Project Benefits with SIMIT -...

Restricted © Siemens Ltd 2014 All rights reserved.

Project Benefits with SIMITSiemens’ Answer to Simulation-Based Engineering & OTS Requirements

Presenters : Ms. Vidya Patil and Mr. Tanmay Deokule, Siemens Ltd. India

Siemens Process Automation Conference (SPACe) 2014, Gurgaon, India

Restricted © Siemens Ltd. 2014 All rights reserved.

During the course of this presentation we shall look at…

Why SIMIT ?

Our SIMIT Experience on live projects.

How SIMIT can help ?

SIMIT Product and Ordering Information.


Customer Expectations

Short Engineering Duration !

Short Commissioning Duration !

Short Shutdowns !

High Quality ! Robust Design ! No Software Failures !

Fastest Operator On-boarding !

Faster time-to-market !


Simulation-based EngineeringApplications of ‘Simulation’ in all phases of project life-cycle.

Concept

Design

OperationOptimization

ServiceSupport

Commissioning

Simulation

Engineering

Training / OTS

Demo system /Acquisition System

ProcessModel

Test SystemQuality Gate

Training of DCS and process operation via HMI

Offline DebuggingOn-Site-Support

CustomerSupport

New StrategiesTest of new HW and SWwith the model

Solving Customer Challenges

Achieve Virtual Commissioning

High Quality Automation Engineering


High Quality Automation EngineeringWhat is needed ??

However, one cannot install all these devices in office environment…


High Quality Automation EngineeringHow SIMIT helps…


High Quality Automation EngineeringHow SIMIT helps…

IO Simulation (Setting Signals & Values)

Basic Actions for Actuators & Sensors

Basic Behaviour (Startup, Shutdown etc.)

Advanced Behaviour (Product / Load change)

Basic Malfunctions

Borderline Situations, Endangerments

SIMIT

=> Robust Software Design


High Quality Automation EngineeringReal-time Dynamic Simulation…

Operator Station

Controller

IO Interface (Signal Level)

Actuators / Sensors

Physical Process

Simulation Reality

PCS7

SIMIT

Simulation Unit


High Quality Automation EngineeringIntegrated Simulation

Changesconventional engineering

time

PLC Programming Test-code Generation

PLC ProgrammingWith integrated simulation

Commissioning

Changes

engineering with integrated simulation

Testing

Changes Changes

FAT

Commissioning

Testing

Time to market (with integrated simulation)

Time to market

=> Smart and Competitive


High Quality Automation EngineeringIntegrated Simulation

Sensor/Actuators Processes VisualizationI/O-Signals

HW-Config

Create interfaces Create diagrams

Engineering Simatic S7 / PCS 7

Symbol table

IEA-Files / Tables

Templates

Physics & Solvers are built in

mcmMK

dtdp

ii

ii

iZi

i

i hhmMdt

dh 1

Full PCS7 Hardware Integration.Support to Table / IEA-Interface.Integrated interface to SIMBA Pro.Ready-to-Use APL Templates built-in.

Key Features


Solving Customer ChallengesNeed for Effective OTS !! (in aviation or process plants alike)

Training on airplane simulators is much safer than training on an actual airplane.

Training on airplane simulators is much less costly than training on an actual airplane.

Training on airplane simulators can be repeated much more often.

Extreme situations can only be trained on a simulator as training on an actual airplane might result in loss of people and equipment.

=> Operator Training Simulators (OTS)


Solving Customer Challenges Need for an Effective OTS…

Reduction in Operator Errors.

Train Operators for Quick Emergency response.

Hand-on training of Complex processes.

Training surface uses the original HMI => operators learn

to use the new DCS/HMI.

Operators assume Control at a highly trained level at a very

early stage.

Key benefits

Simulation of the plant specific process.

Emulation of the I&C hardware.

I&C software is equivalent to the original software.

Physical behavior is based on mathematical models.

Characteristics


Solving Customer Challenges Need for an Effective OTS…

kn

ow

led

ge

leve

l

time

2 weeks

Tra

inin

g

cou

rse

at

beg

inn

ing

missing knowledge for high performance and

safe plant operation

2 weeks

Ext

end

edR

efre

sher

T

rain

ing

knowledge level withrefresher training

Knowledge level with typical

training concept

12 - 24 months

Ref

resh

er

Tra

inin

g

2 days

Ref

resh

er

Tra

inin

g

Ref

resh

er

Tra

inin

g

2 days 2 days

Necessary operator knowledge for high

performance and safe plant operation

One shutdown avoided helps save Millions of USD


Solving Customer Challenges OTS – Market Potential. Additional business volume for Siemens…

Market Prices for OTS:Between USD 300,000 and USD 6 Mio.

TypesGeneric simulators (pulp and paper, …)Plant specific Simulators = High Fidelity OTS (90% of OTS e.g. in O&G)

Competitors in Advanced OTS MarketHoneywell (O&G, Chemical, …)GSE (power plants)Invensys (refinery)

Market size (all industries)Worldwide (2012): USD 485.8 Mio.EMEA (2012) : USD 172.7 Mio.

(Expected) GrowthIn EMEA : 9.5% per year.


Virtual Commissioning SIMIT simulates in real-time what SIMATIC automates in Processes…

Best-in-class simulation engineeringGraphical / signal-flow orientedComponent based modeling User-extensible libraries

Two different simulation approachesHardware-in-the-loop via SIMBA deviceSoftware-in-the-loop via virtual controller(Emulated Controllers)

Simulation of different levels Signals (switchboxes & signal forcing)Devices (actuators & sensors logic)Plant behavior (logical & math. models)

Data Exchange with other Software Applications or Devices e.g. OPC DA.

Key features

Better IO and connection checks, Logic and Control Loop Checks. Reduced time-to-production. Less on-site hours for commissioningReduced risks for asset damage and personnel injury.Clear separation between simulation and production –No simulation programming within automation project.

Key benefits


SIMIT Experience

SIMIT PC With SIMBA BOX

SOFTWARE FAT SET-UP SIMBA BOX / SIMULATION UNIT


SIMIT Experience

OS

IO-Interface

Actuators / Sensors

Physical Process

IO-Interface

Actuators / Sensors

Physical Process

Better check of complete IO-Loop and IO-Address Connections.Response of program against Basic Mal-functions such as Wire-break etc. tested during FAT.No change was required in DCS program to achieve simulation with SIMIT. Digital Signature of SAFETY program maintained as a result.Software Inspection of complex Burner (BMS) process and Compressor logics completed in shorter time duration.Faster and comprehensive checks of SIF Loops including checks in degraded mode for 1oo2, 2oo3 SAFETY loops.Testing for SIMOCODES and DRIVES logic without connecting physical hardware.Faster completion of Software Inspections.

Pros

Additional Effort and Time required for development of Simulation models and graphic representations inside SIMIT.

.

Cons

Controller


SIMIT V8.0 Overview of Packages & Ordering Information

Feldbus

SIMATIC S7

WinCC

... Signals

... Drives, Simocodes

... Processes (simple, basedon math. & log. models)

Field Devices

Actuators / Sensors

Machines / Technological Units

Simulation of...

Interfaces

Basic LibraryDRIVES,SENSORS

Additional LibrariesSTANDARD,FLOWNET, CONTEC

SIMIT


Application1.a. As test bed simulator (TBS)

Shorter commissioning time on site.Optimal quality of delivered DCS HW & SW, due to :

Identification of failures at an early stageTest of the I&C Engineering on the real equipment. Testing & Analysis of critical situations, which cannot be replicated in reality

Protection of machines and aggregates during commissioning.

//

PCS 7 OSServer

PCS 7 OSThin Clients

PCS 7 ES

Characteristics of TBSReal DCS-Hardware linked to Simulation

Model.SIMIT provides the Signal Interface between

real DCS and Simulation Model (Hardwired or Profibus).

The Simulation Model is expandable for training simulator.

Signal tests and process operation tests.Can be used for FAT.

Customer benefits of TBS


Application1.b. As test bed simulator (TBS)

PCS 7 OSServer

PCS 7 OSThin Clients

PCS 7 ES

Remote support via Internet/VPN

Characteristics of TBS

Customer benefits of TBS

Emulated PLC’s linked to Simulation Model.SIMIT provides the Signal Interface between

emulated DCS (PLCSIM or Soft-PLC) and Simulation Model. The Simulation Model is expandable/reusable for training simulator.

Signal tests and process operation tests.Can be used for FAT.

Shorter commissioning time on siteOptimal quality of delivered DCS HW & SW, due to

Identification of failures at an early stageTesting & Analysis of critical situations,

which can not be replicated in realityProtection of machines and aggregates during commissioning


SIMIT V8.0 Overview of Packages & Ordering Information

Standard Library 3D Viewer Interfaces

ProfiBUSProfiNETPRODAVE

Trend & Messaging Scripting Macro Components EditorDynamic Graphics Editor Automatic generation of signal lists for SIMATIC Manager data Runtime for components developed w/ Ultimate

SIMIT V8.0 STANDARD All STANDARD features plus

Interfaces PLCSIMOPC

Engineering efficiency for PCS 7 (SMD)Automatic generation on template / typical base

SIMIT V8.0 PROFESSIONALAll PROFESSIONAL features plus

InterfacesShared Memory (High performance coupling)

Automatic generation of models and connections based on XML interfaceDevelopment of own components (CTE)

SIMIT V8.0 ULTIMATE

Library to build models in the schematics of a P&ID to simulate a piping network with single component liquids/gas (e.g. water) including pressure, temperature and flow

SIMIT V8.0 FLOWNET LIBRARY

Library to build conveyor simulation models

SIMIT V8.0 CONTEC LIBRARY

6DL5260-0AX08-0YA5

6DL5260-0BX08-0YA5

6DL5260-0CX08-0YA5

6DL5260-1AX08-2YB5

6DL5260-1BX08-2YB5


SIMIT – More than just a ProductOur comprehensive offering in Simulation


SIMIT Environment Overview of Packages & Ordering Information

Tabbed Editor

Project area(retractable)

Tabbedtoolbar(retractable)

Librariesarea

Properties area(retractable)

IntegratedfunctionsNew DiagramStart, ...

Dual-screenmode

Homogeneous User-Concept and guidelines with others SIMATIC engineering tools (TIA Portal user concept)

Comfortabledrawing andanimationpossibilities


Thank you for your attention!

Ms. Vidya PatilMr.Tanmay Deokule

Siemens Ltd.

siemens.com/answers


Simulator types and simulation levels

Typically used for OTS…

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