PlantPAx Operator Training In the Cloud - Rockwell … Operator Training In the Cloud Automation...

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© 2012 MYNAH Technologies LLC

PlantPAx Operator Training In the Cloud Automation Fair Philadelphia - November 2012


What is the Cloud? What are “Training Systems in the Cloud”? Why move your system to the Cloud? What do you need to know? Do we have any examples?

Training Systems in the Cloud

Mart Berutti [email protected] +1.636.728.2016 skype: mberutti

mailto:[email protected]


Virtual Confusion

Cool What’s he talking about? $$$!!

Another Geek Party


The Cloud is Everywhere!

Public – services made available to the public through a service provider (ie Google, Amazon)

Private – cloud infrastructure managed by a single organization


Dynamic Simulation in the Cloud


The Cloud at MYNAH


The Cloud is Not Free Money doesn’t grow on trees

you know!


Private Cloud Architecture Single Server Host (most systems) MS Workstation OS (XP, Vista, Win7) or thin client


VMWare Implementation Server – VMWare ESXi Hypervisor VLAN between MiMiC and RSEmulate VMWare vCenter Server - appliance


Business Results Achieved Lower system hardware requirements Stability

• MiMiC to RSEmulate DCOM protected with VLAN Security

• Access to system restricted to one RDP port • Hardware easily installed in secure server room

Flexibility • Multiple control system installs, process models in one

system • Training from any networked PC or thin client • System expansions and upgrades with minimal additional

investment • No problem with old OS (ie Win NT, Win XP)


Extra Business Results Achieved

One button startup!!! System recovery from

failures in record time Swift staging of new

projects VMWare Snapshots


Inside the Cloud – Virtual Plant Virtual Control System – RSEmulate, FactoryTalk View

• Training on identical HMI graphics, alarms, controls • Testing on identical control strategies

Virtual Process – MiMiC Simulation Software • Dynamic, accurate process simulation • Easy-to-use, flexible, powerful

Integrated approach for testing and training • Integrated to automation project schedule • Operations resource for control system life cycle


Value of the Virtual Plant Manage Experienced Operator Shortages Plan for Highly Automated Plants Remove Risk, Increase Safety of Operations Effective Tool for Knowledge Transfer Process Problem Solving, Operation Improvements


First Step – Good, Dynamic Model Dynamic Simulation Requirements

• First Principle Unit Operations Models

• Thermodynamics Properties • Dynamic Pressure / Flow Solver • Accurate Tuning for

Process Dynamics • Real-time response

to controller outputs


Second – IO Models and Tags Simulated IO Definitions – L5K Tag Browser IO and Tieback Models – Bulk Generation Utility


Costly Mistakes Using process design models

• No real-time performance or range of operations conditions

Using an emulated automation system • Identical Operator HMI graphics, alarms, controls • Identical control strategies

Adding simulation to the control system configuration • Adds error and risk to automation system • Increases the complexity of the solution and maintenance costs • “Strive for Control System Purity” Bill Sickinger, SRS

Starting too late • Start early to get the maximum return


Virtual Plant – Right Approach Virtual Control System – RSEmulate / FactoryTalk View

• Consider Use Case – testing, development, training, validation • Consider IO – Traditional, Bus, Industrial Ethernet • Consider 3rd Party Systems

Virtual Process – MiMiC Simulation Software • IO Requirements – SIO Drivers • Model Performance Requirements

Architecture Considerations • Number and location of users • Switch over requirements for multiple uses

Best Practices • Simulate all IO • No additions or deletions to control system configuration


More Sweet Stuff for Training Training Scenarios

• Structured, repeatable, measurable operator training

Snapshots • Control System

and MiMiC restores

Instructor screens • Dynamic PFDs

w instructor controls


Training in the Cloud Example #1 Development / Training System in one Server Team Operator Training Supports physical controllers and DCS Emulator


Training in the Cloud Example #2 Development System supports physical controllers Parallel Training System (Concurrent Operators) Dual Servers with Shared Storage (SAN) VMWare vCenter Server - appliance


Training in the Cloud Example #3 Development System supports physical controllers Parallel Training System (Concurrent Operators) Single large server


VMWare Solution Provider Design, implementation, training of Virtual Dynamic Simulators

2012 Readers Choice #1 Simulation Software Reader’s Survey – Outstanding Customer Support

Dynamic Simulation Leader Over 1200 Registered Sites World-class Software Development Team World-class Simulation Consultants

Dynamic Simulation Leader

Rockwell Automation Encompass Partner for Dynamic Process Simulation Booth 1136

PlantPAx Operator Training In the Cloud - Rockwell … Operator Training In the Cloud Automation...

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