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Reducing Energy

Consumption by Monitoring
Controller Performance
George Buckbee, P.E.
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Presenter

• George Buckbee, ExperTune

George Buckbee, P.E. holds a B.S. and M.S. in Chemical Engineering. As Vice
President of Marketing and Product Development at ExperTune, Inc., he is
co-designer of ExperTune’s PlantTriage software. George has led
ExperTune’s marketing program to deliver high-quality, high-quantity sales
leads. As an experienced practitioner, George has over 20 years of practical
experience in process control across many industries, with over 10 years
devoted to advancing the theory and practice of process and control system
improvement.

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Agenda

• Indicators of Energy Savings Opportunity


• Controller Performance Monitoring
• Case Studies
• Q&A

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Indicators of Opportunity

• Valve Travel
• Opportunity Gap
• Oscillation
• Interaction

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Case Study 1

• Valve Travel

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Case Study 1

2.5” Valve, Reduce by 120 strokes/day = $100/year


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Case Study 2

Oscillations

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Case Study 2

1 Afternoon’s Work = $500,000/year Savings


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Case Study 3

Process Interaction Map

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Case Study 3

Source of Hydrogen Pressure Upsets?

Cooling Tower Temperature


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Case Study 3

Annual Savings = $1,000,000


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Conclusions

• Many Opportunities to Save Energy


– Substantial $$
• Controller Performance Monitoring provides insight
• Things to Look at:
– Valve Travel
– Opportunity Gap
– Oscillations
– Root Cause of Interactions
• Savings Captured Quickly

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Q&A

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