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Nor-Par Online A/S. SCADA/HMI/DCS VISUALIZATION INTEGRATION WITH CHEMSTATIONS’ SOFTWARE. ONLINE PROCESS SIMULATION. SCADA2CC INTERFACE. All the terms below mean exactly the same thing. SCADA = S upervisory C ontrol A nd D ata A cquisition HMI = H uman- M achine I nterface

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online process simulation

Nor-Par Online A/S

SCADA/HMI/DCS VISUALIZATION INTEGRATION WITH CHEMSTATIONS’ SOFTWARE

ONLINE PROCESS SIMULATION

SCADA2CC INTERFACE

slide2

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

SCADA/HMI/Visualization/DCS console 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.

SCADA systems come from independent software houses or from DCS vendors. The most popular independent SCADA systems are Intellution’s FIX, OSI’s PI, and Wonderware’s Intouch. All state-of-art SCADA systems are compatible with Microsoft Excel.

slide3

The Online and Real-Time Process Simulationfrom Nor-Par Online A/S

  • SCADA2CC runs online process simulation driven by true production data in CHEMCAD
  • SCADA2CCD runs real-time process simulation driven by true production data in CC-ReACS and/or CC-DCOLUMN
  • SCADA2CCP runs real-time process simulation driven by true production data in CC-POLYMER and/or CC-DCOLUMN
  • You need to have a SCADA/HMI/Process Visualization/DCS console software compatible with Excel as well as respective Chemstations’ software to use the SCADA2CC/SCADA2CCD/SCADA2CCP solution
scada hmi visualization system structure

CLIENT

PROCESS

MODEL

CLIENT

ETHERNET DATA HIGHWAY

DATASERVER

DATASERVER

FIELDBUS

CONTROLLER

HARDWARE

CONTROLLER

HARDWARE

CONTROLLER

HARDWARE

FIELD

DEVICES

FIELD

DEVICES

FIELD

DEVICES

SCADA/HMI/VISUALIZATION SYSTEM STRUCTURE

OPERATOR WORKSTATIONS

PLANT INFORMATION MANAGEMENT SYSTEMS PIMS

OPC SERVERS

PLC’S

DCS

VALVES & SENSORS

offline data handling

SCADA/HMI/VISUALIZATION

ANALYSIS

 DECISION

DATA OVERLOAD

INADEQUATE

UNCERTAINTY

OFFLINE DATA HANDLING

HOW DO YOU DO IT?

TIME!!!!

FLIES!!!!

scada scada2cc chemcad
SCADA SCADA2CC  CHEMCAD
  • Supervisory Control and Data Acquisition SCADA
    • Also known as Human Machine Interface (HMI) or DCS Visualization
    • Process visualization displays process parameters in real time
    • Trend and history displays of process parameters
    • Alarm monitoring and logging
  • SCADA2CC provides ONLINE link SCADA to CHEMCAD

–Measured parameters to CHEMCAD in real time

– Calculated parameters from CHEMCAD to SCADA in real time

–Excel interface provides parameter optimization tool

–Troubleshoot with calculated and measured parameter comparison

  • CHEMCADCC-ReACSCC-DCOLUMNCC-POLYMER

– Process modeling software in steady and dynamic states

– Calculates parameters for process streams and equipment

software structure

Client’s

SCADA

System

SOFTWARE STRUCTURE

CC-ReACS**

Batch Reactors

CHEMCAD**

Steady State

SCADA2CC*

SCADA2CCD*

SCADA2CCP*

CC-POLYMER**

Polymer Reactors

CC-DCOLUMN**

Dynamic Column

*) From Nor-Par Online A/S

**) From Chemstations Inc.

software packages
Software Packages

SCADA2CC Online Process Simulation (uses CHEMCAD)

SCADA2CCD Real Time Process Simulation

SCADA-2-CCR (uses CC-ReACS)

SCADA-2-CCDC (uses CC-DCOLUMN)

SCADA2CCP Real Time Process Simulation

SCADA-2-CCDC (uses CC –DCOLUMN)

SCADA-2-CCPLMR (uses CC-POLYMER)

Reality Training Simulator

Uses either SCADA2CCD or SCADA2CCPUses CC-ReACS, CC-DCOLUMN, or CC-POLYMER respectively

scada2cc system architecture

OPTIMIZER

PC

STEADY STATE PROCESS MODEL: CHEMCAD

Modem

Option

DYNAMIC PROCESS MODEL:

CC-REACS, CC-DCOLUMN, CC-PLMR

NOR-PAR ONLINE A/S DEALERS

CUSTOMER

SCADA

CLIENT

ETHER NET

DATASERVER

CONTR-OLLER

FIELD

DEVICES

SCADA2CC SYSTEM ARCHITECTURE

SCADA2CC

SCADA2CCD

SCADA2CCP

data flow and control in excel driven by scada2ccd

CC-ReACS

Reads

CC-ReACS

Writes

CC-ReACS

Reads

SCADA

Reads

SCADA

Reads

SCADA

Writes

DATA FLOW and CONTROL in Excel(driven by SCADA2CCD)
online steady state process optimizer

CUSTOMER

SCADA

SCADA VISUALIZATION MIMIC

PROCESSPLANT



SCADA

SYSTEM



SCADA2CC AND CHEMCAD

NORPAR

ONL

I

NE

A

/

S

SCADA2CC



CHEMCAD MODEL

ONLINE STEADY STATE PROCESS OPTIMIZER
online steady state process
ONLINE STEADY STATE PROCESS

ONLINE DATA

SCADA2CC

MODEL

wild

controlled

MODEL

RESPONSES

INPUT

ECONOMIC OPTIMIZATION

Minimum/Maximum

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
  • Requiresleast effort to construct and calibrate the flowsheet
  • Ideal for economic analysis and online optimization
  • Requires CHEMCAD only
  • Can only be applied to process units between intermediate and storage tanks

Dynamic SCADA integration

  • Based on Real Time or Accelerated 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 CHEMCAD and CC-ReACS or CC-DCOLUMN or CC-POLYMER
continuous proces s dynamics
CONTINUOUS PROCESS DYNAMICS

Dynamic

Steady

SCADA visualization

REAL DATA

CALC DATA

online dynamic production optimizer

CUSTOMER

SCADA

SCADA VISUALIZATION MIMIC

PROCESSPLANT



SCADASYSTEM



NORPAR

ONL

I

NE

A

/

S

SCADA2CCD, SCADACC2P

SCADA2CCDSCADA2CCP

DYNAMIC PROCESS MODEL



CC-ReACSCC-DCOLUMNCC-POLYMER

CC-REACS, CC-DCOLUMN, CC-PLMR

ONLINE DYNAMIC PRODUCTION OPTIMIZER
reality training simulator

TRAINING SIMULATOR CUSTOM MIMIC

OFFLINE

PLANT

SCADA

MIMIC



SCADA2CCD

SCADA2CCP

SCADA2CCD, SCADA2CCP



CC-ReACSCC-DCOLUMNCC-POLYMER

VIRTUAL

PLANT

CC-REACS, CC-DCOLUMN, CC-PLMR

NORPAR

ONLINE

A/S

DEALERS

DYNAMIC PROCESS MODEL

REALITY TRAINING SIMULATOR
online simulation benefits

MONITORING

DATABASE

OPERATIONS

MAINTENANCE

ECONOMIC

Integration with client’s own Production Management System like SAP

TRAINING

HISTORY

ONLINE SIMULATION BENEFITS

INTEGRATED PRODUCTION SOLUTION

monitoring benefits

CHEMCAD

“Virtual Plant”

PROCESS MODEL

INTERFACESCADA2CC

SCADASYSTEM

PROCESSPLANT

MONITORING BENEFITS

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

operational benefits

CHEMCAD

“Virtual Plant”

PROCESS MODEL

INTERFACESCADA2CC

SCADASYSTEM

PROCESSPLANT

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

maintenance benefits

CHEMCAD

“Virtual Plant”

PROCESS MODEL

INTERFACESCADA2CC

SCADASYSTEM

PROCESSPLANT

MAINTENANCE BENEFITS

Fault diagnosis &Data reconciliation

Fouling and scaling monitoring

Condition monitoring of expensive equipmentInstrument fault diagnosisInstrument calibration frequency

Maintenance planningUse of historical data for process and mechanical maitenance planning, integrated with SAP or other Process Information Management Systems

reality training benefits
REALITY TRAINING BENEFITS

Improve production efficiency

SCADA operator interface is identical to real plant model

Operators understanding of the process enhanced

Operators can study effect of control settings

Operators 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

SCADAMimic

SCADA2CCDSCADA2CCP

PROCESS MODEL

CC-ReACSCC-DCOLUMNCC-POLYMER

“Virtual Plant”

economic benefits

CHEMCAD

“Virtual Plant”

PROCESS MODEL

INTERFACESCADA2CC

SCADASYSTEM

PROCESSPLANT

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 optimizationAdjust process to minimize production cost Optimize plant throughputsBetter control of purity, increasing the product value Better control of emissions and waste from the process, reducing environmental penalties

Sensitivity analysisSensitivity of yields to process changesSensitivity of energy usage to process changes

savings
SAVINGS

The savings that can be achieved by using the integration of 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
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 one 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 SCADA2CC has brought the client additional savings estimated to $70,000 yearly per each of aforementioned small units.

economic justification
ECONOMIC JUSTIFICATION

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 operating 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
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 qualityWhat are the savings? Ask yourself

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