Session Type: Paper
This session is designed to provide information on critical topics associated with driving value through automation. The topics covered in this session include how to effectively measure the value impact from automation solutions, how management perceives the value of automation and what we can do to guide those perceptions and how providing effective basic control systems can have a huge impact on the value of automation.
Operating managers are continually pressured to reduce costs and be more productive in the light of more dynamic and real-time competition pressure, market opportunities and changing costs as part of a profitable and healthy business. Current performance information and decision-making systems are inadequate for operations personnel trying to improve performance in the plants to take advantage of these dynamic opportunities and improve business performance. This paper presents concepts related to real-time performance measurement and visualization necessary as part of real-time information systems in the operational environment that help to empower operations personnel in their decision-making and thus improving operational performance. In addition, a real-life case study and data will be used to demonstrate these concepts as part of the presentation of the paper.
The process industry is losing trillions of dollars from underperforming control systems. These losses are measured in the form of lost production, energy, materials, safety, quality, and the environment. The underlying root cause of these losses is the failed performance of the humble control loop.
Each control loop consists of an instrument, a controller, and a final control element, usually a valve. The loop's fundamental responsibility is to stabilize the plant. The control loop rejects disturbances, or upsets. It gives the operator visibility to the process and some handles to control the process. A typical process plant has hundreds or thousands of control loops.
There are dozens of failure modes for these control loops. Each failure has consequences to the operation of the plant. Some failures can be immediate and catastrophic, while others can be benign. The worst failures, however, are the hidden failures. Often, they are hidden in plain sight. The impact of these issues may go unnoticed for years.
This presentation examines the issues of underperforming control systems, identifies important failure modes, and provides case study examples to show the true business value of basic control performance.