It has been interesting to watch the recent shift in the attitude toward simulation technologies over the last five or so years. What used to be a “nice to have” add on to a capital project has become, for many organizations, a go-to technology for business success. Companies are under more pressure than ever to increase production while simultaneously curbing waste and energy use—critical differentiators for unlocking the productivity enhancements that deliver shareholder value. But managing both those challenges in parallel is one of the most complex, frustrating, and time-consuming elements of modern process manufacturing.
In response, we’ve seen simulation software move up from the back seat to become a key driver of business success. As Dustin Beebe shares in his recent article in Automation.com, simulation technologies make users’ lives easier across the entire lifecycle of a plant. He explains,
“In the earliest stages of project design, simulation helps reduce capital expenditures by helping project teams evaluate and validate process and automation designs, as well as enabling safer testing with improved results to help teams more easily meet or even shorten project schedules.
Yet even after project completion, simulation software continues to deliver value across its lifecycle. Dynamic simulation tools provide the best possible training platform for new operators, providing them the opportunity to work with systems that look, feel, and respond exactly like the controls they will use every day. These training simulations can be built, deployed, and used well before equipment ever arrives on site, ensuring operators are ready to perform at their best on the very first day of operation. These simulations can then continue to be used to train new hires throughout operations.”
But here’s an additional challenge: with increased popularity comes increased options. There are loads of new simulation software packages available in the marketplace. If a team tries to build one-off solutions for every need, complexity—and associated costs—will increase with each implementation. However, if teams approach their simulation implementations thoughtfully, they can deliver highly integrated solutions that not only meet project goals but continue to deliver value throughout operations for many years to come.
Navigating nebulous needs
One of the key places organizations get tripped up when implementing simulation solutions is in the transition from steady state to dynamic simulation. Often, project teams simply select what seems best for the project in the moment and end up with steady state modeling software that is of little value once the project is finished and operations begin. But true value comes from being able to use a solution across many purposes. That means thinking carefully about reuse. Dustin explains,
“One example of re-use is between steady-state simulation and dynamic simulation. When teams select integrated steady-state and dynamic simulation solutions, they can easily transfer their existing flow sheets, base configuration, and equipment and instrumentation to their dynamic simulation software.”
Users taking advantage of the integration between solutions like Aspen HYSYS® and Emerson’s DeltaV™ Mimic find that the seamless integration helps them shorten project timelines and get the most out of their investments. What’s more, the ability to seamlessly work in multiple fidelities in Mimic simulation software helps teams more easily customize their simulation to their unique operations. Teams can perform high-fidelity dynamic simulation for their core processes, while more quickly and easily building out low fidelity objects at the periphery, where the granular details are less consequential.
An evolving workforce
It is also important to recognize that implementing simulation is made more complex by the dramatic shortage of experienced workers that has evolved in recent years. Today, the very people who need to train on operator simulations to improve their capabilities are often the same people who must implement those systems. As a result, choosing the right simulation software becomes even more consequential. The best dynamic simulation solutions, like Emerson’s DeltaV Mimic, offer intuitive installation and control, as well as out-of-the-box models to help users of any experience level quickly and easily set up their simulation system.
Dustin shares more insight into selecting the optimal simulation software for your organization—including specific examples of the value of flexible fidelity—in his full article over at Automation.com. Head over and check it out before you start your next project, and drive more value from your investment, from day one through the entire lifecycle.
