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KEYS TO A SUCCESSFUL FAST-TRACK ADVANCED PROCESS CONTROL PROJECT

KEYS TO A SUCCESSFUL FAST-TRACK ADVANCED PROCESS CONTROL PROJECT. Celanese Chemical Company. KEYS TO A SUCCESSFUL FAST-TRACK ADVANCED PROCESS CONTROL PROJECT. Agenda Introduction Celanese Background Keys to Successful Fast-Track APC Project

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KEYS TO A SUCCESSFUL FAST-TRACK ADVANCED PROCESS CONTROL PROJECT

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  1. KEYS TO A SUCCESSFUL FAST-TRACK ADVANCED PROCESS CONTROL PROJECT Celanese Chemical Company

  2. KEYS TO A SUCCESSFUL FAST-TRACK ADVANCED PROCESS CONTROL PROJECT Agenda • Introduction • Celanese Background • Keys to Successful Fast-Track APC Project • Objectives, Strategies, and Benefits of the Three Celanese APC Projects • Questions

  3. INTRODUCTION • Pat Benavides - Celanese Chemical Company - Controls Group Section Leader • L.K. Lui - Celanese Chemical Company - Controls Engineer • Brian Alexander - Invensys Performance Solutions - APC Consulting Engineer

  4. CELANESE BACKGROUND • Who We Are • Why Fast-Track Schedule - Maximize Profits! • APC Scope Description

  5. CELANESE - WHO WE ARE • Global Leader in Chemical Industry • Founded 1999 from Hoechst AG • 30 production sites in 11 countries in USA, Europe, and Asia • Products include chemical commodities and specialties, engineering polymers, plastic films and food ingredients

  6. WHY FAST-TRACK SCHEDULE - MAXIMIZE PROFITS! • Take advantage of market pricing fluctuations • Goal of ? Months for completion

  7. APC SCOPE DESCRIPTION • Competitive bids included Invensys Performance Solutions • Celanese chose Invensys Performance Solutions • Three (3) APC projects initiated in 2001 • Two (2) APC projects on Honeywell DCS • One (1) APC project on Foxboro I/A

  8. KEYS TO A SUCCESSFUL FAST-TRACK APC PROJECT • Project Justification • APC Consultant Selection • Cooperation • Efficient APC Project Execution • Training

  9. PROJECT JUSTIFICATION • Contract this work to an outside consultant: quicker and easier justification • Steps for Justifying APC Project • Identify Market Opportunity • Gather and Measure Process Data • Evaluate Process Data • Calculate Benefits • Determine APC Project Costs • Communicate Benefits to Management

  10. APC CONSULTANT SELECTION • Experience • Methodology • Flexibility • Cost • Schedule • DCS Independent

  11. COOPERATION • Open Transfer of Information • Process Information to Consultant • APC and Control Information and Expertise to Celanese • Determine Control Objectives and Strategy • Experience - Process and APC • Receptive to Control Scheme Changes

  12. EFFICIENT APC PROJECT EXECUTION • Experience • minimizes rework; step testing done once • quick DCS mods and instrument repairs • APC consultant is efficient with software tools • Process Knowledge • Involvement of process engineers important • design done only once • dedicated operations support

  13. OBJECTIVES OF THREE APC PROJECTS AT CELANESE • OBJECTIVES • Maximize Production Rates • Improve Product Yields • Improved Catalyst Life • Control Product Quality, Reduced Rerun • Reduce required operator interaction • Maintain the Unit Within Capacity, Temperature, and Flammability Constraints

  14. APC PROJECT CONTROL STRATEGIES • APC to manipulate major process variables • All major controlled variables included • Highly interactive processes - single APC controller per unit

  15. CELANESE APC PROJECT BENEFITS • Maximized feed of one unit by ?% - $? savings • Reduced product venting - $?M savings • Increased product yield - $?M savings • Reduced energy consumption - $?M savings • Minimized reactor shutdowns - $?M savings

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