(161c) Virtual Commissioning and Startup Using Dynamic Simulation – Applications and Benefits

Multi-purpose dynamic simulation (MPDS) is an industry accepted terminology that captures the important concept that dynamic process simulation has applications throughout the asset lifecycle:

• Dynamic simulation can be embraced early on in an asset’s lifecycle to help ensure that the process and electrical design is correctly sized and is inherently safe, controllable and easy to operate. A dynamic model developed during the design stage brings significant value.
• The MPDS concept is that the model built during the design can be connected to the plant controls and then be used for virtual commissioning and startup (vCSU), bringing incremental value.
• Beyond vCSU, the model can readily be delivered as an Operator Training Simulator for workforce competency development.
• The simulator continues to bring value with on-going operations and can be used for troubleshooting, advanced control development and even operational optimization.

The first part of the paper discusses the above concept of Multi-Purpose Dynamic Simulation and specifically how modeling throughout the asset lifecycle brings value each step of the journey.

The paper then drills down in more detail to describe how owner/operators are utilizing dynamic simulation during the Commissioning and Startup phase of a project. Commissioning and startup may be related to a greenfield project where the plant and the controls are new. It may also be related to a revamp or process modification in a brownfield site where the interaction of the controls and the modified process need to be checked. The commissioning and startup may also be tied to a Distributed Control System (DCS) or Safety Instrumented System (SIS) upgrade where there is a need to validate the controls database before the database is deployed to the actual plant.

Virtual commissioning and startup involves building a digital twin or a digital representation of the plant utilizing a dynamic simulation software package. The dynamic model will predict the behavior of the process throughout the entire operating envelope. Starting with cold metal with an inert gas blanket, the model will support, for example, the ability to turn on the charge pumps, turn on the steam and utility systems and follow all the operating procedures through a full start-up to nameplate capacity.

The dynamic process model is connected to controller software from the DCS or SIS or PLC vendor. This so-called soft controller from the control manufacturers can upload the controls database built by the Main Automation Contractor (MAC). The controls database is cross referenced to the process model so all relevant instruments, such as flow or temperature sensors, will pass as measurements to the control software and the controls database will calculate the appropriate action if the measurement deviates from the setpoint of, for example, the temperature or flow controller.

In the industry literature there are many papers published describing the use of dynamic simulation for vCSU and how testing the controls off-line in a safe environment using a virtual plant enabled engineers to identify and eliminate most, if not all problems, before live commissioning begins.

This paper explains what is involved in performing a virtual Commissioning and Startup process using a process digital twin. The paper is unique because it not only covers this key applications of dynamic simulation but it also provides a detailed literature search and captures references where publicly available, quantified benefits detail the large impact that vCSU is delivering to owner/operators.