nor-par press info 26nov2007• time saving and understand-able reports for management some...

Nor-Par a.s The Company that Cares

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Who is Nor-Par? Nor-Par a.s – The Company that Cares (www.norpar.com) is a pro-vider of advanced process simula-tion solutions and software for oil & gas, oil refining, petrochemical, chemical, power, pharmaceutical and specialty process industries. Nor-Par Online A/S is our own software developer company. Nor-Par specializes in delivering true Blue-Print model of your plant’s performance that you can run in your PC. The steady state and dynamic process & control models will be calibrated together with your peo-ple, so you can use it and the models can be changed. Your people will know how to work with the model. It gives you the freedom of modifications. The Blue-Print model is the basis for:

Production Improvement & Optimisation System

Training Simulator Online Process Simulation.

The engine is CHEMCAD and CC-DYNAMICS that are also applied in daily work at plants and engineering companies by hundreds of users.

Nor-Par provides advanced process modelling services and software, in-cluding detailed reactor studies. Nor-Par are experts in applying proc-ess simulation and software to multi-phase pipeline fluid flow including heat transfer, extremely long pipelines, slug flow and waxing handling, which is es-pecially important in the oil & gas in-dustry. Nor-Par is a provider of software and solutions for transient fluid flow (PIPENET), for piping stress analysis (TRIFLEX) and several other technical programs. Nor-Par Online has been acting as software integrator since year 2000. We specialise in vertical and horizontal integration of software systems and so-lution, involving STEP, integration with Control Systems, Historian/SAP. Nor-Par a distributor and an OEM for Chemstations in the process simulation area. Dun & Bradstreed granted Nor-Par with the AAA diploma (the highest credit ranking) in all years 2002-2007.

Table of Contents Process 2

Blue-Print model of plant’s own performance ................ 2 Production Improvement & Optimisation System .......... 3 Training Simulator........................................................... 4 Online Process Simulation ............................................. 5 Integration of Process & Control in Blue-Print models... 6 The Engine ..................................................................... 7 Freedom.......................................................................... 8 Fluid Flow Modelling in CHEMCAD .............................. 9 Horizontal and Vertical System Integration.................... 9

Mechanical Design and Analysis Software 10 TRIFLEX Windows ......................................................... 10

Fluid Flow Software 11 PIPENET from Sunrise Systems Ltd.............................. 11

Credibility and Stability 12 Contact information ........................................................ 12


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Process Blue-Print model of plant’s own performance Nor-Par builds process and control models that match the performance of an operating plant as perfectly as possible with steady state and dy-namic process simulation. Calibrat-ing the model parameters together with the client gives top accurate rendering of the plant behaviour right in your PC.

By running the Blue-Print model of the plant, you can test – in your computer – all your ideas of what you would like to do to with your plant without physical field tests. In a chemical plant, reactors are the most critical object. They are one of the major sources of the manufac-turer’s earning and are very sensi-tive to operating parameters. They are also the most difficult to model. Nor-Par has long-time expertise in modelling reaction systems, involv-ing fast and runaway reactions as well heterogeneous and multi-phase systems. The detailed reactor mod-els play vital role in Blue-Print mod-els of plant’s own performance. Blue-Print models of plant’s per-formance are open to the user (con-trary to “black-box” solutions that only the developer understands and

can change.) The Blue-Print models are developed by Nor-Par in close cooperation with you. You take part in the calibration of the model pa-rameters so you fully understand and trust the model. Blue-Print models are the basis for

Production Improvement & Optimi-sation System, Training Simulator and Online Process Simulation. The same models can be used in R&D and Engineering departments of the plant as well, or they can be passed

to the external engineering company that you work with. Blue-Print models use CHEMCAD and CC-DYNAMICS as the Engine. Benefits from using Blue-Print model of plant’s own performance:

Deep insight into the true nature

of the plant operation, which is very important for all members of the plant’s personnel

Identification of the parameters of the technology that adversely or positively affect the process performance

Finding the room for economical optimisation of the plant, in-crease of yield, product quality, production throughput, energy saving and product documenta-tion

A flowsheet for a part of the plant never tells you the true story; only Blue-Print model of the entire plant gives all an-swers that you need

Identification of interaction be-tween different process equip-ment

Possibility to study emergency situations and the ways to han-dle break-downs or avoiding them

Analysis of performance of the cooling systems, for example in situation of fouling of heat ex-changers

Analysis of trajectories between two stationary states and calcu-lation of the time needed for it

Basis for Production Improve-ment & Optimisation System

Basis for Training Simulator Basis for Online Process Simu-

lation Use in the Production, R&D and

Engineering

A part of the Blue-Print model of plant’s own performance in CC-DYNAMICS


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Production Improvement & Optimisation System The Blue-Print model of plant’s own performance is complex, because it must reflect true operation of a tech-nology. By just using the core Blue-Print model, it might not be obvious to the plant engineer what kind of improvements could be achieved at the plant The Production Improvement & Op-timisation System is “human inter-face” between the Blue-Print model and the engineer, making the model comprehensive and easy to operate by members of the plant personnel. The Production Improvement & Op-timisation System is custom analysis solution and software, developed by Nor-Par for each client and together with each client to fully address the unique demands and specifics of the customer. Nor-Par together with the client build “What-If” database that lets the users test their concepts and ideas of improvements to the plant performance right in the PC that result in economical and technical optimisation of the plant’s perform-ance.. The Production Improvement & Op-timisation System can run the Blue-Print model in acceleration of 2-20

times with regard to real time, which allows seeing the near future conse-quences of modifications to the plant. The acceleration makes it possible to run many analyses in short time. Benefits from using the Production Improvement & Optimisation System are:

All benefits of the Blue-Print model as described before are now easily accessible without necessity of advanced training

"What-if" studies can be run to analyse the effect of multiple process parameters on the plant performance

The user will identify the equip-ment that needs modifications by studying the plant perform-ance under varying set of proc-ess conditions

Studies of interaction and per-formance of control loops

Studies of performance of criti-cal equipment (reactors, distilla-tion columns)

All adjustable parameters (process & control) are visible at a glance in the User Interface and can be modified by the user

All calculated process parame-ters are visible in the User Inter-face

• Time saving and understand-able reports for management

Some businesses such as specialty chemical batch producers need to develop new product and put it in the production fast, using their standard equipment. The Production Im-provement & Optimisation System allows them to replace a great deal of the product development and production scale-up right in the PC, reducing the cost of de-velopment and need for field tests.

Comprehensive interface for running optimisation and "What-If" studies that provides clear reports for the plant management


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Training Simulator The Training Simulator from Nor-Par is the novelty concept of an Operator Training System. Unlike many other operator training systems that are based on simplified and closed “black-box” models, Nor-Par’s Training Simulator is based on the Blue-Print model of the plant’s own performance that truly reflects your own production. CHEMCAD and CC-DYNAMICS is the engine for the Blue-Print model. Since the Blue-Print model has been developed in close cooperation with you, and you have taken part in the model calibration, you know the model and trust it. Together we can keep the Blue-Print model updated with the ongoing changes in your technology, so the model will always stay current with the reality of your production. The Nor-Par’s Training Simulator works on client-server basis. The Blue-Print model of plant’s own performance works on the server, while a group of trainees operate on the ”plant” at the remote stations using the familiar DCS-console or SCADA interface, similar to the one used by the plant’s Control Room. Unplanned and planned events as defined by the client are stored in

the Malfunction Database that is built together with the client accord-ing to precise safety and operational procedures of the client. The client can modify the contents of the Mal-function database as needed. The Nor-Par’s Training Simulator has the Predictive Simulation capa-bility, allowing training of operators in 2-20 times acceleration with re-gard to real time. Often, emergency events that are perceived as very fast due to confusion in the control

room are in fact slower than they appear. Training the operators in the accelerated mode lets them learn more cases during one session. It also allows the operators predict and observe the consequence of their actions in near future faster.

Benefits from using the Nor-Par’s Training Simulator:

It is based on the Blue-Print model of your own current pro-duction, the model that you know, understand and trust; it is not a general “black-box” model. It is not a model of a single process-equipment such as a compressor or a distillation column; the model reflects your entire process plant.

Perfect training of operators in pursuit of high operational ex-cellence by greatly enhanced understanding of the true nature of the technology by the train-ees

Preventing loosing the opera-tional skills

Downtime due to operator’s error reduced; operational plant safety improved

Learning start-up and shutdown procedures

Consequences of operator’s action to environment and to the plant’s economy can be demon-strated

Learning without consequences of risk/damage

A part of graphics interface of a Training Simulator


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Online Process Simulation Online Process Simulation means the integration between the DCS or SCADA or Historian systems of real operating plant and the Blue-Print model of plant’s own performance. It is realized by PLANT2CC and PLANT2CCD software and solutions from Nor-Par, running CHEMCAD and CC-DYNAMICS as the engine. The integration of the Blue-Print model with your systems can be done by a variety of mechanisms, for example, via OPC, OLE or Excel. The Blue-Print model of the plant’s own performance is updated with trusted process and control data from DCS/SCADA/Historian and it provides your systems with synchro-nous update of the information that cannot be physically measured but only be achieved by process simula-tion. Online Process Simulation can pro-vide data that no instrument can measure (for example, heat transfer coefficient at the wall or a reactor; or coke deposit thickness on the inner surface of a tube; or current flooding condition of a distillation column; or thermal efficiency of the entire plant). It will give you process values for plant locations where placing an

instrument is physically impossible of difficult. It will replace the functionality of instruments that are normally not placed in the plant due to high cost. It will reduce the number of expen-sive laboratory analyses. And Online Process Simulation will give you a calculation of current process economics.

The benefits from applying Online Process Simulation are:

Ideal for technologies out-sourced by you to your custom-ers and operated by you from central control office

Surveillance (monitoring) of performance of critical and ex-pensive process equipment (e.g., reactors, pyrolysis fur-naces, large compressors, distil-

lation towers) and better/more accurate control

Online steady state or dynamic process optimization: better control of purity and higher yield; better control of emissions and waste from the plant (re-duced environmental penalties)

Estimation of unmeasured process conditions (soft-sensors)

Fault diagnosis and data recon-ciliation

Capital cost savings (reduced installed instrumentation by use of software sensors)

Production cost savings: o Smarter operation o Economic calculations based on

the model o Significant reducing the amount

of expensive laboratory tests o Integration with DCS, SCADA,

Historian/SAP

Structure of Online Process Simulation


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Integration of Process & Con-trol in Blue-Print models

The only way to get the Blue-Print model of true plant performance leads through integrating the opera-tion of the process and control sub-systems

Nor-Par* has the necessary experi-ence and skill to integrate process and control models and has done such integrations. To full and realis-tically model the control subsystem, Nor-Par can write relevant part of the control code and integrate it with the Blue-Print model. The specialty control code is written by Nor-Par based on unique equations from the client to reflect the unique Control System of the client. This includes Advanced Process Control (APC).

Process & Control integration give you the following benefits:

Since the real world is dynamic, the Blue-Print model gives the closest representation of the operation of a producing plant available with state-of-art simu-lation tool. It is “no compromise” way of modelling, taking into account the size of the equip-ment and the performance of the control system

Possibility to analyse detailed performance of the plant on technical level including the in-

teraction with the Control Sys-tem. This detail of information is necessary for real optimisation of the process to improve the process economics

Guidelines to improve the per-formance of the control loops (valve capacity, controllable area, sensitivity, interaction)

*) In project-cooperation with PID AB, the leading Swedish proc-ess automation company

Small portion of a specialized controller algorithm in C++ language

Intelligent Control Interface to the Integrated System

Custom screen for a specialised controller


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The Engine The Engine for the Blue-Print model of plant’s own performance, Produc-tion Improvement & Optimisation System and Online Process Simula-tion are CHEMCAD and CC-DYNAMICS from Chemstations Inc. For ultimate simulation of heat ex-changers, CC-THERM can be added to the engine pack.

CHEMCAD and CC-DYNAMICS have been chosen due to:

Completely integrated system sharing most of features of CHEMCAD with CC-DYNAMICS and CC-THERM:

o Physical properties o Thermodynamics o Electrolytes o Solids o Crude Oil Database o Specialty models such as

Amine or Glycol Dehydration o DIERS calculation of Relief De-

vices o WAR environmental calcula-

tions by EPA o Equipment sizing o Mass transfer in distillation and

absorption

o Reaction kinetics o Process economics o Sensitivity studies and Opti-

mizer o And hundreds of other vital fea-

tures delivered as standard with the program

True Heat Exchanger simulation model based on the physical geometry of the unit – for pin-point accuracy of the Blue-Print model of plant’s own perform-ance

Full pressure profile for entire plant

Detailed two-phase/heat trans-fer fluid flow in piping networks

Advanced Application Pro-grammer’s Interface based on object technology, making the integration with external applica-tions easy, fast and efficient

Strong integration with Microsoft Excel. OPC protocol for com-munication with DCS/PLC sys-tems built in. STEP compliance

User-Added Components, Thermodynamics, Equipment models, Fluid Flow models as well as own Reaction Kinetic models of the user

Possibility for you and Nor-Par to build new own Unit Opera-tions or to interface CHEMCAD with specialty programs for unit operations that you already have

Wide base of users and popu-larity of the program in the mar-ket

Convenient, flexible and afford-able licensing scheme

CC-DYNAMICS is one of easiest to use dynamic process simulators:

Made easy to use by an aver-age engineer

CC-DYNAMICS is perfectly integrated with CHEMCAD-Steady State, so you can start the dynamic simulation from steady state solution.

CC-DYNAMICS is perfectly integrated with CC-THERM, so you can use the “true heat ex-changer “ model inside dynamic simulation for pin-point accuracy

The DIERS relief device calcu-lation in Dynamics gives you true performance of relief valves and rupture discs under real process upset conditions

This is what you can use CC-DYNAMICS for:

Determining transition time from one steady state to an-other: In many situations, you need to know how much time is needed for the plant to reach steady state after change in op-erating parameters. CC-DYNAMICS allows building a realistic model of the plant, tak-ing into account equipment vol-

umes, accumulation and hold-ups, thermal mass of the equipment, etc. You can easily create the dynamic model start-ing from steady state flowsheet (that is, from CHEMCAD flow-sheet). In the beginning of the dynamic simulation, you define the change in operating pa-rameters and then analyze the response of the plant and then you find the time necessary to reach the next steady state.

Batch, semi-batch and un-steady processes: Let us take as an example straight-run dis-tillation from a kettle. You may ask: “How long time will it take to evaporate 50% of the batch? How much heat will be neces-sary? What will be the composi-tion of the product and the resi-due? Can I do it with my exist-ing equipment?” CC-DYNAMICS will not only give you clear answers to these questions. It will also tell you whether the process is feasible given existing equipment and availability of heating and cool-ing media. You will even get the answer how existing piping and control valves could limit the process and affect the neces-sary time of the batch or semi batch operation. Combined with piping elements of CHEMCAD and CC-THERM heat ex-changer capability, You will be


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able to assess the performance of real technology.

Process safety assessment; safety procedures: CC-DYNAMICS has, among others BREA and DVSL unit operation. BREA can be treated either as a vessel reactor or a vessel with complete heat exchange sub-system (jackets, coils, and agi-tator). DVSL is somewhat sim-pler model of a dynamic vessel. Both BREA and DVSL have built in as a standard feature DIERS technology. DIERS al-lows you automatic and precise calculation of performance of safety relief valve and/or rupture disc. During dynamic calcula-tions, you can also simulate dif-ferent malfunctions and break-downs; this way you are able to define safety procedures and test safety systems (such as in-terlocks). Note: CC-DYNAMICS includes elements of control systems.

Operating procedures: It is possible to run numerous “what-if” studies in CC-DYNAMICS. Since CC-DYNAMICS deals with the real model of the plant, you can work out operating pro-cedures for the plant based on results of your “what-if” studies. This also includes start-up and shutdown procedures.

Batch distillation: CC-DYNAMICS has all features necessary to accurately simu-late batch and semi-batch distil-lation. (No problem to simulate real continuous distillation, ei-ther.)

Emissions from vessels and

“vessel breathing”: Using CC-DYNAMICS, you can accurately determine emissions of volatile components (e.g. VOC = Vola-tile Organic Compounds) to at-

mosphere, which occur during the vessel filling-up/emptying cycles. This also includes emis-sions occurring from “vessel breathing”.

Heating and cooling in ves-sels: CC-DYNAMICS allows you calculating the process of

heating and cooling in vessels. Process Automation and Con-

trol: CC-DYNAMICS has all necessary tools for simulation of interaction of control systems

(DCS and PLC) with the proc-ess.

Freedom The development of Blue-Print models of plant’s own performance, Production Improvement & Optimi-sation System and Online Process Simulation is always done in close cooperation with you. You take part in the calibration of the model pa-rameters. You receive perfect train-ing on the Blue-Print model of plant’s own performance and solu-tions such as Production Improve-ment & Optimisation System or Training Simulator or Online Process Simulation. You therefore trust the model, you know how to operate it and together we can modify the so-lutions in the future. Nor-Par gives you the freedom of modification. Once the solutions and software have been implemented by Nor-Par working hand in hand with you, you can do the changes your-self under supervision of Nor-Par.


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Fluid Flow Modelling in CHEMCAD By long-term working with customers in oil & gas business, Nor-Par ac-quired expertise in advanced fluid flow modelling. To extend standard capabilities of CHEMCAD and CHEMCAD Dynamics, Nor-Par has built libraries and own modules for two-phase fluid flow in piping, slug flow and waxing. Today, our own development combined with the strength of the Chemstations’ soft-ware, allows us and our users relia-bly model:

Two-phase flow in pipelines and piping networks

Simulation of fluid flow in ex-tremely long (for example sub-marine) pipelines

Detailed heat transfer between the pipeline and the ambient (air, water, seawater, soil), in-cluding multiple insulation layers

Profiles of any fluid property along the pipeline

Slug flow handling Waxing handling Hydrate handling Flaring

Horizontal and Vertical System Integration The software and solutions from Nor-Par easily fit into vertical and horizontal scheme of systems pre-sent at a manufacturing plant. Our software and solutions support modern communication protocols such as OPC, OLE and STEP.

Nor-Par Online has been expert of integration with SCADA and Histo-rian systems from its origin in year 2000. We support integration with Historian/SAP. The system integra-tion includes Control Systems of the plant together with Advanced Process Control (APC).

Vertical integration of solutions from Nor-Par


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Mechanical Design and Analysis Software TRIFLEX Windows Nor-Par also takes cares of the me-chanical software market. We pro-vide TRIFLEX from PipingSolutions Inc, which is static and dynamic pip-ing stress analysis software. TRIFLEX is de facto industry stan-dard program in the Norwegian and Danish oil & gas industry. It is also very popular in the power engineer-ing market. The strengths of TRIFLEX are:

Finite Element Method static and dynamic pipe stress analy-sis

Broad range of piping codes for Code Compliance, including ASME B31 (1, 3, 4, 5, 8, Class 2 and 3); all Norwegian, Danish and Swedish codes; Russian and Polish code; UK standard, offshore and FRP piping codes; CODETI and EuroNorm 13480-3

Piping and structural steel data-bases

FRP/GRP pipes, wind loads, buoyancy, soil interaction

Response Spectrum Analysis and Time History Analysis for Dynamics

Nozzle calculation by WRC 107/207

Perfect 3-D graphics Interfaces with 3-D CAD sys-

tems Built-in capability for creating

isometric Making its own Stress Isometric

drawings Interface with PIPENET Tran-

sient


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Fluid Flow Software PIPENET from Sunrise Sys-tems Ltd.

PIPENET Spray/Sprinkler

For clients designing and analysing fire protection networks, Nor-Par provides PIPENET Spray/Sprinkler.

PIPENET Transient For applications such as fire protec-tion networks, submarine and cross-country pipelines, loading systems, offshore water injection systems, for power plants, District Heating net-works and all industries experiencing transient fluid flow problems, Nor-Par recommends PIPENET Tran-sient.

PIPENET Transient is integrated with TRIFLEX Dynamic, to use the forces occurring during transient fluid flow in the dynamic piping stress calculation package.

PIPENET Standard Nor-Par also delivers PIPENET Standard, which is design and analysis software for very large utility piping networks. PIPENET is made by Sunrise Sys-tems Ltd, Cambridge, UK.

Trans-mountain oil pipeline model in PIPENET Transient

Firewater ringmain network at oil refinery, PIPENET Spray


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Credibility and Stability

Nor-Par a.s – formerly an engineer-ing company established in 1959 – became the software provider in early 1990's Nor-Par Online A/S is our own soft-ware developer, making Production Improvement & Optimisation Sys-tem, Training Simulator and PLANT2CC / PLANT2CCD as well as integration between different software systems. Dun & Bradstreed granted Nor-Par with the AAA diploma (the highest credit ranking) in all years 2002-2007 This proves our credibility and stability that not many can boast with.

Contact information Nor-Par a.s Nordstrandveien 76 N-1164 Oslo Norway Phone: +47 22 28 69 00 Fax: +47 22 28 69 81 e-mail: [email protected] WWW: www.norpar.com

nor-par press info 26nov2007• time saving and understand-able reports for management some...

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