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Process Control & Optimization
Overview
Process control and optimization (PCO) is the discipline of adjusting a process to maintain or optimize a specified set of parameters without violating process constraints. The PCO market is being driven by rising demand for energy-efficient production processes, safety and security concerns, and the development of IoT systems that can reliably predict process deviations. Fundamentally, there are three parameters that can be adjusted to affect optimal performance.
- Equipment optimization: The first step is to verify that the existing equipment is being used to its fullest advantage by examining operating data to identify equipment bottlenecks.
- Operating procedures: Operating procedures may vary widely from person-to-person or from shift-to-shift. Automation of the plant can help significantly. But automation will be of no help if the operators take control and run the plant in manual.
- Control optimization: In a typical processing plant, such as a chemical plant or oil refinery, there are hundreds or even thousands of control loops. Each control loop is responsible for controlling one part of the process, such as maintaining a temperature, level, or flow. If the control loop is not properly designed and tuned, the process runs below its optimum. The process will be more expensive to operate, and equipment will wear out prematurely. For each control loop to run optimally, identification of sensor, valve, and tuning problems is important. It has been well documented that over 35% of control loops typically have problems. The process of continuously monitoring and optimizing the entire plant is sometimes called performance supervision.
Applicable Industries
- Transportation
- Equipment & Machinery
- Chemicals
Applicable Functions
- Discrete Manufacturing
- Quality Assurance
Market Size
The advanced process control market is estimated to reach USD 1.4 billion by 2020; growing at a CAGR of 11.79% from 2014 to 2020.
Source: Markets and Markets
Case Studies.
Case Study
Centrica Connected Homes
With the acquisition of hardware and platform partner, AlertMe, in 2015, Centrica Connected Home was faced with the prospect of a significant shift in focus. Previously the relationship had been one of vendor-customer with AlertMe also pursuing it's own goals for expansion and licensing of its software. After the acquisition, Centrica Connected Home moved to quickly integrate the technical talent from the two companies and then to realign the development efforts of the teams.The new common goals of product evolution, feature enhancement and international launch, presented a number of challenges in the form of a rapid scaling requirement for their live platform, whilst maintaining stability and availability. Added to these demands on the company were an expansion into new markets, and brand new product launches, including smart boiler service and a growing ecosystem of new Hive smart home devices. They even found the time to develop deeply functional Alexa skills for their products and hence be a Smart Home Launch Partner for the Amazon Echo in the UK in 2016.
Case Study
NIST Teams Up with Sparks Dynamics to Drive Down Energy Costs
Faced with an antiquated inefficient compressed air system and the challenge of fully benchmarking the existing system performance, NIST knew they needed a professional energy ally so they could focus on what they do best—technology and standards development.
Case Study
Guangzhou Metro Line 3 CMCS Network System Packaged Manufacturing
Construction summaryLine 3 is built with total length of 35.86km, 18 stations, 1 depot, 2 parking lots, 2 master substations and 1 control center. Line 3 is designed to be south-north like a “Y”. The main branch starts from Guangzhou East Railway Station at north, extends to the south by Zhujiang along Tiyu West Road and ends at Fanyu Square along planning Fanyu Road. The sub-branch starts from Tianhe bus station at north and combines with the main branch at Tiyu West Road to the southeast along Wushan.