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Process Control & Optimization

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.

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  • INDUSTRIES
  • Chemicals
    Equipment & Machinery
    Transportation
  • FUNCTIONS
  • Discrete Manufacturing
    Quality Assurance
  • CASE STUDIES
  • Eurotech: Transport of the Future at Heathrow
    Ultra Global was developing a ULTra Personal Rapid Transit (PRT) system for Heathrow airport. A single board embedded computer which can provide the performance, reliability and scalability to handle PRT system's communication and security requirements is needed.
    ZTE: CSL Faster and Stronger
    In order to keep a leading position in the new Internet era, CSL makes a strategic decision to upgrade the whole network, for guaranteeing the development of high-speed data service.
    nicheBees: Discrete Manufacturing Industries (Audiology)
    • Planning at the client’s end is done at Excel Sheets by planners on day to day basis (Elimination of manual activities in planning) • Multisite planning required for more visibility of all companies with single company in Baan • Constraints based finite Material planning • Simulation Capability with what-if analysis is required on day to day basis for users to simulate some situations like rush orders & their Impact on existing plan • Quota Arrangement to distribute planned supply orders between different supply sources • SIC planning for material movement between warehouses • Sales Commitment to customer should be more realistic based on capacity • Relation between sales orders and planned supply was required to see the complete chain from Purchase to Sales for demands • Firm Allocations of Supply orders to demand time phased inventory planning dynamically based on upcoming demand
  • 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

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