Operational Excellence Transformation is Yokogawa and KBC’s co-innovated portfolio of solutions and services.We provides comprehensive solutions for business automation in all four areas using consulting and digital technology.
Yokogawa's Operational Risk Management deals with managing safety, health and environmental risks on both individual and process levels in a reliable and risk-free manner. It involves the end-to-end process of designing, visualizing and orchestrating plant production and business systems.
By combining Yokogawa’s product portfolio and KBC’s consulting services, we provide our customers best practices and domain knowledge that empower them to improve their operations, as well as a digital platform that supports such activities and initiatives. Our Operational Risk Management scope does not only cover partial improvements in the organization, but also optimizations in plant operations to achieve continuously improving safety, reliability and operability.
·Supply Chain Optimization
- Optimize management of supply, whether oil in the ground or feedstocks for a refinery or chemical asset, in light of product market demands. This provides operators with the agility to take full advantage of market conditions.
·Asset Operations and Optimization
- Optimize the potential of physical assets, by pushing throughput and maximizing the production of the highest value products, whilst minimizing variable costs such as energy.
- Deliver small and large capex projects, on time and on budget, to deliver growth and meet environmental requirements.
·Asset Management and Integrity
- Confidently ensure asset reliability and availability, whilst controlling maintenance costs. This assures the asset always meets expectations and is always available to capitalize on short term market opportunities.
As raw material costs increase this is drawing increasing attention towards improvement of process efficiency, all industries now recognize Regulatory Control Stabilization to be the baseline step for all process efficiency initiatives. In depth evaluation is required to improve the effectiveness of the regulatory control loops and achieve regulatory control stabilization (e.g. control configuration, PID tuning, instrumentation).
Regulatory control stabilization and PID loop tuning are also pre-requisites for advanced process control (APC) implementation. Yokogawa's decades of hands-on experience as a global supplier of process automation solutions has provided a wealth of knowledge and understanding in regulatory control loops, both before and after APC implementation.
Quality, Efficiency, and Operators Workload Significantly Impact Profitability
Problematic control loops negatively affect many aspects of your plant. PID setup and tuning without a proper methodology leads to trial-and-error tuning, leaving the total regulatory control strategy sub-optimized and lacking a consistent control objective across all control loops (e.g. averaging level control).
Plant safety is paramount to the continuance of production operations and all process industries now recognize the importance of regulatory control stabilization as the baseline for plant safety. To achieve stability, plants must evaluate and improve the effectiveness of regulatory control loops (e.g. control configuration, PID tuning, instrumentation).
Also, control loops operated in manual mode require careful monitoring and overall have poor performance. They will lead to an increase in operators’ workload and are unable to maintain the consistent safety, product quality, and economical efficiency of your plants.
Regulatory Control Optimization to Enable Improved Production
Yokogawa's regulatory control stabilization service is a packaged service product including necessary engineering and consulting services to stabilize safety, improve efficiency, and reduce operators’ workload.
Tune VP is designed to estimate the optimized P, I, D tuning parameters for the PID controllers reside in FCS of CENTUM DCS system. This application provides an effective and easy to use solution for PID controller tuning with the following key features:
Economical Efficiency Now, Optimization Opportunities for the Future
The benefits of APC are vast. Companies can enjoy near immediate benefits in economic efficiency and safety, while several optimization opportunities are possible for the future. More specifically:
TuneVP is designed to estimate the optimized PID tuning parameters for various PID controllers such as CENTUM DCS, Foundation Fieldbus Controllers, GE Fanuc PLCs, etc.
Process dynamic response data obtained from step testing or normal operational setpoint value (SV) or manipulated output value (MV) change are collected via OPC interface. Transfer function model is derived from MV and PV (process variable) data relationship. Based on the model, IMC tuning method is used to calculate the optimized PID parameters, in tandem with the closed loop PID controller response simulation.
Process: BTX plant
Purpose: Reduce the fluctuation of tray temperature in distillation column
Benefits: Stabilize product quality and reduce the number of operator intervention (MV change in manual mode)
Benefits: Stabilize product quality (C2 in propane) and increase propane yield
Process: Chemical plant
*Deliverable of a full Service Report at the final stage
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