Simulation Applications for Test and Training

Simulation is an important part for errection, commissioning and operation of a plant. In our solutions the process of a plant is being simulated, the controllers are connected directly (hardware-in-the-loop) or emulated on a PC and the original user interface is simulated. The result is a much better software quality, a shorter commissioning duration, shorter disturbances and higher availability because of optimally trained operators.

The challenge

TBS: Our partners have the goal, that the process control system has already a very high quality before start of commissioning. The result is that commissioning duration is shortened and so also the total project duration. The fact that a plant can be used earlier for production also leads to a gain of image at the end customer.

OGS: Shortening of the total project duration is a key factor for the end customer. Also suppliers of automation systems can use this argument at acquisition time. Already in parallel to commissioning or even before commissioning the operators of the end customer can learn operation of the new control system from first operation steps to handling the complete system.

OTS: The goal of the operator of a plant is maximum availability. Disturbances have to be avoided. With an OTS operators are being trained in critical situations to avoid down times or production loss. Also disturbances of the past can be analysed and replicated in the simulator and measures to avoid them in futures can be developed. Additionally it is possible to validate optimizations without risks at the simulator.

OGS and OTS applications are also optimally applicable for knowledge management, e.g to train new operators within the shortest possible time.

Our solution

The Siemens Simulation Center has a very broad knowhow in the following items:

• Simulation of physical processes

• Emulation of automation systems (SIMATIC S5 and S7) on a PC platform

• Integration of the original process control system or visualisation system into the simulation solution

The combination of this knowhow makes it possible to implement the requirements of our customers individually by provision of simulators in three aligned and scalable stages of expansion:

Testbed Simulator (TBS):
In this stage a process model which is specific to the realized plant is connected to the original automation system (hardware-in-the-loop). The benefit of this simulator is the validation of the automation software in a factory acceptance test and so it conforms to a kind of pre-commissioning. Our partner has the safety to deliver software with very high quality. The results are shorter commissioning duration and also shorter total project duration. In some cases a TBS can also be executed with emulated programmable controls (e.g. if the hardware has already been shipped on site).

Operator Guidance Simulator (OGS):
An OGS is used after the TBS or independently. The usage starts before begin of operation of a plant. In the engineering phase the process model of the plant is connected to an emulated application of the process control level. The benefit of this simulator is that operators can learn how to operate the applications of the new automation and basic or simplified processes. By gaining knowledge about the usage of the applications the customer is able to take over operation earlier, which shortens commissioning and total duration of the project. Customer has the additional benefit, that the operators act efficiently already at an early time.

Operator Training Simulator (OTS):
In this application the process model will be enhanced to replicate near to reality behaviour of the process of the plant. The automation software of the simulator is identical to the actual running version at the plant. Now the simulation is extended to include also malfunction scenarios. With this scenarios it is also possible to train critical situations. So the operators are kept on the highest possible level of knowledge to recognise malfunctions as early as possible and to act in the right manner to avoid critical situations and loss of production and money. This guarantees a high availability of the plant and avoids loss of production or even penalties.

Good reasons for simulation applications TBS, OGS, OTS:

• high quality of process control software by early detection of application failures

• shortened total project duration by shorter commissioning

• protection of equipment and risk free test of optimizations with a simulator

• fast training of operators

• high availability of the plant because of optimally trained operators