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Columbian Chemicals acheives major business benefits with

Case Study

Increased production rates and decreased energy costs were delivered very quickly, and with an excellent Return on Investment (ROI). Learn how Columbian Chemicals achieved major business benefits through the use of PlantTriage®.

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Experience in the Chemical Industry

ExperTune has been improving control loops in the Chemical industry for over 20 years. ExperTune's tools have been tested on a host of process unit operations in the chemical industry, including reactors, dryers, separators, and columns, to name a few. In every case, these tools have been able to improve control, and increase process performance.

Specialized processes, specialized equipment, and tight product specifications are the hallmarks of the chemical industry. With thousands of control loops to look after, you don't have a lot of time to look after each loop individually. You need some tools that help you see the big picture, while not losing track of the details.

Control Loop Monitoring software looks after your thousands of control loops, 24 hours a day. Based on criteria that you have set, the PlantTriage Control Loop Monitoring System scans the entire process, finds the important information, filters it based on your needs, and notifies you directly.

Seeing it All

TreeMap plots two assessments together in a meaningful color map.

The Big Picture

PlantTriage's Dashboard displays concentrated information so that you can see at a glance exactly what information you want. Because the information is provided in a web browser interface, you can get all this information from your desktop computer. For example, the TreeMap, shown here, is a new, powerful visualization tool that helps focus your attention on the "Hot Spots".

Learn more about the TreeMap

And The Intimate Details

As you Drill-Down into the data, PlantTriage quickly brings you to the detailed root-cause information. With custom Dashboards, you get all the detailed information that you need to solve problems with instrumentation, controllers, and valves.

Fully Integrated Modeling, Analysis, and Tuning

Your time is valuable. You shouldn't have to waste time piecing together information from 5 different sources. PlantTriage® automatically gathers data, identifies process models, completes assessments, and notifies you of the results. It does all of this during normal process operation, without any interventions or process bumping required from you. The results can be delivered to you as an email, or displayed in your user-customized web browser interface.

For detailed loop analysis, the data is automatically passed, in context, to ExperTune's PID Tuner/Analyzer.

Knowing What to Do About It

Simple Diagnostic Messages for every control loop in the plant.

PlantTriage® tools are designed to make the analysis easy. You will see charts and graphs of the information that is important to you. Whether you are in Maintenance, Operations, Management, or Engineering, PlantTriage® can show you exactly what you need to see to make decisions.

Tools to help you in your job:

Powerful, award-winning, state-of-the-art control loop analysis tools are included with PlantTriage. Control Engineers have every possible advantage to identify process models, tune control loops, diagnose instrument and valve problems.

Advanced Controls

PlantTriage goes beyond single-loop analysis. Model-predictive Controllers can also be supervised within PlantTriage. At a glance, you can see when and where MPC controllers are constrained, and even receive notifications when the model and process are not tracking closely.

Fixing the Fundamentals

The best APC package in the world is useless if your valves are not performing. ExperTune's experience has been that over 30% of valves in Refinery operations have performance issues. This includes problems with stiction, hysteresis, valve sizing, and slow response. PlantTriage helps to identify when valves are having problems. The included PID Tuner/Analyzer package can help you to troubleshoot and identify exactly what is wrong while the process is running.

Maintaining Security

With its secure web-browser access, PlantTriage keeps end users and their heavy data demands off of the control network. Optional Shadow Server technology can be applied for an even greater measure of security.

Gaining Alignment

No matter what your role, you don't run the plant by yourself. Many other people are involved in making decisions that affect production, maintenance, finances, and quality. PlantTriage and PID Tuner provide out-of-the-box reporting tools that help you to make your case. You can even email these reports directly to you, export data to Excel for further analysis or to include in a presentation. This helps everyone to see the problem as you see it, and makes gaining alignment faster than ever.

Control Loop Optimization

PlantTriage includes a copy of ExperTune PID Tuner/Analyzer, repeatedly recognized by users as the #1 controller tuning software package. This includes tools for PID Tuning, Linearization, and Optimization. Learn more about control loop optimization.

Develop Your Expertise

The average ExperTune instructor has over 20 years of hands-on process control experience.

The way to improve your career is develop yourself. ExperTune's training programs provide a mix of theory and practice to help you to solve problems quickly. Join one of our training sessions or schedule one for your site.

Training courses for every step in your career. Whether you are just starting out, or you are an experienced loop optimizer, you will get practical guidance from our experienced instructors.

Click here for more on training.


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