Utilização de simulador de processos industriais integrado ao sistema supervisório para validação de lógicas e estratégias de controle em uma fábrica de celulose

Abstract

The success of a project with the dimensions and particularities that an integrated cellulose producer demands, is directly related to the quality of the activities and stages that precede the startup phase of the plant. One of the fundamental activities of the automation discipline is the TAF (Factory Acceptance Test), which is carried out before the commissioning period, and has, among other objectives, the validation and testing of strategies and logics of implemented controls. In this project we used the Operator Training Simulator (OTS), which consists of the integration of high fidelity dynamic simulator with the Digital Distributed Control System (SDCD) to enable the training of the plant operators allowing them to perform operational procedures, develop familiarity with the synoptic screens and other resources available in the supervisory system, using a virtual environment that reproduces with high fidelity the conditions and behaviors of a real productive process. The final configurations of the OTS occurred in the Joint TAF phase, contemplating activities such as: Mapping of communication points, modeling adjustments, evaluation of sequential starting and stopping of the plant, observation of responses to control actions, tuning of meshes, etc. The structure of the OTS and the activities carried out in the Joint TAF phase allowed the reappraisal of strategies and control logics acting in an integrated manner, which allowed the identification of improvement opportunities and correction needs, which were classified into three main categories of benefits being for operation (77%), security (13%) and maintenance (10%).