ONLINE PROCESS SIMULATION
SCADA/HMI/DCS VISUALIZATION INTEGRATION WITH CHEMSTATIONS’ SOFTWARE
SCADA2CC INTERFACE
Nor-Par Online A/S
1
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 stateof-art SCADA systems are compatible with Microsoft Excel.
2
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
3
SCADA/HMI/VISUALIZATION SYSTEM STRUCTURE
OPERATOR WORKSTATIONS
PLANT INFORMATION MANAGEMENT SYSTEMS PIMS
CLIENT
PROCESS
MODEL
CLIENT
ETHERNET DATA
HIGHWAY
DATA
SERVER
DATA
SERVER
FIELDBUS
OPC SERVERS
VALVES & SENSORS
PLC’S
DCS
CONTROLLER
HARDWARE
CONTROLLER
HARDWARE
CONTROLLER
HARDWARE
FIELD
DEVICES
FIELD
DEVICES
FIELD
DEVICES
4
OFFLINE DATA HANDLING
HOW DO YOU DO IT?
SCADA/HMI/
VISUALIZATION
 ANALYSIS  DECISION
DATA OVERLOAD
TIME!!!!
INADEQUATE
UNCERTAINTY
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
– Calculates parameters for process streams and equipment
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SOFTWARE STRUCTURE
Client’s
SCADA
System
CC-ReACS**
Batch Reactors
SCADA2CC*
SCADA2CCD
CHEMCAD**
Steady State
*
SCADA2CCP*
CC-POLYMER**
Polymer Reactors
*)
From Nor-Par Online A/S
**)
From Chemstations Inc.
CC-DCOLUMN**
Dynamic Column
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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
CLIENT
OPTIMIZER
PC
STEADY STATE PROCESS MODEL: CHEMCAD
Modem
Option
ETHER NET
DATA
SERVER
DYNAMIC PROCESS MODEL:
CC-REACS, CC-DCOLUMN, CC-PLMR
CONTROLLER
4
9
8
TC
3
Heat Transfer Oil
Return
5
2
7
T 49
W 13696
11
5
TC
1
10
T 49
W 45000
15
T 138
6
W 45000
T 49
W 31304
FIELD
DEVICES
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13
18
8
12
13
10
4
12
6
7
2
T 138
W 0
16
Coolant
CUSTOMER
T 138
Heat Transfer Oil
Supply
3
T 138
W 45000
1
T 300
W 13697
W 45000
11
NOR-PAR
ONLINE A/S DEALERS
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DATA FLOW and CONTROL in Excel (driven by SCADA2CCD)
CC-ReACS CC-ReACS
Reads
Writes
SYSTEM
RULES
UNIT OP
& DESCRIPTION
DATA
FORMAT
Equipment 1
REACTOR
SCADA-2-CCR Ref. Row
SCADA Ref. Row
UNIT OP
& DESCRIPTION
Common Ref. Row
Equipment 11
Reactor
Contents
Temperature
Controller
PARAMETERS CONTROLLED BY CHEMCAD
Contents
Temperature
UnitOp
Blank
Description
Data
Units
0.00
DATA
FORMAT
Data
Units
CC-ReACS
Reads
Reactor Wall Contents
Temperature Pressure
0.00
0.00
Liquid
Volume
0.00
PARAMETERS CONTROLLED BY SCADA
Contents
Controller Proportional
Temperature SP
On/Off
Band
120.00
1.00
25.00
°C
%
Integral
Time
0.00
Mins
Derivative
Time
15.00
Mins
PARAMETER CONTROLLED BY EXCEL
SCADA
Reads
SCADA
Writes
ADAPTIVE CONTROL
IF((D21-D13)<10,30,0)
SCADA
Reads
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ONLINE STEADY STATE PROCESS OPTIMIZER
PROCESS
PLANT


SCADA
SYSTEM


SCADA2CC


CHEMCAD
MODEL
C
U
ST
O
M
E
R
SCADA VISUALIZATION MIMIC
S
C
A
D
A
N
O
R
PA
R
SCADA2CC AND CHEMCAD
O
N
L
I
N
E
A
/
S
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ONLINE STEADY STATE PROCESS
4
3
7
8
7
2
6
6
5
4
5
1
3
2
22
8
12
11
28
23
10
27
13
20
11
13
9
1
10
9
ONLINE DATA
16
12
SCADA2CC
wild
15
30
33
14
14
Feed 1: BZ
INPUT
31
29
15
17
MODEL
32
18
34
controlled
MODEL
RESPONSES
ECONOMIC OPTIMIZATION
Minimum/Maximum
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STEADY STATE OR DYNAMICS
Steady State SCADA integration
Dynamic SCADA integration
 Based on Online Process Simulation
 Based on Real Time or Accelerated
Dynamic Process Simulation
principle
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
 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 CCReACS or CC-DCOLUMN or CCPOLYMER
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CONTINUOUS PROCESS DYNAMICS
2
10
8
11
12
11
9
10
09
Steady
9Dynamic
24 BZ wildSCADA visualization
BZfeed state
35
01
REAL DATA
CALC DATA
14
12
14
ONLINE DYNAMIC PRODUCTION OPTIMIZER
SCADA VISUALIZATION MIMIC
PROCESS PLANT


SCADA SYSTEM


SCADA2CCD
SCADA2CCP


CC-ReACS
CC-DCOLUMN
CC-POLYMER
C
U
S
T
O
M
E
R
S
C
A
D
A
SCADA2CCD, SCADACC2P
N
O
R
P
A
R
O
N
L
I
N
E
DYNAMIC PROCESS MODEL
4
2
3
7
T 49
W 13696
11
5
TC
1
6
10
T 49
W 45000
15
T 138
W 45000
T 49
W 31304
17
13
18
A
/
S
9
8
TC
Heat Transfer Oil
Return
5
8
12
13
10
4
12
6
7
2
T 138
W 0
16
T 138
Coolant
W 45000
11
Heat Transfer Oil
Supply
3
1
CC-REACS,
CC-DCOLUMN, CC-PLMR
T 138
W 45000
T 300
W 13697
15
REALITY TRAINING SIMULATOR
TRAINING SIMULATOR CUSTOM MIMIC
OFFLINE
PLANT
SCADA
MIMIC


SCADA2CCD
SCADA2CCP


CC-ReACS
CC-DCOLUMN
CC-POLYMER
N
O
RP
A
R
O
N
L
I
N
E
A
/
S
SCADA2CCD, SCADA2CCP
DYNAMIC PROCESS MODEL
DE
AL
ER
S
4
2
3
7
T 49
W 136
11
5
TC
1
6
10
T 49
W 45000
15
T 138
W 45000
T 49
W 31304
17
13
18
VIRTUAL
PLANT
9
8
TC
Heat Tra
Ret
5
8
12
13
10
4
12
6
7
2
T 138
W 0
16
T 138
Coolant
W 45000
11
Heat Tran
Supp
3
CC-REACS,
CC-DCOLUMN, CC-PLMR
T 138
W 45000
1
T 300
W 136
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ONLINE SIMULATION BENEFITS
INTEGRATED PRODUCTION SOLUTION
MONITORING
OPERATIONS
DATABASE
MAINTENANCE
ECONOMIC
TRAINING
HISTORY
Integration with client’s
own Production
Management System
like SAP
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MONITORING BENEFITS
CHEMCAD
“Virtual Plant”
PROCESS
MODEL
INTERFACE
SCADA2CC
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
SCADA
SYSTEM
PROCESS
PLANT
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
18
OPERATIONAL BENEFITS
CHEMCAD
“Virtual Plant”
PROCESS
MODEL
INTERFACE
SCADA2CC
SCADA
SYSTEM
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
PROCESS
PLANT
Model inaccuracy easier to detect and correct
Online optimization based on true data
Cost savings
Historical data
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MAINTENANCE BENEFITS
CHEMCAD
“Virtual Plant”
PROCESS
MODEL
INTERFACE
SCADA2CC
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
20
REALITY TRAINING BENEFITS
SCADA
Mimic
SCADA2CCD
SCADA2CCP
PROCESS
MODEL
CC-ReACS
CC-DCOLUMN
CC-POLYMER
“Virtual Plant”
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
21
ECONOMIC BENEFITS
CHEMCAD
“Virtual Plant”
PROCESS
MODEL
INTERFACE
SCADA2CC
SCADA
SYSTEM
PROCESS
PLANT
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
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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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