PCS 7 Takes you Beyond the Limits of ...
Process Simulation
Process Simulation
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Process Simulation and Operator Training are fast becoming a "standard" part of process automation systems as a means of minimizing risk, reducing lifecycle costs, and improving process / operator performance. A wide variety of simulation options are available, differing based on their level of fidelity, functionality, and cost. Each type of simulation is optimized to meet different goals ranging from the testing of hardware and software at FAT up to full-blown thermochemical simulation of a reactive process.
With PCS 7, different options are available to allow you to create a cost-effective solution for process simulation and operator training. We offer a modular building block approach to address the entire spectrum of simulation needs:
Process Simulation & Operator Training - Benefits
Numerous benefits can be achieved by leveraging simulation tools. Although often viewed as an additional up-front cost, an investment in simulation tools typically pays for itself quickly by providing benefits during the entire lifecycle of a plant.
These benefits (and more) can be achieved by leveraging the simulation options available for use with PCS 7:
• Reduces Design and Installation Costs (while minimizing errors) • Compresses the time required for Factory Acceptance Testing (FAT) • Allows cabinet assembly and checkout of hardware to be performed in parallel with software (engineering) development • Allows operations folks to be trained before touching a live system • Improves performance of operators - helping to prevent unplanned downtime and maximize yield • Reduces time required and risk associated with startup • Helps to optimize operations in order to minimize raw material usage and energy consumption • Allows thorough testing of configuration changes offline before installing on a running system |
Modular Approach to Process Simulation
 | This modular approach uses a suite of products that have been designed to work together, which makes it very easy to add new simulation capabilities during different stages of the lifecycle of a plant. Thus, the simulation created for logic checkout at FAT can be re-used and adapted to create operator training and/or process simulation. |
Controller Simulator (PLCSim) – Allows development and testing of configuration logic without controller hardware SIMBApro – For simulation of I/O signal response (conventional I/O and digital fieldbus) in order to test timing and system loading SIMIT – Modular software simulation package that can be used for panel checkout, loopback testing, to simulate mass flow (through pipes, tanks, pumps, valves and heat exchangers), batch / recipe development and operator training 3rd Party Packages (such as HYSYS)- Can be easily connected via OPC to create simulation of advanced thermochemical reactions |
One of the keys to effective use of simulation packages is tight integration, with the control system engineering tools. With the Siemens simulation packages, the majority of the simulation logic can be created directly from the actual control system configuration via export/import or via the system’s bulk engineering tools. |
This minimizes additional engineering efforts (for the sole purpose of creating simulation), and provides traceability between the control system configuration and the simulation. |
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