Virtual Controller Technology

A virtual controller is a software application that runs the DCS control algorithms on a personal computer instead of a plant DCS controller. This technology allows the use of the SAME DCS control configuration, HMI graphics and engineering tools on the simulator as in the plant. The benefits include the following. 1. DCS / safety system control configuration checkout prior to plant commissioning and throughout the operational life of the plant. 2. High fidelity operator training in a non-destructive environment, where a. Control responses are based on the same control algorithms as the plant control system b. Operator HMI is identical to plant HMI in all functionality 3. C&I personnel training for trouble-shooting control configuration and the use of DCS engineering tools. 4. Ability to checkout and train on advanced process control, online optimization and performance monitoring applications that run above the DCS layer. 5. Ease of simulator maintenance due to the use of the same control configuration and DCS engineering tools in the plant. The above benefits are NOT possible with an emulated solution where control configuration and graphics are developed within the simulation tool rather than using actual DCS control configuration and HMI.

DCS / Safety System Controls Checkout

Todays ROI requirements demand that the control configuration be accurate when it arrives at the plant site. Undetected and unresolved software errors can cause costly delays in plant startup and commissioning. Virtual controller technology allows testing of the control configuration as well as HMI graphics prior to actual plant commissioning. When integrated with a validated process model, it allows testing, validation of controls and training through various operational situations in the plant. Test motor start/stop logic and validate permissive logic Test safety / shutdown systems and logic sequences Check graphics displays Test I/O ranges and pre-tune control loops. Evaluate controls stability during complex plant transients Control modifications that are required for start-up and proper plant operation can be validated on the simulator and then implemented on the plant. Invensys clients who have taken advantage of this type of testing and pre-startup training have experienced significant reduction in DCS commissioning and startup time. The elimination of extra start-up days through DCS / safety system Checkout using a fully rigorous dynamic model is by itself a common justification for simulator purchase.

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In an emulated solution, the general DCS control philosophy can be tested. However, control algorithms and HMI representation tools are different in the simulator compared to the plant DCS. So, majority of the above mentioned benefits cannot be realized in the emulated solution.

Controls Analysis, Configuration, and Tuning Test Bed

Another benefit of virtual controller technology is the ability to carry out training of plant personnel such as Instrumentation Technicians and I&C Engineers. This technology allows bi-directional transfer of control configuration and DCS HMI graphics from the plant DCS to the simulator. This approach to developing a plant simulator will allow client personnel to Troubleshoot problems that occur on the actual plant controls on the simulator Test control design changes and pre-tune new control loops before implementing them on the actual plant Tune emergency control loops without risking plant operation Develop and conduct control system analyses In an emulated solution, the above benefits are not possible since the control algorithms and HMI representation are based on different tools compared to that of the plant DCS.

Advanced Applications above the DCS layer

In a virtual controller based solution, the simulator has DCS operator and engineering stations with actual DCS operator and engineering software installed. As a result, the interfaces and interactions with advanced applications such as advanced process control, online optimization and performance monitoring can be completely represented on the simulator. This allows both testing of these applications prior to commissioning on the plant, as well as training of respective personnel on these applications prior to plant use. In an emulated solution, it may be possible to install some of these applications to allow training. However, application testing and interface testing with the DCS configuration will not be possible.

Simulator Maintenance
During the operational life of any plant, changes happen and are necessary. These changes can be in process design (plant process equipment / piping) and plant control system (control configuration and graphics). Due to capital intensive nature of process design changes, one can expect less frequent process design changes compared to plant control system changes. Simulator and the plant going out of sync after simulator delivery is the primary cause of simulator obsolescence. Ease of simulator maintenance, especially the control system representation, is a major consideration to protect the investment. In a virtual controller based simulator, DCS engineering tools on the simulator are the same as that of the plant. So, client personnel dont need to learn a new set of skills to maintain the DCS representation on the simulator. Any changes made to the plant DCS can be easily done on the simulator. In fact, some Invensys simulator clients have an internal policy to test ANY changes to the plant DCS on the simulator

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prior to making them on the plant. This ensures that the simulator is always up-to-date and serves to minimize the cost of simulator maintenance. In an emulated solution, the DCS representation is based on a different set of tools (different software) compared to the plant DCS. Hence, any change in the plant DCS will require additional effort to keep the simulator control representation up-to-date. Also, any control changes in the plant can only be put through a test of concept since the control algorithms and HMI representation are different from the plant in the emulated solution.

Simulator Project Stakeholders

Other than the simulator vendor, the following stakeholders are involved in a simulator project while a new plant facility is being installed. 1. Owner / Operator of the plant facility 2. Engineering design contractor and equipment suppliers 3. Plant control system vendor For a successful simulator delivery, plant design and control system data needs to flow from the above three stakeholders to the simulator vendor. The plant control system vendor and simulator vendor should work together to fully realize the benefits of a virtual control solution. If the plant control system and simulator contracts are awarded separately, the following should be considered. 1. Plant control system vendor has a virtual controller solution for their proposed DCS 2. Simulator vendor has the ability to link their process models to the control system vendors virtual controller A contractual mechanism is present that allows plant control system vendor personnel and simulator vendor personnel to conduct joint testing and controls checkout in the presence of the owner/operator and design contractor.

Summary
As per Invensys experience, the benefits of testing and validating plant control system configuration / graphics, initial operator training and continued use throughout the lifecycle of the plant easily justify the use of a virtual controller based simulator compared to an emulated solution.

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