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1、Shadow Plant Simulation forBasell Spheripol Polymers Polibrasil selected the Basell Spheripol process to expand polypropylene production capacity at their facilities. A critical component of their startup strategy was to establish a comprehensive Operator Training Program to help prepare their plant
2、 assets for safe and profitable operation. Honeywell and Basell Work Together to Develop Operator Training Solutions The unique business relationship between Basell and Honeywell provides the opportunity to mutually promote comprehensive training solutions in the market of Basells corporate producer
3、s and external licensees of Spheripol process technology. Past customers include multiple locations for ExxonMobil Chemical and TVK in Hungary. Shadow Plant Simulation Suitability forSpheripol TechnologyBasell provided their proprietary Spheripol technology as dynamic components in Shadow Plants sim
4、ulation engine. The dynamic behavior of the Spheripol reactor has been confirmed by actual plant data captured with information systems in more than 10 Basell plants for various process/equipment configurations, feedstocks and polymer products. These results confirm Shadow Plants suitability for of
5、equipment performance, control strategies and operating scenarios during detailed plant design. As a visualization tool, Shadow Plant models help engineers make better decisions by seeing future behavior of plant assets prior to initial operations. This establishes a formal management of change proc
6、ess for evaluating, improving and confirming readiness of plant assets for safe operation. This also ensures trainees are presented with realistic behavior preparing them for operation. Basell Process Knowledge Embedded in Shadow Plant TimeReactorSolid(%)ReactorThermalLoadPlant DataShadow Plant Data
7、Plant DataShadow Plant DataShadow Plant Dynamic ResponseCompared with Actual Plant Data名师资料总结 - - -精品资料欢迎下载 - - - - - - - - - - - - - - - - - - 名师精心整理 - - - - - - - 第 1 页，共 3 页 - - - - - - - - - Shadow Plant Simulation for Basell Spheripol Polymers2 The Solution The Honeywell Shadow Plant System is
8、a dynamic simulator specifically designed for training operators and maintenance personnel in the process industries. Besides meeting training requirements, the simulation is also ideally suited for other uses, such as validation of plant design, verification of control configuration and testing of
9、what if scenarios by engineers and operators. The simulator is customized to exactly replicate the actual plant and operate effectively in real time for single or multiple units of considerable size and complexity. Based on Windows XP, the software is unmatched in plant replication accuracy. The int
10、uitive Shadow Plant interface is designed to easily run simulation sequences, trigger process upsets, monitor the process and document performance. With its open design, users can also build, tune and update the simulation model and perform diagnostic actions through controlled access to the simulat
11、or. Shadow Plant delivers realism so accurate it is hard to tell the difference between the simulation and the real plant. Results?The start-up procedure was agreed upon with the Basell start-up team so that they could ensure that the entire sequence was perfectly understood and could be repeated ma
12、ny times by board operators prior to the actual plant start-up. ?Basells start-up team committed fewer people to the site for a shorter period of time than usual. ?Basell started the Gas Phase Reactor in a very short period after the HOMO start-up. Basell was running at nominal throughput since the
13、second month of operation. ?Introduced Operators to the complex inter-relationships between the process controls and interlock system. ?Opportunities were identified to optimize operating procedures and control configuration prior to operation. ?Operators were prepared and confident that they could
14、respond appropriately to abnormal situations. Benefits Operator Security - Operators came from a plant that used PLCs and pneumatic controllers only and they easily adapted to the dynamics of a Distributed Control System. Operator Learning - The customized control system helped Operators learn about
15、 new interlock systems being introduced in their plant. Improved Start-Up - Polibrasil prepared for startup while achieving nominal production rates months ahead of schedule with fewer people assigned to the startup team.Predictive Behavior - Non-intuitive plant behavior shown on the simulator was c
16、onfirmed in the real world. Efficient Plant Operations- The plant operated closer to constraints, reducing operating costs, maximizing plant availability and improved product quality. Shadow Plant Integration with Existing Applications Shadow Plant is also integrated with the Experion? Process Knowl
17、edge System (PKS). It makes use of Honeywell s regulatory and safety management products providing a foundation to build advanced applications (like Profit? Suite) and information systems. In doing this, the training simulator is well suited to serve as a build and runtime environment for automation
18、 system development enabling a management of change process allowing control system engineers to evaluate and enhance system configurations in the lab prior to plant migration. SummaryHoneywell s Shadow Plant System and lifecycle work practice helped Polibrasil prepare for startup while achieving no
19、minal production rates months ahead of schedule with fewer people assigned to the startup team. Shadow Plant played a very important role in this successful start-up, which was better than the customers best expectations Shadow Plant? and Profit? are registered trademarks and Experion? is a trademar
20、k of Honeywell International. 名师资料总结 - - -精品资料欢迎下载 - - - - - - - - - - - - - - - - - - 名师精心整理 - - - - - - - 第 2 页，共 3 页 - - - - - - - - - Shadow Plant Simulation for Basell Spheripol Polymers3 Experion PKS ServerHoneywell ICONOperator ConsolePlant NetworkShadow Plant Instructor StationShadow Plant F
21、ieldOperator StationShadow PlantEngineering StationExperion PKS Sim-C200Experion PKSSim-C200Experion PKSSim-C200C200C200C200C200ServerServerC200C200FSCFSCShadow Plant is founded on the Experion Process Knowledge System . For More Information To learn more about how Honeywells Shadow Plant System can
22、 improve your people performance, visit our Web site or contact your Honeywell account manager. Honeywell Process Solutions 2500 Union Hills Dr. Phoenix, AZ 85027 Tel: 1.877.466.3993 SS-04-111-ENG November 2004 Printed in USA ? 2004 Honeywell International Inc. 名师资料总结 - - -精品资料欢迎下载 - - - - - - - - - - - - - - - - - - 名师精心整理 - - - - - - - 第 3 页，共 3 页 - - - - - - - - -