ONLINE PROCESS SIMULATION

Transcription

1 ONLINE PROCESS SIMULATION ONLINE, REAL-TIME AND PREDICTIVE PROCESS DATA INTEGRATION WITH CHEMSTATIONS SOFTWARE PLANT2CC/PLANT2CCD INTERFACE Nor-Par Online A/S 1

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. 2

3 Samples of SCADA systems Modern SCADA systems are all Windows-based, run on a PC, and are compatible with Microsoft Excel. Independent SCADA DCS vendor SCADA Intellution FiX Honeywell PHD, FiX Oil Systems Inc. PI Foxboro IA Series Wonderware InTouch Omron SCS AspenTech Aspen Process Explorer Siemens Simatic WinCC US Data Factory Link Rockwell RS View 3

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 4

5 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/HMI/VISUALIZATION SYSTEM STRUCTURE OPERATOR WORKSTATIONS PLANT INFORMATION MANAGEMENT SYSTEMS PIMS CLIENT PROCESS MODEL CLIENT ETHERNET DATA HIGHWAY DATA SERVER DATA SERVER OPC SERVERS PLC S DCS CONTROLLER HARDWARE FIELDBUS CONTROLLER HARDWARE CONTROLLER HARDWARE FIELD DEVICES FIELD DEVICES FIELD DEVICES VALVES & SENSORS 6

7 SCADA/HMI/ VISUALIZATION OFFLINE DATA HANDLING HOW DO YOU DO IT?! ANALYSIS! DECISION DATA OVERLOAD INADEQUATE UNCERTAINTY TIME!!!! FLIES!!!! 7

8 CHEMCAD 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 8

9 SOFTWARE STRUCTURE Client s SCADA System CC-ReACS ** Batch Reactors CC-POLYMER ** Polymer Reactors PLANT2CC * PLANT2CCD * CHEMCAD ** Steady State CC-DCOLUMN ** Dynamic Column *) From Nor-Par Online A/S **) From Chemstations Inc. 9

10 PLANT2CC 2CC(D) SYSTEM ARCHITECTURE SCADA CLIENT THE PC STEADY STATE PROCESS MODEL: CHEMCAD ETHER NET PLANT2CC DATA SERVER DYNAMIC PROCESS MODEL: CC-REACS, CC-DCOLUMN CONTR- OLLER FIELD DEVICES PLANT2CCD T 138 W TC 13 Coolant T 138 W T 138 W 0 4 T TC 5 6 W T W T 49 W Heat Transfer Oil Return T 49 W Heat Transfer Oil Supply T 300 W CUSTOMER NOR-PAR ONLINE A/S 10

11 ONLINE STEADY STATE PROCESS OPTIMIZER PROCESS PLANT! " C U S T O M E R SCADA VISUALIZATION MIMIC SCADA SYSTEM S C A D A! PLANT2CC! " " CHEMCAD MODEL N O R P A R O N L I N E A / S PLANT2CC AND CHEMCAD 11

12 STEADY STATE OR DYNAMICS Steady State SCADA integration Dynamic 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 optimization " Requires CHEMCAD only " Can only be applied to process units between intermediate and storage tanks " 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 12

13 ONLINE DYNAMIC PRODUCTION OPTIMIZER PROCESS PLANT "! SCADA SYSTEM "! C U S T O M E R S C A D A SCADA VISUALIZATION MIMIC PLANT2CCD! " CC-ReACS CC-DCOLUMN N O R P A R O N L I N E A / S 18 T 138 W TC Coolant T T 138 W 0 W TC 5 6 T 49 W PLANT2CCD DYNAMIC PROCESS MODEL T W T 49 W CC-REACS, CC-DCOLUMN 1 Heat Transfer Oil Return T 49 W Heat Transfer Oil Supply T 300 W

14 TRAINING & EDUCATION SIMULATOR TRAINING SIMULATOR CUSTOM MIMIC OFFLINE PLANT SCADA MIMIC! T & E Simulator Controller Scenario Database! " " CC-ReACS CC-DCOLUMN N O R P A R O N L I N E A / S D E A L E R S T 138 W T & E Simulator Controller/Scenario Database DYNAMIC PROCESS MODEL 11 TC T TC T 49 W T 49 W Heat Transfer Oil Return T 49 W Heat Transfer Oil Supply VIRTUAL PLANT Coolant T 138 W 0 W T 138 W CC-REACS, CC-DCOLUMN T 300 W

15 ONLINE SIMULATION BENEFITS INTEGRATED PRODUCTION SOLUTION MONITORING OPERATIONS MAINTENANCE DATABASE ECONOMIC TRAINING HISTORY Integration with client s own Production Management System like SAP 15

16 CHEMCAD Virtual Plant PROCESS MODEL INTERFACE PLANT2CC SCADA SYSTEM PROCESS PLANT 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 16

17 OPERATIONAL BENEFITS CHEMCAD Virtual Plant PROCESS MODEL INTERFACE PLANT2CC SCADA SYSTEM PROCESS PLANT 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 17

18 MAINTENANCE BENEFITS CHEMCAD Virtual Plant PROCESS MODEL INTERFACE PLANT2CC SCADA SYSTEM 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 18

19 TRAINING & EDUCATION BENEFITS SCADA Mimic T & E S Controller Scenario Database PROCESS MODEL CC-ReACS CC-DCOLUMN Virtual Plant 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 19

20 CHEMCAD Virtual Plant PROCESS MODEL INTERFACE PLANT2CC SCADA SYSTEM PROCESS PLANT 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 20

21 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 21

22 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 PLANT2CC has brought the client additional savings estimated to $70,000 yearly per each of aforementioned small units. 22

23 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 % 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 % of the operating cost 23

24 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 24