© 2008 MYNAH Technologies Maximizing Efficiency: Using 3 rd -Gen Simulation for Testing & Operator Training © 2008 MYNAH Technologies Jason Covington

© 2008 MYNAH Technologies

Maximizing Efficiency: Using 3rd-Gen Simulation for Testing & Operator TrainingMaximizing Efficiency: Using 3rd-Gen Simulation for Testing & Operator Training


Jason Covington


Problems Encountered

Increased oversight, regulation, operational costs

Retirements & lack of skilled operatorsDifficulty testing automation systems

Fiduciary liability issuesZero tolerance for downtime

Constraints with time and $Competition


Operational Needs

• Integrated Solutions Approach to all projects• Lifecycle Management of Entire Process, esp.

for New Projects• Offline Training Systems for Safety, Security• Offline Testing to Keep Plants Productive• Fast, Comprehensive Implementation• Meet Validated Requirements


Reduce CapEx Costs• Testing automation system application software• Training Operators before startup of new units

Increase OpEx Results - Maximize Plant Efficiency• Testing automation system enhancements and additions• Re-training and qualifying operators on existing

operations

Remove Risk, Increase Safety

Simulation is Proven Solution


Time to Market - reduce startup time$100-500K / day

Product Quality - reduce off-spec product$50K-$1MM / run

Operating Cost - reduce unscheduled downtime$5-50K / hour

Reduce Risk – reduce unknown failures and incidents - $50K - $1MM / incident

Simulation Measured Results


Simulation in the Past1st-Gen Simulation: Microcomputer• Used microcomputers to compile Fortran and C subroutines for

process and IO models

2nd-Gen Simulation: Most Products Today• Windows-based, using menus and dialog boxes for configuring process

and IO models • Time consuming, requiring weeks-months to develop simulations• Too difficult to use, not designed for operator training• Costly, can be upwards of $1MM USD

Internal Custom Jobs, Excel Spreadsheets• Messy, unmanageable• Unusable later on, impractical• Waste of man hours, extending projects past deadlines, poor results


Built for SAT and OTS • Non-intrusive simulation interfaces• Integrated Operator Training Management System• Protects control system integrity

Is Easy to use, Saves Time & $• Designed for use by the end-user or integrator• Automatic integration with control system • Auto-generation of simulation database

Is Flexible, Powerful, Dynamic• Scalable from small to large applications• Selective application of simulation models• Dynamic, accurate modeling functions

3rd-Gen Simulation Difference


Seamless integration with control systemEmulates the plant’s processIncorporates Customizable .NET GUIsExchanges XML dataUses MS SQL Server Express DatabaseAccesses modeling and OTM data via OPCUses IEC function block simulation objectsProvides Simulation Generation Tools

3rd-Generation Simulation


3rd-Gen Simulation Fulfills GAMP4, Section 9, Requirements!

Requirements for Process Simulation• “Frozen Software” – prior to Software Integration and System

Acceptance Testing• Removal of “dead code” prior to testing

Simulation Supplier Requirements Appendix 4• Documented Quality and Software Development Program in

line with industry best practices• Product should be designed for process control system testing

and operator training• Commercially-available, standard tool (COTS), not highly-

customized for use (delivered object code)

Reducing Validation Costs


Value of Offline Testing and Training

Simulation Lifecycle & ROIVa

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3rd-Generation Simulation Specifications• High-Performance Simulation Engine• Simulated IO Drivers for Schneider Unity, OPC, Modbus,

others• Complete Library of Process Modeling Functions• Graphical User Interfaces• Operator Training Management Module• Unit Operation Application Packages• Modeling Functions

3rd-Generation Specifications


Simulated IO Drivers for Open Modbus TCP/IP• SIO Bridge multiple register read/writes to large blocks of data• SIO Tags allow models to use data from any register• 1x, 3x register writes – Simulation is Modbus (write) Master• 32 Runtime Modbus Slaves per Simulation Workstation

Simulation for Modbus TCP/IP

Control System Workstations

Modbus TCP/IP ControllersModbus

TCP/IPNetwork


Simulated IO Drivers for UnityPro / OFS v3.2• SIO OPC Client Bridge reads / writes to data registers• MiMiC CAPP Interface allows direct writes to input channels• 32 Runtime PLCs / PLC Simulator per MiMiC Workstation• Unity OFS Utility Generates SIO Tags, IO Models from UnityPro

Simulation of UnityPro / OFS

HMI Workstations

Unity Controllers

OFSSimulation Network

UnityProPLC Simulator


Integrated Operator Training Management

Integrated Operator Training System


Simulation for End Users & Integrators• Simulation Models• Model Library• Simulated IO (SIO)• User Views• Training Scenarios• Database Control• Import / Export

Manageable Simulation


Generate Models Easily

Unity OFS Data Extraction Utility• Reads Located, Un-located

Variables from UnityPro• User selects mapping

of Unity Data Type toSim Data Type

• Simulation Tags andSIO in Sim database


Automatic Integration with Control System• Simple start/stop

simulation menu• Simulated IO (SIO)

selected at startup

Automatic Integration


Configurable User Interface - Views• MView – Tabular data of Model, IO, or Training data• Data Monitor – Dynamic trends of Simulation or OPC data• Component Studio – Dynamic Process Flow Diagrams

Configurable Views


Scalable from small to large applications• Unlimited Simulation Node Definition• 32 Runtime Simulation Nodes• 20,000 Simulated IO per Node• Unlimited concurrent training sessions• Unlimited operator training scenarios• Multiprocessor support• Dynamic memory allocation support• Server option for 10 Clients using Windows Terminal Services • One Second Model Execution can be sped up / slowed down 10x

Selective application of simulation modelsDynamic, accurate modeling functions

Scalable, Selective, Dynamic


Automatic Engineering Unit Conversions

Automatic Unit Conversions

Engineering Unit Conversion


Integrated Steam Tables Thermodynamic Properties BlocksFirst Principles Modeling BlocksIEC1131 Structured Text Calc Model Block

Advanced Models & Blocks


Dynamic High-Fidelity Unit Operation ModelingIntuitive configuration and data visualization

Dynamic & High-Fidelity


Reduce Time to Market - $100K to $1MM/day• Application software fully tested before startup• Operators trained before startup of new units

Increase First Product Quality - $50K to $1MM / batch or run• Batch, advanced control fully tested• Operators trained on all process operations

Reduced Unscheduled Downtime - $50 to $100K per hour• No hidden issues in application software• Operator responses trained and measured

Reduce Risk to Process and Operations Staff – Priceless!

The Next Unity or PLC Project


MiMiC Simulation SoftwareOver 900 Systems Installed in 60 countries, winning awards from:• Control Magazine Readers’ Choice Award 2006, 2007, 2008

Exceptional Customer Service• Control Engineering Editor’s Choice Award 2003• Chemical Processing Readers’ Choice Award 2008

Getting More Information – www.mynah.com• White Papers, E-Seminars, Podcasts• MiMiC Users’ Forum – www.mynah.com/forum/• MYNAH E-News, RSS Feed – Updates, KBAs, FAQs

Contact for Questions• Jason Covington, +1.636.681.1587• Skype ID: Jason.Covington• [email protected]

Schneider CAPP Solution

http://www.mynah.com/

http://www.mynah.com/forum/

mailto:[email protected]

Documents

© 2008 MYNAH Technologies Maximizing Efficiency: Using 3 rd -Gen Simulation for Testing & Operator Training © 2008 MYNAH Technologies Jason Covington