ONLINE%20PROCESS%20SIMULATION

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ONLINE PROCESS SIMULATION
SCADA/HMI/DCS VISUALIZATION INTEGRATION WITH
CHEMSTATIONS SOFTWARE
SCADA2CC 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

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 Intellutions FIX,
OSIs PI, and Wonderwares Intouch. All
state-of-art SCADA systems are compatible with
Microsoft Excel.
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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

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SCADA/HMI/VISUALIZATION SYSTEM STRUCTURE
OPERATOR WORKSTATIONS
PLANT INFORMATION MANAGEMENT SYSTEMS PIMS

OPC SERVERS
PLCS DCS
VALVES SENSORS
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OFFLINE DATA HANDLING
HOW DO YOU DO IT?
FLIES!!!!
TIME!!!!
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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
• CHEMCAD CC-ReACS CC-DCOLUMN CC-POLYMER
• Process modeling software in steady and
  dynamic states
• Calculates parameters for process streams and
  equipment

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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.
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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 SCADA2CCP Uses
  CC-ReACS, CC-DCOLUMN, or CC-POLYMER respectively

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SCADA2CC SYSTEM ARCHITECTURE
SCADA2CC
SCADA2CCD SCADA2CCP
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DATA FLOW and CONTROL in Excel (driven by
SCADA2CCD)
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ONLINE STEADY STATE PROCESS OPTIMIZER
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ONLINE STEADY STATE PROCESS
ONLINE DATA
SCADA2CC
MODEL
wild
controlled
MODEL RESPONSES
INPUT
ECONOMIC OPTIMIZATION
Minimum/Maximum
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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
  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

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CONTINUOUS PROCESS DYNAMICS
Dynamic
Steady
SCADA visualization
REAL DATA
CALC DATA
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ONLINE DYNAMIC PRODUCTION OPTIMIZER
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REALITY TRAINING SIMULATOR
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ONLINE SIMULATION BENEFITS
INTEGRATED PRODUCTION SOLUTION
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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,specifi
c heat Study interactions of dependent variables
Estimation of physical properties All
calculated stream properties in CHEMCAD can be
returned to Excel for analysis
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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
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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
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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
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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
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
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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

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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.
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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

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WHAT ARE THE OTHER SAVINGS?

• If you could deliver the product with better
  specifications, and every production unit could
  be better controlledWhat 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