Digital transformation is rapidly impacting the oil and gas processing industry. According to an Accenture report, in 2018, up to 60% of refineries increased their investments in digital technologies, and 67% believed that a lack of digital solutions would reduce their competitive advantage. While new software and hardware are being developed to meet this demand, established strategies will also play a significant role in the digital revolution. The change lies in how tools such as operator training simulators are implemented, deployed, and used to achieve optimal plant performance.
For decades, process simulators have been a critical tool in the petrochemical industry. Simulators have been used in two key phases of the plant lifecycle. In the initial design phase, steady-state models enable engineers to design and determine the dimensions of critical equipment and ensure that heat and material balances are met.
Subsequently, once the plant is operational, operations staff use the Dynamic Operator Training Simulator (OTS) to train new employees and, during the design validation and operation and maintenance phases of the plant lifecycle (as shown in Figure 1), to provide further training to experienced workers to update their skills. Thus, there is no interaction with the simulator in many other phases of engineering and operation.
Figure 1: The chart illustrates the key stages of the plant lifecycle and the nodes that can be simulated. Image credit: Honeywell.
Managers can leverage high-fidelity simulations throughout the entire plant lifecycle, viewing the simulator as a digital replica of the physical plant to maximize ROI. Advances in computing technology are bridging the gap between design and operation, allowing for simultaneous engineering studies and operations training using a complete plant model with the highest fidelity. In bridging this gap, more stages of the plant lifecycle are entering the realm of simulation, unlocking the immense potential of process simulators as a tool from design to operation.
Static and dynamic simulation models
Static process simulation software is heavily relied upon in the front-end engineering and design (FEED) phase of brownfield and new construction projects. A comprehensive model of the plant provides engineers with a complete view of heat and material balance to constrain design cases and other operating conditions. Furthermore, simulation software can be used for feasibility studies, evaluating different process configurations, and identifying risks. Engineers can use this information to ensure the safety and environmental compliance of designs and to maximize the efficiency of asset operations and business.
Static simulation is typically the most frequently used tool at this stage of the plant lifecycle. However, dynamic models can be used for feasibility studies. Mature simulation software allows end users to seamlessly migrate from static to dynamic models. In this case, the services required to build the initial model should be performed in advance during the front-end engineering and design phases. The advantages of the simulator can be realized towards the end of the lifecycle phase while minimizing service investment.
Simulation of factory design and verification
While static models ensure operation under defined steady-state conditions, dynamic simulators allow engineers to verify successful plant operation at every stage, from black start to full-power operation. Once the plant design is complete, engineers can use simulators to ensure the design meets objectives and that all equipment satisfies the requirements of the startup procedure and operating sequence.
By meeting the requirements of process and mechanical datasheets during the model development phase, end users can verify that all equipment in the simulation matches the physical equipment in the field. With this knowledge, engineers can meticulously examine every piece of equipment in the plant, from individual pipe sections to complex multi-channel heat exchangers. Due to the ability to pre-program the model scenario, engineers can continuously run the plant using predefined procedures and examine process responses using incremental changes to the plant design.
While using simulators to inspect plant processes is highly beneficial, even greater value is realized during control system integration. After the design and testing of controls, simulators can provide much more insight into process automation. Most modern control systems can simulate process values, allowing basic tests to be performed on the control loop. However, high-fidelity simulators offer realistic process responses that are virtually impossible to replicate through experience.
Advanced modeling software can provide meaningful insights into more "hypothetical" scenarios. Control systems will undergo more sophisticated testing that more closely resembles actual factory responses. This allows engineers to identify potential problems early in the design process, preventing them from escalating and leading to time-consuming and laborious corrective actions.
Validation and design of safety systems are a crucial part of commissioning any new facility. All manufacturing companies strive to minimize the number of safety incidents on-site. However, safety systems are rarely triggered, and it can take years to identify flawed designs or procedures.
The simulator provides real-time process response, allowing users to scrutinize and analyze safety protocols under abnormal operating conditions. Using predefined operating protocols, users can operate the plant under various abnormal conditions, such as compressor surge, depressurization/combustion events, and total shutdown. Through a continuous iterative process, safety systems are constantly tested and upgraded to account for all possible outcomes. Once changes are proposed, the Hazard and Operability (HAZOP) team can use the simulator to support studies and investigate the integrity of the planned designs.
Virtual factory debugging and startup
While simulators cannot help build new facilities, engineers can continue to use them during this period to ensure commissioning and startup proceed as smoothly as possible. Many components of the plant, from process equipment to controls and alarms, are being fully functional for the first time. Many unforeseen problems may arise during this period, requiring immediate attention to avoid lengthy and costly delays.
Performing commissioning and startup in a virtual environment allows for earlier resolution of many issues encountered during the commissioning and startup process. Virtual commissioning and startup, involving all key stakeholders, can expose numerous deficiencies and allow for timely and controlled correction. For example, virtual commissioning and startup provides engineers with opportunities to test detailed startup procedures, fully utilize distributed control systems ( DCS ) and human-machine interfaces ( HMIs ), verify alarm suppression, and adjust critical control loops. Many of these activities were previously crammed into already tight startup schedules with little room for error. This second layer of validation allows assets validated and tested in a virtual environment to be delivered to operations.
Factory Operation and Maintenance
Factory simulators can aid in training operators. Many factories implement procedures that require employees to follow extensive, simulator-based training programs to maintain a certain level of training. Best practice is to use training programs to track and document operator performance to assess key performance indicators against factory standards. Management can track factory performance and understand the effectiveness of actual operational training programs in real time (see Figure 2).
Figure 2: Honeywell UniSim Operating System provides a simulation environment for operator training.
Recent advancements in augmented reality (AR) and virtual reality (VR) technologies have extended simulator-based training to field operators. Workers can safely perform unconventional tasks in virtualized or mixed reality environments under the guidance of trainers. This hands-on training can cultivate a safer and more capable workforce. By viewing process simulators as part of a factory's digital twin, users gain access to new avenues for exploring ways to optimize the factory lifecycle.
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