online process simulation - nor-parnorpar.com/plant2cc presentation.pdf · online process...
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ONLINE PROCESS SIMULATIONONLINE PROCESS SIMULATIONONLINE, REAL-TIME AND PREDICTIVE PROCESS DATA INTEGRATION WITH CHEMSTATIONS’ SOFTWARE
Nor-Par Online A/S
PLANT2CC/PLANT2CCD INTERFACE
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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) ina form that a human can understand. The plant personnel can also manipulate the settings of DCS/PLC directly from suchSCADA systems, as a modern alternative to a traditional control room.
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Samples of SCADA systemsModern SCADA systems are all Windows-based, run on a PC, and are compatible with Microsoft Excel.
RS ViewRockwellFactory LinkUS Data
Simatic WinCCSiemensAspen Process Explorer
AspenTech
SCSOmronInTouchWonderware
IA SeriesFoxboroPIOil Systems Inc.
PHD, FiXHoneywellFiXIntellution
DCS vendor SCADAIndependent SCADA
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Online, Real-Time and Predictive Process Simulationfrom 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
WhatSCADA (or)
HMI (or)Visualization (or)DCS Console (or)
Real-Time Databasedoes your Plant use?
Before we continue, let’s have this matter clear
☺
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SCADASCADA/HMI/VISUALIZATION/HMI/VISUALIZATION SYSTEM STRUCTURESYSTEM STRUCTURE
CLIENT
DATASERVER
CONTROLLERHARDWARE
FIELDDEVICES
CONTROLLERHARDWARE
CLIENT
ETHERNET DATA HIGHWAY
DATASERVER
CONTROLLERHARDWARE
FIELDDEVICES
FIELDDEVICES
FIELDBUS
PROCESSMODEL
VALVES & SENSORS
PLC’SDCS
PLANT INFORMATION MANAGEMENT SYSTEMS PIMS
OPC SERVERS
OPERATOR WORKSTATIONS
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OFFLINE DATA HANDLINGOFFLINE DATA HANDLING
DATA OVERLOAD
SCADASCADA/HMI//HMI/VISUALIZATIONVISUALIZATION
INADEQUATE
!! ANALYSISANALYSISHOW DO YOU DO IT?HOW DO YOU DO IT?
UNCERTAINTY
!! DECISIONDECISION
FLIES!!!!FLIES!!!!TIME!!!!TIME!!!!
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CHEMCADCHEMCADThe Process Simulation EngineThe 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 fromChemstations Inc, which is powerful, easy to use, and has themost modern integration capabilities
• CHEMCAD is Steady State process simulator. CC-ReACS, CC-DCOLUMN and CC-POLYMER are Dynamic process simulators
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SOFTWARE STRUCTURESOFTWARE STRUCTURE
CCCC--ReACSReACS****
Batch ReactorsBatch Reactors
Client’sClient’sSCADASCADASystemSystem
CHEMCADCHEMCAD****
Steady State
CCCC--POLYMERPOLYMER****
Polymer ReactorsCCCC--DCOLUMNDCOLUMN****
Dynamic Column
PLANT2CCPLANT2CC**
PLANT2CCDPLANT2CCD**
*) From Nor-Par Online A/S**) From Chemstations Inc.
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PLANTPLANT2CC2CC(D)(D) SYSTEM ARCHITECTURESYSTEM ARCHITECTURE
CUSTOMER
SCADACLIENT
DATASERVER
CONTR-OLLER
FIELDDEVICES
ETHER NET
1
TC2
3
4 5
67
12
5 6
78 9
10
8 10
TC11
1213341213
15
16
17
18
11
T 300
W 13697 T 138
W 45000
T 138
W 0
T 49
W 45000
T 49
W 13696
T 49
W 31304
T 138
W 45000
T 138
W 45000
Coolant
Heat Transfer Oil Supply
Heat Transfer Oil Return
DYNAMIC PROCESS MODEL:CC-REACS, CC-DCOLUMN
THE PC STEADY STATE PROCESS MODEL: CHEMCAD
NOR-PAR ONLINE A/S
PLA
NT2
CC
PLA
NT2
CC
D
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ONLINE STEADY STATE PROCESS ONLINE STEADY STATE PROCESS OPTIMIZEROPTIMIZER
PLANT2CC AND CHEMCADNORPARONLINEA/S
CUSTOMER
SCADA
SCADA VISUALIZATION MIMIC
PROCESSPLANT
PLANT2CC
CHEMCAD MODEL
SCADASYSTEM
""!!""!!
""!!
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STEADY STATE OR DYNAMICSSTEADY STATE OR DYNAMICSSteady State SCADA integration
" Based on Online Process Simulation principle, modeling the plant behaviorby continuous series of steady state approximations
" Requires least 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 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 orCC-DCOLUMN
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ONLINE DYNAMIC PRODUCTION OPTIMIZER ONLINE DYNAMIC PRODUCTION OPTIMIZER
1
TC2
3
4 5
67
12
5 6
78 9
10
8 10
TC11
1213341213
15
16
17
18
11
T 300
W 13697 T 138
W 45000
T 138
W 0
T 49
W 45000
T 49
W 13696
T 49
W 31304
T 138
W 45000
T 138
W 45000
Coolant
Heat Transfer Oil Supply
Heat Transfer Oil Return
DYNAMIC PROCESS MODEL
PLANT2CCD
SCADA VISUALIZATION MIMIC
NORPARONLINEA/S
CUSTOMER
SCADA
CC-REACS, CC-DCOLUMN
PROCESS PLANT
PLANT2CCD
CC-ReACSCC-DCOLUMN
SCADA SYSTEM
""!!""!!
""!!
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TRAININGTRAINING & EDUCATION& EDUCATION SIMULATORSIMULATOR
1
TC2
3
4 5
67
12
5 6
78 9
10
8 10
TC11
1213341213
15
16
17
18
11
T 300
W 13697 T 138
W 45000
T 138
W 0
T 49
W 45000
T 49
W 13696
T 49
W 31304
T 138
W 45000
T 138
W 45000
Coolant
Heat Transfer Oil Supply
Heat Transfer Oil Return
NORPARONLINEA/SDEALERS
T & E Simulator Controller/Scenario Database
DYNAMIC PROCESS MODEL
TRAINING SIMULATOR CUSTOM MIMIC
CC-REACS, CC-DCOLUMN
T & E SimulatorController
Scenario Database
CC-ReACSCC-DCOLUMN
SCADAMIMIC
""!!""!!
VIRTUALPLANT
OFFLINEPLANT
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ONLINE SIMULATION BENEFITSONLINE SIMULATION BENEFITS
INTEGRATED PRODUCTION SOLUTIONINTEGRATED PRODUCTION SOLUTION
MONITORING
OPERATIONS
MAINTENANCE
ECONOMIC
TRAINING
DATABASE
Integration with client’s own Production Management System like SAPHISTORY
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MONITORING BENEFITS MONITORING BENEFITS
SCADASYSTEM
INTERFACEPLANT2CC
PROCESS MODEL
CHEMCAD“Virtual Plant”
PROCESSPLANT
Soft sensor (no instrument installed or available)Component composition predictionPrediction of inferred measurements
Estimation of unmeasured process conditionsComponent concentrations in reactorTemperature profiles in reactors and columns
Concentration profiles in the columnsHeat transfer coefficients,fouling,specific heatStudy interactions of dependent variables
Estimation of physical propertiesAll calculated stream properties in CHEMCAD can be returned to Excel for analysis
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OPERATIONAL BENEFITSOPERATIONAL BENEFITSAllows calibration of process modelUsing true data from the productionCalibration of process and control modelsAids prediction of optimum performance
Tool for speeding up troubleshootingPredict the onset of production problemsIdentify problems from SCADA and model historyLearn to start up and shut down the plant for increased safety
Provide help for improving the process modelModel inaccuracy easier to detect and correctOnline optimization based on true dataCost savingsHistorical data
SCADASYSTEM
INTERFACEPLANT2CC
PROCESS MODEL
CHEMCAD“Virtual Plant”
PROCESSPLANT
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MAINTENANCE BENEFITSMAINTENANCE BENEFITS
SCADASYSTEM
INTERFACEPLANT2CC
PROCESS MODEL
CHEMCAD“Virtual Plant”
PROCESSPLANT
Fault diagnosis & Data reconciliationFouling and scaling monitoringCondition 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
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TRAININGTRAINING & EDUCATION & EDUCATION BENEFITS BENEFITS
Improve production efficiencySCADA operator interface is identical to real plant modelEngineers understanding of the process enhancedEngineers can study effect of control settingsEngineers can study parameter interactionsDowntime due to operator error reducedLearning start-up and shutdown proceduresConsequences of operator actions to environment(Environmental Impact factors by WAR technology)Improve production safety
Operational plant safety improvedLearning without the consequences of risk/damage
SCADAMimic
T & E S ControllerScenario Database
PROCESS MODEL
CC-ReACSCC-DCOLUMN“Virtual Plant”
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ECONOMIC BENEFITSECONOMIC BENEFITSCapital cost savingsInfer measurements from calibrated modelReduced installed instrumentation
Production cost savingsEconomic calculations based on modelIntegration with SAP systemReducing 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
SCADASYSTEM
INTERFACEPLANT2CC
PROCESS MODEL
CHEMCAD“Virtual Plant”
PROCESSPLANT
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SAVINGSSAVINGSThe 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
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SAVINGS EXAMPLESAVINGS 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 PLANT2CC has brought the client additional savings estimated to $70,000 yearly per each of aforementioned small units.
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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 least0.5 – 0.8% of the operating cost
ECONOMIC JUSTIFICATIONECONOMIC JUSTIFICATION
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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 return many times the investment in CHEMCAD and the SCADA integration