Page 391 - Design of Simple and Robust Process Plants

378 Chapter 9 Operation Optimization
9.6
Project Methodology for Operation Optimization

The methodology for the implementation of an OO project is described. The overall
step-wise methodology is presented in a flow diagram (Table 9.2), which emphases
the successive steps to be taken for an optimization project. The details of each step
are described in the subsections, and the methodology is described for the imple-
mentation of a CLO of a continuous process. Before a project is even started, a feasi-
bility study must be prepared to define the scope, costs, savings, and the economics
of a potential project. The project is concluded with an appropriate evaluation and
an adequate maintenance structure. This section will be concluded with a short note
about the implementation of off-line optimizations as well as dynamic optimiza-
tions.

Table 9.2. Project methodology, flow diagram for OO projects.

(0)Feasibility study
(1)Scope definition
(2)Develop and install performance measurement and start tracking process performance
(3)Develop control structure and CVs, MVs, DOFs
(4)Build executive and implement data analysis for steady-state detection and performance meter
Parallel activities
Develop control develop model
(5C)Inventory of control improvements (5M)Develop and validate reactor model
(6C)Design and install additional (6M)Develop process model with reactor
Instrumentation model including optimizer
(7C)Design and implement improved basic (7M)Test process model for robustness on
control and test plant stability and process conditions and prices
disturbance rejection
(8C)Design and implement model-based
constraint control test plant stability
and disturbance rejection
(9)Implement data analysis on selected data
(10)Implement data reconciliation

(11)Implement simultaneous data reconciliation and parameter estimation
(12)Validate model
(13)Implement closed loop optimization
(14)Evaluate project and build up maintenance structure