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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
PUBLIC INFORMATION
Mynah Technologies Building the Virtual Plant Utilizing the PlantPAx® System
Spencer Absher
Simulation Solution Engineer - Mynah Technologies
June, 2015
• Demographic Time Bomb
• 7 Years to Operator
Competency
• Automation Adds
Complexity
Dawn of NA Process Industry
• Hidden errors in
configuration
• Incorrect operator actions
• Operating procedures in
error
Managing Automation System Risks
The Virtual Plant Can Help
Pilot – over 100 variables Operator – over 1000 variables
Operator Effectiveness – 31% Increase
Savings from Simulator Use - $15.3MM
Components of Virtual Plant
• Offline Control System • Production to Offline
• Dynamic and Real-time Model • Appropriate fidelity
• Correct Implementation • Virtual environment
Life Cycle Virtual Plant
• Capital Project Execution • Developed early in the project for:
Process and control system
engineering
Control system validation
Operator training
• Operational Excellence Initiatives • Returns in operation:
Process control improvements
New operator training
Optimization and modification studies
Offline Control System
• Identical to Production
• Logic and control strategies
• Operator graphics
• Environment and architecture
• Testing, training, both?
• RSLogix Emulate
• Logix Controllers
• Physical or virtual network
Dynamic Simulator
• Real-time and Appropriate Fidelity
• Quickly converging model
• Fast updates to control system
• Integration at IO Layer
• Nonintrusive model
• No control system emulation
• Compatible with hard and soft
solutions
• Tools for Testing and Training
Implementation
• Control System Equipment
• Real controllers for testing
• Emulated controllers for training
• Both for best life cycle results
• Implementation Environment
• Multiple individual machines
• Virtual system
The Approach
• First Principles Unit Operations Models
• Thermodynamic properties
• Dynamic Pressure-Flow Network
• Accurate Dead Time, Holdups, Gains
• Real-time Response for Control System
Implementation
• Communication with real controllers
• Tag access or DF1
• Testing of controller loading and
redundancy
• IO and logic checkout
• Communication with emulated
controllers in RSLogix Emulate
• Operator training and control system
optimization
Operational Challenges and Simulation
• Many challenges to operating a
process plant
• Using virtual plant through plant
life cycle is demonstrated solution
• Irreplacable tool for CapEx and
OpEx