| A simulation model is developed and maintained for the Louisville Plant of Rohm and Haas company. The scope of the simulation includes two polymerization reactors in the KVK unit and supporting equipment. The simulator software package, SimSuite Pro, is a real-time dynamic simulator developed by GSE Systems, Inc. GSE Systems is also the manufacturer of the D/3 DCS system used in KVK.; The simulator models many chemical engineering phenomena including heat transfer, mass transfer, reaction kinetics, and fluid dynamics. Additional code written for the standard reactor module includes concentration of Gas A, a critical parameter in these particular polymerization processes.; Once the simulation model is complete, training procedures are written and simulation initial conditions and scenarios are developed for use in operator training sessions. The training sessions developed are lessons on overridden valves and interpretation of software flags, tank weight versus flow queries, dropping an abnormal batch, Emergency-Stopping and aborting a batch, reaction in the component feed tank, and dying reactions. Training sessions are used for training of new operators and re-qualification of experienced operators.; The simulator is also used extensively for pre-startup software check-out when new programs or database devices are added. This practice saves a great deal of downtime by avoiding the need to troubleshoot software changes on actual equipment. Use of the simulation model increases productivity and safety in the reactor unit by providing a better training mechanism and software checkout system for the unit. |
