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 = 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.
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
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
SCADA/HMI/VISUALIZATION ANALYSIS DECISION DATA OVERLOAD INADEQUATE UNCERTAINTY OFFLINE DATA HANDLING HOW DO YOU DO IT? TIME!!!! FLIES!!!!
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
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 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
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
CC-ReACS Reads CC-ReACS Writes CC-ReACS Reads SCADA Reads SCADA Reads SCADA Writes DATA FLOW and CONTROL in Excel(driven by SCADA2CCD)
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 DATA SCADA2CC MODEL wild controlled MODEL RESPONSES INPUT ECONOMIC OPTIMIZATION Minimum/Maximum
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 PROCESS DYNAMICS Dynamic Steady SCADA visualization REAL DATA CALC DATA
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
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
MONITORING DATABASE OPERATIONS MAINTENANCE ECONOMIC Integration with client’s own Production Management System like SAP TRAINING HISTORY ONLINE SIMULATION BENEFITS INTEGRATED PRODUCTION SOLUTION
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
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
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 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”
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 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 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 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? • 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