Breakthrough Product 2009 Invensys proprietary & confidential

Seiya Hirohama, Ph.D Invensys Operations Management

Nov. 2012

Role of Console Operator

1. Safe operation of the plant 2. Maximize on-stream

runtime and prevent damage to process equipment

3. Monitor plant emissions and adhere to environmental compliance

4. Operate to maximize yield and minimize utility cost.

2

Why is Training Challenging? Plants are becoming highly integrated with complex control strategies.

The number of closed loops per console operator has been increasing.

Reduced field operating maintenance staff

Additional subsystems to monitor / interact :

• Machine monitoring system.

• Field instrument diagnostics.

• PCS, SIS , PLC and SCADA system diagnostics

• Production management, EMS, LIMS , Leak detection etc.

3

Need Formal Training With Best Available Technology

Safety & Plant Availability are Directly Impacted by Operations

An ARC Report (Sept 2010) reports that operator error results in 42 percent of unscheduled plant shutdowns

Arson/Sabotage

Design Error

Natural Hazard

Process Upsets

Unknown Causes

Operational Error

Mechanical Failure

3

4

7

10

12

26

38

ACCIDENT (Incident) PERCENTAGES Health and Safety Executive reports 26% of accidents occur due to operational error

Safety Availability

The OTS concept: reality vs. simulation

PLANT CONTROLS Control Room / HMI

DCS MARSHALLING CABINET

I/O

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I/OI/O

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FCP`

FCP

ESD CABINET

Real

Traditional Operator Training Simulator – for Control Room/Console Operators

Dynamic Simulation

DCS ESD

Software Emulation

Same / Similar HMI Hardware Simulation

Traditional Operator Training Simulators train console operators in the control room.

What about Field Operators? What about Maintenance staff?

Safety & Performance Depends on Teamwork

But What About Team Training?

Slide 6

EYESIM – Immersive Training Simulator (ITS)

ITS is a VIRTUAL REALITY PLANT that links Control Room Operators..…

.... by means of high fidelity Process Simulation and a Virtual Walkthrough Plant Environment

for COMPLETE PLANT CREW TRAINING!

...to Field Operators ..

...to Maintenance Staff

Integrated OTS and EYESIM ITS

Intranet Internet SIM4ME

Control room

HMI

Dynamic process model Instructor station

Control system emulation (e.g. FSIM plus for Foxboro I/A)

Operator consoles

ESD CABINET

DCS MARSHALLING CABINET

I/O

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I/OI/O

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FCP`

FCP

DCS DYNSIM Engine

Field

Virtual Engine

Invensys EYESIM Plant Crew Training System

Control Room (OTS) Field Operators (EYESIM)

Instructor Station

Simulation Executive

Team Communication - VOIP

3D Modelling – Source data 3D CAD models All major CAD vendor files Microstation, SmartPlant, PDMS, Autodesk and more................

3D Laser Scanning “Point Cloud” All file major file formats Leica Systems, *.pts, *.igs, *.sab, *.emb, *.bin and more

3D Modelling process....

3D CAD Source file 3D Library Models Photorealistic 3D Real-time Stereoscopic Results

Interactivity

Augmented Reality

Slide 14

Maintenance: Equipment pre-analysis & Training

Reliable evaluation/validation of maintenance planning

Training on Safety and Critical Tasks

• Rarely performed in reality

• React quickly and correctly

• High stress conditions

• Team training

• Communications

1. TOTAL Normandy Refinery – A comprehensive full scale ITS on a Steam Methane Reforming Unit including both Control Room and Field Operators with more than 100 field actions.

2. US Department of Energy – A Training Center including OTS and “VR CAVE” for field operators training on a complete IGCC plant: Coal Gasification + CO2 Capture + Tail Gas Treatment + Power production. More than 100 scenarios, 30 malfunctions and 600 field operator actions

3. ENI Refining – Five EYESIM Kiosks for different refineries in Italy. The Kiosk is used to encourage operators to understand key safety messages and operating procedures for the more complex plant equipment

Success stories

Slide 17

Success stories

Slide 18

4. Tecnatom – Application for the Spanish Nuclear Industry. Field operators are exposed to a potential “dose” during site activities and maintenance. The VR training system allows operators to train and practice field and maintenance operations in a safe environment

5. BG Group – An application of EYESIM™ Kiosk for design as a Competency Assessment System for Oil and Gas field and maintenance Operators prior to sending them Offshore

6. Sumitomo – Combined OTS and ITS for Crude Unit – project kicked off in May 2012

NETL Dynamic Simulator R&T Center • Mission

– R&D, demonstration, education, and training for advanced energy solutions

• Objectives

– Portfolio of full-scope, high-fidelity, real-time dynamic simulators for IGCC plant with CO2 capture

• NETL Partners

– Invensys Operations Management

– FCS, Enginomix, EPRI/CoalFleet

• Funding

– NETL’s Gasification Program

– NETL’s Carbon Sequestration Program

NETL Dynamic Simulator R&T Center Outline of the project

• Customer: DOE NETL

• Scope of modeling:

– Entire IGCC system

• Duration: 2008-2011

• Steady state model: PRO/II

• Dynamic model: DYNSIM® Power (with ElecSolve)

• OTS: Above model + EYESIM

NETL Dynamic Simulator R&T Center

Scope of the modeling

NETL Dynamic Simulator R&T Center

DCS Display

NETL Dynamic Simulator R&T Center

Configuration

OTS for Almaraz nuclear plant

Pilot OTS project

Almaraz nuclear plant in Spain

(3L Westinghouse, 2 Pressurized Water Reactors 939MW, 894 MW）

Scope of OTS: controlled area and its environment

Pilot project is finished in May 2011)

OTS for Almaraz nuclear plant

EYESIM is linked with DCS training simulator supplied by Techatom.

OTS for Almaraz nuclear plant Examples of training scenario

• Operators walk through controlled area to a local control panel to open/close a valve of steam generator. (normally valves are controlled by DCS, but the local panel has priority when emergency signal is detected.)

OTS for Almaraz nuclear plant Examples of training scenario

• The operator access many information during the walk through the control area

• Can feel the situation of black out

• Radiation is automatically calculated

• Operator can monitor radiation exposure

Conclusions

• Invensys OTS and ITS Solution provides complete Plant Crew Training

• Well trained staff are critical to maintaining safety, availability and profitability

• Invensys solutions are completely scalable from an individual unit to a complete plant

• Invensys is here to help you with your training needs

Thank you!