Operator Training Simulators – Intro and Marketing

August 13, 2009

Here’s a little something that I wrote,

you might want to play it note for note…

Enough 80s already.

Operator Training Simulators

Operator Training Simulators (OTS) train operators on fundamental plant operations and improve their ability to optimize plant performance with the same simulation tool. OTS mirrors the exact look and feel of a plant, captures operator best practices, provides a standardized, level training ground to evaluate operator performance and enables operators to exercise best practices.

Sample - Condensate Stabilizer OTS

Sample - Condensate Stabilizer OTS

The model is capable of simulating the following operations:

  • Start-up operations
  • Normal steady-state operations
  • Normal shutdown operations
  • Emergency shutdown operations.

In addition to the above operations, the system is capable of simulating operations dictated by process disturbances and equipment failures introduced by the instructor.

The core element of any training simulator system is the simulation model of the plant unit operations and process controls. The UniSim system provides the ability to construct simulation model without computer programming knowledge by providing a library of building block modules used for simulating the behavior of devices such as pumps, columns, heat exchangers, valves, compressors, vessels and DCS control points. Major equipment types vary significantly from one plant to another. This variability is not generally in the overall functionality of the equipment, but in specific details such as geometry, configuration details, piping, service, etc. This variability greatly affects the operation of the equipment and hence the dynamic simulation of that operation.

Honeywell USO

Honeywell USO

The approach used in the UniSim system is to model the operation of such equipment using modules that are more fundamental. These modules contain a mathematical engineering model (based on first principles of chemical engineering) of the equipment type including heat, material and momentum balances, thermodynamic and operating equations, both algebraic and differential. Each equipment types can be further defined using equipment parameters that customise the module to reflect the actual operating and physical characteristics of the device.

The Instructor Station (I/S) is the control center of the simulator. The I/S allows access to the simulator’s special features, which do not exist at the actual site. These include:

  • RUN, FREEZE and RESUME execution of the process model and control system representation in a completely time synchronized manner.
  • SAVE and RESTORE model states for future retrieval.
  • EXECUTE the model FASTER or SLOWER than real time.
  • Introduce malfunctions.
  • Initiate scenarios.

The I/S interface also lets the instructor monitor the progress of the training session with lists and trends of process and control system variables.

Honeywell USO

Honeywell USO

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Design & Interfaces

August 2, 2009

I was reading a book called The Inmates Are Running the Asylum. No, it’s not about Arkham Asylum, but takes on the view that despite appearances, business executives are not the ones in charge of the high-tech world, it’s the engineers running the show.

Currently, I’ve been looking at DCS screen shots, and was wondering how could we improve the displays so that the end user can reach their goals. Ideas that the book throws up are

  • Interaction vs interface design
  • Homo logicus
  • Dancing bears(!)
  • Design for personas
  • Goal directed design

I think I’ll start throwing the above buzzwords around when we get the opportunity to design interfaces from scratch. Maybe get an industrial designer in, go in bold directions…

iTouch DCS anyone?

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Breaking into O&G Control Systems

September 16, 2008

I guess you might have heard of the Large Hadron Collider hacker break in. It made me wonder as to whether this can happen to offshore control and safety systems. Here’s my thoughts on the topic:

  • You need a doorway to hack into a system. Most (all that I’ve seen) offshore systems are standalone, and don’t have LAN, let alone Internet connections. Heck, for most of the DCS the only way you can transfer data is via 3.5″ disk (or was that 5.25″?). No USB ports, no CD drive. Maybe an RS-232 port, but you have to be on site to break in.
  • If there is a web interface, you can be pretty sure that the PC acting as a gateway has the usual bells and whistles to prevent unauthorized entry. This assumes that the link allows two way communication.
  • Even if you found a door, the architecture of a DCS is pretty specialised. Those who have hacked Windows, Macs, Linux systems will find their knowledge useless here. You won’t find published available APIs, object structures, weak kinks in the software, even a typical programming language. It’s all process loops, logic controls, and stuff. There’s no need to support third party development because, well there is no third party.
  • You might just get into the DCS, but the worst you can do is shutdown the platform. All the safety stuff is handle by the safety systems, which have triple redundancy, programmed PLCs, etc. I’d like to see someone hack remotely into that.

BTW, the above comments are based on my own limited knowledge of DCS / Safety system setups. There’s someone out there who can correct me.

My version of security? You have to reach 10,000 points in a Tetris game before you get access to the guts of the machine.

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Posted by Wata