The proven best practice for automation system testing, including Factory Acceptance Test (FAT) and operation procedure test, is to use a dynamic simulation integrated with the off-line automation system. Using this approach, FATs can be more thorough, less costly and less dependent upon plant availability. In addition, operating procedures can be tested and proven before the plant is operational ready.
System integrators benefit from using dynamic simulation for automation system testing in the following ways:
Dynamic simulation provides excellent returns for the life cycle operation of the process plant. Also, by using dynamic simulation for capital projects, the following additional business benefits can be realized:
Process control improvements can be developed, tested, and demonstrated to operations management without affecting the operation or production of the actual plant. Users report system startup savings of weeks or even months with returns of $500,000 to $5,000,000.
Training new operators on process operations, startup/ shutdown procedures, and hazardous or infrequent process occurrences can be accomplished without affecting the running process. Process plants run well and trip less resulting in operational savings of $1,000,000 per year or greater.
Evaluating new and experienced plant operations can be done on pre-developed training scenarios. Trained operators make fewer mistakes. Avoiding process plant upsets or shutdowns can save $500,000 to $1,000,000 per incident.
Process optimization and modification studies can be done on the dynamic simulator providing the process engineers with a tool that accurately models the process dynamics not seen in steady-state design models. Advanced control strategies are tested, tuned and validated off-line reducing operational losses of $100,000 - $500,000. Evaluating new operating procedures for different conditions can result in operational savings of 1-2% or $1,000,000 to $2,000,000 per year.
Process and regulatory documentation can be developed and tested on the dynamic simulator without impacting the operation of the process. One user claimed operations savings of $1,000,000 per year by using the virtual plant for regulatory documentation development
MYNAH Technologies simulation solutions using Mimic Simulation Software provide unique value to plant operations and automation suppliers by our focus and support of the following key capabilities:
For additional information, please contact MYNAH Technologies at firstname.lastname@example.org or +1.636.728.0000.
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