ONLINE PROCESS SIMULATION ONLINE PROCESS SIMULATION ONLINE, - - PowerPoint PPT Presentation

1

ONLINE PROCESS SIMULATION ONLINE PROCESS SIMULATION

ONLINE, REAL-TIME AND PREDICTIVE PROCESS DATA INTEGRATION WITH CHEMSTATIONS’ SOFTWARE

Nor-Par Online A/S

PLANT2CC/PLANT2CCD INTERFACE

2

All the terms below mean exactly the same thing

• SCADA = Supervisory Control And Data Acquisition
• HMI = Human-Machine Interface
• Process Visualization software
• DCS console software
• Real Time Database (RTDB)

SCADA/HMI/Visualization/DCS console/RTDB is a class of software that presents data available at DCS (Distributed Control System) or PLC (Programmable Logic Controller) in a form that a human can understand. The plant personnel can also manipulate the settings of DCS/PLC directly from such SCADA systems, as a modern alternative to a traditional control room.

3

Samples of SCADA systems

Modern SCADA systems are all Windows-based, run on a PC, and are compatible with Microsoft Excel. RS View Rockwell Factory Link US Data Simatic WinCC Siemens Aspen Process Explorer AspenTech SCS Omron InTouch Wonderware IA Series Foxboro PI Oil Systems Inc. PHD, FiX Honeywell FiX Intellution

DCS vendor SCADA Independent SCADA

4

Online, Real-Time and Predictive Process Simulation from Nor-Par Online A/S

• PLANT2CC runs online process simulation driven by true

production data in CHEMCAD

• PLANT2CCD runs real-time and predictive process

simulation driven by true production data in CC-ReACS and/or CC-DCOLUMN

• You need to have a SCADA/HMI/Process

Visualization/DCS console/RTDB software compatible with Excel as well as respective Chemstations’ software to use the PLANT2CC/PLANT2CCD solution

What SCADA (or) HMI (or) Visualization (or) DCS Console (or) Real-Time Database does your Plant use?

Before we continue, let’s have this matter clear

☺

6

SCADA SCADA/HMI/VISUALIZATION /HMI/VISUALIZATION SYSTEM STRUCTURE SYSTEM STRUCTURE

CLIENT DATA SERVER CONTROLLER HARDWARE FIELD DEVICES CONTROLLER HARDWARE CLIENT ETHERNET DATA HIGHWAY DATA SERVER CONTROLLER HARDWARE FIELD DEVICES FIELD DEVICES FIELDBUS PROCESS MODEL

VALVES & SENSORS PLC’S DCS PLANT INFORMATION MANAGEMENT SYSTEMS PIMS OPC SERVERS OPERATOR WORKSTATIONS

7

OFFLINE DATA HANDLING OFFLINE DATA HANDLING

DATA OVERLOAD

SCADA SCADA/HMI/ /HMI/ VISUALIZATION VISUALIZATION

INADEQUATE

! !

ANALYSIS ANALYSIS

HOW DO YOU DO IT? HOW DO YOU DO IT? UNCERTAINTY

! !

DECISION DECISION

FLIES!!!! FLIES!!!! TIME!!!! TIME!!!!

8

CHEMCAD CHEMCAD The Process Simulation Engine The Process Simulation Engine

• Process models (flowsheets) are built and solved in a process
• simulator. The process simulator works as a mathematical

engine for solving mass and heat balances, fluid property and equipment parameter calculations, as well as equipment sizing

• We support the superior process simulation software from

Chemstations Inc, which is powerful, easy to use, and has the most modern integration capabilities

• CHEMCAD is Steady State process simulator. CC-ReACS,

CC-DCOLUMN and CC-POLYMER are Dynamic process simulators

9

SOFTWARE STRUCTURE SOFTWARE STRUCTURE

CC CC-

• ReACS

ReACS**

**

Batch Reactors Batch Reactors

Client’s Client’s SCADA SCADA System System

CHEMCAD CHEMCAD**

**

Steady State CC CC-

• POLYMER

POLYMER**

**

Polymer Reactors CC CC-

• DCOLUMN

DCOLUMN**

**

Dynamic Column

PLANT2CC PLANT2CC*

*

PLANT2CCD PLANT2CCD*

*

*) From Nor-Par Online A/S **) From Chemstations Inc.

10

PLANT PLANT2CC 2CC(D) (D) SYSTEM ARCHITECTURE SYSTEM ARCHITECTURE

CUSTOMER SCADA

CLIENT DATA SERVER CONTR- OLLER FIELD DEVICES ETHER NET

DYNAMIC PROCESS MODEL: CC-REACS, CC-DCOLUMN

THE PC

STEADY STATE PROCESS MODEL: CHEMCAD NOR-PAR ONLINE A/S

PLANT2CC PLANT2CCD

11

ONLINE STEADY STATE PROCESS ONLINE STEADY STATE PROCESS OPTIMIZER OPTIMIZER

PLANT2CC AND CHEMCAD

N O R P A R O N L I N E A / S C U S T O M E R S C A D A

SCADA VISUALIZATION MIMIC

PROCESS PLANT PLANT2CC CHEMCAD MODEL SCADA SYSTEM

" " ! ! " " ! ! " " ! !

12

STEADY STATE OR DYNAMICS STEADY STATE OR DYNAMICS

Steady State SCADA integration " Based on Online Process Simulation

principle, modeling the plant behavior by continuous series of steady state approximations " Requires least effort to construct and calibrate the flowsheet " Ideal for economic analysis and online

• ptimization

" Requires CHEMCAD only " Can only be applied to process units between intermediate and storage tanks

Dynamic SCADA integration

" Based on Real Time or Predictive Dynamic Process Simulation principle " Takes into account true dynamic behavior of the plant, including equipment size, accumulation, and control system unit operations " Ideal for troubleshooting, control loop tuning and real time optimization " Requires CC-ReACS or CC-DCOLUMN

13

ONLINE DYNAMIC PRODUCTION OPTIMIZER ONLINE DYNAMIC PRODUCTION OPTIMIZER

1 TC 2 3 4 5 6 7 1 2 5 6 7 8 9 10 8 10 TC 11 12 13 3 4 12 13 15 16 17 18 11

Coolant Heat Transfer Oil Supply Heat Transfer Oil Return

DYNAMIC PROCESS MODEL

PLANT2CCD SCADA VISUALIZATION MIMIC

N O R P A R O N L I N E

A / S

C U S T O M E R S C A D A CC-REACS, CC-DCOLUMN

PROCESS PLANT PLANT2CCD CC-ReACS CC-DCOLUMN SCADA SYSTEM

" " ! ! " " ! ! " " ! !

14

TRAINING TRAINING & EDUCATION & EDUCATION SIMULATOR SIMULATOR

1 TC 2 3 4 5 6 7 1 2 5 6 7 8 9 10 8 10 TC 11 12 13 3 4 12 13 15 16 17 18 11

Coolant Heat Transfer Oil Supply Heat Transfer Oil Return

N O R P A R O N L I N E A / S D E A L E R S

T & E Simulator Controller/Scenario Database

DYNAMIC PROCESS MODEL

TRAINING SIMULATOR CUSTOM MIMIC

CC-REACS, CC-DCOLUMN

T & E Simulator Controller Scenario Database CC-ReACS CC-DCOLUMN SCADA MIMIC

" " ! ! " " ! !

VIRTUAL PLANT OFFLINE PLANT

15

ONLINE SIMULATION BENEFITS ONLINE SIMULATION BENEFITS INTEGRATED PRODUCTION SOLUTION INTEGRATED PRODUCTION SOLUTION

MONITORING OPERATIONS MAINTENANCE ECONOMIC TRAINING

DATABASE

Integration with client’s

• wn Production

Management System like SAP HISTORY

16

MONITORING BENEFITS MONITORING BENEFITS

SCADA SYSTEM INTERFACE PLANT2CC PROCESS MODEL CHEMCAD “Virtual Plant” PROCESS PLANT

Soft sensor (no instrument installed or available) Component composition prediction Prediction of inferred measurements Estimation of unmeasured process conditions Component concentrations in reactor Temperature profiles in reactors and columns Concentration profiles in the columns Heat transfer coefficients,fouling,specific heat Study interactions of dependent variables Estimation of physical properties All calculated stream properties in CHEMCAD can be returned to Excel for analysis

17

OPERATIONAL BENEFITS OPERATIONAL BENEFITS

Allows calibration of process model

Using true data from the production Calibration of process and control models Aids prediction of optimum performance

Tool for speeding up troubleshooting

Predict the onset of production problems Identify problems from SCADA and model history Learn to start up and shut down the plant for increased safety

Provide help for improving the process model

Model inaccuracy easier to detect and correct Online optimization based on true data Cost savings Historical data

SCADA SYSTEM INTERFACE PLANT2CC PROCESS MODEL CHEMCAD “Virtual Plant” PROCESS PLANT

18

MAINTENANCE BENEFITS MAINTENANCE BENEFITS

SCADA SYSTEM INTERFACE PLANT2CC PROCESS MODEL CHEMCAD “Virtual Plant” PROCESS PLANT

Fault diagnosis & Data reconciliation Fouling and scaling monitoring Condition monitoring of expensive equipment Instrument fault diagnosis Instrument calibration frequency Maintenance planning Use of historical data for process and mechanical maitenance planning, integrated with SAP or other Process Information Management Systems

19

TRAINING TRAINING & EDUCATION & EDUCATION BENEFITS BENEFITS

Improve production efficiency

SCADA operator interface is identical to real plant model Engineers understanding of the process enhanced Engineers can study effect of control settings Engineers can study parameter interactions Downtime due to operator error reduced Learning start-up and shutdown procedures Consequences of operator actions to environment (Environmental Impact factors by WAR technology)

Improve production safety

Operational plant safety improved Learning without the consequences of risk/damage

SCADA Mimic T & E S Controller Scenario Database PROCESS MODEL CC-ReACS CC-DCOLUMN “Virtual Plant”

20

ECONOMIC BENEFITS ECONOMIC BENEFITS

Capital cost savings Infer measurements from calibrated model Reduced installed instrumentation Production cost savings Economic calculations based on model Integration with SAP system Reducing cost on maintenance, start-up and shutdown On-line optimization Adjust process to minimize production cost Optimize plant throughputs Better control of purity, increasing the product value Better control of emissions and waste from the process, reducing environmental penalties Sensitivity analysis Sensitivity of yields to process changes Sensitivity of energy usage to process changes

SCADA SYSTEM INTERFACE PLANT2CC PROCESS MODEL CHEMCAD “Virtual Plant” PROCESS PLANT

21

SAVINGS SAVINGS

The savings that can be achieved by using the integration

• f SCADA with Chemstations software will be result of:
• Running the plant with high quality product, less

pollution, and faster using the existing equipment

• Online optimization of the production
• Maintaining better product and production

documentation, according to FDA and other procedures/standards

• Reducing the duration and cost of start-up
• Limiting shutdowns only to planned ones
• Avoiding breakdowns and unpleasant failures
• Optimizing, calibration and tuning the control system in

short period of time

• Training operators to higher level of understanding

22

SAVINGS EXAMPLE SAVINGS EXAMPLE

We are talking about substantial savings. We have a client that makes and operates many 5 kt/y units for on-site production of Chlorine Dioxide. This is

• ne the smallest production capacities at which

continuous processes are operated. This technology was mastered by the client who had been using CHEMCAD and a SCADA system for several years. Yet, applying the PLANT2CC has brought the client additional savings estimated to $70,000 yearly per each of aforementioned small units.

23

We have understood from works we have done under secrecy agreements with some of our clients that:

• For a well operated advanced plant producing commodity

chemicals and already using SCADA systems for several years, the savings could be estimated to 1 – 1½ % of

• perating cost
• For a commodity chemical manufacturer who has just started

using SCADA systems, the savings could be at least 1½ - 3% of the operating cost

• For a large plant such as Oil Refinery already using SCADA

systems for several years, the savings could be estimated to 0.2 – 0.5% of the operating cost

• For a large plant such as Oil Refinery that has just started

with SCADA systems, the annual savings could be at least 0.5 – 0.8% of the operating cost

ECONOMIC JUSTIFICATION ECONOMIC JUSTIFICATION

24

WHAT ARE THE OTHER SAVINGS? WHAT ARE THE OTHER SAVINGS?

• If you could deliver the product with better specifications,

and every production unit could be better controlled… What are the savings? Ask yourself

• If you could quickly change to make another product with

existing equipment, especially if you need to follow the FDA rules and get the FDA acceptance… What are the savings? Ask yourself

• If you could get a large contract based on better

production planning, better documentation, and better product quality What are the savings? Ask yourself

For some it could be 50% savings, and for some 5%. We believe 10% of savings first year will return many times the investment in CHEMCAD and the SCADA integration