PPCL Logo Process Plant Computing Limited

Tel: +44 1753 893090 |

LinkedIn Twitter

Register below for one of our live webinars that share new approaches to process improvement & optimisation. 

Or watch one of our pre-recorded webinars here...


Operating Envelopes for Batch, Semi-batch, Grade Transitions, Cyclic Operation, Startup, and other Time Dependent Processes

Operating envelopes are fairly straightforward to understand in the context of fully-developed, steady-state processes, but often the processes we’re dealing with aren’t that simple. Time dependent variation in batch, semi-batch, product transitions and many other complications require multiple operating envelopes with movement between them, or even fully time-varying envelopes.

This webinar shows the application to these time-dependent processes. Dramatic reduction of quality variability and improvement of cycle times for batch processes, product/grade transitions and plant start-up can be achieved by finding the best historic operating envelope, identifying the processing stages and targeting the key variables that drive process differences.

Smarter processing is within your reach! Attend this webinar and let us show you how.


Can't make it? Click here to access our previously recorded webinars


Enhancing the value of Digital Twins with GPC

Come see how Geometric Process Control (GPC) naturally fits into the Digital Twin framework, enhancing the value of combined process descriptions and data.

Digital Twins are showing great promise for the processing industries. The applications of Digital Twins span disciplines of operation, including process control, predictive maintenance, optimization, virtual testing, process improvement, and more. But these benefits come from bringing more and more diverse data sources together, and engineers already struggle to make use of the smaller datasets they use today! Powerful data analysis and visualization tools are needed that don’t require huge manpower investment. This is the first place GPC brings benefits.

In this webinar I will show you how comparing model and process performance, identifying and tracking process changes, and identifying key variables and targets for best operation are natural combinations of Digital Twins and GPC visualization. These tasks can be done faster and more insightfully than with other technologies.


Science-based Alarm Rationalization Transforms Operation Quality

Operator alarms are the most powerful tool operators have for keeping units running safely and efficiently.

The single biggest cause of poor operator alarm performance is an inconsistent set of values of the alarm limits. The missing understanding has been that alarm limits are not independent of each other but are linked by an Operating Envelope or Operating Window spanning many hundreds or even thousands of variables from different data bases. PPCL’s Geometric Process Control (GPC) technology makes it simple to find and see historic process operations, making it possible to easily see the entire relationship between the process operating envelope and existing or proposed alarm limits.

Rationalising your Operator Alarms using Operating Envelopes could be the gateway to larger financial benefits with less investment than other applications available to you. That matters especially in 2021 and 2022.


Build an Abnormal Event Detection Model


Abnormal events like mechanical faults and unexpected disturbances cause process variation leading to degraded quality and even lost production time due to the actions of safety systems resulting in trips. By giving the operator advanced warning of these developing situations, it can provide crucial extra time to react and keep the system running, improving the time on line as well as providing quality and safety benefits.

The cost of developing a simulation or mechanistic model of every unit and equipment is high, requiring specialized modelling training and manpower to evaluate failure scenarios. This makes it prohibitive for most (or all) equipment and process units.

In this webinar we demonstrate Geometric Process Control, a low-cost process visualization technology for building models that can be used to understand historic events as well as providing a real-time model that can capture deviations in real-time, alerting operations to impending degraded process operation. We’ll show you how you can do it too. We’ll include case studies that illustrate the ease of investigation and model building, and include some successful impacts of real-time monitoring.

Improving Energy Efficiency in Process Plants

This webinar presents examples of using our novel process analysis and control technology to show how process can be made easier to operate without increasing energy usage while still replicating low energy usage conditions found in the past. Once it is known how the plant should be operated it becomes easy to compare that with how it operates now and calculate the cost advantage to making operating changes. We’ll share success stories, where users have been able to make dramatic improvements by visualizing their own historic process data.

Using GPC to Reduce Variability, Increase Efficiency and Make More Money

Geometric Process Control (GPC), the only technology for viewing and exploiting fully multi-dimensional operating envelopes, brings proven benefits in productivity and safety to the many sites using it. This free webinar provides an overview of the technology with real-world application examples.

GPC lets engineers make fuller use of historic data than they have ever considered, enabling more questions to be asked and answered. By reducing process variability and targeting best operation, this provides measurable benefits in reducing costs, improving uptime, increasing quality, and providing a safer process. Operating envelopes connect business strategy, operations management and process operations, contributing to OpEx implmentation. We will present cases where our users have reduced energy costs, improved process reliability, and streamlined alarm improvement In contrast with current data fads, such as machine learning, and artificial intelligence, which often provide counter-intuitive results that result in more questions from users than they answer, GPC builds on the understanding and intuition already present in your organization to extract new information from historic data. And does this in a fully visual way that makes the correlations and dependences clear without detailed mathematical background.

Driving Operational Excellence: the Science Linking Operating Envelopes and KPIs 

A key part of Operational Excellence (OpEx) is implementing a business culture that uses appropriate leading and lagging Key Performance Indicators (KPIs) to drive business objectives. Leading KPIs are used to inform real-time operations, and poor KPIs that are contradictory or don’t contribute to lagging KPI achievement are common, and impair, rather than enabling, the execution of business strategy.

Operating Envelopes, the full multi-dimensional relationship between process variables links the process, leading, and lagging KPIs. By using this envelope based on historic operation, potential KPIs can be identified and evaluated for consistency, both with one another, but also in driving lagging KPIs and business targets. Geometric Process Control (GPC), pioneered by PPCL, makes this possible and should be part of any process-based Operational Excellence program.

In this free webinar we will show you how the full feed-to-product process operating envelope can be visualized along with current and potential KPI targets. This allows the suitability and consistency of leading and lagging KPIs to be evaluated and improved, providing the link missing today.


GPC for better operation and control of Multi-Mode, Multi-Phase and Grade Transition Processes

Have you got a Multi-Mode, Multi-Phase or Grade Transition process? 

Many continuous processes have just one Normal Operating Mode (other than StartUp and Shutdown) and thus just one Normal Operating Envelope. But some processes have more than one normal Operating Mode or Phase and thus have to have more than one Normal Operating Envelope and have to be able to switch Operations between them.

Examples of such processes include: Multi-Mode continuous processes with wide ranges of feed composition or external variables or where a very large turn-down is required (right now there are continuous processes struggling because of reduced demand to run economically at 60% throughput to avoid shutting down), grade transition processes in polymer industries, and recipe-driven multi-Phase batch processes that may also be multi-Stage. Each Mode or Phase or Transition represents a different set of relationships between process and result variables so has an Operating Envelope of its own. How do multiple operating envelopes relate and connect to each other?

In this webinar I will show you how easy it is with GPC (Geometric Process Control) to separate the individual multi-variable operating envelopes for each Mode, Phase or Transition and then have GPC automatically build linked real-time Operating Envelope models for each one for much better operator alarms, open-loop operator guidance, fault prediction and closed-loop control. No maths or equations or advanced maths qualifications needed and designed for use by the front-line process, control and automation engineers who have the best knowledge of their process and its actual operating limitations and practices. It's no more difficult than creating a single-Envelope model for a continuous process, as you have seen demonstrated in many of our other webinars. It just takes a little longer.


Operational Process Improvement: You Already have the Data

You already have the data for enormous potential in improving plant operation through making operational changes to capture, repeat, and improve best historic operation. Understanding your process behavior is key to unlocking benefits such as higher throughput, better product, lowest costs, less waste, and more uptime.

This free webinar will show you visual tools that engineering and operations can use to extract and exploit the wealth of information available.

An Operating Envelope is the relationship between variables that gives the best achievement of one or more objectives such as yield, throughput, quality, KPI attainment, cost, or a combination. This can be very complex when multiple optima exist, and until now, very difficult to see with more than a handful of variables.

We will demonstrate a straightforward visual method of quickly finding consistent limits for operating windows that capture desired performance for many variables at once. This can be repeated for different objectives so that conflicts between different target operations can be seen before they are implemented. You can even see how that newly proposed KPI and its limits will perform and whether the operating window is sufficient to achieve the required targets.


PPCL © Copyright 2011-2019. All Rights Reserved. | Terms of use | Privacy Policy | P.O. Box 43, Gerrards Cross, Buckinghamshire, SL9 8UX. UK.