The Performance Engineering Package is the ideal set of tools for increasing engineering productivity on all I/A Series projects. The package is a combination of two leading I/A Series software products, FoxCAE and FSIM Plus.
The combination of these two products is a natural fit. The features of FoxCAE, including tag lists, typicals and auto documentation generation, allow for quick and easy development of consistent control configurations. Coupling FoxCAE with the simulation environment offered by FSIM Plus results in a test bed for executing the entire plant's control configuration without the need for I/A hardware. The I/O hardware, control processors, and field equipment are built into the simulation software.
Benefits
The maintainability and scalability of the Performance Engineering Package provides you with a tool that grows and changes as your needs do. From the original design inception through the implementation and on to plant improvements, this package offers you benefits that continuously meet your needs. These benefits include:
- Reduction in project schedules
- Capturing experts knowledge
- Ensuring thorough offline testing
- Providing a training environment
- Providing a platform for continuous improvement
How It Works
The Performance Engineering Package is comprised of user-friendly tools to make the design, development, and implementation tasks of an I/A Series project as easy as possible. In the following paragraphs, we take a look at the typical implementation steps.
The engineer uses FoxCAE either to select a pre-configured and pre-tested control primitive from a library of "typicals" or to create a custom control loop. The functionality in the control scheme matches the process functionality.
Using FSIM Plus, a one-to-one mapping is completed by either selecting a pre-configured and pre-tested process model from a library of "templates" or creating a custom process model that defines the process.
The control loop and the process model communicate via a "cross reference" database. This link closes the loop and allows for testing, training, and continuous improvements.
Reduce Project Schedules
The typical I/A Series Project can be broken down into five main phases:
- Project definition
- Control configuration implementation
- Hardware and software testing
- Shipment and installation
- Site work
The following timeline shows a typical 12 month automation project. Each phase is run in series, meaning that once one phase is complete the next one can begin. This is due to the fact that the control hardware is required for each phase. In this model, if one phase is delayed, the entire project suffers.
As we see in the next timeline, the I/A Series project schedule can be reduced by one or more months with the use of the Performance Engineering Package!
In this timeline, we see that the control configuration implementation time is slightly longer since the process models must also be configured. The control configuration implementation phase can be de-coupled from the shipment and installation of the hardware, since the control configuration can be tested without the actual control hardware. The software testing time is reduced through the use of the FSIM Plus tools throughout the engineering process. In turn, the site work time will be reduced because of the more thorough testing completed at the factory.
Capture Experts' Knowledge
With the Performance Engineering Package, the time, resources, and most importantly the expertise that is applied to the project is not lost at the end of the project, but instead is captured for future use. This "captured knowledge" resides in the typicals/templates, in the propagation of knowledge, and in the documentation.
Typicals/Templates
Experts select, create, and save the optimal control configurations based on individual customer needs. In the process model, any model or graphic configuration can be saved as a template.
Propagation of Knowledge
The Performance Engineering Package contains sophisticated tools for rapidly configuring equipment, unit or plant-wide controls. The information contained within the typicals and templates can be used to generate bulk databases, as well as simulation models. As a result, you can design and develop consistent control configurations throughout the plant as well as company-wide.
Documentation
Graphical loop drawings are generated for new I/A Series configurations as the controls are built. The back-documentation feature takes any compound from a current control database and automatically generates its loop documentation.
Thorough Offline Testing
Through the use of the Performance Engineering Package, you can feel confident in the design and development of your control configuration. The simulation environment allows for in-depth checkout and validation of the control configuration as well as the system graphics before the system gets installed onsite.
Validation and Checkout
Why wait until almost the end of the project to test the control system? Incorporating the Performance Engineering Package into the engineering process will not only ensure you of a better end product, but will help you save time and money!
Every control configuration must go through a checkout and validation phase prior to installation in the field. With the combination of FoxCAE and FSIM Plus, the building and testing phases can be integrated into one.
As the building blocks of the control configuration are designed and configured, they can each be validated prior to further integration. With each addition of complexity, the control system gets validated.
- Validate Systems (Integrated Units)
- Validate Units (Multiple Component Groups)
- Validate Component Groups (Multiple Loops)
- Validate Typicals (Single Loops)
The end result is a completely validated control configuration that is ready to install.
Malfunction / Abnormality Testing
Do you know how the control system will respond to abnormalities? Will your control system be ready to handle equipment failures, incorrect manual operations, or inconsistencies in data?
With the built-in capability of FSIM Plus, known as malfunctions, abnormal situations can be tested before they happen. Pump trips, valve failures, manual operations, and signal discrepancies are all just a few clicks away.
Coupling the built-in malfunctions with the capability of save and restore makes testing abnormalities quick and easy. A starting point within the control system is saved as an initial state or condition. From the initial condition, test runs are completed to determine the effects of abnormalities. If there is an inconsistency with the control scheme, it can be modified and the scenario tested once again to complete the validation.
Are you missing what is causing the trip? Place the simulation in single step mode and let the control configuration step through one time step at a time. Instantly, debugging time is reduced!
The Training Environment
The control configuration test bed that has helped you design and validate your control configuration can also provide a non-destructive environment to train your operations and engineering personnel. Training can take place either in parallel to the validation of the control configuration or after the system has been installed onsite. A variety of training possibilities are available. These include:
User Familiarization - If the I/A Series system is new to the operators, they can become familiar with the operating environment before they have to operate the "live" process.
Plant Operations - Operators can be trained on normal plant operations, including startup and shutdown procedures.
Emergency Response Training - Prepare your operators and engineers to deal with emergencies before they happen!
The training environment provides full Instructor Station functionality. The simulation features include:
- Run/Freeze
- Single Step
- Save/Restore
- Malfunctions
- Trainee Performance Monitoring
- Remote Functions
- Trends
Platform for Continuous Improvements
The benefits don't stop once you get your system installed and your personnel trained. As a result of the scalability and maintainability of the simulation environment, the Performance Engineering Package will continue to be an effective tool in the years that follow.
The integrated control test bed and simulation platform can assist you in developing and testing control system and process design improvements.
The design, development, and testing can be completed without putting the real system at risk. Once the new design is validated, then it can be loaded directly into the control system without modification.
Minimum System Requirements
The Performance Engineering Package requires a minimum set of hardware and software. These include:
Hardware
- Sun Ultra 5 for the FSIM Plus workstation
- AW70 computer with I/A Series Software
- DNBT and cable set for both the FSIM Plus workstation and the AW70
- 1x8 Mounting Structure
Software
- FSIM Plus license
- FoxCAE license
The diagram below shows a typical setup using the Performance Engineering Package.
