lifecycle ots: using simulation models from engineering

© Inprocess

Lifecycle OTS: Using Simulation Models from Engineering Design to Plant Operations

Leonardo Carpio

✓ OTS Lifecycle dynamic modelling

1. Process Design & Control Validation

2. Integration and Control narrative

verification

3. Procedures Verification & Early Senior

CRO´s Training

4. ICSS Database Checkout

5. Operator Training System

6. OTS Support operations

Agenda

© Inprocess 3

What could go wrong in an FPSO?

Picture © bp p.l.c.

PROCESS DESIGN

• Recycle valve sizing• Hot Gas Bypass req.• Compressor driver

constraint• GT constraint• Set points consistency

among process areas• Trip value settings

OPERATINGPROCEDURES

• Transition conditions• Not feasible in real• Excessive flaring• Not safe Emergency

procedures

CONTROL NARRATIVES

• Modules interaction• Wrong parameters for

loops, alarms, timing• SIS definition

ICSS CODE• Wrong Tags, Units,

Ranges, modules…• Errors in sequences• Wrong loops tuning• Alarms overload• SIS implementation

HUMAN ERROR

• Insufficient quality training• Unseen abnormalities• Lack of monitoring,

diagnose and operation support tools

SHORT TERM IMPACTCauses spurious trips, equipment damages and delays in start-up in the

order of 10-20 days

LONG TERM IMPACTCompromise the production

along the whole FPSO life

LONG TERM IMPACTDecrease the %uptime along the

whole FPSO life

Basic Engineering (FEED)

Detailed Engineering

(EPC)

Commissioning & Start-up

Operations & Maintenance

Simulation Lifecycle and Digitalization

Inherently Safer Design

Operational Excellence

© by inprocess 4

Simulation and Process Lifecycle flowchart

Dynamic Model built

Additional equipment,

ICSS/UCP Control

Narrative, CEMs, interlocks

Model

Adjust

Engineering Study

ICSS HMI Emulated with

Inprocess Instructor Station

Process Trainers

ICSS HMI

displays

ICSS

Database

Control Logic

ICSS Checkout

Model

Connectivity

Instructor Station, Training Scenarios,

Additional ICSS Consoles

Direct-Connect OTS

Model from

engineering Studies

Plant Data

Engineering Data

Analysis of

critical units

Control Narrative and

Procedure Verification

Early CRO Training

-Knowledge

Transfer

ICSS Virtual

Commissioning

OTS ready

Training

Support

Operations with

Digital Twin

OTS

Maintenance

Blue boxes indicate the areas included in thescope of the Dynamic Simulation Study

Stg 1: Process Design & Control Validation

GAS INJECTION COMPRESSIONDEHYDRATION & TEG

REGENERATION

HP FLASH GAS COMPRESSION

HHPSEPARATION

HPSEPARATION

PRODUCED WATER & SEA WATER

DSS→

Main focus is on the critical units (compressors or areas where significant control interactions are foreseen) in order to verify the operability and safety of the plant. Any early stage finding can be handled easily, to achieve: the best solution with minimum design modifications at minimum costs.

Blue boxes indicate the areas included in thescope of the Dynamic Simulation Study

Stg 2: OTS model scope

GAS INJECTION COMPRESSIONDEHYDRATION & TEG

REGENERATION

HP FLASH GAS COMPRESSION

NAG SLUG CATCHER

NAG SEPARATION

MP FLASH GAS COMPRESSION

LP FLASH GAS COMPRESSION

MP & LP SEPARATIONCRUDE TRANSFER

HHPSEPARATION

HPSEPARATION

PRODUCED WATER & SEA WATER

DSS→

Green boxes indicate the areas added tothe HYSYS Dynamic model for training

Training→ +

HEATING COOLING

MEDIA

MEG REG.SYSTEM

HP & LP FLARE

FG SYSTEM

The Dynamic model from the DSS will be expanded with new units, the latest control logic implemented and the UCP sequences from the compressor packages.

The model will be used to verify the Control Narrative Specifications:

• Control interactions with UCP

• Normal operation

• During non-design conditions

• During specific procedures

• Understanding the limits of the system

• Alarm & Trip limits

• Controller pre-setting

• Verify equipment protection

Stg 2 – Operating Procedures (Comprehensive Control Narrative Verification).

Flare Controller Set Points Instrument Ranges &Trip Settings

Calculations & Override Controllers

Selectors & SP strategies

Loops Interactions

Phase 3A: Procedures Verification

Early verification of Operating Procedures with timing and transitions conditions

Scope:

- Individual Units

- Overall Start-up process

Combining Expertise’s:

Mix of experienced Engineers / Operators know-how with realistic response of Process Trainer

Operating Procedures are drafted and validated in a closeinteraction between experienced operators and simulation experts

Phase 3B: Process Trainer - Early CRO´s Training

Using the Inprocess Instructor Station softwarewith the Process model as simulation engine,an HMI layer is added on top of the Processmodel using the same displays of the ICSScontrol room.

Early CRO´s and Supervisor Training

Knowledge Transfer

• Control Interactions and Issues

• Limits of the system

Training Scope

• ICSS displays familiarization andoperability verification

• Start-up / Shutdown Procedures

• Trip scenarios

• Disturbances and Malfunctions

© by inprocess 10

database checkout – standalone validation - benefitsBenefits of the ICSS Checkout

• Early Database checkout: DCS modules don’t need to befinalised to start its validation.

• Parallel Debugging: Pending on the available licenses(Process model+ DCS), the different modules can be testedin parallel.

• IO signals and transmitters verification: Ranges, Units,Alarm & Trip settings, missing or wrong connections.

• Controllers & Logic:

• Implementation according to the latest controlphilosophy

• Controllability and operability

• SP, PV, OP Ranges and additional functionalities

Phase 4: ICSS Checkout

Dynamic Model

To transmitter

To Controller

Input

IO Block

Controller Output

IO Block

Output

DCS Controller validation cycle

• Sequences ( Compressor, PLC’s, Backwash systems, etc)

• Implemented according to the latest control narrativeand Functional Descriptions

• Sequence/ logic verification

• Transient dynamic verification

• Cause and Effect Matrix: Verification of the DCSimplementation and evaluation of its transient dynamics

11

OTS Deployment

Process Plant

Control System

Interface

Process model Dynamics


DCS Emulation

Emulated Controls

Direct-Connect Fully Emulated

Panel Operator Instructor Station & Field Devices

Instructor Station & Field Devices

Emulated Panel Operator

Phase 6: OTS Support Operations

Following the lifecycle dynamic modeling approach provides increased added value to the project itself. As it is based on a highly reliablefirst principle model linked with the actual ICSS.

A direct connect OTS based on a first principlemodel allows:

• The evaluation of the operability of the plantunder non design conditions (e.g. Start Upoperations).

• Analysis of alternative control strategies.

• The evaluation of potential plant optimizations(i.e. Debottlenecking studies).

• The evaluation of alternative operating modes.

• The determination of potential limitations inprocess or utility areas.


Speeds-Up procedures (NSD, SU, etc.)

Start-Up date reduced

Flare minimized

Commissioning time reduced

Trips reduced

Safety increased

Plant performance improved

Controllability and operability improvedPHASE 1

Process design and unit control validation

PHASE 2

Integration and control narrative verification

PHASE 3

Procedure verification and process trainer

PHASE 4

ICSS Integration and Checkout

PHASE 5

Operator training system

PHASE 6

OTS Support Operations

Operators: gain confidence and awareness of the plants behavior and interactions

Detects missing equipment or unreachable interlock conditions.Operators have more availability

Any early stage finding can be handled easily, to achieve:• The best solution• with minimum design modifications• At minimum costs.

Lifecycle Dynamic Modeling: Benefits

Final product:Is a valuable tool which can be used for training purposes and as a basis for control logic modifications, optimizations, control tuning, support operations in unforeseen conditions or configurations.

Each phase of the lifecycle approach addresses specific targets , which are aligned with the needs of the project. The model is developed once and refined in successive refined as more detailed information is available.

lifecycle ots: using simulation models from engineering

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