To achieve operational excellence in process plants, operators need to embrace methodical thinking to create sustainable improvements. The usual practice for an operating team is to continue with plant operations as it was originally intended, without modifications or reevaluations. To some extent, that is justifiable, as the primary role for operators is to maintain production in safe and well-understood parameters. However, mindful modifications can have considerable benefits.
As we know, to account for guarantees by technology providers or as a caution against uncertain parameters, process plants as designed operate at wider thresholds compared to what might be necessary. Thus, operating a plant at initial design conditions may result in suboptimal results. To run efficiently, operating parameters should be evaluated by a team of experienced professionals. Some concepts that can be guiding principles include:
Process validation/simulation of the open art section of the plant to optimise the operating parameters.
A plant may give better product specifications and thus satisfy operational requirements but these specifications do not account for increased costs.
This study will ensure operational optimisation to meet product specifications.
Matching energy consumption with the right specs is an example of how cost savings can be designed for.
Overall energy consumption analysis
Minimizing energy consumption not simply to save operating costs, but also to achieve a broader objective in managing the energy footprint to reduce global warming.
Process Control Monitoring
An area that often gets overlooked, but has the potential for saving considerable costs with minimal investment
Achieved through periodic review and systematic focus on operating parameters and fine-tuning operational settings to get maximum benefits.
These investigations do not need large teams or even in-person engagements. Analysis can be done by remote interactions with the operating team and relying on read-only access to the operating parameters.
Studies can be planned in phases and done gradually. The initial process study is only to monitor the control parameters every 3-4 months and do the benefits analysis.
Opportunity to identify necessary modifications to get benefits and perform cost-saving analysis for implementation.
The combination of these techniques can not only benefit plant operators with cost savings but have the added bonus of helping the environment. These studies can be initiated with minimal upfront service costs to identify options to save energy for production units and thus, achieve operational excellence.
BrightAgami is available to support operating companies using some or all the above techniques and help realize long term benefits.
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