Process Optimisation

Why should you optimise the Process Control System? - The short answer is; in most cases it is more expensive to not optimise the process controller system. Also, optimising the system is likely to lower the plant’s carbon footprint by reducing the energy consumption. Optimising the process regulation system usually results in a decrease of energy consumption of about 5-15%.

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Why Process Optimisation?

The chemical industry is fiercely competitive and is constantly trying to significantly improve existing process technologies or develop new technology to satisfy the growing demand. It is essential that the processes are operated to meet key production objectives, such as process safety, environmental regulations, and product specifications.
These key production objectives must be satisfied even when the process is subjected to disturbances during operation. Process operation must ensure proper management of process variability and this task is accomplished by a (well-designed) automatic process control system, with a proper set of parameters.
A chemical plant may have thousands of measurements and control loops. Although the Proportional-Integral-Derivative (PID) controller has only three parameters, it can be quite difficult to find good values (settings), without a systematic approach.

Finding poorly tuned controllers in process plants is in fact quite common!

A visit to a process plant will likely show the following shape of the control system:
  • 85% of controllers perform inefficiently when operated in automatic mode
  • 65% of the controllers are poorly tuned, masking control related problems
  • 30% of PID control loops are operated in manual mode
  • 20% of control systems are not properly configured to meet their objectives.
The poorly tuned controllers are not always easy to identify as the plant can function “ok”, but even if the controller system does not appear to have any issues, there might be a huge hidden potential for increase in profit by giving the parameters for the controllers some attention.

What does Eldor offer?

Eldor are experts on process control systems, and has recently established its process optimisation service and is ready to offer services for finding smooth tuning parameters for the Process Control System, including software for monitoring the process control loops performance.
Eldor is a certified Control Station partner. With this partnership, Eldor offers an advanced monitoring service of the Process Control system, which can detect mechanical issues, PID-tuning issues, general loop performance, and interaction, before they significantly impact the production. We recently hosted a webinar with Control Station where we explained how to ensure continuously optimised control system performance.
Watch the webinar here!
A typical yield from optimising the process regulation system usually results in an increase in production throughput of 2-5% and increases the production yield by 5-10%, while decreasing the energy consumption with 5-15%, and decreasing the defects occurring in the production plant with 25-50%.

Resources on process optimisation


Overview of different solutions for process optimisation


What is Process optimisation and why is it important?

This white paper provides the reader with a generous introduction into process optimisation and explains the importance of having an optimised process.