Exploring New Features that Allow for Simulation and Offline Development Opportunities for your PlantPAx® DCS

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PUBLIC
Simulation and Offline Development Opportunities for Your
PlantPAx® DCS, and AADvance SIS

PLANT-WIDE
Control and Optimization
SCALABLE
and Modular
SECURE
Open and Information-enabled
FLEXIBLE
Delivery and Support

Agenda
Questions
Training System Features/Benefits
System Architecture
Client Case Study
Company Overview

Cape Software, Overview
Background:
 Delivered first simulator in 1990
 Over 300 VP Link licenses worldwide
 OTS and Code Validation Projects, $10K to millions
 Two TÜV Functional Safety Engineers on staff
 Increased project depth with Wood Group staff
Products:
 VP Link : Dynamic Process Simulation suite
 Connects to multiple Control Systems
 Drivers and Database Management tools ease configuration
 Mid-Fidelity and Rigorous modules
 Additional Tools for long-lifetime projects
 Test Compiler
 Logic Validation for safety systems for IEC 61508/61511
 Automates your Test Plan for speed and repeatability
Industries Served
 Upstream Oil & Gas
 Specialty Chemicals
 Refining
 Food & Beverage
 Pharmaceuticals
 Electric
 Gas & Pipeline
 Paper
 Government Labs
 DoE
 NASA

Client Case Study
 Marine Well Containment Company (MWCC) is the leading well
containment provider for deepwater U.S. Gulf of Mexico.
 MWCC’s model relies on dedicated equipment and a skilled organization
 This model makes comprehensive training crucial
 MWCC only deploys its equipment in the event of a well control incident;
making it essential to simulate true-to-life operations to help ensure
readiness

Relevant Equipment Overview
 MWCC’s system is modular; Cape Software interacts with three key
components of the overall system to provide a simulated experience:
 Subsea Containment Assembly – Capping Stack
 Cap & Flow Equipment
 Two Modular Capture Vessels (MCV)
Capping Stacks
Cap & Flow
Equipment
Modular Capture
Vessels
21 3

Simulation System Architecture
Local
Router
Remote Router
Subsea HMI
Subsea
Controller
x 5
Plant Automation
System Server
Studio
5000®
Workstation
AADvance
Workstation
HMI Terminal
Server
x 21
Historianx 4
Topsides Controllers
Safety Controllers
Plant Automation
System Server
Studio 5000®
Workstation
AADvance
Workstation
HMI Terminal
Server
x 21
x 4
Topsides Controllers
Safety Controllers
Remote Router
VP Link Server
Virtuoso Server
MCV A
MCV B
Remote Instructor Station
Backup
 PlantPAx®, AADvance and Subsea Controllers
Remote Operator Station

Virtualization Layout
 PlantPAx®, AADvance and Subsea Controllers (all virtualized)
9
 Topside Controls (per ship)
 3 SoftLogix™ controllers
 21 AADvance simulated
controllers
 FactoryTalk® View Server,
Clients, Historian
 Subsea Controls
 SoftLogix™ controller
 Dedicated Subsea HMI

Simulator Architecture - Network
 Dedicated router and server at Cape’s office enables local maintenance.
 Shared 100 Mb line in
 Network extended to MWCC shore base in Ingleside, TX
 Certificate-based encrypted full-time VPN
 6 dual screen thin clients
 Remote dedicated router simplifies network requirements at customer site
 Remote equipment can be easily extended or relocated
All hosted on Secure, Private Cloud

Simulator Architecture, cont’d
 CIP Messaging between Topsides Controllers – handled by SoftLogix™ controllers
 CIP Messaging between Topsides and Safety Controllers – handled by simulator
 Produce/Consume between Safety Controllers on same ship – handled by controllers
 Safety Communication between controllers on different ships – handled by simulator
 Subsea Communications to Electrical Power Unit (EPU) – handled by simulator
 Modbus Communications to other hardware – handled by simulator
 I/O Values between Topsides Controllers and Model – handled by simulator
 I/O Values between Safety Controllers and Model – handled by simulator
 Values to/from FactoryTalk HMI & Historian – all handled natively
Communications is the key

Simulator Architecture - Modeling
Two models, working together, common user interface
 VP LinkTM Model for Topsides
 Tracks Oil, Water and Gas
 Uses proprietary non-linear
pressure/flow simultaneous network
solver.
 Easy to modify on-the-fly
 Virtuoso Model for Subsea
 Rigorous three-phase flow
 Advanced Well model
 Used in design
Simple things should be simple, complex things should be possible.

Training System Features Benefits
 Controls & Graphics,
Alarms, Historian are
copied from the live system
 Magic conversion to SoftLogix™
 Topsides Process model with Oil, Water
and Gas
 Rigorous Virtuoso subsea dynamic model
 Pre-built scenarios instructors can choose
from
 Instructor can create ad-hoc training
situations
 Easy to keep up-to-date
 Exact representation of control and HMI
behavior
 Demonstrates control strategy behavior
 Accurate three-phase flow in various
regimes
 Allows instructor to rank trainee responses
to the same situation
 Allows instructor to adjust difficulty based
on trainee proficiency

Training System Features – Instructor UI

…or can be custom to show model details
 Easy to build. Drag
and drop fields on
the page.
 Useful for showing
how model “innards”
work.

Instructor’s Interface can mimic actual FactoryTalk screens…
 Familiar interface for
trainers who are
experienced operators.
 Automated “screen
scraping” procedure
inspects PlantPAx®
graphics to determine
where to lay out
simulation tags and
objects.

 Coordinates all models and
controls
 Run & Pause for those
elements that support
that functionality
 Saves and Restores Initial
Conditions
Simulation Operation Control Panel

Recent Developments
Use New Studio 5000® Logix Emulator for OTS
Enables powerful operator training capabilities by connecting an
emulated control system to process simulators
 Snapshot/Restore functionality enables the ability to restore process
to an instant in time for situational training
 Data interface provides robust mechanism to inject simulated
process control dynamics into the system
 Enables ability to halt/resume execution of the controller for pausing
a process
 Crazy fast interface to the controller, benchmarked at over 20,000
values/second. This allows for accurate simulation of very fast
processes including compressor surge, paper & packaging
machines, etc.

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