ProNamics Control Inc.

"Your process and control optimization and troubleshooting professionals"
























BC Hydro Power Smart Alliance Member



June 25, 2010



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ProNamics Celebrates 10 Years

In the past 10 years ProNamics has conducted hundreds of courses. We have trained in excess of 1000 E/I Tech's, Control Specialists, Engineers and operators.
Process Optimization & Troubleshooting Techniques
 For process engineers, control and instrument engineers and operations management
  • Fall, Baton Rouge, LA
    •
    Pipeline Process Control Optimization Techniques
     For process engineers, control engineers or E/I technicians and maintenance and design engineers.
  • November 30 to December 2, Edmonton, AB
    		• Process Control Optimization
     For instrument techs, planners, supervisors, engineers and process control engineers
  • TBA
    •
    In the past 10 years ProNamics has conducted hundreds of process & control optimization and troubleshooting surveys on boilers, pulp mills, paper mills, petroleum pipelines and natural gas processing plant in more than 7 countries. .

    Opportunities for Output Linearization
    Highly non-linear process dynamics can severely degrade loop performance. For the majority of control loops, the tuning constants are based on the process dynamics measured at one operating condition . We hope that the tuning will ‘work’ over the entire operating range. All too frequently we get sluggish response in some operating regimes and fast/oscillatory response in others.

    Improper valve selection is frequently a source of non-linear process dynamics , resulting in an ‘installed’ process gain that varies substantially with valve position. In these cases Output Linearization should be considered as a means of compensating for the non-linear valve response.

    Please click on Output Linearization to read more about this strategy and to take the quiz.

    Optimizing Pumping System Performance
    Pumping systems are composed of pumps, pipelines, control valves and other process equipment. A program to improve pump system performance needs to consider the entire system - not just the pump. Proposed modifications to the pumping system need to be assessed according to the impact on energy consumption. process variability, control performance and maintenance costs. Please refer to our Pump System Performance Survey information sheet for further details on ProNamics approach to this important activity.

    Click on the November 08 challenge answers to view the answers to our challenge questions posted in the last update. The ProNamics ‘Stock Flow Simulator’ was used to generate the detailed results for each option under consideration. This simulator was designed to assist in pumping system optimization and considers the impact of process modifications on pumping cost, control performance and process variability. Click on the Process Simulator 2009 brochure for more information.

    Benefits of Optimization Services

    Paper Machine Optimizations
    ProNamics recent paper machine optimization surveys have increased machine efficiencies, improved registration and reduced cull.

    • Control improvements to stock blending eliminated excessive fiber flow and consistency cycling improving machine efficiencies during light weight grades.
    • Reductions in totalhead variability by eliminating cavitation in the lean stock piping through adjusting cleaner pressures eliminated high rush/drag variability and mis-registration.
    • Control valve and control performance improvements to the dearator overflow level contol reduce machine direction basis weight variability reducing cull during light weight grades.

    Boiler Optimizations
    ProNamics recent utility, hog and recovery boiler optimization surveys have increased boiler uptime, increased hog consumption, reduced gas usage, improved boiler efficiency and reduced steam header pressure variability.

    • Control improvements implemented to drum level control have reduced boiler trips due to drum high/low level trips.
    • Control improvements implemented on boiler master controls and constraint controller dramatically increase hog consumption and reduced gas usage while reducing steam header pressure control induced variability.
    • Process and control testing identified several damper and control loop health issues resulting in poor air/fuel ratio control resulting in high boiler excess air/O2 reducing the boiler efficiency.

    Pipeline Pressure Control Optimization
    ProNamics recent petroleum pipeline pressure control optimization services have resulted in dramatic improvements in line operation reducing line trips, manifold over pressure and maintenance.

    • Control improvements implemented on a meter back pressure application has greatly reduced shipper line pressure cycling which was resulting in line trips under certain operating conditions.
    • Control improvements implemented on a holding pressure application greatly eliminated extremely high manifold pressure excursions during line rate changes and greatly improving the line operation at low rates. The line was not controllable under low line rates, resulting in the customer to consider other shipper options.

    Improving control loop performance by retuning P I D controllers is the 'low hanging fruit' of process optimization surveys. There is minimal capital investment required, yet there is the potential for very substantial economic benefits. The retuned controller may be more capable of attenuating disturbances and keeping a key process variable on target. Alternately, implementing a tuning strategy which is based on optimizing the process objectives may move variability away from key processes. The retuned controller may reduce equipment wear and premature failure of loop elements. Whatever the case, the re-tuning effort can provide economic benefits by improving product quality and process efficiency, and reducing maintenance costs.

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