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How To Leverage Your Data? Presented by Michel Ruel, Top Control Inc.

How To Leverage Your Data? Presented by Michel Ruel, Top Control Inc. Top Control : history. 1994-2009 Training, consulting, optimization Offices in USA, Canada Strategic partner of Matrikon Customers in 31 countries. Tools for Operational Excellence. Value added solutions:

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How To Leverage Your Data? Presented by Michel Ruel, Top Control Inc.

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  1. How To Leverage Your Data? Presented by Michel Ruel, Top Control Inc.

  2. Top Control : history • 1994-2009 • Training, consulting, optimization • Offices in USA, Canada • Strategic partner of Matrikon • Customers in 31 countries

  3. Tools for Operational Excellence • Value added solutions: • Alarm management • Control performance monitoring • Equipment condition monitoring • Process performance monitoring • Data connectivity • Data management • Data and process visualization • Engineering analysis

  4. Data→Knowledge → Diagnostics Result$ Diagnostics Analysis Performance Process systems Data

  5. Control Complexity Follow-up effort Qualifications 1, 2…% 1, 2…% 1, 2,…% 1, 2…% RTO Multivariable Models Automated Control strategies Tuning, modeling PID Configuration, tuning Valves, transmitters, sensors Calibration, maintenance Process equipments, pumps, reservoirs… Maintenance

  6. SAVINGS $$$ Impacts SAVINGS $$$ SAVINGS $$$ Time

  7. The reality Numbers from audits, articles and our field experience • 20 % Control loops, improper design • 30 % Control valve related problems • 15 % Not installed properly • 30 % Nonsensical tuning parameters • 85 % Improper tuning parameters • only 25 % give a better performance in automatic control!!

  8. Problems: What Could Go Wrong SP PV CO Mode Tuning is only one of the problems… Operations: SP, Mode Variability Normal mode? Tuning FIC-101 FIC-101 In service? In control? Noise Oscillations FT-101 Control design Interactions with other loops Process model Non-linearities Fouling Disturbance Hysteresis Valve at limit Process design Stiction

  9. Expected Results • Variability: ÷2 • Cycling: removed • Valve travel: ÷5 (valve wear  2 ) • Robustness: X 2 • Performance: X 2 • Service factor • Tuning • Repair • Review control strategies • Optimize Quality: Efficiency: Throughput : Energy: Maintenance costs: MPC deployment, re-testing: 30% 1 to 5% 1 to 5% 1 to 10% 30% 70%

  10. Expected Benefits of Optimization • Increase process performance • Use resources (human & material) wisely • Reduced energy costs • Reduced waste • Reduced variability • Reduced valve maintenance • Reduced pollution • Cycling removed • Increased up-time • Improved product quality • Improved efficiency • Better operation • Improved safety • Smoother start-up

  11. Conclusions • 1-Usage 2-Stability 3-Performance • Resources are used where they are really needed • Process control systems are used to their fullpotential • Operation and production are optimal • Maintenance and engineering are efficiently used.

  12. Boiler 3, November 2007 vs April 2008

  13. November 2007 vs April 2008

  14. An example at White Birch: PIC 1900 (tuning parameters adapted to load) 3 times better

  15. Steam cost over 6 months

  16. Regularity Support Interest 100% 100% 100% 90% 90% 90% 80% 80% 80% 70% 70% 70% 60% 60% 60% % % % 50% 50% 50% 40% 40% 40% 30% 30% 30% 20% 20% 20% 10% 10% 10% 0% 0% 0% 0 0 0 20 20 20 40 40 40 60 60 60 80 80 80 100 100 100 120 120 120 Time Time Time Small Gestures That Count! • Actions • Daily • Weekly • Monthly • Yearly • Workflow, procedures • What can be automated? • How can the process be sustained? • How can optimization be optimized? Succes$ Result$ New$

  17. Michel Ruel President Top Control Inc mruel@topcontrol.com Thank You • (877)867-6473 • www.topcontrol.com

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