Global Specialty Chemical

Project Understanding:

Global Specialty Chemical company asked Wunderlich-Malec to explore the status/maturity of their current DCS implementations across the North American sites with the intent of identifying and executing improvements on designated sites in the US.

Scope of Work includes:

1. Explore the status/maturity of current DCS implementations:
   • DCS support such as DCS information extraction, control-loop configuration/re-configuration
   • PID tuning
   • Historian
2. Analyze data and produce a report that includes:
   • Control-loop(s) with either (or both) poor setpoint tracking or regulatory control performance that requires further tuning
   • Observed instrument/control valve issues
   • Alarm Classifications
   • Control-loops that are candidates for future APC implementation (MVs).
3. The outcome of interviews performed with site personnel.

Outcomes:

Some of the outcomes as identified by the customer:

1. Before and after comparison for this particular process T/25 (with 2nd and 3rd additions) batch.  In summary (between 2nd and 3rd addition), improvements are:
   • Time reduced by 56 minutes.
   • Temperature drop reduced by as much as 85 degF.
   • Eliminates the need to switch between cool-on and heat-on.
2. These are the initial results for 1 product
   • New temperature cascade control implemented in process drying.
   • Drying time (for the same product) reduced by ~50%
3. Other examples: