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ONLINE PROCESS SIMULATIONONLINE PROCESS SIMULATION

Nor-Par Online A/S

SCADA2CC INTERFACE

SCADA/HMI/DCS VISUALIZATION INTEGRATION WITH CHEMSTATIONS’ SOFTWARE

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• SCADA = Supervisory Control And Data Acquisition• HMI = Human-Machine Interface• Process Visualization software

• DCS console software

All the terms below mean exactly the same thing

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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• 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

The Online and Real-Time Process Simulation

from Nor-Par Online A/S

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SCADASCADA/HMI/VISUALIZATION/HMI/VISUALIZATION SYSTEM STRUCTURE SYSTEM STRUCTURE

CLIENT

DATASERVER

CONTROLLERHARDWARE

FIELDDEVICES

CONTROLLERHARDWARE

CLIENT

ETHERNET DATA HIGHWAY

DATASERVER

CONTROLLERHARDWARE

FIELDDEVICES

FIELDDEVICES

FIELDBUS

PROCESSMODEL

VALVES & SENSORS

PLC’SDCS

OPERATOR WORKSTATIONS PLANT INFORMATION MANAGEMENT SYSTEMS PIMS

OPC SERVERS

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OFFLINE DATA HANDLINGOFFLINE DATA HANDLING

DATA OVERLOAD

SCADASCADA/HMI//HMI/VISUALIZATIONVISUALIZATION

INADEQUATE

ANALYSISANALYSIS

UNCERTAINTY

DECISIONDECISION

FLIES!!!!FLIES!!!!TIME!!!!TIME!!!!

HOW DO YOU DO IT?HOW DO YOU DO IT?

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SCADA SCADA SCADA2CC SCADA2CC CHEMCAD 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 STRUCTURESOFTWARE STRUCTURE

CC-ReACSCC-ReACS****

Batch ReactorsBatch ReactorsCHEMCADCHEMCAD****

Steady State

CC-POLYMERCC-POLYMER****

Polymer ReactorsCC-DCOLUMNCC-DCOLUMN****

Dynamic Column

SCADASCADA2C2CCC**

SCADA2CSCADA2CCDCD**

SCADA2CSCADA2CCPCP**

Client’sClient’sSCADASCADASystemSystem

*) From Nor-Par Online A/S

**) From Chemstations Inc.

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Software PackagesSCADA2CC 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 ARCHITECTURESCADA2CC SYSTEM ARCHITECTURE

CUSTOMER

SCADA

CLIENT

DATASERVER

CONTR-OLLER

FIELDDEVICES

ETHER NET

1

TC

2

3

45

67

12

5 6

78 9

10

8 10

TC

11

1213341213

15

16

17

18

11

T 300

W 13697 T 138

W 45000

T 138

W 0

T 49

W 45000

T 49

W 13696

T 49

W 31304

T 138

W 45000

T 138

W 45000

Coolant

Heat Transfer Oil Supply

Heat Transfer Oil Return

DYNAMIC PROCESS MODEL:CC-REACS, CC-DCOLUMN, CC-PLMR

OPTIMIZERPC

STEADY STATE PROCESS MODEL: CHEMCAD

NOR-PAR ONLINE A/S DEALERS

ModemOption

SC

AD

A2C

C

SC

AD

A2C

CD

SC

AD

A2C

CP

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DATA FLOW and CONTROL in ExcelDATA FLOW and CONTROL in Excel (driven by SCADA2CCD)(driven by SCADA2CCD)

SYSTEM UNIT OP DATARULES & DESCRIPTION FORMAT

Equipment 1 Contents Reactor Wall Contents LiquidREACTOR Temperature Temperature Pressure Volume

SCADA-2-CCR Ref. Row UnitOpBlank

DescriptionSCADA Ref. Row Data 0.00 0.00 0.00 0.00

Units

UNIT OP DATA& DESCRIPTION FORMAT

Equipment 11 Contents Controller Proportional Integral DerivativeReactor Temperature SP On/Off Band Time Time

Common Ref. Row Contents Data 120.00 1.00 25.00 0.00 15.00Temperature Units °C % Mins Mins

Controller

PARAMETER CONTROLLED BY EXCEL

IF((D21-D13)<10,30,0)ADAPTIVE CONTROL

PARAMETERS CONTROLLED BY CHEMCAD

PARAMETERS CONTROLLED BY SCADA

CC-ReACSWrites

SCADAReads

SCADAWrites

CC-ReACSReads

CC-ReACSReads

SCADAReads

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ONLINE STEADY STATE PROCESS ONLINE STEADY STATE PROCESS OPTIMIZEROPTIMIZER

PROCESSPLANT

SCADA2CC

CHEMCAD MODEL

SCADASYSTEM

SCADA2CC AND CHEMCADNORPAR

ONLINE

A/S

CU

STOMER

SCADA

SCADA VISUALIZATION MIMIC

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ONLINE STEADY STATE PROCESSONLINE STEADY STATE PROCESS

ONLINE DATA SCADA2CC MODEL

INPUT

wild

MODELRESPONSES

controlled

ECONOMIC OPTIMIZATIONMinimum/Maximum

1234 567

8

12345678

9

10

910

11

11 13

16

17

18

19

20

2122

23

12 13

19

2021

22

2324

25

262728

12

14

15

29

30

14

16

31

32

15

1718

33

34

Product

Feed2: H2

Feed 1: BZ

Loss

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STEADY STATE OR DYNAMICSSTEADY 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 PROCESCONTINUOUS PROCESSS DYNAMICS DYNAMICS

Steady Dynamic SCADA visualization

REAL DATA

CALC DATA

8

9

10

10

11 13

19

20 24

25

262728

12

1415

29

30

14

16

31

32

15

17

33

34

249

35BZfeed state

16

18

18

19

22

23

01

03 04 05 06

20

07

09

BZ wild

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SCADA

SCADA SCADA

12

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ONLINE DYNAMIC PRODUCTION OPTIMIZER ONLINE DYNAMIC PRODUCTION OPTIMIZER

PROCESS PLANT

SCADA2CCDSCADA2CCP

CC-ReACSCC-DCOLUMNCC-POLYMER

SCADA SYSTEM

1

TC

2

3

45

67

12

5 6

78 9

10

8 10

TC

11

1213341213

15

16

17

18

11

T 300

W 13697 T 138

W 45000

T 138

W 0

T 49

W 45000

T 49

W 13696

T 49

W 31304

T 138

W 45000

T 138

W 45000

Coolant

Heat Transfer Oil Supply

Heat Transfer Oil Return

DYNAMIC PROCESS MODEL

SCADA2CCD, SCADACC2P

SCADA VISUALIZATION MIMIC

NORPAR

ONLINE

A/S

CUSTOMER

SCADA

CC-REACS, CC-DCOLUMN, CC-PLMR

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REALITY TRAINING SIMULATORREALITY TRAINING SIMULATOR

1

TC

2

3

45

67

12

5 6

78 9

10

8 10

TC

11

1213341213

15

16

17

18

11

T 300

W 13697 T 138

W 45000

T 138

W 0

T 49

W 45000

T 49

W 13696

T 49

W 31304

T 138

W 45000

T 138

W 45000

Coolant

Heat Transfer Oil Supply

Heat Transfer Oil Return

SCADA2CCDSCADA2CCP

CC-ReACSCC-DCOLUMNCC-POLYMER

SCADAMIMIC

VIRTUALPLANT

OFFLINEPLANT

NO

RPAR

ONLINE

A/S

DEALERS

SCADA2CCD, SCADA2CCP

DYNAMIC PROCESS MODEL

TRAINING SIMULATOR CUSTOM MIMIC

CC-REACS, CC-DCOLUMN, CC-PLMR

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ONLINE SIMULATION BENEFITSONLINE SIMULATION BENEFITS

INTEGRATED PRODUCTION SOLUTIONINTEGRATED PRODUCTION SOLUTION

MONITORING

OPERATIONS

MAINTENANCE

ECONOMIC

TRAINING

DATABASE

Integration with client’s own Production Management System like SAPHISTORY

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MONITORING BENEFITS MONITORING BENEFITS Soft sensor (no instrument installed or available)

Component composition predictionPrediction 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

SCADASYSTEM

INTERFACE

SCADA2CC

PROCESS MODEL

CHEMCAD“Virtual Plant”

PROCESSPLANT

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OPERATIONAL BENEFITSOPERATIONAL 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 troubleshootingPredict the onset of production problemsIdentify problems from SCADA and model historyLearn 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 dataCost savingsHistorical data

SCADASYSTEM

INTERFACE

SCADA2CC

PROCESS MODEL

CHEMCAD“Virtual Plant”

PROCESSPLANT

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MAINTENANCE BENEFITSMAINTENANCE BENEFITS

SCADASYSTEM

INTERFACE

SCADA2CC

PROCESS MODEL

CHEMCAD“Virtual Plant”

PROCESSPLANT

Fault diagnosis & Data reconciliationFouling and scaling monitoringCondition 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 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 BENEFITSECONOMIC BENEFITSCapital cost savingsInfer measurements from calibrated modelReduced installed instrumentation

Production cost savingsEconomic calculations based on modelIntegration with SAP systemReducing 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

SCADASYSTEM

INTERFACE

SCADA2CC

PROCESS MODEL

CHEMCAD“Virtual Plant”

PROCESSPLANT

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SAVINGSSAVINGS

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

The savings that can be achieved by using the integration of SCADA with Chemstations software will be result of:

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SAVINGS EXAMPLESAVINGS 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 JUSTIFICATIONECONOMIC JUSTIFICATIONWe 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?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 return many times the investment in CHEMCAD and the SCADA integration