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Capturing and Replicating Optimal Process Operation


The key to repeating best operation is understanding your process behavior. This is necessary to achieve higher throughput, lower costs, least waste and minimum downtime. While some of this is known in the process design, much of what is taken as true about your process is likely wrong or contradictory. The resolution to these conflicts and a true process picture are already present implicitly in your plant historian, built from years of experience. This webinar will show you visual tools which engineers 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 or cost. This can be very complex when multiple optima exist and, until now, very difficult to see with more than a handful of variables. In the past, targets would be found individually, discounting the inherent relationship between the variables. Doing this is tedious and it is difficult to move them in accordance with new or modified goals through KPI targets and would often conflict with other limits such as safety alarms, integrity operating limit and operator alarm limits.

Feed-to-product operating envelopes make it easy not only to reproduce best operation by identifying key variables and operating ranges to ensure consistent operation or provide MPC constraints, but also to generate new information by comparing operation under different external conditions to question why it is where it is. This can be done graphically without advanced statistical or analytic techniques.

In this webinar we demonstrate a straightforward visual method of quickly finding consistent limits for operating windows which 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. 


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