customizing your operator training simulation with simit
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Customizing Your Operator Training Simulation with SIMITA Step-by-Step Approach
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2018 Automation Summit
• Title: Customizing Your Operator Training Simulation with SIMIT
• Track: Digitalization
• Presenter: Harry Pigler
• Company: Pigler Automation, LLC
• Session # (for your survey): 8.4
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About Pigler Automation, LLC
Pigler Automation, LLC is a Siemens Solution Provider for PCS7 located in Longmont, Colorado
• Founded in 2005
• PCS7 Certified SIEMENS Solution Partner
• 10 engineers on staff
• Industries served: chemical, power, mining...
• We specialize in:
• Turn-key process control solutions• PCS7 conversions & upgrades• Onsite & remote support services• Customized Siemens PCS7 training
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Biography
Harry Pigler
• Born and raised in Germany, US and Austrian Nationality
• Electrical Engineering Degree from Universität Erlangen-
Nürnberg, Germany (Dipl. Ing.)
• 20+ years employment with Siemens in Germany and the US
• Chief Operating Officer with Pigler Automation, LLC since 2005
• PCS7 Certified Process Control Engineer
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Creating an OTS Tailored to Our Customer’s Needs
Our Task:
Create an Operator Training Simulation for a three-unit hydropower plant
Our Customer‘s Requirements:
• Simulation set-up should be portable and user-friendly
• Virtual Controllers should be utilized
• Medium-fidelity simulation desired
• For experienced personnel to train or refresh on rare but critical plant
upsets.
• Less-experienced personnel to train on normal operations (start-up,
shutdown, etc.)
• Order of events should remain time-critical, where an operator response
is required in real-time
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Our Solution
• Medium fidelity OTS with customized breaker and generator control components
• Five distributed Virtual Controllers used
• 3 VCs for the Units• 1 VC for Station
Service• 1 VC for Switchyard
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Our Solution
• Custom component created with SIMIT CTE to mimic both the governor and excitation controls
• Responsive to start and stop commands, mode changes, as well as MW and MVarsetpoints
• Flexible enough to use on wide variety of hydro turbines
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Our Solution
• Ability to dynamically trigger specific tripping mechanisms
• Cause & Effect OTS dashboard provided with a variety of more focused failure scenarios, with expected outcomes for reference
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Creating an OTS, Step-by-Step
• Real PLC or VC?• Quantity? Need to
Distribute?
Know your customer’s setup
• Training requirements• What scenarios to
focus on?• What level of fidelity?
Understand your customer’s scope • Core of work to be
done in SIMIT Simulation Platform
• Highly customized work to be done in SIMIT CTE
Design & Implement
• Get initial feedback• Make revisions to
process simulation as required
Test• “Train the trainers”• Provide support as
needed
Deploy
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Our Focus Today: Design & Implementation Exercise
Globex Corporation desires an OTS for their auxiliary plant functions. Specifically, their plant power distribution & cooling water system
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Our Focus Today: Design & Implementation Exercise
Our Customer’s Setup:
• All auxiliary plant functionality handled by one non-redundant PLC
• Single OS-server, one OS Client set-up
Our Customer’s Scope:
• OTS should be a low to medium fidelity, portable simulation• Use of a Virtual Controller preferred• Training should encompass valve feedback and pump failures,
as well as power circuit breaker failures during normal operation
• All events should occur in ‘real-time’
What We’ll Cover:
• Working with custom templates in SIMIT for pump feedback & fault response
• Creating custom components utilizing SIMIT CTE (Component Type Editor)
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Simulating Pump Responses with a Custom Template
• We need to simulate the response of two on/off cooling water booster
pumps
• Let‘s create a custom template in SIMIT based on the MotorLean
template available in the library
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Simulating Pump Responses with a Custom Template
• We create a new template
in the Project templates
folder named SimpleMotor
• Next, we copy in the
MotorLean components &
make adjustments
• Couplings renamed for
simplicity
• Motor name made visible
• Fault response logic
added
• Save!
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Simulating Pump Responses with a Custom Template
• We then create a charts folder
named Cooling Water and drag
and drop the Simple Motor
template into it
• The Instantiate template dialog
will appear – enter the correct
values for each placeholder
• Rename the chart 10-M-0110
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Simulating Pump Responses with a Custom Template
• We can use the SimpleMotor
template to quickly create the
logic for the second booster
pump
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OTS Dashboard Screen
During an operator training session, we
want to minimize the need to switch
between SIMIT screens
• An overview screen will contain the
basic OTS controls to trigger various
equipment failures
• Connectors bridge the signals
between charts
• A switch control component is used to
initiate a pump or valve feedback
failure during training
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Simulating a Power Circuit Breaker
We need to simulate the response of a Power
Circuit Breaker (PCB) with auto recloser action for
use in the Power Distribution System simulation
• The auto recloser should check for a fault
condition
• If the fault condition is no longer active AND
the last command to the breaker was to
close, the recloser should close the breaker
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Simulating a Power Circuit Breaker, Our Options
We could create a macro in SIMIT, which
is a similar to a Chart-In-Chart setup in
PCS7
• Macros utilize components from the
library as building blocks
• Easier, sometimes faster to use
• Is part of the basic SIMIT package
• Less flexible than using SIMIT CTE
• No link or faceplate available
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Simulating a Power Circuit Breaker, Our Options
We want to be able to visualize the power
distribution system on the OTS Dashboard in SIMIT;
therefore, we will require the PCB to have its own
link and faceplate in SIMIT
• We would also like to avoid creating a
complicated macro
• Don‘t want to be limited by the SIMIT library
components as our basic building blocks
...We need to create a new component in SIMIT
CTE
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Creating a PCB Breaker Component in SIMIT CTE
The SIMIT Component Type Editor (CTE) tool is
used to create custom components
• Standalone tool
• Additional SIMIT license required
• Less intuitive, but more flexible
• Software programming experience required
• Be prepared for old school troubleshooting:
!!No Debug Functionality Available!!
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Creating a PCB Breaker Component in SIMIT CTE
• First, we select Connectors to
open the connection editor
• Connectors need to be defined –
these are the input and output
signals of the component
• Each should be assigned a
unique name, type and direction
(input or output)
• Inputs can be assigned default
values
• The Number field should always
be a 1
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Creating a PCB Breaker Component in SIMIT CTE
• Parameters can be defined in order to configure instances of the component
• In Parameter, we can create two new parameters:
• An integer, BreakerNumber, will contain the breaker‘s assigned tag
• A text entry, Area, will contain the breaker‘s location
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Creating a PCB Breaker Component in SIMIT CTE
• Connector signals do not retain memory between cyclic executions of the component in runtime,
instead they are re-calculated with every execution
• State variables serve as the memory of the component, and will retain their value between cyclic
executions
• In States, three new variables have been created to retain the components open/close, fault and
recloser state
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Creating a PCB Breaker Component in SIMIT CTE
All code is placed inside
of a BLOCK in the cyclic
calculation area
• Code is executed in
a sequential fashion,
from the beginning to
END_BLOCK
• The block itself is
executed cyclically
• Script syntax can be
found in the SIMIT
Simulation Platform
manual, by pressing
F1, or by selecting
Help Show help in
the SIMIT CTE
toolbar
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Creating a PCB Breaker Component in SIMIT CTE
Connectors with the Symbol
& property view usage
assigned will be displayed
automatically on the basic
symbol
• The basic symbol is the
graphical representation
of the component used in
SIMIT charts
• Input and output
connections are
displayed with green and
red arrows
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Creating a PCB Breaker Component in SIMIT CTE
A Link (block icon) has been
created for the component to
act as a different graphical
representation in SIMIT
• The breaker status will be
indicated by the color of
the block
• An open status will be
gray in color, and a
closed status will be red
• Holding Shift & Ctrl while
dragging and dropping
the basic symbol will
display the component‘s
link in SIMIT
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Putting it all Together, Finalizing the OTS Dashboard
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Testing the OTS
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What’s Next
• More SIMIT OTS work on the horizon
• We are currently working on a Pigler Automation SIMIT
component library for Hydropower Plants
• Pigler Automation to continue to participate in SIMIT
beta testing
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Customizing Your Operator Training Simulation with SIMIT
Name: Harry Pigler
Company: Pigler Automation, LLC
Email: Harry.Pigler@PiglerAutomation.com
Phone: (866) 871-1456 ext. 2
Cell: (303) 817-1121
Session # (for your survey): 8.4
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