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Plant Performance Optimization

7 November 03:45 p.m. - 05:15 p.m.

Session Type: Paper

Track: Asset Lifecycle Management and Optimization/Strategy

Paths(s): TechnicianTechnician   ManagementManagement   ExecutiveExecutive   EngineerEngineer   Academia/R&D/ScientistAcademia/R&D/Scientist   

In this paper session, industry experts will discuss the leveraging of technology and services to improve overall plant performance. Areas of focus include process automation system support services, intelligent device enabled asset monitoring, and real-time energy demand management.


Automation Service Solutions for the 21st Century

Kevin Starr, ABB Read Bio

Kevin Starr works for ABB Process Automation Division and has worked for ABB for over 26 years. He is currently responsible for the development and implementation of service solutions that result in the increased life cycle and utilization of Industrial Automation systems.  He holds a Masters degree in electrical engineering from Ohio State University, and a Bachelor of Science degree in electrical engineering from Ohio University, both with emphasis in process control. Since then, Kevin has installed, tuned and trained on industrial process control systems, controllers and instrumentation. He had an article on Asset Optimization published in the first edition of Pulp and Papers Solution Magazine. He has written a book on process control, "Single Loop Control Methods", that has sold over 3000 copies worldwide. He currently has 12 patents as a result of his efforts with process control.

In 1986, Kevin started working for ABB's pulp and paper division.  He was responsible for installing and tuning ABB Paper Control products.  In 1990 Kevin started working as an instructor.  He developed training courses for system operation and process control. In 2000 Kevin worked with the research and development group to create machine direction, cross direction, and remote monitoring products.  In 2003 he became part of the US Pulp and Paper service team. In 2007 he became part of the global service product development team where he currently is acting as the Research and Development Manager.

Kevin has worked in a wide variety of process control industries, including paper, power, metal, plastic, rubber, chemical, mining, oil and gas, and water treatment.

He has taught process control techniques in Ireland, India, Singapore, Canada, Germany, Switzerland, Sweden, Indonesia, and in numerous locations throughout the United States.  Along with courseware development responsibilities, Kevin also acted as the lead control engineer for the development of software tools for the analysis and optimization of control loops.

Kevin has been involved with technical public speaking since 1993. In 1993 he was the keynote speaker for the central Ohio Instrument Society of America control conference and exhibit.   Kevin was a presenter in the Cincinnati ISA conference and exhibit in 1995, and has been a speaker for the local chapter of the Columbus section of ISA.   Kevin was a process control product representative at the 1995 Singapore ABB Global Training Services workshop.  He was also a keynote speaker at the 1996 ABB Worldwide Pulp and Paper Conference in Kilarney Ireland.  In 1999, he was a speaker at TAPPI international in Williamsburg, Virginia and he spoke at ABB's Automation World in Atlanta.  He presented a paper in the 2000 TAPPI conference in San Antonio Texas as well as the regional 2003 TAPPI conference in Seattle Washington.  He has also given papers in every US Power and Automation Trade show since 2003


Analysis from a number of automation systems in multiple industries indicate that up to 75% of the automation investment is not providing benefit and is often creating process problems instead of solving them due to the lack of a comprehensive modern service program. No longer is service limited to mechanical devices. As automation improves and industrial plants become more integrated, the need to expand the definition of service to include the automation systems and process applications is required. ABB is an industrial automation solution provide and delivering solutions to such industries as pulp and paper, oil and gas, minerals and mining, power, and marine and turbo for years. As a result of our experience we have noticed significant trends in services needed to extend the life cycle of an automation system as well as improving the performance of those solutions. We now have over 1000 years of service activity recorded and are able to define service distribution models that address today's service requirements regardless of the manufacturer. This paper highlights these service models with consideration of preventive maintenance, reactive maintenance, and optimization (process) maintenance. Today's service requires advanced solutions based on the latest technology coupled with proven methods to ensure the optimal distribution of service effort.

Getting More from Plant Floor Intelligence

Paula Hollywood, ARC Read Bio

Paula has over 30 years experience in marketing and sales of industrial field instruments that utilize a vast array of technologies including magnetic, coriolis, radar, electrochemistry, capacitance, and ultrasonic.

Paula's focus areas include Field Devices (Flow, Level, and Pressure), Process Analytical Chemistry, Intelligent Pumping Systems, and Laboratory Information Management Systems. As a member of ARC's Asset Lifecycle Management team, Paula also covers reliability and authored a Worldwide Outlook report on the asset reliability market.

Prior to ARC, Paula spent 14 years at The Foxboro Company in various capacities including two years in the Delaware field sales office in both inside and outside sales roles. She spent seven years with Kentrol, Inc., a manufacturer's representative company, as an inside sales rep where she was primarily responsible for sizing and selection of field devices including control valves and flow meters. At Kentrol she was also a member of the Quality Improvement Team. Prior to joining ARC, Paula was level product manager at Krohne America, Inc. for four years where her responsibilities included product technical support and directing US sales and marketing activities for all level products.

Paula has a BS from Northeastern University and an MS from the University of Massachusetts Boston.


Asset monitoring sources include IT, control systems, process equipment, and field instrumentation.  Smart instrumentation for measurement of process variables alone is archaic.  Intelligent device integration provides greater flexibility and process intimacy for decision support resulting in safer, more reliable, and optimized processes at lower cost.  This session will present strategies that leverage the rich information embedded in intelligent devices to improve plant safety and performance.

Achieve Sustainability Goals through Automated Demand Management

Patty Solberg, Powerit Solutions Read Bio

Patty Solberg is the Director of Product Marketing at Powerit Solutions. She focuses on market research and requirements gathering, as well as analyzing trends and needs in the SmartGrid and industrial automation markets.  She began working at Powerit in 2011.  Patty comes to the CleanTech community from telecommunications products, where she has a background in product marketing and product management for multimillion dollar product lines, including DSL gateways (most recently with 2Wire) and fiber communications and test equipment.  Patty has a bachelor’s degree in electrical engineering from Loyola Marymount University, in Los Angeles, CA.


Many companies incorporate sustainability goals into their core corporate objectives. After upgrading lighting and installing VFDs, industrial facilities are seeking other ways to reduce utility spend, without impacting production throughput. While large energy efficiency gains may be difficult to achieve without an overhaul of a manufacturing process or upgrading equipment, reducing peak electrical demand, which accounts for a significant portion of the overall industrial electric bill, is possible with a supervisory energy management system.  This presentation will discuss the benefits of automating the facility’s use of energy, specifically electrical demand, to reduce peak demand charges, automate demand response participation and react to real time pricing changes.

A demand management system allows the real-time use and price of energy and demand to be a factor in production decisions, enabling a facility to control their energy costs.  A successful demand management system must be designed to leverage and extend the capabilities of existing automation infrastructure within a facility. The system must integrate with existing systems in such a way that there is minimal or no impact to production throughput and no compromising of product quality or safety.