ONLINE PROCESS SIMULATION

SCADA/HMI/DCS VISUALIZATION INTEGRATION WITH CHEMSTATIONS’ SOFTWARE

SCADA2CC INTERFACE

Nor-Par Online A/S

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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
Intellution’s FIX, OSI’s PI, and Wonderware’s Intouch. All state-
of-art SCADA systems are compatible with Microsoft Excel.
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 The Online and Real-Time Process
Simulation
•
from 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

CLIENT PROCESS CLIENT
MODEL

ETHERNET DATA
HIGHWAY

DATA DATA
SERVER SERVER

FIELDBUS
OPC SERVERS
PLC’S
DCS CONTROLLER CONTROLLER CONTROLLER
HARDWARE HARDWARE HARDWARE

FIELD FIELD FIELD

DEVICES DEVICES DEVICES

VALVES & SENSORS 4

 OFFLINE DATA HANDLING
HOW DO YOU DO IT?
SCADA/HMI/
VISUALIZATION  ANALYSIS  DECISION

DATA OVERLOAD INADEQUATE UNCERTAINTY

TIME!!!! FLIES!!!!
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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
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– Calculates parameters for process streams and equipment
 SOFTWARE STRUCTURE

Client’s
SCADA
System
SCADA2CC
CC-ReACS** * CHEMCAD**
Batch Reactors Steady State
SCADA2CC
D*
SCADA2CC
CC-POLYMER** CC-DCOLUMN**
Polymer Reactors
P* 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
SCADA OPTIMIZER STEADY STATE PROCESS MODEL: CHEMCAD
CLIENT PC

Modem
Option
ETHER NET

CC2 ADACS
DATA
SERVER

DYNAMIC PROCESS MODEL:

CC-REACS, CC-DCOLUMN, CC-PLMR
4 Heat Transfer Oil
CONTR- 5
Return
2 8 9

OLLER TC
3
7 T 49
W 13696
11
TC 5 6 10
1
T 49
15 W 45000
T 138
W 45000
T 49
W 31304
17
8
12 10 6
13 7 Heat Transfer Oil
18 13 12 4 3 Supply

FIELD T 138
W 0
2 1
16 T 300

DEVICES T 138
W 45000
W 13697
DCC2 ADACS
P CC2 ADACS

T 138
Coolant
W 45000
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CUSTOMER NOR-PAR ONLINE A/S DEALERS

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 DATA FLOW and CONTROL in Excel (driven by SCADA2CCD)
CC-ReACS CC-ReACS CC-ReACS
Reads Writes Reads
S YS T EM UNIT O P DAT A
P ARAM ET ERS CO NT RO LL ED BY CHEM CAD
RULES & DES CRIP T IO N F O RM AT

Eq uip m e n t 1 Co n te n ts Re a ctor W a llCo n te n ts Liq u id

REACT O R T e m p e ra ture T e m p e ra tu re P re ssu re V o lu m e
S CADA-2-CCR Re f. Ro w UnitO p
B lank
Des c ription
S CADA Re f. Row Data 0.00 0.00 0.00 0.00
Units

UNIT O P DAT A
P ARAM ET ERS CO NT RO L LED BY S CADA
& DES CRIP T IO N F O RM AT

Equ ip m e nt 11 Co n te n ts Con tro lle r P rop o rtio n a l In te g ra l De riva tive

Re a cto r T e m p e ra tu re S P O n /O ff Ba n d T im e T im e
Co m m o n Re f. Ro w Co nte n ts Data 120.00 1.00 25.00 0.00 15.00
T e m p e ra tu re Units °C % M ins M ins
Co n trolle r

P ARAM ETER CO NTRO LL ED BY EX CEL

ADAP T IV E CO NT RO L IF ((D21-D13)< 10,30,0)

SCADA
Reads

SCADA SCADA
Writes Reads 10
ONLINE STEADY STATE PROCESS
OPTIMIZER
C SCADA VISUALIZATION MIMIC
U
PROCESS ST
O
PLANT M
E

 R

S
C
SCADA A
D
SYSTEM A

N SCADA2CC AND CHEMCAD




O
R
P
A

SCADA2CC R
O
NL



I
N
E

CHEMCAD A
/
MODEL S
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ONLINE STEADY STATE PROCESS
4 7 3 6 2 5 1
Feed2: H2
8 7 6 5 4 3 2 1

22 21

28 27 26
10 23 Loss
8

11 12 13 25
19
20
24 23

11 13
9 16 19
10 29 31 33
9 14 15

Feed 1: BZ 14 16
17
15 18
12 18
30 32 34
17
20
21

Product

22

ONLINE DATA SCADA2CC MODEL

wild controlled

INPUT MODEL
RESPONSES

ECONOMIC OPTIMIZATION
Minimum/Maximum 12
 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
28 27 26
10
8
11 12 25
19
20
24

11 13
9
10 29 31 33 19
14 16
09 15
23
15
9 14 16
24 BZ wild 17 18
BZfeed state 03 04 05 06 18
12
35 34
30 32
01
20
SCADA
07

SCADA
SCADA
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Steady Dynamic SCADA visualization

REAL DATA
CALC DATA
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ONLINE DYNAMIC PRODUCTION OPTIMIZER
SCADA VISUALIZATION MIMIC
C
PROCESS PLANT U
S
T


O
M
E
R

SCADA SYSTEM S
C
A


D
A

N SCADA2CCD, SCADACC2P
O
SCADA2CCD R DYNAMIC PROCESS MODEL
P
SCADA2CCP A
2
4

8
5
9
H e a t T ra n s f e r O il
R e tu rn

R TC
3
7 T 49
W 1369 6
11



O TC
1
5
T 49
6 10

N T 13 8
15 W 4 5000

W 45 000

L T 49
W 3 1304

I
17
8
12 10

CC-ReACS
13 7 6 H e a t T ra n s fe r O il
N 18 13 12 4 3
2 1
S u p p ly

E
T 138

16 W 0 T 300
T 138

CC-DCOLUMN
W 1369 7
W 45000
T 138
C o o la n t
A W 4500 0

/
11
CC-REACS,
CC-POLYMER S CC-DCOLUMN, CC-PLMR
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 REALITY TRAINING SIMULATOR
TRAINING SIMULATOR CUSTOM MIMIC

OFFLINE
PLANT
N
SCADA O
RP
MIMIC A
R



O
N
L
I
SCADA2CCD N
E
SCADA2CCP A
SCADA2CCD, SCADA2CCP

/ DYNAMIC PROCESS MODEL




S
DE 4
5
Heat Transfer Oil
Return

AL 2
TC 7
8 9
T 49
3
ER 11
W 13696

CC-ReACS TC 5 6 10
S 1
T 49
15 W 45000
T 138

CC-DCOLUMN
W 45000
T 49
W 31304
17
8

CC-POLYMER
12 10 6
13 7 Heat Transfer Oil
18 13 12 4 3 Supply
T 138 2 1
16 W 0 T 300
T 138
W 13697
W 45000
T 138
Coolant

VIRTUAL
W 45000
11
CC-REACS,
CC-DCOLUMN, CC-PLMR
PLANT
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 ONLINE SIMULATION BENEFITS

INTEGRATED PRODUCTION SOLUTION

MONITORING

OPERATIONS
DATABASE
MAINTENANCE

ECONOMIC

TRAINING Integration with client’s

own Production
Management System
HISTORY like SAP 17
 MONITORING BENEFITS
CHEMCAD
“Virtual Plant”
Soft sensor (no instrument installed or available)
PROCESS
MODEL Component composition prediction
Prediction of inferred measurements
Estimation of unmeasured process conditions
INTERFAC
E Component concentrations in reactor
SCADA2CC
Temperature profiles in reactors and columns
SCADA Concentration profiles in the columns
SYSTEM
Heat transfer coefficients,fouling,specific heat
Study interactions of dependent variables
PROCESS Estimation of physical properties
PLANT
All calculated stream properties in CHEMCAD
can be returned to Excel for analysis
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 OPERATIONAL BENEFITS
CHEMCAD Allows calibration of process model
“Virtual Plant”
Using true data from the production
PROCESS
MODEL Calibration of process and control models
Aids prediction of optimum performance

INTERFAC Tool for speeding up troubleshooting

E
SCADA2CC Predict the onset of production problems
Identify problems from SCADA and model history
Learn to start up and shut down the plant for
SCADA increased safety
SYSTEM

Provide help for improving the process model

PROCESS
Model inaccuracy easier to detect and correct
PLANT Online optimization based on true data
Cost savings
Historical data
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 MAINTENANCE BENEFITS
CHEMCAD
“Virtual Plant”
Fault diagnosis & Data reconciliation
PROCESS
MODEL Fouling and scaling monitoring
Condition monitoring of expensive equipment
Instrument fault diagnosis
INTERFAC
E Instrument calibration frequency
SCADA2CC
Maintenance planning
SCADA
Use of historical data for process and
SYSTEM mechanical maitenance planning, integrated
with SAP or other Process Information
Management Systems
PROCESS
PLANT

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 REALITY TRAINING BENEFITS

SCADA
Improve production efficiency
Mimic SCADA operator interface is identical to real plant model
Operators understanding of the process enhanced
Operators can study effect of control settings
SCADA2CCD Operators can study parameter interactions
SCADA2CCP Downtime due to operator error reduced
Learning start-up and shutdown procedures
Consequences of operator actions to environment
PROCESS (Environmental Impact factors by WAR technology)
MODEL
Improve production safety
CC-ReACS
CC-DCOLUMN Operational plant safety improved
CC-POLYMER Learning without the consequences of risk/damage
“Virtual Plant”

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 ECONOMIC BENEFITS
Capital cost savings
CHEMCAD Infer measurements from calibrated model
“Virtual Plant” Reduced installed instrumentation
PROCESS
MODEL
Production cost savings
Economic calculations based on model
Integration with SAP system
INTERFAC
E Reducing cost on maintenance, start-up and shutdown
SCADA2CC
On-line optimization
Adjust process to minimize production cost
SCADA Optimize plant throughputs
SYSTEM Better control of purity, increasing the product value
Better control of emissions and waste from the process,
reducing environmental penalties
PROCESS
PLANT Sensitivity analysis
Sensitivity of yields to process changes
Sensitivity 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 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
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