2014 software global client conference - …iom.invensys.com/en/softwaregcc14presentations/simsci/ss...
TRANSCRIPT
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2014 Software Global Client Conference
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SS S&T-01,
Simulation &
Training: Strategy &
Business Update
Alastair Fraser
September 30, 2014
Strategy Strategy
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2014 Software Global Client Conference
Mobile App: Please take a moment…
Check into Session by:
●Select Detailed Schedule
●Select the specific session
●Click on “Check in”
Take Session Survey by:
●Select Detailed Schedule
●Select the specific session
●Scroll Down to “Survey” and Provide Feedback
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2014 Software Global Client Conference
The Challenge – Demographics, Safety & Increasing Levels of
Automation - All Impacting Operations
10
15
20
25
30
1925 1975 2025
Bir
th R
ate
/1
00
0
Pe
op
le Baby Boomers
Retiring
“Based upon information it received, the Panel
believes that at most of BP’s U.S. Refineries,
the implementation of and over reliance on
computer-based training contributes to
inadequate process safety training of refinery
employees” – Baker Report (2007)
Control Loops
per Operator
Operator
Initiated
Moves/Day
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2014 Software Global Client Conference
• North America: Ageing and retiring workforce, Safety, Knowledge Transfer, Significant
spending on gas, shale, oil sands, upstream
• Europe: Ageing and retiring workforce, Safety, Knowledge Transfer, Limited spending in
major process industries, access to oil & gas driving market, LNG import
• Mid East: new workforce in difficult locations, many new plants and more downstream
processing with strong upstream, LNG
• Asia Pacific: Massive expansion of production and process industries, new workforces
in difficult locations, new plants, major expansion of power plants, LNG
• Latin America: Existing process industries with some expansion, Power expanding, new
workforce
Simulation & Training
Regional Market Trends
Strong desire for Simulation & Training Solutions along with Value Add Services
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2014 Software Global Client Conference
●Vision (what we will be) The Schneider Electric Simulation & Training Business Unit will be the trusted advisor and leading
provider of solutions that inspire and empower our client’s workforce to improve safety, operational
performance and asset availability.
●Mission (reason we exist, core values) The mission of the Schneider Electric Simulation & Training Business Unit (SETSBU) is to mitigate
risk for our clients in the process industries by providing technology and services for design
verification, control validation and enhanced operational competence. The SETSBU will be an
empowered and trusted team with global centers of excellence that collaborate and support each
team member to deliver industry leading customer satisfaction and to provide career advancement
with personal satisfaction and development.
Vision and Mission
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2014 Software Global Client Conference
Is my design right
before I purchase
my equipment?
DESIGN DCS & PLC
CONFIGURATION STARTUP OPERATIONS
Invensys Dynamic Simulation Suite –
One Solution, Many Applications, High Value
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
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2014 Software Global Client Conference
Phased Approach to Realizing Value Across the Enterprise
Engineering Studies
DCS, PLC, TMC
and SIS Logic
Checkout
Field Operator Training
Corporate OTS Cloud
Operator Training
Simulator
Generic Training
Simulators
FEED Pulse
Site Enterprise
Plant Pulse
Learning Management
Systems
Field
Control Room Engineering C&I
Fundamental Proactive Collaborative Assessable Training Needs
Assessment
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2014 Software Global Client Conference
FEED PULSE
Initially 1-2 days
●Objective is Process Design Validation
Benefits Assessment
●Meeting with Senior Management to
highlight typical benefits of dynamic
simulation and other tools
●Identifies potential application areas and
value
●Interviews with Engineering teams
Typically 45-60 minutes per group
●Identifies opportunities & value
●Output is a summary presentation and
report to engineering management
●Recommended Interviews
Utilities, Rotating Equipment, Safety, HAZOP,
Piping, Equipment and other groups
Pulse Value Assessments
PLANT PULSE
Initially 1-2 days
• Objective is to site wide assessment of
potential benefits of Training Solutions
• Interviews with site team/other stakeholders
Typically 45-60 minutes per group
• Identifies site objectives, needs,
opportunities & value
Benefit assessments, identify immediate focus
areas
• Output is a summary presentation and
report to site/stakeholders
• Recommended Interviews
Operations Management, Operators (experienced
and new), Process Engineering, Process Controls,
Learning and Development
Industry
Challenges
& Trends
Design &
Operational
Excellence
Can I be
Confident
This will
Work
Conclusions
Benefits
Assessment
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2014 Software Global Client Conference
● Safety, Safety, Safety
● Upgrading/migrating controls
● Adding new processes or capacities
● Developing new controls strategies
● Knowledge capture of experienced workers
● Training the next generation of workers
Drivers for Operator Training Simulators &
Training Services
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2014 Software Global Client Conference
A Well Trained Staff Improves Operations
An ARC Report (2010) reports
that operator error results in
42 percent of unscheduled
plant shutdowns
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2014 Software Global Client Conference
A Well Trained Staff Improves Safety
Arson/Sabotage Design Error
Natural Hazard Process Upsets
Unknown Causes Operational Error
Mechanical Failure
3
4
7
10 12
26
38
Accident (Incident) Percentages
The US Health and Safety
Executive reports that
26% of accidents occur
due to operational error
0 25 50 75 100
Operational error
Unknown
Natural hazard
Sabotage/arson
Loss in $ million
Average cost per
major incident related
to Operator error
exceeds $80M.
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2014 Software Global Client Conference
Typical Simulator Objectives
●Controls Testing / Commissioning Time & Risk Reduction
● A Control Checkout and Logic Testing Tool
● Process Analysis
● Decision Supporting Tool
● An Engineering Tool
●Knowledge Management
● Console & Field Operator Training
● Operator Certification
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2014 Software Global Client Conference
“Learn-By-Doing”
Most Effective Learning Method
0102030405060708090
100
Lecture
Reading
Audio/V
isual/C
BT
Demonstra
tion
Discussio
n Gro
up
Learn-B
y-Doin
g
Teaching O
thers
For skills training, operators can learn more in minutes of
real environment training than in hours of lecture
instruction
Simulation Exercises
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2014 Software Global Client Conference
Single Scalable, Proven Flexible OTS Platform
1.0
Generic
Operator
Training
Simulator
2.0 Traditional Operator
Training Simulator
3.0 Immersive Field Operator
Training Simulator
4.0 Integrated Operator and Field Operator Training
Simulator
5.0 Corporate Operator
Training Simulator
Sustainability Programs,
Training and Consulting Services
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2014 Software Global Client Conference
Mining
Chemicals
Power
Refining
LNG Oil and Gas
Over 700 Successful OTS/Studies Projects
Projects delivered to more than:
100 Different Clients in over
10 Different Industries in over
40 Different Countries on
15+ Different Controls/SIS/PLC Systems
Delivery
Excellence
Centre
Schneider Software Operator Training Simulator Experience
Site
Delivery
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2014 Software Global Client Conference
User quotes……
“The OTS does react as if it were the real plant. For the most part the
simulator reacts as expected to plant upsets etc.”
“We saved a week on our controls checkout at startup saving us an
estimated $ 2.9 Million”
“The thing I like the most about the simulator is I can tell, within 10 min
of training a new operator, just what his strengths and weaknesses
are. It is very good as an evaluation tool”
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2014 Software Global Client Conference
Simulation and Training
Key Growth Initiatives
SAGD/Upstream
Gas/LNG Processing
Metals/Minerals/Mining
Training Services
Generic Simulators
HPI & Power
Fertilizers/Chemicals
EYESIM
Control/Logic Validation
Corporate OTS
Cloud OTS
Training as a
Service - TaaS
Foundation Fossil Power
Refining
Petrochemicals
Pipelines
OTS & Leak Detection
(Telvent SimSuite)
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DYNSIM
SCP
Foxboro Evosim
Gregor Fernholz
Janet Parker
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2014 Software Global Client Conference
Simulation & Training
• Autonaming rules • User Templates • Improved Thermo and
Diagnostics • Efficient model tuning • IT enhancements • Efficiency
enhancements • GUI Enrichment for
Improved Ergonomics and Ease of Use
DYNSIM 5.2
• Server 2012 support • Schneider-Electric branding • User configurable defaults • Silent install • Enhanced Search tool
DYNSIM 5.2.1
• Corporate OTS infrastructure
• Enhanced Scenarios and TPM capabilities
• Thermo: PC-SAFT • Thermo: Nitric Acid library • ElecSolve productization • New Antisurge Controller • Accelerate to steady-state • Alarm Manager • New Reboiler/Kettle model • Basic Undo/Redo • Efficiency enhancements • GUI enhancements • Win8 testing
DYNSIM 5.3
• TaaS infrastructure • Benchmark in the industry for
speed and robustness • DYNSIM Power Migration • Tier2 VLWE Flash • SimCentral Flash Integration • Footprint in the Chemical &
Fertilizer Industries • Expand into existing Schneider-
Electric industry verticals • Intergraph: auto-model
generation
DYNSIM 5.4 and later
• Foxboro Evosim • SCP280 • WW Historian
SCP v2
• Updates to VR • Enhanced use • SDK
EYESIM 2.x
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2014 Software Global Client Conference
DYNSIM Strategy
OTS & Studies ● Support above average market growth of our
business.
● Expand business in new markets. Leverage
Schneider-Electric customer base.
● From OTS vendor to Simulation and Training
solution provider.
Software ● Meet business needs (above)
● End-user experience for design and training.
● Engineering Efficiency.
More value. For our customers.
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2014 Software Global Client Conference
DYNSIM 5.3 Themes
Growth
New Industries
New Applications
New Business models
Competitiveness
Technology lead
Engineering Efficiency
Speed & Robustness
Usability
Training Experience
Ergonomics
GUI enhancements
Trends
Cloud
Virtualization
IT requirements
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2014 Software Global Client Conference
DYNSIM Roadmap
• Autonaming rules • User Templates • Improved Thermo and
Diagnostics • Efficient model tuning • IT enhancements • Efficiency
enhancements • GUI Enrichment for
Improved Ergonomics and Ease of Use
DYNSIM 5.2
• Server 2012 support • Schneider-Electric branding • User configurable defaults • Silent install • Enhanced Search tool
DYNSIM 5.2.1
• Corporate OTS infrastructure
• Enhanced Scenarios and TPM capabilities
• Thermo: PC-SAFT • Thermo: Nitric Acid library • ElecSolve productization • New Antisurge Controller • Accelerate to steady-state • Alarm Manager • New Reboiler/Kettle model • Basic Undo/Redo • Efficiency enhancements • GUI enhancements • Win8 testing
DYNSIM 5.3
• TaaS infrastructure • Benchmark in the industry for speed and
robustness • DYNSIM Power Migration • Tier2 VLWE Flash • SimCentral Flash Integration • Footprint in the Chemical & Fertilizer
Industries • Expand into existing Schneider-Electric
industry verticals • Intergraph: auto-model generation
DYNSIM 5.4 and later
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2014 Software Global Client Conference
Overview Control Emulations Strategy and Roadmap
Strategy
● Remain current with Foxboro, Triconex, and
Wonderware
● Develop and maintain simulation engines that
fit our core business needs
RoadMap
● SCP support for CP280 / Control Core
Services V9
● Foxboro Evo Simulation V6
● Wonderware Historian Emulation update
● HIMA engine
● RSEmulate engine
● PLC/SIS/DCS Emulator
● Schneider-Electric Unity Pro Link
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3d Immersive
Virtual Reality
Training
Peter Richmond
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2014 Software Global Client Conference
Immersive 3d virtual reality
EYESIM
Next generation of training tools….
For the
Next generation of operator….
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2014 Software Global Client Conference
Immersive 3d virtual reality
EYESIM
3D
CAD
Laser
Scan
Augmented
Reality
Mobile
Apps
Dynamic
Simulation
Operating
Scenarios
HD
Photo Dynamic
Animation
EYESIM
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2014 Software Global Client Conference
One Platform - Many applications Licensed Technology
VR Showroom
Crew
Training
Safety
Scenarios
Procedure
Training
Hazop Design
Evaluation
Equipment
Understanding
Maintenance
Planning
EYESIM
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2014 Software Global Client Conference
Strategy & Roadmap - Training
3D
●Scalability
● Single Object Complex Plant
● Simple graphics /functions photorealistic and with complex scenarios
● Full VR Suite deploy mobile app or cloud implementation
●Automation and workflow
● Rules based auto creation of environment from 3D CAD
● SDK enhancement for project efficiency
●New VR hardware Integration
● Oculus v2
● VR Control, Omni Platform
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2014 Software Global Client Conference
Strategy & Roadmap - Operations
●Mobility and Advanced Augmented Reality for the field
● Object recognition and tracking
● Integration of workflow tools and data sources
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Training Services
Graham Provost
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2014 Software Global Client Conference
Strategy - Training Services
• SimSci Training Services specializes in full scope industrial training design,
development and delivery supporting Simulators, Plant Operations, and Maintenance.
• As training consultants, we focus on identifying, advising & filling gaps in training and
other human performance factors in industrial facilities. Areas of expertise include:
• Simulator Training Programs – Control Room, and Field Operator
• Onsite Operator Instruction
• Industrial Documentation, including Ops and Maintenance Procedures, etc.
• Operator Training Programs, Job Position Responsibility Allocation and
Qualification Program Development
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2014 Software Global Client Conference
Areas of Focus
Advanced Controls
Analysis / CRO Training Training Needs Analysis
and Design, Job
Progression Planning
Trainee Self Study OTS
Training Packages
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2014 Software Global Client Conference
Areas of Focus
Cloud-based Simulation and Training
Platform
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2014 Software Global Client Conference
Areas of Focus
SimSci LMS
Open Source
Dynsim Integrated
Simulator Training Learning
Management System
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Global Practice for
Simulation & Training
Ian Willetts
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2014 Software Global Client Conference
The Challenge – Demographics, Safety & Increasing Levels of
Automation - All Impacting Operations
10
15
20
25
30
1925 1975 2025
Bir
th R
ate
/1
00
0
Pe
op
le Baby Boomers
Retiring
“Based upon information it received, the Panel
believes that at most of BP’s U.S. Refineries,
the implementation of and over reliance on
computer-based training contributes to
inadequate process safety training of refinery
employees” – Baker Report (2007)
Control Loops
per Operator
Operator
Initiated
Moves/Day
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2014 Software Global Client Conference
Best
Technology
The Job To Be Done – Raising Operator Competence
● People
● Approach
● Customers
● Sustainability
Right
Services
Game
Changing
Solutions
Generic
Operator
Training
Simulators
Traditional Operator
Training Simulators
Immersive Field Operator
Training Simulators
Integrated Operator and Field
Operator Training Simulators
Corporate Operator Training
Simulators
Sustainability Programs
Training and Consulting Services
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2014 Software Global Client Conference
SIMULATION & TRAINING
PRACTICE
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2014 Software Global Client Conference
Training and Simulation Practice - Resources
EURA 17
• Madrid 15
• Others 2
SDC
Hyderabad: 74
APAC 45
• China 39
• Japan 3
• Others 3
North America 54
• Calgary 11
• Carlsbad 19
• Houston 20
• Others 4
Latin America: 13
• Brazil 6
• Argentina 6
• Chile 1
Total : 214
Four Regional Practices
SDC
Cairo : 11
Two Software Delivery Centers
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2014 Software Global Client Conference
Training and Simulation Practice - Resources
Experience Profile - Collating Data Currently - placeholders
0
10
20
30
40
50
BachelorsDegree
MastersDegree
Doctorate
47
35
1
Academic Qualification Profile
25
20
28
10
Total Experience Profile
12 years and above 5 to 12 years
2 to 5 years Less than 2 years
0.0
2.0
4.0
6.0
Total ExpInvensys
ExpSimulation
Process
5.6
2.4 3.8
1.8
Average Experience Profile
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2014 Software Global Client Conference
Training and Simulation Practice - Resources
EURA 17
• Madrid 15
• Others 2
SDC
Hyderabad: 74
APAC 45
• China 39
• Japan 3
• Others 3
North America 54
• Calgary 11
• Carlsbad 19
• Houston 20
• Others 4
Latin America: 13
• Brazil 6
• Argentina 6
• Chile 1
Total : 214
Four Regional Practices
SDC
Cairo : 11
Two Software Delivery Centers
0
20
40
60
80
100
120
Projects Delivered Each Year
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2014 Software Global Client Conference
Our Methodology
●Proven Methodologies to maintain schedule and reduce risk
●World Class resources and industry knowledge
●Drive efficiencies and consistency
●Quality management system modeled after ISO9001
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2014 Software Global Client Conference
Quality Management System e-QuIP
● Key ‘High Level' Quality Stage Gates:
1. Project Kickoff
2. Functional Design Specification
3. Interactive Client Workshop reviews
4. Model Validation Test
5. Factory Acceptance Test
6. Site Acceptance Test
●Global Practice Tools:
1. OTS Project Estimator and Schedule Creation
2. Modeling Guidelines
3. Test document templates
4. Productivity tools
5. Project Management Information Systems
6. Knowledge Database and Lessons Learned on all projects
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2014 Software Global Client Conference
Simulation & Training Delivery Success
Project Description
• Site wide deployment of OTS across a single
refinery in South Korea (Ulsan) in one year
• Eight process units including CDU,VDU,HMP,
RFCC,PX, Aromatics, HCU, ARDS
Value Delivered
• S-Oil testing normal and abnormal operating
scenarios to raise worker competence
• Goal to reduce plant downtime and increase
availability
• Secondary goal to ensure plant safety
Approach and Issues
• Excellent Coordination of resource across our
teams in Korea, Beijing and India to meet
intense resource requirements
• Single Simulation Platform across all units
• Three different types of DCS in the one
refinery
Project Results
• Client very satisfied with Schneider delivering
on our commitments – project completed just
three months ago
• Client kind enough to present at this Global
Customer Conference – Thank you.
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47 Confidential Property of Schneider Electric
Simulation and Training agenda – at a glance
> Simulation & Training Track in
Panzacola H-2 (here)
> Expo Night
Tuesday Wednesday Thursday
Demo Area Booths 21-23
> Simulation & Training Track in
Panzacola H-2 (here – full
day)
> SimSci Wine Reception
8PM Butler Room
> Simulation & Training Track in
Panzacola H-2 (here – full
day)
> DYNSIM 5.2 and 5.2.1
“What’s new” in SS TSS02
1:30pm-2:30pm (Wekiwa 3)
> Booth 21: DYNSIM and Control Emulation: Hands-on latest releases.
> Booth 22: Power Plant OTS: A full-scale OTS of a power plant.
> Booth 23: Immersive OTS: Latest and coolest 3D training system.
> Times: Lunch breaks and Expo Nights
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48 Confidential Property of Schneider Electric
Related Support, Services, Training & Expo Demos
> SimSci Tech Support
Support
Training
> DYNSIM Training Course
> Instructor Training
> OTS Maintenance Course
> Control Emulations Training Courses
> OTS, Checkout, Studies Projects
> OTS & Studies Consulting
> Training Program Development
> Customer First for Simulation & Training
Services
Expo Demos
> Dynamic Simulation and SimSci APC 2014
> Power Plant Operator Training Simulator
> Immersive Operator Training System
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49 ©2014 Schneider Electric. All Rights Reserved.
All trademarks are owned by Schneider Electric Industries SAS or its affiliated companies or their respective owners.