1. Slide 1

2. © 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners. SSE-09 Dynamic Simulation From Checkout to Optimization Howard Jemison

3. Slide 3 Agenda ●Operator Training Simulator Overview ●Control System Checkout with Simulation ●Advanced Process Control with Simulation “A computer lets you make more mistakes faster than any other invention in human history, with the possible exceptions of handguns and tequila.” – Mitch Ratcliffe

4. Slide 4 Industry Pressures - The “Perfect Storm” High Energy Costs Utilization Down Supply > Demand Margins Down Environmental Regulations Loss or Lack of Experience Population in ME and NA between ages 15-24

5. Slide 5 Operator Training Simulator PlantDynamic Process Model Control system DCS + ESD Software Emulation Operator consoles HMI Same or similar

6. Slide 6 The Current Human Resource Crisis Industrial companies in a human resource crisis Fewer people entering the industrial workforce 10,000 retiring per day for the next 19 years Large inexperienced youth population

7. Slide 7 New Approach to Training This comes from a combination of training approaches geared to minimizing time to efficiency, then driving new levels of operational and financial performance

8. Slide 8 New Approach to Training This comes from a combination of training approaches geared to minimizing time to efficiency, then driving new levels of operational and financial performance

9. Slide 9 DESIGN DCS & PLC CONFIGURATION STARTUP OPERATIONS Dynamic Simulation Suite – Applications across the Process Lifecycle World Class Operator Training Simulators Coordinated Training of Control Room and Field Operators Control System Checkout SIS, TMC and PLC Controls Logic Testing/Verification SIS, TMC and PLC Controls Logic Testing/Verification

10. Slide 10 Operator Training Simulators

11. Slide 11 “Operators train for emergency preparedness under real-world conditions” “The operators understand how to avoid upsets and shutdowns and improve efficiency, safety and reliability” “EMRE estimates the training can reduce the time taken for the operator to progress to the top level of operator competency by 30 to 50%” “….improves employees abilities to respond to potential emergencies”

12. Slide 12 “Operators train for emergency preparedness under real-world conditions” “The operators understand how to avoid upsets and shutdowns and improve efficiency, safety and reliability” “EMRE estimates the training can reduce the time taken for the operator to progress to the top level of operator competency by 30 to 50%” “….improves employees abilities to respond to potential emergencies”

13. Slide 13 Well Trained Staff Improve Safety & Plant Availability Operations An ARC Report (2010) reports that operator error results in 42 percent of unscheduled plant shutdowns Arson/Sabotage Design Error Natural Hazard Process Upsets Unknown Causes Operational Error Mechanical Failure 3 4 7 10 12 26 38 ACCIDENT (Incident) PERCENTAGES US Health and Safety Executive reports 26% of accidents occur due to operational error

14. Slide 14 How Much Money Will We Save? Average cost per major incident related to operator error exceeds $80M. Findings by the Chemical Safety Topical Committee (funded by DOE) reveal an average of one chemical incident/day. Average cost to comply with ORPS process is estimated at $2M per incident *

15. Slide 15 Deethanizer Process Diagram Propane in overhead target 1.5% Ethane in bottoms target 4% Reflux drum Reboiler steam Top product Reflux Bottom product

16. Slide 16 Forcing Inputs TAGDESCRIPTIONTYPE AI101PROPANE IN OVERHEADAIN AI102ETHANE IN BOTTOMSAIN AC101 PROPANE IN OVERHEAD CONTROL PIDX AC102ETHANE IN BOTTOMS CONTROLPIDX LC101CONDENSER TANK LEVELPIDX TT102TOP COLUMN TEMPERATUREAIN TT103 BOTTOM COLUMN TEMPERATURE AIN FC101FEED FLOWPIDX FC102BOTTOM PRODUCT FLOWPIDX LC102REBOILER TANK LEVELPIDX PC101COLUMN PRESSUREPIDX FC103REBOILER STEAM FLOWPIDX FC104TOP PRODUCT FLOWPIDX FC105REFLUX FLOWPIDX Create a simulation Deploy the controls Create an I/O cross reference list Force an input

17. Slide 17 Automatic Loop Validation TAGDESCRIPTIONTYPE AI101PROPANE IN OVERHEADAIN AI102ETHANE IN BOTTOMSAIN AC101 PROPANE IN OVERHEAD CONTROL PIDX AC102ETHANE IN BOTTOMS CONTROLPIDX LC101CONDENSER TANK LEVELPIDX TT102TOP COLUMN TEMPERATUREAIN TT103 BOTTOM COLUMN TEMPERATURE AIN FC101FEED FLOWPIDX FC102BOTTOM PRODUCT FLOWPIDX LC102REBOILER TANK LEVELPIDX PC101COLUMN PRESSUREPIDX FC103REBOILER STEAM FLOWPIDX FC104TOP PRODUCT FLOWPIDX FC105REFLUX FLOWPIDX Create an Excel input file Automatically force inputs Automatically validate loop output

18. Slide 18 Demo: Automatic Loop Validation

19. Slide 19 Bulk Configuring Tieback TAGDESCRIPTIONTYPE AI101PROPANE IN OVERHEADAIN AI102ETHANE IN BOTTOMSAIN AC101 PROPANE IN OVERHEAD CONTROL PIDX AC102ETHANE IN BOTTOMS CONTROLPIDX LC101CONDENSER TANK LEVELPIDX TT102TOP COLUMN TEMPERATUREAIN TT103 BOTTOM COLUMN TEMPERATURE AIN FC101FEED FLOWPIDX FC102BOTTOM PRODUCT FLOWPIDX LC102REBOILER TANK LEVELPIDX PC101COLUMN PRESSUREPIDX FC103REBOILER STEAM FLOWPIDX FC104TOP PRODUCT FLOWPIDX FC105REFLUX FLOWPIDX Create a simulation Deploy the controls Create an I/O cross reference list Start Bulk Configurator Create tieback based on the I/O tag names

20. Slide 20 Bulk Configuring Tieback Control System Tag or I/O name Create a model object to match the physical plant or use Lead/Lag or point objects Give the object a name that correlates to the Tag or I/O DEETHANIZER:FT105.POINTValve: FV105 PID: FC105

21. Slide 21 Deethanizer Process Diagram Propane in overhead target 1.5% Ethane in bottoms target 4% Reflux drum level ~ 0.5 m Top column temperature range 260 – 300 K Bottom column temperature range 360 – 400 K Controlled Variables Reboiler steam flow ~ 2200 kg/hr Overhead pressure ~ 3050 kPa Manipulated Variables Top product flow ~ 6700 kg/hr Reflux flow rate ~ 12000 kg/hr

22. Slide 22 Deethanizer Optimization

23. Slide 23 Demo: Deethanizer Optimization