2014 Software Global Client Conference - …iom.invensys.com/EN/SoftwareGCC14Presentations/SimSci/SS S_ T-01... · the implementation of and over reliance on ... Vision and Mission

2014 Software Global Client Conference

SS S&T-01,

Simulation &

Training: Strategy &

Business Update

Alastair Fraser

September 30, 2014

Strategy Strategy


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The Challenge – Demographics, Safety & Increasing Levels of

Automation - All Impacting Operations

10

15

20

25

30

1925 1975 2025

Bir

th R

ate

/1

00

0

Pe

op

le Baby Boomers

Retiring

“Based upon information it received, the Panel

believes that at most of BP’s U.S. Refineries,

the implementation of and over reliance on

computer-based training contributes to

inadequate process safety training of refinery

employees” – Baker Report (2007)

Control Loops

per Operator

Operator

Initiated

Moves/Day


• North America: Ageing and retiring workforce, Safety, Knowledge Transfer, Significant

spending on gas, shale, oil sands, upstream

• Europe: Ageing and retiring workforce, Safety, Knowledge Transfer, Limited spending in

major process industries, access to oil & gas driving market, LNG import

• Mid East: new workforce in difficult locations, many new plants and more downstream

processing with strong upstream, LNG

• Asia Pacific: Massive expansion of production and process industries, new workforces

in difficult locations, new plants, major expansion of power plants, LNG

• Latin America: Existing process industries with some expansion, Power expanding, new

workforce

Simulation & Training

Regional Market Trends

Strong desire for Simulation & Training Solutions along with Value Add Services


●Vision (what we will be) The Schneider Electric Simulation & Training Business Unit will be the trusted advisor and leading

provider of solutions that inspire and empower our client’s workforce to improve safety, operational

performance and asset availability.

●Mission (reason we exist, core values) The mission of the Schneider Electric Simulation & Training Business Unit (SETSBU) is to mitigate

risk for our clients in the process industries by providing technology and services for design

verification, control validation and enhanced operational competence. The SETSBU will be an

empowered and trusted team with global centers of excellence that collaborate and support each

team member to deliver industry leading customer satisfaction and to provide career advancement

with personal satisfaction and development.

Vision and Mission


Is my design right

before I purchase

my equipment?

DESIGN DCS & PLC

CONFIGURATION STARTUP OPERATIONS

Invensys Dynamic Simulation Suite –

One Solution, Many Applications, High Value

DCS Control logic

configured correctly

the first time

PLC/SIS/TMC logic Configured Correctly the

First Time

World Class Operator Training Simulators

Coordinated Training of Control Room and

Field Operators

Support and Maintenance Programs and

Learning Management System Consulting Services


Phased Approach to Realizing Value Across the Enterprise

Engineering Studies

DCS, PLC, TMC

and SIS Logic

Checkout

Field Operator Training

Corporate OTS Cloud

Operator Training

Simulator

Generic Training

Simulators

FEED Pulse

Site Enterprise

Plant Pulse

Learning Management

Systems

Field

Control Room Engineering C&I

Fundamental Proactive Collaborative Assessable Training Needs

Assessment


FEED PULSE

Initially 1-2 days

●Objective is Process Design Validation

Benefits Assessment

●Meeting with Senior Management to

highlight typical benefits of dynamic

simulation and other tools

●Identifies potential application areas and

value

●Interviews with Engineering teams

Typically 45-60 minutes per group

●Identifies opportunities & value

●Output is a summary presentation and

report to engineering management

●Recommended Interviews

Utilities, Rotating Equipment, Safety, HAZOP,

Piping, Equipment and other groups

Pulse Value Assessments

PLANT PULSE

Initially 1-2 days

• Objective is to site wide assessment of

potential benefits of Training Solutions

• Interviews with site team/other stakeholders

Typically 45-60 minutes per group

• Identifies site objectives, needs,

opportunities & value

Benefit assessments, identify immediate focus

areas

• Output is a summary presentation and

report to site/stakeholders

• Recommended Interviews

Operations Management, Operators (experienced

and new), Process Engineering, Process Controls,

Learning and Development

Industry

Challenges

& Trends

Design &

Operational

Excellence

Can I be

Confident

This will

Work

Conclusions

Benefits

Assessment


● Safety, Safety, Safety

● Upgrading/migrating controls

● Adding new processes or capacities

● Developing new controls strategies

● Knowledge capture of experienced workers

● Training the next generation of workers

Drivers for Operator Training Simulators &

Training Services


A Well Trained Staff Improves Operations

An ARC Report (2010) reports

that operator error results in

42 percent of unscheduled

plant shutdowns


A Well Trained Staff Improves Safety

Arson/Sabotage Design Error

Natural Hazard Process Upsets

Unknown Causes Operational Error

Mechanical Failure

3

4

7

10 12

26

38

Accident (Incident) Percentages

The US Health and Safety

Executive reports that

26% of accidents occur

due to operational error

0 25 50 75 100

Operational error

Unknown

Natural hazard

Sabotage/arson

Loss in $ million

Average cost per

major incident related

to Operator error

exceeds $80M.


Typical Simulator Objectives

●Controls Testing / Commissioning Time & Risk Reduction

● A Control Checkout and Logic Testing Tool

● Process Analysis

● Decision Supporting Tool

● An Engineering Tool

●Knowledge Management

● Console & Field Operator Training

● Operator Certification


“Learn-By-Doing”

Most Effective Learning Method

0102030405060708090

100

Lecture

Reading

Audio/V

isual/C

BT

Demonstra

tion

Discussio

n Gro

up

Learn-B

y-Doin

g

Teaching O

thers

For skills training, operators can learn more in minutes of

real environment training than in hours of lecture

instruction

Simulation Exercises


Single Scalable, Proven Flexible OTS Platform

1.0

Generic

Operator

Training

Simulator

2.0 Traditional Operator

Training Simulator

3.0 Immersive Field Operator

Training Simulator

4.0 Integrated Operator and Field Operator Training

Simulator

5.0 Corporate Operator

Training Simulator

Sustainability Programs,

Training and Consulting Services


Mining

Chemicals

Power

Refining

LNG Oil and Gas

Over 700 Successful OTS/Studies Projects

Projects delivered to more than:

100 Different Clients in over

10 Different Industries in over

40 Different Countries on

15+ Different Controls/SIS/PLC Systems

Delivery

Excellence

Centre

Schneider Software Operator Training Simulator Experience

Site

Delivery


User quotes……

“The OTS does react as if it were the real plant. For the most part the

simulator reacts as expected to plant upsets etc.”

“We saved a week on our controls checkout at startup saving us an

estimated $ 2.9 Million”

“The thing I like the most about the simulator is I can tell, within 10 min

of training a new operator, just what his strengths and weaknesses

are. It is very good as an evaluation tool”


Simulation and Training

Key Growth Initiatives

SAGD/Upstream

Gas/LNG Processing

Metals/Minerals/Mining

Training Services

Generic Simulators

HPI & Power

Fertilizers/Chemicals

EYESIM

Control/Logic Validation

Corporate OTS

Cloud OTS

Training as a

Service - TaaS

Foundation Fossil Power

Refining

Petrochemicals

Pipelines

OTS & Leak Detection

(Telvent SimSuite)

DYNSIM

SCP

Foxboro Evosim

Gregor Fernholz

Janet Parker



• Autonaming rules • User Templates • Improved Thermo and

Diagnostics • Efficient model tuning • IT enhancements • Efficiency

enhancements • GUI Enrichment for

Improved Ergonomics and Ease of Use

DYNSIM 5.2

• Server 2012 support • Schneider-Electric branding • User configurable defaults • Silent install • Enhanced Search tool

DYNSIM 5.2.1

• Corporate OTS infrastructure

• Enhanced Scenarios and TPM capabilities

• Thermo: PC-SAFT • Thermo: Nitric Acid library • ElecSolve productization • New Antisurge Controller • Accelerate to steady-state • Alarm Manager • New Reboiler/Kettle model • Basic Undo/Redo • Efficiency enhancements • GUI enhancements • Win8 testing

DYNSIM 5.3

• TaaS infrastructure • Benchmark in the industry for

speed and robustness • DYNSIM Power Migration • Tier2 VLWE Flash • SimCentral Flash Integration • Footprint in the Chemical &

Fertilizer Industries • Expand into existing Schneider-

Electric industry verticals • Intergraph: auto-model

generation

DYNSIM 5.4 and later

• Foxboro Evosim • SCP280 • WW Historian

SCP v2

• Updates to VR • Enhanced use • SDK

EYESIM 2.x


DYNSIM Strategy

OTS & Studies ● Support above average market growth of our

business.

● Expand business in new markets. Leverage

Schneider-Electric customer base.

● From OTS vendor to Simulation and Training

solution provider.

Software ● Meet business needs (above)

● End-user experience for design and training.

● Engineering Efficiency.

More value. For our customers.


DYNSIM 5.3 Themes

Growth

New Industries

New Applications

New Business models

Competitiveness

Technology lead

Engineering Efficiency

Speed & Robustness

Usability

Training Experience

Ergonomics

GUI enhancements

Trends

Cloud

Virtualization

IT requirements


DYNSIM Roadmap

• Autonaming rules • User Templates • Improved Thermo and

Diagnostics • Efficient model tuning • IT enhancements • Efficiency

enhancements • GUI Enrichment for

Improved Ergonomics and Ease of Use

DYNSIM 5.2

• Server 2012 support • Schneider-Electric branding • User configurable defaults • Silent install • Enhanced Search tool

DYNSIM 5.2.1

• Corporate OTS infrastructure

• Enhanced Scenarios and TPM capabilities

• Thermo: PC-SAFT • Thermo: Nitric Acid library • ElecSolve productization • New Antisurge Controller • Accelerate to steady-state • Alarm Manager • New Reboiler/Kettle model • Basic Undo/Redo • Efficiency enhancements • GUI enhancements • Win8 testing

DYNSIM 5.3

• TaaS infrastructure • Benchmark in the industry for speed and

robustness • DYNSIM Power Migration • Tier2 VLWE Flash • SimCentral Flash Integration • Footprint in the Chemical & Fertilizer

Industries • Expand into existing Schneider-Electric

industry verticals • Intergraph: auto-model generation

DYNSIM 5.4 and later


Overview Control Emulations Strategy and Roadmap

Strategy

● Remain current with Foxboro, Triconex, and

Wonderware

● Develop and maintain simulation engines that

fit our core business needs

RoadMap

● SCP support for CP280 / Control Core

Services V9

● Foxboro Evo Simulation V6

● Wonderware Historian Emulation update

● HIMA engine

● RSEmulate engine

● PLC/SIS/DCS Emulator

● Schneider-Electric Unity Pro Link

3d Immersive

Virtual Reality

Training

Peter Richmond


Immersive 3d virtual reality

EYESIM

Next generation of training tools….

For the

Next generation of operator….


Immersive 3d virtual reality

EYESIM

3D

CAD

Laser

Scan

Augmented

Reality

Mobile

Apps

Dynamic

Simulation

Operating

Scenarios

HD

Photo Dynamic

Animation

EYESIM


One Platform - Many applications Licensed Technology

VR Showroom

Crew

Training

Safety

Scenarios

Procedure

Training

Hazop Design

Evaluation

Equipment

Understanding

Maintenance

Planning

EYESIM


Strategy & Roadmap - Training

3D

●Scalability

● Single Object Complex Plant

● Simple graphics /functions photorealistic and with complex scenarios

● Full VR Suite deploy mobile app or cloud implementation

●Automation and workflow

● Rules based auto creation of environment from 3D CAD

● SDK enhancement for project efficiency

●New VR hardware Integration

● Oculus v2

● VR Control, Omni Platform


Strategy & Roadmap - Operations

●Mobility and Advanced Augmented Reality for the field

● Object recognition and tracking

● Integration of workflow tools and data sources

Training Services

Graham Provost


Strategy - Training Services

• SimSci Training Services specializes in full scope industrial training design,

development and delivery supporting Simulators, Plant Operations, and Maintenance.

• As training consultants, we focus on identifying, advising & filling gaps in training and

other human performance factors in industrial facilities. Areas of expertise include:

• Simulator Training Programs – Control Room, and Field Operator

• Onsite Operator Instruction

• Industrial Documentation, including Ops and Maintenance Procedures, etc.

• Operator Training Programs, Job Position Responsibility Allocation and

Qualification Program Development


Areas of Focus

Advanced Controls

Analysis / CRO Training Training Needs Analysis

and Design, Job

Progression Planning

Trainee Self Study OTS

Training Packages


Areas of Focus

Cloud-based Simulation and Training

Platform


Areas of Focus

SimSci LMS

Open Source

Dynsim Integrated

Simulator Training Learning

Management System

Global Practice for


Ian Willetts


The Challenge – Demographics, Safety & Increasing Levels of

Automation - All Impacting Operations

10

15

20

25

30

1925 1975 2025

Bir

th R

ate

/1

00

0

Pe

op

le Baby Boomers

Retiring

“Based upon information it received, the Panel

believes that at most of BP’s U.S. Refineries,

the implementation of and over reliance on

computer-based training contributes to

inadequate process safety training of refinery

employees” – Baker Report (2007)

Control Loops

per Operator

Operator

Initiated

Moves/Day


Best

Technology

The Job To Be Done – Raising Operator Competence

● People

● Approach

● Customers

● Sustainability

Right

Services

Game

Changing

Solutions

Generic

Operator

Training

Simulators

Traditional Operator

Training Simulators

Immersive Field Operator

Training Simulators

Integrated Operator and Field

Operator Training Simulators

Corporate Operator Training

Simulators

Sustainability Programs

Training and Consulting Services


SIMULATION & TRAINING

PRACTICE


Training and Simulation Practice - Resources

EURA 17

• Madrid 15

• Others 2

SDC

Hyderabad: 74

APAC 45

• China 39

• Japan 3

• Others 3

North America 54

• Calgary 11

• Carlsbad 19

• Houston 20

• Others 4

Latin America: 13

• Brazil 6

• Argentina 6

• Chile 1

Total : 214

Four Regional Practices

SDC

Cairo : 11

Two Software Delivery Centers



Experience Profile - Collating Data Currently - placeholders

0

10

20

30

40

50

BachelorsDegree

MastersDegree

Doctorate

47

35

1

Academic Qualification Profile

25

20

28

10

Total Experience Profile

12 years and above 5 to 12 years

2 to 5 years Less than 2 years

0.0

2.0

4.0

6.0

Total ExpInvensys

ExpSimulation

Process

5.6

2.4 3.8

1.8

Average Experience Profile



EURA 17

• Madrid 15

• Others 2

SDC

Hyderabad: 74

APAC 45

• China 39

• Japan 3

• Others 3

North America 54

• Calgary 11

• Carlsbad 19

• Houston 20

• Others 4

Latin America: 13

• Brazil 6

• Argentina 6

• Chile 1

Total : 214

Four Regional Practices

SDC

Cairo : 11

Two Software Delivery Centers

0

20

40

60

80

100

120

Projects Delivered Each Year


Our Methodology

●Proven Methodologies to maintain schedule and reduce risk

●World Class resources and industry knowledge

●Drive efficiencies and consistency

●Quality management system modeled after ISO9001


Quality Management System e-QuIP

● Key ‘High Level' Quality Stage Gates:

1. Project Kickoff

2. Functional Design Specification

3. Interactive Client Workshop reviews

4. Model Validation Test

5. Factory Acceptance Test

6. Site Acceptance Test

●Global Practice Tools:

1. OTS Project Estimator and Schedule Creation

2. Modeling Guidelines

3. Test document templates

4. Productivity tools

5. Project Management Information Systems

6. Knowledge Database and Lessons Learned on all projects


Simulation & Training Delivery Success

Project Description

• Site wide deployment of OTS across a single

refinery in South Korea (Ulsan) in one year

• Eight process units including CDU,VDU,HMP,

RFCC,PX, Aromatics, HCU, ARDS

Value Delivered

• S-Oil testing normal and abnormal operating

scenarios to raise worker competence

• Goal to reduce plant downtime and increase

availability

• Secondary goal to ensure plant safety

Approach and Issues

• Excellent Coordination of resource across our

teams in Korea, Beijing and India to meet

intense resource requirements

• Single Simulation Platform across all units

• Three different types of DCS in the one

refinery

Project Results

• Client very satisfied with Schneider delivering

on our commitments – project completed just

three months ago

• Client kind enough to present at this Global

Customer Conference – Thank you.

47 Confidential Property of Schneider Electric

Simulation and Training agenda – at a glance

> Simulation & Training Track in

Panzacola H-2 (here)

> Expo Night

Tuesday Wednesday Thursday

Demo Area Booths 21-23


Panzacola H-2 (here – full

day)

> SimSci Wine Reception

8PM Butler Room


Panzacola H-2 (here – full

day)

> DYNSIM 5.2 and 5.2.1

“What’s new” in SS TSS02

1:30pm-2:30pm (Wekiwa 3)

> Booth 21: DYNSIM and Control Emulation: Hands-on latest releases.

> Booth 22: Power Plant OTS: A full-scale OTS of a power plant.

> Booth 23: Immersive OTS: Latest and coolest 3D training system.

> Times: Lunch breaks and Expo Nights

48 Confidential Property of Schneider Electric

Related Support, Services, Training & Expo Demos

> SimSci Tech Support

Support

Training

> DYNSIM Training Course

> Instructor Training

> OTS Maintenance Course

> Control Emulations Training Courses

> OTS, Checkout, Studies Projects

> OTS & Studies Consulting

> Training Program Development

> Customer First for Simulation & Training

Services

Expo Demos

> Dynamic Simulation and SimSci APC 2014

> Power Plant Operator Training Simulator

> Immersive Operator Training System

49 ©2014 Schneider Electric. All Rights Reserved.

All trademarks are owned by Schneider Electric Industries SAS or its affiliated companies or their respective owners.

Documents

2014 Software Global Client Conference - …iom.invensys.com/EN/SoftwareGCC14Presentations/SimSci/SS S_ T-01... · the implementation of and over reliance on ... Vision and Mission