过程控制与优化
概述
过程控制和优化 (PCO) 是在不违反过程约束的情况下调整过程以维持或优化一组指定参数的学科。 PCO 市场受到对节能生产流程、安全和安保问题的需求不断增长以及能够可靠预测流程偏差的物联网系统开发的推动。从根本上说,可以调整三个参数以影响最佳性能。 - 设备优化:第一步是通过检查运行数据以识别设备瓶颈来验证现有设备是否被充分利用。 - 操作程序:操作程序可能因人而异或因班次而异。工厂的自动化可以提供很大帮助。但是,如果操作员控制并手动运行工厂,自动化将无济于事。 - 控制优化:在典型的加工厂,例如化工厂或炼油厂,有数百甚至数千个控制回路。每个控制回路负责控制过程的一部分,例如保持温度、液位或流量。如果控制回路没有正确设计和调整,则过程会低于其最佳值。该过程的操作成本将更高,并且设备会过早磨损。为了使每个控制回路以最佳方式运行,识别传感器、阀门和调整问题很重要。已充分证明超过 35% 的控制回路通常存在问题。持续监控和优化整个工厂的过程有时称为绩效监督。
适用行业
- 运输
- 设备与机械
- 化学品
适用功能
- 离散制造
- 质量保证
市场规模
案例研究.
Case Study
Operational Efficiency through IoT
A GSPC (Gujarat State Petroleum Corporation) Group company; GSPL is a pioneer in developing energy transportation infrastructure and connecting natural gas supply sources including LNG terminals to growing markets. The company transports over 22.99 MMSCMD of natural gas to around 133 Customers. Their customers include Refineries, Steel Plants, Fertilizer Plants, Petrochemical Plants, Power Plants, Glass industries, Textiles, Chemical, City Gas Distribution Companies and other miscellaneous industries. The major challenges GSPL was facing were: - Prohibitively High Energy Bills. - Lack of Monitoring Solutions to track energy consumption across the entire pipeline. - Inability to Gather Data from all 124 terminal stations into a central location. - Inability to do a Comprehensive Data Analysis to balance consumption. Requirements In addition to addressing the challenges, GSPL also had some additional requirements, such as: - Automated Data Collection. - Alarms and Alerts for specific electrical parameters that require special attention. - Actionable Insights for Proactive and Autonomous energy management. - Online Platform to monitor, analyze and act. - Centralized Remote Monitoring and Analysis.
Case Study
MasterCard Improves Customer Experience Through Self-Service Data Prep
Derek Madison, Leader of Business Financial Support at MasterCard, oversees the validation of transactions and cash between two systems, whether they’re MasterCard owned or not. He was charged with identifying new ways to increase efficiency and improve MasterCard processes. At the outset, the 13-person team had to manually reconcile system interfaces using reports that resided on the company’s mainframe. Their first order of business each day was to print 20-30 individual, multi-page reports. Using a ruler to keep their place within each report, they would then hand-key the relevant data, line by line, into Excel for validation. “We’re talking about a task that took 40-80 hours each week,” recalls Madison, “As a growing company with rapidly expanding product offerings, we had to find a better way to prepare this data for analysis.”
Case Study
McAfee Speeds to Market with OEM Alliance Solution
McAfee, the world’s largest dedicated security technology company, delivers proactive and proven solutions and services that help secure systems, networks, and mobile devices around the world. With over $600 million dollars of procurement per year, McAfee relies on its dynamic OEM appliance manufacturing partners to develop extremely reliable, high-performance new products quickly and efficiently. Most importantly, McAfee requires its suppliers to deliver the same high-quality engineering and support that its customers have come to expect. In any product lifecycle, flexibility is the key ingredient to a successful deployment. During McAfee’s development of a new turnkey solution, Intel announced the introduction of new processors, which would become generally available at the same time as the planned debut of the McAfee appliances. Being able to take advantage of these new processors without delaying the introduction of the new appliances introduced a new challenge and McAfee needed a partner to step up to remove the potential obstacle.