Kongsberg Digital  

K-Spice® - Process and Control Design Verification allows continuous simulations to run throughout project development and operational phases, enabling process and control design verification.

As your project progresses from concept phase through to commissioning, available technical information increases and the simulator functionality evolves in parallel.

The typical engineering and design phase starts with a steady-state simulation model for heat and mass balance, followed by a more detailed dynamic process simulator. The sooner the dynamic process model is built, the sooner it can be used to improve and validate process and control system design.

K-SPICE® DESIGN – FOR EARLY ISSUE DETECTION
Avoid costly re-engineering and start-up delays through three verification and test areas:

DESIGN VERIFICATION
Increase the understanding of process interactions and dynamics, and develop and verify process design, including HAZOP analysis cases.

CONTROL PHILOSOPHY VERIFICATION
Develop and verify basic control and advanced process control strategies.

SAFETY ANALYSIS
Test how the process will behave during a process shutdown.

The dynamic process model is connected to and controlled by an identical copy of the Integrated Control and Safety System (ICSS) used for the specific plant. It will familiarize the operators in how to use the Operator Station interface together with the operational procedures. The system can monitor any value or status in the model and give or take away points based on a defined range. It grades the order in which actions are done making it useful for procedure validation. K-Spice® Train can also set malfunctions based on time or trigger events defined in the training scenario.

• Includes integrated subsea and topsides models
• Process startup
• Process familiarization
• Emergency response training
• Control system training
• Refresher course
• Assessment evaluation tool (Exercise Manager)

UNIFY PEOPLE, DATA AND KNOWLEDGE

Get new possibilities for design validation processes, cross-team collaboration, workflow execution, data unification, and sophisticated simulation capabilities. From upstream to downstream, Kognitwin empowers a wide range of energy facilities to drive successful digitalization and move towards more autonomous operations.

BECOME AN ENERGY EXPERT

Gain full insight into facility assets, unlocking the potential for remote training, data capture, net-zero emissions reporting, and optimized operations. Our industrial work surface helps customers visualize and contextualize operations digitally from any location, at any time, so that anyone in the team can become an energy expert.

BREAK DOWN DATA SILOS

A digital twin helps break down operational and project silos to provide a single source of information by ingesting, cleaning, integrating, and contextualizing data in one place.  Now users can connect information from several sources and take informed data-driven decisions.

• Advanced thermal modelling: Accurate information determined during stratified flow and blow down conditions.  Buried pipe models provide heat conduction from the inner surface of the pipe to the exterior surface of the soil for estimating corrosion rates and pipe-wall temperatures.
• Slug flow modelling: Slug Capturing® is the first commercially available solution to accurately predict hydrodynamic slug behavior without user input, capturing the initiation and growth of waves and hydrodynamic slugs.
• Model validation: Extensively validated against the most comprehensive experimental data sets to ensure that the models are as representative as possible.
• Latest technology: 3D visualization makes understanding of the multiphase flow easier and includes a comprehensive relational database.  Links seamlessly to the K-Spice® Dynamic Process Simulator for unrivalled Integrated Simulation

By utilizing high fidelity thermodynamics and physics models based on first principles, K-Spice® Analyze can continuously give you deep insight into how your process equipment should be performing. Comparing simulated against actual measurements, K-Spice Analyze® enables you to trend increasing deviations over time, allowing for advanced maintenance optimization based on performance decline. K-Spice® Analyze also provides detailed information about the current state of the monitored equipment enabling the possibility to run optimization studies for the current operating limitations. All required measurements will be fed into the K-Spice® Analyze system either from plant measured data or calculated data from the K-Spice® Match model if the plant transmitter is missing or has failed. Current supported equipment for performance monitoring:

• Centrifugal Compressor
• Centrifugal Pump
• Displacement Pump
• Heat Exchanger
• Control/Choke valves
• Transmitter

• Includes all features of K-Spice® Design, our dynamic engineering process simulator
• Includes dynamic well/pipe modules, that work seamlessly with process equipment such as Slug Catchers, Separators, Pumps, Compressors and more.
• Work either on stand-alone process studies OR combined multiphase pipelines + process studies
• Compressor studies
• Chemical injection studies
• Water hammer studies
• Well operations studies (including ESP)
• Closed loop gas lift studies
• Slugging effects on topsides studies
• Production startup studies
• Control philosophy studies
• Slugging related instabilities in process pipe

Access to the data and a current dynamic model assist in decision support, avoiding potential problems and contributing to your operation’s optimal production and performance. In addition to the real-time model these systems provide a look-ahead mode, where it is possible to predict what will happen in the future with the present operation, and a planning mode, where the operators can plan future operations:

• 24/7 flow assurance model that is always in-sync with the field conditions
• Automatically monitors and returns feedback on future problems
• Plans future operations
• Smart Applications to meet operational challenges:
• Hydrate/wax formation margin prediction
• Cool down time monitoring
• Slug/pig tracking
• Chemical injection monitoring
• Holdup monitoring
• Corrosion/erosion monitoring
• Leak monitoring
• Composition tracking

Allows models to be built using minimal data at an early stage in a project for early design analysis, which can then be developed in stages as data becomes available, into a high-fidelity representation of the production facility.

• Development and verification of process design and ICSS control strategies
• Support HAZOP studies
• Equipment sizing and specification
• Analysis of compressor system design
• Load balancing
• Sensitivity to process disturbances and upsets
• Development and verification of the operational procedures
• Test how the process will behave during a process shutdown
• Verify that the shutdown logic protects the process
• Test the ability to reset all active shutdowns and start up the process after complete process shutdown
• Detailed testing of all causes and effects
• Investigate integrity of safety systems

This is a major improvement compared to traditional methods, where a process model must be run manually to match a specific condition. With K- Spice® Match, the model is connected to the real plant, and follows the status of reality at all times. This makes it possible to create an initial condition for your model at any time, and you can start your study or training session with fresh conditions. The process model following the real plant operation provides confidence to the process engineer.

• Replicate the plant status and behavior
• Validate simulator model
• Data comparison
• Initialize “what-if” simulations, optimize simulations and training simulator sessions
• Perform incident re-runs
• Distribution of initial conditions and complete models backups
• Share simulation cases and models
• Effective maintenance of the simulator model

By utilizing both machine learning and dynamic physical models it provides an extremely fast and robust solution. This gives a unique insight into how the system performs and allows the user to see how the system performs during transient situations. It is a supplement to advanced multiphase flow meters and can also be an alternative. The dynamic model used in K-Spice Meter is synchronized in real time using control signals from the field, e.g. when a valve is opened in the field, the same valve will open in the model. The machine learning model will be based on transmitter values and choke positions which will provide accurate flows for the 3 phases.

• Reliable subsea multiphase metering per well based on high fidelity flow assurance model
• Detection of gas or water breakthrough in the wells
• An alternative to physical subsea meters which are typically very expensive and unreliable
• Installation and maintenance of such systems is much simpler than for physical meters

Solution is unique in terms of full integration towards the electrical equipment driving the process equipment, giving a high fidelity electromechanical power model driving the high fidelity process equipment. The total package yields a complete sandbox environment for full validation / verification and energy optimization.

• Fully integrated with the high fidelity process model enabling a complete system for energy optimization both in terms of energy usage and flaring
• Can be integrated towards any DCS vendor
• Retrofit capable – The K-Spice® Power Model is an easy add on to your already existing simulator
• Supports direct integration with NetSim where gas turbines is modelled at the highest accuracy in the market
• Enable realistic testing of Micronet Fuel Control logic against SAS in one environment
• Startup power evaluation of Direct On-Line machines
• Adds insight into how power surges or voltage dips affect the stability of the process
• Evaluate and optimize load shedding strategies