Benefits of
Control Loop Optimization
George Buckbee
Top Control, Inc.
How Does Optimization Fit in
Today’s Business Environment?
• Higher Energy Costs
• Greater Demands on Process Variability
Tighter Environmental Limits
– Less Waste
– less Scrap
• Increased Production Pressures
• Increased Productivity Targets
• Tight Capital Budget
1
Direct Benefits of Optimization
•
•
•
•
Improved Control Response
Reduced Valve Movement
Process Stability
Less Operator Distraction
How Good is my Plant?
• 20 % Control loops, improper design
• 30 % Control valves, related problems
• 15 % Not installed properly
• 30 % Tuning: Makes no sense!
• 85 % Improper tuning parameters
• 25 % Only, give better
performance in AUTO
2
Translating Benefits to Dollars
• Improved Control Response =
èReduced Product Variability
• Reduced Valve Movement =
èReduced Maintenance Cost
• Process Stability =
è Up Time
• Less Operator Distraction =
èLess Scrap, Fewer Environmental Incidents
Typical Benefits :
Paper Machine
Variability
Reduction
Response Time
50% Reduction,
MD
20% Reduction
Production
Increase
Dollar Value
1% to 10%
$200K - $3MM
3
Typical Benefits:
Refinery or Chemical Plant
Variability
Reduction
Response Time
30% Reduction
Production
Increase
Dollar Value
0.5%
35% Reduction
$500K - $5MM
Typical Benefits:
Steel Mill
Variability
Reduction
Response Time
50% Reduction
Production
Increase
Dollar Value
1% to 5%
30% Reduction
$200K - $1.5MM
4
Typical Benefits:
Boiler / Utilities
Variability
Reduction
Response Time
50% Reduction
Production
Increase
Dollar Value
0.5% to 1.5%
(energy svgs)
$100K - $2MM
15% Reduction
Conclusions
• Benefits of Optimization are Quite Large!
• Optimization is a good fit with today’s
business environment
Questions?
5