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Optimized process controls for optimum performance

Business solutions:Expert services + proven methodology + world-class tools= improved business performance

Keith PhillipsControl Engineer, SABIC-IP

“By tightening the upstream control and optimizing the hydrogen process, we are able to achieve annual savings in energy consumption of over $1 million.”

Metso Automation Services

Control performancebusiness solution

Metso Automation, Inc., www.metso.com/automationservices E899

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Background:• SABIC is one of the world’s largest chemicals, fertilizers, plastics and metals producers (annual sales ~$75 billion)• SABIC-IP produces a variety of plastics for OEMs in the automotive and computer electronics markets• Company wanted to � nd a way to stabilize plant processes to reduce energy and maintenance costs

Combating rising energy and maintenance costsSABIC-IP, Burkville, Alabama, USA

Solution:Control performance business solution

Results:• Annual energy savings of $1 million due to tighter control of energy process• Oscillating loops reduced from 40% to 16%• Loops unable to hold setpoint reduced from 12% to 2%

Customer case with proven results

Move to the optimum operating pointBy ensuring that critical control systems are optimized, Metso’s control performance business solution helps make the plant-wide process more stable. With improved process stability, the operating point can be moved closer to its optimum.

The change of operating point and its impact depends on individual production targets. While maintaining other variables, it can be used to deliver one or more of the following bene� ts:• Enhanced process stability• Reduced resource usage (typical energy reduction of 0.5–2%)• Increased production yield (typical increase 1–10%)• Improved quality• Decreased environmental impact• Maximized equipment lifetime

Surge and sustain principalProduction variables change constantly as targets shift and equipment ages. Without ongoing monitoring, most of the control gains and bene� ts can be lost within six months. Metso control performance business solution is designed to provide an initial surge in performance. We then sustain and build on process e� ciency improvements by o� ering continuous monitoring and improvement over the lifetime of our agreement.

Establish performance goals and KPIsThe � rst stage in helping you unlock more business value is to agree key performance indicators (KPI) and set an initial performance benchmark. This helps you to quickly and easily measure the performance of your process controls.

Measure and report on performance and pro� tabilityWe monitor performance over time, and identify the controls that have a negative impact on process performance. Using this in-depth information, we provide regular reports identifying control issues and potential solutions, track the results of corrective actions and highlight progress against the agreed KPIs.

Getting to the core of the problemMetso ExperTune PlantTriage software quickly

identi� es under-performing controls that are signi� cantly a� ecting performance. Our experts assess the likely root cause and, where necessary, visit your site for veri� cation. We then recommend corrective actions which can include repair, upgrade, a new control strategy or optimizing the control’s response.

Intelligent corrective actionMetso’s intelligent approach means that we prioritize corrective actions to the areas that have the most signi� cant impact on production e� ciency, where economic value is greatest, and where you will get the fastest payback.

Corrective actions can be carried out by Metso’s service team. Alternatively, we can work with your suppliers to ensure the appropriate repairs, upgrades or control strategy changes have been implemented.

The impact of the corrective actions is always veri� ed by continuous monitoring of control performance.

Ongoing performance improvementWe ensure the optimal control response by taking corrective action and controller tuning. We identify potential parameter changes, simulate the controls to test the impact of the change and, when veri� ed, work with you to implement the changes in the live system.

Controls are tuned to meet the demands of your process, whether that means improving stability, reducing variation or increasing speed of response. We also suggest setpoint moves that capture the business value from these improved controls.

A positive impact on the entire plant

Optimized control systems can deliver signi� cant improvements in:• Manufacturing effi ciency• Production output• End-product quality• Waste management• Energy and raw material costs Although the goals are clear, they can be di� cult to achieve due to:• Too much process data• Limited manpower• Skills shortages• Too many day-to-day tasks to handle

Metso o� ers a complete control performance optimization package:• Access to world-class expertise• Award-winning smart tools (Metso ExperTune PlantTriage)• Optimization activities focused on controls providing the greatest return• Identifi es the root cause of control issues• Intelligent corrective actions• Regular reports and smart notifi cations• Track record of controls optimization

Concrete results, fast payback

Fast identi� cation of areas having the greatest production impact

Agree performance goals and set KPIs

Identify root causes and corrective actions

Continuous performance improvement

Award-winning softwareMetso ExperTune PlantTriage® is a winner of Control Engineering magazine’s 2013 Engineers’ Choice Award in the Diagnostics Software category.

The software provides Metso control performance business solution specialists with a powerful tool for online monitoring, tuning and analysis of process and control information. ExperTune software tools have been in continuous development for more than two decades, and have delivered proven results.

A solution that maximizes your business pro� tability over time