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CPC Dynamic Simulator

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9 views17 pages

CPC Dynamic Simulator

Uploaded by

ahcene
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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DYNAMIC SIMULATIONS

CPCC LOOP REACTOR TECHNOLOGY OPTIONS

Purpose

Applications of Dynamic Simulations for CPCC Loop Reactor


Technology

Date Chevron Phillips Chemical Company LP Slide No.


Dynamic Simulation Applications

Operator Training Simulators

Engineering Studies

Date Chevron Phillips Chemical Company LP Slide No.


Operator Training Simulators
Advantages (New Plants)
Train Operators for Plant Startup and Commissioning.
Capture Best Operation Practices Acquired by
Extensive Operating and Design Knowledge
Identify Design or Process Operating Constraints
During Early Phases of the Project.
Check Plant Design
Test Control Schemes

Date Chevron Phillips Chemical Company LP Slide No.


Accurate Dynamic Plant Model
Increases Familiarity
Realistic Plant
with Plant Safety Systems
Response
Satisfies OSHA
1910 Regulations Risk Free Training

Reduces Startup Wide Range of


Training Time & Cost Operation

Extends Knowledge Consistent &


of Plant Repeatable Exercises

Extends Real Plant Automated Training


Experience & Certification

Date Chevron Phillips Chemical Company LP Slide No.


Operator Training Simulators
Advantages (Existing Plants)
Train New Operators.
Refresher Training for Operator Certification.
Improve Standard Operating Procedures for Plant.
Capture Best Operation Practices Acquired by
Extensive Operating and Design Knowledge

Date Chevron Phillips Chemical Company LP Slide No.


Effect of Practice on Operator Skill

100
Operator Skill Level

80
60 Without Practice
40 With Practice

20
0
0 2 4 6 8 10
Time on Job

Date Chevron Phillips Chemical Company LP Slide No.


Operator Training Simulators
Types & Applications
Generic Models
Standardized Models for Critical Unit Operation Training.
(Cost: <= $200K)
Custom Models
Customised Models for Technology Specific Training.
(Cost: = $400K to $900K)
PC Interface Based - Process Training.
DCS Interface Based - Process & DCS Training.
Date Chevron Phillips Chemical Company LP Slide No.
Operator Training Simulators
Comparison - Custom Models

PC Based Interface DCS Based Interface

Lower Cost Higher Cost (125% to 140%)


Higher Portability & Mobility Lower Portability and Mobility
Shorter Delivery Time (8 to 12 weeks) Longer Delivery Time (16 to 20 weeks)

Generic Look and Feel True DCS Look and Feel


Low DCS Functionality Uses Same Functionality
Useful for Process Training Only Process Training + DCS Training
(True Plant Training)

Date Chevron Phillips Chemical Company LP Slide No.


OTS - Typical Architecture
DCS-like Trainee
DCS Controls Emulator Consoles
Optional
Simulation
Computer

System/Logging
Instructor Station/ Printer
Engineer Console
Hosts
- Simulation Platform
- Dynamic Model
- Trips & Interlocks
- Instructor Functions
- Simulator Controls
- Model/DCS Interface
Hosts
- Operator graphics
- Operator keyboard

Date Chevron Phillips Chemical Company LP Slide No.


Date Chevron Phillips Chemical Company LP Slide No.
Date Chevron Phillips Chemical Company LP Slide No.
Dynamic Simulation for Engineering Studies

Derived from Steady State Models.


Developed Using Aspentech Software.
More Rigorous Models.
Uses CPCC Proprietary Property Packages.

Date Chevron Phillips Chemical Company LP Slide No.


 Uses of Dynamic Simulation for Engineering
Studies
 Better Designs Leading to Lower Capital Costs
and Safer Plant Designs.
 Improved Plant Operations Leading to Lower
Operating Costs

Date Chevron Phillips Chemical Company LP Slide No.


Dynamic Simulation for Engineering Studies
Case Studies:
Dynamic Modeling of Polyethylene Reactor.
Reactor Cooling System Debottleneck Study.
Flare Load Dynamic Simulation.
Dynamic Simulation for Plant Operability Analysis.

Date Chevron Phillips Chemical Company LP Slide No.


Conclusions
 Operator Training Simulators
 Generic Models: Useful for Specific Unit
Operations like Distillation Column, Compressor,
Reactor etc.
 Custom Model: Useful for Process Technology
Training.
 Process Trainers: Low Cost Process Training
Simulators
 DCS Based Interface: Process and DCS Training
Simulators for Complete Plant Training.
 Choose Process Trainers with Upgrade Feature to OTS
Date Chevron Phillips Chemical Company LP Slide No.
BENEFITS OF SIMULATOR FOR POLYMED

POLYMED OPERATING COSTS


KILL – If the operator kills the reactor when not needed, it
will result in approx. 18 hours of lost production. Typically
the profit on PE is about 3 cents (US $) per lb.

For Polymed’s average production, 18 hours of lost


production is valued at:
16,883 x 2.2046 x $0.03 x 76 DA = 1,527,500 DA
kg/hr lb/kg lb US $ = US $ 20,100

Date Chevron Phillips Chemical Company LP Slide No.


BENEFITS OF SIMULATOR FOR POLYMED

POLYMED OPERATING COSTS


PLUGGED RX – If the operator plugs the reactor needlessly,
it will result in approx. 3 weeks of lost production. Typically
the profit on PE is about 3 cents (US $) per lb.
For Polymed’s average production, 3 weeks of lost
production is valued at:
3 weeks x 7 days x 24 hrs x 16,883 x 2.2046 x $0.03 x 76 DA
weeks day kg/hr kg/lb lb US $
= 42,770,500 DA
= US $ 562,800

Date Chevron Phillips Chemical Company LP Slide No.

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