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| BUSINESS UNITS:
OPTIMIZATION |
This is another core service in which we stand above the rest.
We believe that unit based optimization is more powerful, more robust, easier to understand and implement and less costly than plant wide optimization.
We have developed several proprietary methods of optimizing each facility unit taking into account all the parameters that can affect the profit margin. We will incorporate these optimization solutions into the advanced controls.
We provide several calculations on-line that bring out the performance of the unit. Once trended, these values can be used to pinpoint areas where the plant performed above or below expectation and analysis could be made to find out the root cause. This tool has been very successful in the past and had been very beneficial to our clients.
We can provide an open-loop or a closed-loop solution. The open-loop solution is more popular presently but the closed-loop solution is more powerful especially in the case where the solution can be resolved by the controller
An example of where we have implemented a closed loop solution is where we have calculations that will reduce the profitability of a particular product once there is less demand for it or once the tank(s) is/are full. A closed-loop solution will then optimize production of the other products at the expense of the undesired product.
Here is an example is where we implemented an open-loop solution in an Air separation plant where we had just installed MPC. Upon analyzing the data, we discovered that two weeks after implementing MPC, our profit margin had taken a dive from about $260/hr profit to about $63/hr. We made an inquiry and found out that the Liquifier warm turbine was leaking and some Main Air Compressor (MAC) coolers/chillers were not working well. A quick calculation showed that at the Air rate, the plant was loosing about $5,000 per day. The problem was escalated and resolved in 2 day. The problem had existed for a little over two weeks prior. Had the plant personnel made it a priority to utilize this earlier, they would have saved about $75,000 because they eventually had to repair the problem and customer demand was high. Many of these problems exist today and need immediate attention. This is where we thrive and enjoy bringing solutions to such complex issues.
These solutions will help point out for example the best spot to run the compressor or turbine at particular conditions, the most best column delta P for the conditions, the best temperature profile etc and above all, the most economic point to run the plant with all equipment working well.
We will not only implement these solutions but will like to work with you in analyzing the data be it daily, weekly or monthly. It is easy to transfer data these days. We will like to work with you in analyzing your plant data and recommending solutions without setting foot at the site. We will come to the plant only to install the solution saving you time and money. |
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