION CONTROL OUTPUT POSITION STATE LOGIC EQUATION COEFFICIENTS mA % Av Bv FAIL CLOSED 4 Closed 0 = 4Av+Bv 0.0625 -0.25 20 100 Open 1 1 = 20Av+Bv OPEN 1 = 4Av+Bv -0.0625 1.25 0 = 20Av+Bv Controller Output (mA) 4 20 V a l v e Open Closed Fail Open Signal to Close Av = -0.0625 Bv = 1.25 Cooling Valve Av = 0.0625 Bv = -0.25 Fail Closed Signal to Open 20 Controller Output (mA) 4 V a l v e Open Closed Heating Valve

DYNAMIC TRAINING SIMULATOR CONTROLLER AND CONTROL VALVE SET UP www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com DYNAMIC TRAINING SIMULATOR CONTROLLER AND CONTROL VALVE SET UP Measurement calibrated range 0.1 to 3m for 4 to 20 mA signal Measurement vessel tank level Calculated value to be used in simulation Same parameter may be declared but not calculated Linear valve characteristic is good for level

DYNAMIC TRAINING SIMULATOR SET UP DYNAMIC VESSEL www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com DYNAMIC TRAINING SIMULATOR SET UP DYNAMIC VESSEL Static head included in output stream

CRYOGENIC BATCH REACTOR OPTIMISATION TRAINING SIMULATOR STRUCTURE CRYOGENIC BATCH REACTOR OPTIMISATION DataMap DYNAMIC MODEL DCS-SCADA MIMIC EXCEL DDE  CHEMCAD DYNAMIC PROCESS MODEL OPC INTERFACE TRAINING SIMULATOR CUSTOM MIMIC OPC SERVER OPC CLIENT www.chemstations.net www.chemcad.co.uk

DYNAMIC TRAINING SIMULATOR CHEMCAD OPC SERVER www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com DYNAMIC TRAINING SIMULATOR CHEMCAD OPC SERVER

DYNAMIC TRAINING SIMULATOR MATRIKON OPC CLIENT www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com DYNAMIC TRAINING SIMULATOR MATRIKON OPC CLIENT

DYNAMIC TRAINING SIMULATOR DATA MAP 1 PARAMETER SELECTION www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com DYNAMIC TRAINING SIMULATOR DATA MAP 1 PARAMETER SELECTION Browse to control spreadsheet when opening job If job copied the original spreadsheet location will be used Control XL Data Map CHEMCAD Execution Rules Cell allocation is fixed and unique If location in control spreadsheet is changed, correct cell allocation

DYNAMIC TRAINING SIMULATOR DATA MAP 2 PARAMETER SELECTION www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com DYNAMIC TRAINING SIMULATOR DATA MAP 2 PARAMETER SELECTION Data to Excel control spreadsheet for dynamic graphs Control XL Data Map CHEMCAD Execution Rules Execution Rules controls data flow between CHEMCAD and Excel Recommend disconnecting Data Maps before closing CHEMCAD Job

DYNAMIC TRAINING SIMULATOR SET UP DYNAMIC MODE www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com DYNAMIC TRAINING SIMULATOR SET UP DYNAMIC MODE CHEMCAD Job: Level Control with GUI Switch to dynamic mode under convergence Set up for On-line Training Simulator (OTS) Set Run Time to 360 minutes with 1 minute step size Record desired streams 3, 8, 9 & 12 (close when in OTS) Record desired UnitOps 3 & 6 (close when in OTS Select Run Time plot options Run from Initial State Plot results Set plot time units to reasonable value based on step size, in this case minutes

DYNAMIC TRAINING SIMULATOR OTS CONVERGENCE SETTINGS www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com DYNAMIC TRAINING SIMULATOR OTS CONVERGENCE SETTINGS CHEMCAD Job: Level Model with GUI Simulation speed up vs real time Allows simulation to run Can change parameter during run

DYNAMIC TRAINING SIMULATOR OPERATING INSTRUCTIONS www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com DYNAMIC TRAINING SIMULATOR OPERATING INSTRUCTIONS Operating Instructions 1. Reset Macro/graphs to initial state 2. Reset CHEMCAD Level Model with GUI to initial state 3. Start row insert Macro 4. Start CHEMCAD simulation 5. Macro will run for 63 15s steps until message complete 6. Stop CHEMCAD simulation by pressing Esc Do not stop simulator until Macro is complete!

DYNAMIC TRAINING SIMULATOR GRAHICAL USER INTERFACE (GUI) www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com DYNAMIC TRAINING SIMULATOR GRAHICAL USER INTERFACE (GUI)

DYNAMIC TRAINING SIMULATOR PERFORMANCE TESTING www.chemcad.co.uk SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com DYNAMIC TRAINING SIMULATOR PERFORMANCE TESTING Use training simulator to study the following: Study effects of control valve sizing and characteristics Study effect of measurement calibration span and elevation Study effects of different control mode settings Tune for optimum performance Study supply valve failure conditions Study effect of pump shutdown

CRYOGENIC BATCH REACTOR OPTIMISATION TRAINING SIMULATOR BENEFITS CRYOGENIC BATCH REACTOR OPTIMISATION Improve production efficiency SCADA operator interface is identical to real plant Operators understanding of the process enhanced Operators can study effect of control settings Operators can study parameter interactions Downtime due to operator error reduced Practice start-up and shutdown procedures Consequences of operator actions to environment Improve production safety Operational plant safety improved Train without consequences of risk/damage SCADA Mimic OPC or DataMap PROCESS MODEL CHEMCAD DYNAMIC www.chemstations.net www.chemcad.co.uk

CRYOGENIC BATCH REACTOR OPTIMISATION TYPICAL TRAINING SIMULATOR STRUCTURE CRYOGENIC BATCH REACTOR OPTIMISATION DataMap DYNAMIC MODEL DCS-SCADA MIMIC EXCEL DDE  DYNAMIC PROCESS MODEL OPC INTERFACE TRAINING SIMULATOR CUSTOM MIMIC OPC SERVER OPC CLIENT www.chemstations.net www.chemcad.co.uk