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Presentation CHEMCAD Simulation Software Training Simulator

Presentation CHEMCAD Simulation Software Training Simulator John Edwards, P&I Design Ltd July 2016. www.chemstations.com. DYNAMIC TRAINING SIMULATOR FLOWSHEET. SIMULATION SUITE. CHEMCAD SOFTWARE. www.chemstations.com. www.chemcad.co.uk. Case D3.13 Level Model with GUI.

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Presentation CHEMCAD Simulation Software Training Simulator

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  1. Presentation CHEMCAD Simulation Software Training Simulator John Edwards, P&I Design Ltd July 2016 www.chemstations.com

  2. DYNAMIC TRAINING SIMULATORFLOWSHEET SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com www.chemcad.co.uk Case D3.13 Level Model with GUI

  3. DYNAMIC TRAINING SIMULATORSET INLET FLOW RAMP SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com www.chemcad.co.uk

  4. DYNAMIC TRAINING SIMULATORCONTROL VALVE & CONTROLLER ACTIONS SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com www.chemcad.co.uk Level Valve 3 Open Av = 0.0625 Bv = -0.25 V a l v e Fail Closed Signal to Open Closed 20 4 Controller Output (mA) CHEMCAD Job: Level Model with GUI Must connect vapor line

  5. DYNAMIC TRAINING SIMULATORCONTROL VALVE CHARACTERISTIC 100 90 ANY CHARACTERISTIC QUICK OPENING CHARACTERISTIC 80 70 60 LINEAR VALVE COEFFICIENT (Cv) VALVE STROKE (%) EQUAL PERCENTAGE 50 QUICK OPENING 40 30 SIMULATION SUITE CHEMCAD SOFTWARE 20 10 VALVE POSITIONER BUTTERFLY VALVE 0 0 10 20 30 40 50 60 70 80 90 100 FLOW % www.chemstations.com www.chemcad.co.uk Equal % for flow control Linear for level and pressure control

  6. DYNAMIC TRAINING SIMULATORCONTROL VALVE ACTION SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com www.chemcad.co.uk Open V a l v e Closed Cooling Valve Heating Valve Open Av = 0.0625 Bv = -0.25 V a l v e Av = -0.0625 Bv = 1.25 Fail Closed Signal to Open Fail Open Signal to Close Closed 20 4 Controller Output (mA) 4 20 Controller Output (mA)

  7. DYNAMIC TRAINING SIMULATORCONTROLLER AND CONTROL VALVE SET UP SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com www.chemcad.co.uk Measurement calibrated range 0.1 to 3m for 4 to 20 mA signal Measurement vessel tank level Calculated value to be used in simulation Same parameter may be declared but not calculated Linear valve characteristic is good for level

  8. DYNAMIC TRAINING SIMULATORSET UP DYNAMIC VESSEL SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com www.chemcad.co.uk Static head included in output stream

  9. CRYOGENIC BATCH REACTOR OPTIMISATION TRAINING SIMULATOR STRUCTURE DCS-SCADA MIMIC DCS-SCADA MIMIC TRAINING SIMULATOR CUSTOM MIMIC OPC CLIENT EXCEL DDE   DataMap OPC SERVER OPC INTERFACE   CHEMCAD DYNAMIC PROCESS MODEL DYNAMIC MODEL DYNAMIC MODEL www.chemstations.net www.chemcad.co.uk

  10. DYNAMIC TRAINING SIMULATORCHEMCAD OPC SERVER SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com www.chemcad.co.uk

  11. DYNAMIC TRAINING SIMULATORMATRIKON OPC CLIENT SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com www.chemcad.co.uk

  12. DYNAMIC TRAINING SIMULATORDATA MAP 1 PARAMETER SELECTION Control XL Execution Rules Data Map SIMULATION SUITE CHEMCAD SOFTWARE Execution Rules CHEMCAD www.chemstations.com www.chemcad.co.uk Browse to control spreadsheet when opening job If job copied the original spreadsheet location will be used Cell allocation is fixed and unique If location in control spreadsheet is changed, correct cell allocation

  13. DYNAMIC TRAINING SIMULATORDATA MAP 2 PARAMETER SELECTION Control XL Execution Rules Data Map SIMULATION SUITE CHEMCAD SOFTWARE Execution Rules CHEMCAD www.chemstations.com www.chemcad.co.uk Data to Excel control spreadsheet for dynamic graphs Execution Rules controls data flow between CHEMCAD and Excel Recommend disconnecting Data Maps before closing CHEMCAD Job

  14. DYNAMIC TRAINING SIMULATORSET UP DYNAMIC MODE SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com www.chemcad.co.uk CHEMCAD Job: Level Control with GUI • Switch to dynamic mode under convergence • Set up for On-line Training Simulator (OTS) • Set Run Time to 360 minutes with 1 minute step size • Record desired streams 3, 8, 9 & 12 (close when in OTS) • Record desired UnitOps 3 & 6 (close when in OTS • Select Run Time plot options • Run from Initial State • Plot results Set plot time units to reasonable value based on step size, in this case minutes

  15. DYNAMIC TRAINING SIMULATOROTS CONVERGENCE SETTINGS SIMULATION SUITE CHEMCAD SOFTWARE Allows simulation to run Can change parameter during run Simulation speed up vs real time www.chemstations.com www.chemcad.co.uk CHEMCAD Job: Level Model with GUI

  16. DYNAMIC TRAINING SIMULATOROPERATING INSTRUCTIONS SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com www.chemcad.co.uk Operating Instructions 1. Reset Macro/graphs to initial state 2. Reset CHEMCAD Level Model with GUI to initial state 3. Start row insert Macro 4. Start CHEMCAD simulation 5. Macro will run for 63 15s steps until message complete 6. Stop CHEMCAD simulation by pressing Esc Do not stop simulator until Macro is complete!

  17. DYNAMIC TRAINING SIMULATORGRAHICAL USER INTERFACE (GUI) SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com www.chemcad.co.uk

  18. DYNAMIC TRAINING SIMULATOR PERFORMANCE TESTING SIMULATION SUITE CHEMCAD SOFTWARE www.chemstations.com www.chemcad.co.uk Use training simulator to study the following: • Study effects of control valve sizing and characteristics • Study effect of measurement calibration span and elevation • Study effects of different control mode settings • Tune for optimum performance • Study supply valve failure conditions • Study effect of pump shutdown

  19. CRYOGENIC BATCH REACTOR OPTIMISATION TRAINING SIMULATOR BENEFITS SCADAMimic OPC orDataMap PROCESS MODEL CHEMCAD DYNAMIC Improve production efficiency • SCADA operator interface is identical to real plant • Operators understanding of the process enhanced • Operators can study effect of control settings • Operators can study parameter interactions • Downtime due to operator error reduced • Practice start-up and shutdown procedures • Consequences of operator actions to environment Improve production safety • Operational plant safety improved • Train without consequences of risk/damage www.chemstations.net www.chemcad.co.uk

  20. CRYOGENIC BATCH REACTOR OPTIMISATION TYPICAL TRAINING SIMULATOR STRUCTURE TRAINING SIMULATOR CUSTOM MIMIC DCS-SCADA MIMIC DCS-SCADA MIMIC OPC CLIENT EXCEL DDE   DataMap OPC SERVER OPC INTERFACE DYNAMIC PROCESS MODEL   DYNAMIC MODEL DYNAMIC MODEL www.chemstations.net www.chemcad.co.uk

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