Simulation and Design Software (original) (raw)
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Simulation and Design Software Systems for Testing and Training Process Automation Projects
Simulation and Design Software Systems for Testing and Training Process Automation Projects Dr. Osama Mohammed Elmardi Suleiman Khayal, 2019
Introduction Chemical engineers are accustomed to software for designing processes and simulation. Simulation systems such as Matlab and Aspen Plus are commonly referenced in chemical engineering curricula as required courseware and study tools. Automation professionals are also becoming used to applying simulation to operator training, system testing, and commissioning of plant process control systems. Plant design simulation programs are substantially different from systems used for training and commissioning. Many of the most common plant design simulation programs are steady state, low-resolution simulations that are not usable for automation or plant life-cycle management.. Simulation Simulation is usually integrated into the plant life cycle at the front-end engineering and design stage and used to test application software using a simulated I/O system and process models in an offline environment. The same simulation system can then be used to train operations staff on the automation and control systems and the application software that will be running on the hardware platform. In the most advanced cases, integration with manufacturing execution systems (MES) and electronic batch records (EBR) systems can be tested while the operations staff is trained. Once installed, the simulation system can be used to test and validate upgrades to the control system before they are installed. The simulator then becomes an effective tool for testing control system modifications in a controlled, offline environment. In addition, plant operations staff and new operators can become
Process Simulation and Control Center: An automated pilot plant laboratory
Computer Applications in Engineering Education, 1998
The Department of Chemical Engineering at Michigan Technological University (MTU), with technical and financial assistance from its industrial partners, has incorporated the concepts of distributed control and process management into the curriculum via the Process Simulation and Control Center (PSCC). The PSCC includes two highly instrumented pilot plants (a siloxane polymerization batch reactor and a solvent recovery distillation process), controlled by a Honeywell TPS distributed control system. The TUTOR 3000 computer-based training program prepares the students to run the two pilot plants. Process data are compressed and archived by OSI Software's PI data management system and then are imported directly into spreadsheets and other computer applications on the departmental student network for analysis and reporting. The PSCC is a state-ofthe-art facility that prepares MTU chemical engineering students for the computer-based industrial environment that they will encounter when they graduate.
Integration of Process and Control Simulation Into the Engineering Process
Testing of a chemical plant is done mainly during its start-up and commissioning phase and in general requires a considerable amount of time and money to correct hardware and software problems. Using model based plant simulation directly after completion of detailed plant engineering, the main testing and debugging could be done by simulated virtual plant thus reducing the time and cost of the start-up phase. This paper describes an approach to generate the required plant models automatically from a model catalogue in parallel to the engineering process.
Training Course in Simulation of Chemical Process Control
Universitat Politècnica de Catalunya, 2020
This chapter recollects all the calculation and the information about the decisions taken in the design practice of each case. Information about the valve sizing can be found in the simulation chapter for each case.
Educational Simulators for Industrial Process Control
Simulation and Modeling Methodologies, Technologies and Applications, 2013
The paper shows a Windows© NT/XP/7 application oriented to learn control skills to process engineers. It is a dynamic simulation based tool with a friendly user interface that contains two sets of diverse process control problems (more than twenty study cases are available). It is possible to study typical control problems as cascade, ratio, selective, override and feedforward control techniques and the tuning, configuration and operation of PID controllers. Additionally, it allows analyzing complex control systems installed in boilers, furnaces, distillation columns or reactors and special industrial control techniques to ensure the process safety. In order to outline the functional features of the tool, one of the simplest modules is shown. To conclude, an overview of the methodology and software used to develop this tool is also outlined. In particular, an object oriented modeling and simulation tool is used to develop the simulation models, a self-developed SCADA is used as graphical user interface and the simulation-SCADA communications are supported by the OPC standard. Finally, it must be remarked that this tool is used successfully in an industrial master of instrumentation and process control.
The Virtual Chemical Engineering Unit Operations Laboratory
2003 Annual Conference Proceedings
There appears to be a growing trend in the chemical process industry (CPI) to reduce the dependency on pilot-plant studies by increasing the use of computer process modeling. For the CPI, this approach is reliable, safe, and cost effective. In the traditional pedagogy of unit operations laboratory, students are required to conduct experiments on lab-scale equipment. This practice may lead to a mismatch between the student's learning experience and later employment expectations. Therefore, while the traditional unit operations laboratory ought to remain an integral part of the chemical engineering curriculum, the instructional material should be modified to adapt to the increasing use of information technology in the chemical process industries. It is expected that with an increase in the authenticity and reliability of this form of pedagogy, student learning will be enhanced. A simultaneous benefit is a reduction in the financial burden associated with purchasing and maintaining expensive physical laboratory equipment and supplies. To address this adaptation, we are developing a virtual unit operations laboratory. The pedagogical format includes the following. (1)The partial replacement of selected lab-scale physical unit operations experiments with computer visualization of data from full-scale, industrial chemical processes. Using the process simulator, CHEMCAD™, which contains both steady state and dynamic unit operations models, we demonstrate the separation of mixture of organic acids using multiple distillation columns in series. The module simulates an actual separation train at the Celanese plant in Pampa, TX. We obtain excellent agreement with the archival data donated by Celanese. We also explore process conditions and alternative designs with the module, as would be done in an industrial process engineering department. (2)Virtual analogs to the lab scale unit operations experiments of heat exchange, mass transfer, and humidification. Using LabVIEW software, we have developed a realistic control room interface overlaying a mathematical model of the unit operation. The student conducts the virtual experiment in the same fashion as the physical experiment.
Experiences on Utilising Plant Scale Dynamic Simulation in Process Industry
This paper will consider the role of simulation in process industry and major obstacles to adopting new technologies. The benefits of process simulators are illustrated with five practical applications. These applications were realised with APROS simulator, the structure of which is explained very briefly.
Simulation Practice and Theory, 1997
This paper describes an application of multivariable control hardware and algorithm testing by means of simulation in a process control environment. This approach is in some other fields known as hardware-in-the-loop simulation. It is shown that general purpose simulation language can be used in the process control which is frequently not problematic from the fast dynamics point of view. The case study involves a semibatch distillation column. Descriptions of the process model, the selected control design approach and the implementation of control algorithms are given. The main results are presented and the method used for the control design evaluation is discussed. 154 J. Kocijan. R. Karba/Simulation Practice and Theory 5 (1997) 153-165