Cape Software Inc.

Houston TX

Cedric Oudinot, Cape Software 2006

The Virtual Process

Overview and Applications

A dynamic representation of a chemical

process to an offline control system.

Cedric Oudinot, Cape Software 2006

What is VP Link ?

The Virtual Process

Loop

MFP controllers
Or emulated

Read value of outputs

Controller(s)

Write simulated inputs

VP Link
Server

Calculate
Process
Variables

Cedric Oudinot, Cape Software 2006

Object Oriented and Tag-based.

Direct Connect bypasses hardware I/O boards
Interfaces with real or emulated controllers

Cedric Oudinot, Cape Software 2006

Some of our customers...

ABB Mod300, Advant, Bailey Infi 90

Triconex:Tricon/Trident/Emulator
Honeywell Experion PKS TDC,TPS , FSC
Honeywell Plantscape / Rockwell ProcessLogix
Foxboro I/A series, Archestra, A2
Honeywell Experion PKS ,TPS , Honeywell FSC
Honeywell Plantscape / Rockwell ProcessLogix
GE Fanuc series 90
A-B PLC5/SLC500,CLX, Modicon,Siemens-Ti 505
Siemens APACS, PCS7, S7

Yokogawa ProSafeRS
Yokogawa CS3000/R3
Etc...

Cedric Oudinot, Cape Software 2006

Supported Control Systems

VP Link components in a
client / server architecture
Graphic
Client
(trainer)

VP Link
Server
(model execution)
Rigorous
Module:
Compressor

Rigorous
Module:
Distillation 2

Rigorous
Modules:
Distillation
Column 1

VP Link
ESD/SIS driver

VP Link
DCS driver

VP Link components run seamlessly across the network

Cedric Oudinot, Cape Software 2006

Scoring Engine

Cedric Oudinot, Cape Software 2006

Emulated Vs Stimulated ?

Virtual Process network topology for

Hardware Bailey Infi 90
Trainer Station

MFP Controllers

SIS Controller or
emulated

Trainee
Console

Cedric Oudinot, Cape Software 2006

VP Link/ Infi 90 Interface

Virtual Process network topology for

emulated Bailey Infi 90 system
Est. CPU Load at Dow Chemical,
with 18 MFP controllers &
specified platform, is <5%
nominal.

OperateIT
ProcessOperateIT
Portal B
Clients
(CFE)
Process
Portal B
OperateIT

upgraded to SCSI
CIU interface
provided

Bailey DCS
Simulator
Client

Clients
(CFE)
Process
Portal B
OperateIT
Clients
(CFE)
Process
Portal B

SCSI

Bailey DCS
Simulator
Service

Cape Software
VP-Link

OperateIT
Process Portal B
Server (CFE)

RS-232

Read/Write Field IO
Via OLE Automation
API

Default.INI File

WinCAD EWS
Or
ComposerIT EWS
(CFE)

DCS MFP Controller CFG File

DCS MFP Controller CFG File

Emulates INICI03
(E0) CIU

DCS MFP Controller CFG File

DCS MFP Controller CFG File
PC Platform

Cedric Oudinot, Cape Software 2006

Clients (CFE)

 HMI Graphics Import in Toolbook for realistic

trainer interface
Actual displays used for HIS in Operator Training
environment
Fast COM Interface ,over Ethernet for emulated
Robust Modbus interface for hardware based system
Utilization of non-modified actual Control Program

Cedric Oudinot, Cape Software 2006

VP Link for Bailey System

Specifics

I- Logic Validation

Cedric Oudinot, Cape Software 2006

VP Link Applications

Incremental Cost

Minimal to
moderate
impact

IAT

Time

FAT

Maximal
cost impact

SAT

PSSR

Cedric Oudinot, Cape Software 2006

Cost of changes over a typical

project development cycle

V-Approach methodology:
application to validation
Safety
Requirement
Spec

Pre Start-Up
Safety
Review

Develop
Scenarios

Cause &
Effect
Function
Block
Design

Black Box
Testing

Deliverable
Deliverable
Verification
Verification

Functional
Logic

Cedric Oudinot, Cape Software 2006

Run manual
Tests

Narrative

Logic Validation with VP Link

9 VP Link Allows:

How ?
Automates repetitive testing task (ie resets etc)
Facilitates FAT with customized graphics
Collaborative testing framework thru distributed
architecture

Thoroughly debug prior to online download, ie,

Management of Change and periodical testing
Test Compiler complies with IEC61508/61511

Cedric Oudinot, Cape Software 2006

9 Graphics verification
9 Logic checkout at I/O / block / module / system level
9 Interlock schedule approval
9 Integrated Testing :Mapping to DCS and interaction
between DCS/PLC logic ( gateway points tests)

Simulation Screen shots

Automated Tag sheet

Cedric Oudinot, Cape Software 2006

Input/Output sheets per ESD

HMI for advanced testing

or training

II- Operator Training Simulator

(OTS)

Cedric Oudinot, Cape Software 2006

VP Link Applications

II- Goals of Operator Training

Knowledge
Transfer

Turnaround

Run

Train Operators for Emergency Response

Faults / Malfunctions / Upsets (Real or Instrumentation)
Exercise Startup / Shutdown Procedures
Familiarize staff
with HMI, Overlays, Navigation,
Alarm Pages, Trend Displays

Pre-Startup

FAT

Cedric Oudinot, Cape Software 2006

Assess trainees
proficiency
Refresher Training
Re-certification

To ESD, or not to ESD ?

Behaves the same as the real system (no runs out
of normal operating conditions)
Form operators on proper sequences and thought
processes, with real alarming monitoring and
trip/shut-downs

Emulated ESD or Hardware can be used

Single VP link database used for DCS & SIS
Communication between DCS and SIS is
usually enabled natively
If not, VP Link can act as data gateway

Cedric Oudinot, Cape Software 2006

Essential for training simulator

realism/operator buy-in

A closer look at the competition

Cedric Oudinot, Cape Software 2006

What kind of process

simulation do you need ?

Marginal cost Analysis of

process model fidelity
~ 2,000 I/O
Oil Refining unit(FCC, HDC etc)

$900,000.00
$800,000.00
$700,000.00

Logic Validation

$600,000.00

OTS /
Engineering

$500,000.00
$400,000.00
$300,000.00
$200,000.00

VP Link

$100,000.00
$0.00

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Cedric Oudinot, Cape Software 2006

Simulation Investment Vs level of Fidelity

Why is Hybrid modeling

more cost effective ?
No compositional (I/O based) = more flexibility
A note about Fidelity
All dynamics CAN be captured
Fidelity isRigorous
perceived
by Operators
modules
available: ONLY through
Heat Exchanger, Compressor & OPEN blocks
Reactor module ( catalytic,treating,cracking etc)
Fidelity should
reflect
the overall
accuracy
of the
Liquid
Flow Network
/ HxNGen
(and documentation)
Sequential
and Simultaneous
Matrix Solving
schemes integrate
SYSTEM=
process simulator
+ control
environment
seamlessly
Approximations compensated for by the control outputs

Layer Approach minimizes model upkeep costs

VP Link allows exactly for desired model fidelity
Accuracy: 99% quasi Steady State / 85% full transient

Cedric Oudinot, Cape Software 2006

monitoredprocess
variables
Distillation
modules

Operator Knowledge Assessment :

the Scoring Engine

Targets (timing, rate, value, tolerance window)

Actions ( I/O activity)
Order (logical relationship between steps)

Independent trainees logs with:

normalized scores
relevant actions & timing

Cedric Oudinot, Cape Software 2006

Excel configuration Front End

Scenario launched sequences

 Actual control program is solved in native environment

for realistic control response
Trainees operate the virtual plant using the actual field
consoles, graphics and keyboards
ESD (Emergency Shutdown Device) is fully integrated
in the process model and OTS
HMI graphics are imported in VP Link to offer an
intuitive trainer interface
High Quality process modeling tools, simulating the
most complex chemical processes
(Rx,Dist,Compressors)
Scoring Engine for knowledge retention metrics
Experienced , in-house Chemical engineers to deliver
turnkey, customized training solutions for your process

Cedric Oudinot, Cape Software 2006

Operator Training System

(OTS) using VP Link