Ethylene Cracker: SCADA - Essay Example

Ethylene Cracker Name Institution Date Ethylene Cracker SCADA SCADA is a system that operates with coded signals over the communication channels with an aim of controlling remote equipment. In the ethylene cracker gas plant, SCADA plays a significant role in controlling the industrial processes (Godwin, et al, 2013). When designing the SCADA system for an ethylene cracker gas plant, an appropriate platform is chosen to support different features. A resolution of 1280 by 800 is appropriate for the gas plant and is usually considered during the design. It is also important to note that the resolution is readily available in the market and hence making the design process easy. The type of features to be included is also important during the design process. This is considering that the ethylene cracker gas plant requires a lot of features in order to control the system. The drivers and OPC options should be well selected for the purposes of ensuring that it can be supported by PLC system. The SCADA system design of the ethylene gas plant crackers enables the operators to use the computer to monitor different operations and activities at the plant (Bagaria, et al, 2011). The capacity of the plant should therefore be considered during the design process. This is because the process leads to the automation of the plant. Different devices are usually used in the SCADA system for the ethylene cracker gas plants. A complete SCADA system must be composed of sensors communication equipment, controllers, human machine interfaces, software and hardware. source In an ethylene cracker gas plant, the devices are usually connected to a complex system for the purposes of automation. Flow meters with pulse outputs are usually required for the purposes of carrying out the automation process. Other devices that are required include a one flow switch, temperature transmitter, conductivity and PH transmitters (Carcano, et al, 2011). The devices play an important role in providing the digital signal which is required for monitoring the operations at the plant. The information is usually displayed on a computer for the purposes of ensuring that the processes are controlled automatically. The use of the devices also enables the operators to measure accurately, monitor, display and data log different parameters in real time and hence enabling the automation process to be carried out. Citect SCADA software is usually used for the purpose of controlling the different processes. This software is usually used since it supports the third party PLCs. Cicode is the programming language that is usually used by Citect SCADA software. The programming language is similar to Pascal programming language and hence its effectiveness when using windows. The software is also convenient as it can communicate directly with different programmable electronic devices. It also has the ability to have new drivers written when required. The software also plays an important role in indicating the state of equipment and hence its effectiveness in monitoring the ethylene cracker gas plant (Matsui, et al, 2014). Indicating the state of equipment is important in terms of ensuring that the gas plant can be monitored effectively. The SCADA system usually deploys multiple technologies that are useful in the ethylene crackers gas plant. The multiple technologies play an important role in ensuring that different parameters can be monitored. The system allows for access to real time data anywhere in the world and hence improving on the decision making process (Baliga, et al, 2013). The efficiencies of the ethylene gas crackers can be improved through the use of SCADA. It is also important to note that it can be successfully incorporated in the existing system and hence eliminating the need of a complete overhaul o the existing system. It also plays a significant role in terms of yielding high results while at the same time minimizing on the costs. Through the use of SCADA, it is possible to make data driven decisions which are useful in ensuring that the operations at the plant are efficient and effective. This is also considering that the data can be accessed in real time. All the processes are usually controlled during the production of ethylene which plays an important role in controlling the required capacity. The use of technology is also important in controlling the amount that is required and hence ensuring that the required amounts can be produced. The use of SCADA in the ethylene crackers gas plant is also useful in ensuring that the capacity of the furnace is well designed in order to meet the production process (Devold, 2013). The standards of IT are also raised when using the system and hence ensuring that efficiency is achieved at all time during the production process. HMI HMI is the human machine interface and it is useful in the ethylene crackers gas plant for the purposes of carrying out the monitoring process. The human machine interface usually involves a peripheral hardware for input and output (Qi & Li, 2013). In the Ethylene cracker gas plant, the human machine interface usually handles the human machine interactions and hence ensuring that the monitoring process is carried out effectively. The ethylene cracker gas plant is a complex system and it is usually computerized. A good design plays an important role in making the interaction process intuitive and hence impacting positively on the monitoring process. This is also considering that a feedback has to be provided by the HMI. The design consists of different stages which includes interaction, specification, interface software specification and prototyping. The interaction involves the process of determining the general functionality. It is also useful in determining the number of functions that will be controlled by the interface. It is also important to consider the concepts of the operator feedback during the design process. The feedback is useful in providing information and hence facilitating the interaction (Tian & Li, 2013). This is also considering that the effectiveness and efficiency is usually determined by the feedback that is obtained. In an ethylene cracker gas plant, feedback is usually required in order to determine the appropriate action that should be carried out. The actions can also be carried out automatically through the use of the computer which is also part of the system. The design of an ethylene cracker gas plant must ensure that it is able to meet the quality assurance standards. In an ethylene cracker gas plant, various devices are required for the purposes of ensuring that the interaction is successful. Software and hardware are among the devices that are required during the interaction process (Pandey & Rangaiah, 2013). The hardware includes the computer, membrane switches, rubber keypads or touch screens. The touch screen is modern and it enables the interaction to take place via touch. The hardware is usually composed of different aspects of the ethylene cracker gas plant. Schneider electric device model is useful in the Human machine interface in the ethylene cracker gas plant. Due to the nature of the activities at the ethylene cracker gas plants, the HMI must be able to withstand variations in temperatures, excessive heat, shock and vibrations. A broad range of switching technologies is also required for the purposes of enhancing the interface functionality. It is also important to note that the safety issues are important during the human machine interface process. Key locks are usually put in place for the purposes of security while the stop buttons are usually in place for the purposes of ensuring that the system is safe (Lee, et al, 2014). The HMI plays an important role in terms of controlling the production process. Cost effectiveness at the plants can be attained through the use of the HMI. At the design stages, the devices to be used are usually considered in order to ensure that the interaction will be effective. Source, < http://images.pennwellnet.com/ogj/images/ogj2/9601jge01.gif> In the ethylene cracker gas plants different software can be used for the purposes of controlling the Human Machine Interface. Vijeo designer software is commonly used in the ethylene cracker gas plants. This is because it has the ability of ensuring that the interaction can be carried out remotely. It is also useful in supporting Schneider electric model (Geng, et al, 2012). It can also work effectively with the SCADA system and hence ensuring that the interaction process is effective and the monitoring process can be monitored. The performance of the gas plant can therefore be enhanced and all the aspects of production can also be improved and hence ensuring that the process is effective. In a manufacturing and production environment, the use of HMI is useful in offering control, reducing downtime and increasing efficiency. The installation of HMI is also easy and it can be used a long the other systems like SCADA and PLCs in an ethylene cracker gas plant. It can also be modified depending on the needs of the production process and hence its ability to meet the requirements of the production plant (Nolan, 2014). The installation of the system in the ethylene cracker gas plant requires some expertise although it is mot a complicated process. It is also important to note that the capacity of the plant is an important factor during the installation of an ethylene gas plant. Human Machine Interface is also important in terms of ensuring that the safety at the plant is enhanced. PLC system According to Yan (2012), the PLC system is a digital computer that is used for the purposes of automation or control of machinery in the factory. In an Ethylene cracker gas plant, the PLC system is usually used for the purposes of controlling the temperatures, noise or vibrations (Yan, 2012). The system is also useful in terms of controlling the industrial processes in the ethylene cracker gas plant. The system is also useful in terms of process control, distributed control system and networking. The power of the modern PLC system is almost similar to that of a desktop computer. The design of the PLC system is therefore important for the purposes of ensuring that it carries out the data handling and storage effectively. The PLC is usually classified into three levels during the design process. The operations and enterprise level is considered the top level. It is then followed by control level. The control level is the main processing unit and it is usually sued for the purpose of controlling the machinery and the processes on the factory floor. The final level is composed of the actuators and the sensors which is usually located in the field. Connectivity is usually put in place for the purposes of linking the different levels and hence enabling the monitoring and control process to take place at the ethylene crackers gas plant. The Ethernet is being used for the purposes of controlling the processes and it is also useful in maintain effective communication (Chen, et al, 2012). An effective design is thus useful in linking all the three levels and hence ensuring that efficiency is achieved. Source, The PLC system in an ethylene cracker gas plant is comprised of various devices that enable the system to function effectively. The devices in an ethylene cracker gas plant is the input and output modules (Bao, Wu & Yan, 2014). At the ethylene cracker gas plant, the output module is usually used for the purposes of controlling actuators, valves and motors. This is considering that there are a high number of valves in the ethylene cracker gas plant. A circuit is also in place for the purposes of controlling the flow of current. Switches and multiplexers are also part of the PLC system device. A variety of sensors is also in place for the purposes of controlling the digital signals, process control, control system and data acquisition. The PLC input mode usually plays an important role during the process of monitoring the signals in an ethylene cracker gas plant. Voltage converters are also in place for the purposes of ensuring that the system works effectively. The control of voltage is important fir the purpose of ensuring that the process is effective. This is considering that high voltages are usually required in some of the components of the ethylene cracker gas plant. The PLCs play an important role in ensuring that the processes are monitored while at the same time the power consumption is also controlled (Hu, et al, 2013). It is also important to note that a PLC system usually act as a link between SCADA and HMI systems and hence ensuring that the control and monitoring process is carried out effectively. Software is usually required in a PLC system to ensure that the processes in the ethylene cracker gas plant are monitored effectively. Unity pro software with ladder logic diagram is usually used for the purposes of controlling the ethylene cracker gas plant. The software is usually used in the plants since it allows the users to share information and hence making it easy to make decisions (Feng & Xia, 2011). It is also important to note that the software optimizes the operations by cutting down on the development costs. Ethylene gas cracker plants are currently undergoing modernization for the purposes of improving on its efficiency. A lot of improvements have been made since the discovery of the first ethylene gas cracker plant in 1919 by George Curme (Wang, et al, 2011). The capacities of the plants have also been increased for the purposes of increasing production. The existing cracking furnaces are being redesigned in order to be equipped with technology and to increase on the capacity. The downtime is also reduced and hence increasing on the efficiency of the operations at the ethylene cracker gas plant. Maintenance is low. This ensures that the cost of maintenance is reduced throughout the lifecycle of the system. The level of accuracies of the PLC system is also high and hence playing an important role in increasing productivity at the plant. All the input and output signals usually come from the PLC system and hence its ability to enhance the communication process. The PLC system in the furnace usually acts as a brain as it is responsible for logic and communication process (Cheng & Wan, 2013). The automation of the furnaces is usually achieved through the use of a PLC system. The automation is responsible for the control of processes at the furnace and hence improving on the human machine interaction. Safety measures are also in place and this is useful in ensuring that the processes are safe. References Wang, H.et al. (2011). Intelligent severity control stabilizes ethylene crackers. Oil and Gas Journal, 109(6), 104. He, C., & You, F. (2014). Shale Gas Processing Integrated with Ethylene Production: Novel Process Designs, Exergy Analysis, and Techno-Economic Analysis. Industrial & Engineering Chemistry Research, 53(28), 11442-11459. Godwin, J. et al. (2013). 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Retractable Conveyor Control System Design Based on PLC. Advanced Materials Research, 655, 1332-1336. Read More