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
Reduce the Energy Consumption of Air Cooled Condensers
Altiux's client organization is at the forefront of technology adoption in its manufacturing processes and had already implemented advanced control systems. However operating expenses still remained on the higher side due to inefficiencies in certain processes which required manual intervention. The challenge for Altiux was to understand the nature and root causes of these inefficiencies and make recommendations for reducing the operating expenses. Our observation was that data was being generated with a millisecond level resolution and hundreds of simultaneous fluctuations made it near impossible for the operators to make optimal control decisions consistently. As significant investments had already been made in the instrumentation of the operational equipment, the management was hesitant to make modifications to existing systems and processes. Altiux was asked to make recommendations such that it could blend in with existing processes and additional capital expenditure or staff retraining was not required. The Air Cooled Condenser system at the client's captive power plant was operated using a series of VFD fans. The rotational speed of these fans were being manually set from the control centre, based upon the experience of the operator. Moreover the fans were being operated in different speeds, with fans closer to the turbine operating at near full speed. Thus the first phase of Altiux engagement involved optimization of the captive power plant's steam cooling subsystem.
Case Study
AWS Migration
Due to its ever increasing customers and connections Wyless required more scalability and efficiency but definitely at a cheaper cost. Usage records & calculations for more than 2 million connections does not reside in gigabyte of space, it requires terabytes of space. Where connectivity is the key to your success or failure in business, you don’t want your machines to be responsible for slow response. Wyless had all of its servers managed at another hosting. Ex-Hosting became non-scalable to support the ever-expanding needs of expansion Wyless required. But moving instance from Ex-hosting was the biggest challenge. Wyless had issues of stability, network availability, scalability & OS. Resulting in not able to scale up the resources like Disk, CPU and Ram without incurring downtime.
Case Study
Brooklyn Botanic Garden Ponds: OptiNimbus for Combined Sewer Overflow Reduction
Brooklyn Botanic Garden sought a comprehensive site water harvesting and recirculation system to maintain its landscape, water features, and special tree and plant species while minimizing impacts on the environment by reducing wet-weather discharge.