Simulation in the Water Industry Doug Johnson Emerson Process Management Power & Water Solutions

Key Messages A time of unprecedented challenges Worker force asked to do more with less Number of expected retirements is staggering Loss of experience and expertise New, less experienced workers risk mistakes as they learn Simulators can help accelerate learning Superb training tool, but have been too costly and complex New automation technologies bring scalable simulation within reach

From Maintenance Technician to Mayor… Today’s Water Professionals Face Unprecedented Challenges Water & Wastewater Authorities CAPITAL EQUIPMENT PROTECTION CHANGING REGULATIONS MEDIA & PUBLIC SCRUTINY ESCALATING COSTS ENERGY & “GREEN” PROGRAMS SECURITY CONCERNS WEATHER EMERGENCIES WORKFORCE ISSUES SUPPLY CHAIN PROBLEMS VIOLATION AVOIDANCE LIMITED OPERATIONAL VISIBILITY RAPID TECHNOLOGY OBSOLESENCE

Workforce Issues – A Growing Concern Utility Expected Retirements over Next 5 Years Source: AWWA State of the Industry Report (Mann & Runge)

Retirements Bring Challenges Aging Workforce How will you capture the wealth of existing process knowledge to share with new generations? Regulations Will new workers be able to avoid “learning curve” mistakes that can result in violations, safety issues and equipment damage? Abnormal Situations Is your staff equipped to deal with abnormal events? How can you help them to prepare?

Growing Trend: Retirees Are Sometimes Not Replaced Some authorities plan, as a strategy, to reduce staff through attrition Politically less controversial than layoffs Can result in critical positions being compromised as positions are combined Result: Inexperience combined with reduced focus Help needed to handle both jobs Position Canceled

Simulation Can Help Accelerate Learning Operator training and qualification programs Procedure development and validation Abnormal situation Awareness and response Post-event analysis and prevention Control logic development, testing, and verification Plant engineering test bed for process improvements

Who Benefits from Simulation? Operators Understand process fundamentals Reinforcing cause & effect relationships Identify and diagnose fault conditions Prepare to handle emergencies and abnormal conditions Improved operational techniques Emergency management procedures training Engineers & Technicians Dynamic design verification Pre-evaluate process equipment changes Test control change before implementation Develop & test advanced control schemes Control tuning Process optimization Process troubleshooting Management Reduces costs Reduces risk of environmental violation Improves safety Strengthens ability to handle emergency situations

Why Haven’t Simulators Been More Popular? Expensive – often 10’s of $M Typical previous uses in high-risk environments Aircraft training and design Nuclear power operations Complex model software development Separate equipment required for the simulator Duplicate control room plus simulator computers

New Technologies Make Simulation More Affordable Automation-based simulation is simpler and cost-effective Leverages plant control system Provides scalable, engineered simulation solutions Helps transition personnel and technology during times of change Aids in understanding of complex operations and unique plant characteristics Transfers knowledge from current operations experts to the next generation What is the cost of a mistake? Injury Regulatory Violations Equipment Damage

Flexible Simulation Solutions for Accurate Decision Making Scalable simulators can be tailored to meet the unique operational challenges of your facility Provides a wide range of engineered simulation solutions to fit needs and budget From tie-back simulation to high-fidelity simulation Tie-back Logic Scalable Functionality High-fidelity Models

Scalable Solutions Bring Simulation Within Reach Simulation can be expanded as needs change Functionality System verification (FAT) Ovation navigation Procedure development & validation Startup/Shutdown training Steady state operations training Abnormal conditions training “What-If” Budget Model Sophistication

Flexible Simulation Using Virtual Technology Replicates control system controllers in a few desktop workstations Executes control logic, algorithms, and control timing directly within the workstations Incorporates full functionality of acutal DCS controllers Model constructed from algorithm library identical to control system BENEFITS Minimizes hardware costs Provides smaller system footprint Offers a portable configuration Uses well-known desktop systems

Actual Plant vs. Simulation: Key System Components Plant Process Controllers & I/O Operator Interface Actual Hard Station Control Plant Modeling System 20 Virtual Controllers Simulation LT Optional Emulated Hard Station Instructor Station 14

Typical Configuration for Tie-back Simulation Functionality Domain Controller OPERATOR Stations Network ENGINEER Station and Database Server OPTIONAL VIRTUAL Controllers VIRTUAL Controllers Each PC can support up to 20 virtual controllers SM-PPT-XX-100 [2]

Tie-Back Simulation Most cost-effective Valuable tool for: Fundamental operator training Control system navigation Process familiarization Widely applied for control logic checkout prior to loading on the actual control system Models specific processes for basic operator training and testing Creates models using authentic control system algorithms Interacts with plant’s control strategies through simulated software logic Presents standard operator and engineer workstation functionality Provides hands-on training for key processes Additional complexity can be easily added

Typical Configuration for High-fidelity Simulation Functionality . . . . . . . . . Engineer- Domain Controller Operator Stations Database Server Network Virtual Controllers Hard Panel Station Instructor Station Model Station Up to 20 virtual controllers in one PC Hard Panel Station provides operator training interface for non-DCS subsystems Instructor Station manipulates the model to change process conditions, introduce failures, run training scenarios Virtual Controllers run the actual Ovation DCS application Model Station is a server that: Runs first principles high fidelity plant model and stores configuration Manages & maps model I/O to plant control I/O Station also includes SimAPI Libraries

Simulation with High-fidelity Functionality Primary uses include: Training control room operators Testing new control strategies Evaluating plant responses when subjected malfunctions and other abnormal events and conditions Simulates all plant operating modes process and equipment startup and shutdown normal operation, abnormal and emergency operating conditions Trains operators on information acquisition and diagnostic skills Recognition of equipment malfunction and appropriate responses Isolating failures under emergency conditions Trains operators in process effectiveness and efficiency, focusing on optimizing operating procedures Demonstrate existing operating procedures Validates new procedures Demonstrate effect of equipment malfunctions on processes

Simulation Project Implementation Gather Info / Plant Walk Down Model Design Implementation Testing Step 1 – Plant Walk Down Working closely with plant personnel Simulator simulator specialists perform a plant walk down to: Confirm the scope of supply Verify project schedule Interview plant staff to investigate plant processes and operations

Simulation Project Implementation Plant Walk Down Model Design Implementation Testing Step 2 – Model Design Create design document that details modeling requirements Review design ensure modeling accuracy This is done by both the customer and the simulator team

Simulation Project Implementation Plant Walk Down Model Design Implementation Testing Step 3 – Implementation Load simulation models and control logic into simulation hardware Test integration of models and logic to verify proper operation

Simulation Project Implementation Plant Walk Down Model Design Implementation Testing Step 4 – Testing Perform formal factory acceptance test Exercise models using a variety of plant conditions

Timelines for Simulation Development Process Modeling Design Complete Steady State Simulation Conversion to Dynamic Configuration Complete Integration Training 12-14 months High-Fidelity Simulation Example of simulation development project schedule and complexity Tie-Back Simulation 2-4 weeks Control System Check-out

Simulation Instructor Training Instructor training is important to simulation effectiveness Training will help your instructors learn how to best utilize your simulator Prepares your simulator instructor to confidently apply simulation to your training program

Questions?