Simulation in the planning

Existing plants are mapped in the actual state and optimised through targeted modifications within the model (see figure 1). Thus e.g. the application of a different control strategy can lead to greater performance.

If these examinations were carried out at the real plant, it would take up a great deal of time and result in high costs. However, changes to the system can easily be made in the planning phase with the aid of the simulation model.

Figure 1: Stages of a simulation study

Early application of a simulation in the planning process often already helps with fundamental decisions at the start of a planning. A simulation model, which grows with the state of detailing and knowledge of the planning, accelerates the planning process and supports an iterative course of action in the decision-making process.

Simulation in the implementation

The simulation model serves the control programmers as a template for the generation of the plant control. The result is faster, minimal fault commissioning. A coupling of the central administration computer (decision support control computer) with the simulation model facilitates commissioning before use within the plant.
The transient behaviour can be run through in various scenarios. This is particularly important when commissioning is carried out in running operation and a smooth transition into the new plant is required.
With the aid of the model the operating personnel can be prepared for the new system and trained specifically with regard to important plant conditions.

Simulation during operation

The anticipatory test of the daily schedule of a plant gives information on required provision of personnel and resources, on order throughput times and plant utilisation. The optimisation of the sequence of production orders in the run-up to the daily operation can be verified with the aid of the simulation model.  

Of course, you do not leave the application of simulation to chance. Very specific aims form the basis for the success of a simulation study.