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Improve the security and performance of your plant with alarm management, performance supervision, asset supervision, web-based data visualisation, optimisation, advanced control, and tuning with the new TaiJi tool.

Rethink your working methods and obtain immediate results thanks to our services, trainings, and consulting expertise. Manage changes intelligently with our proven solutions.

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Results > Business Cases / Testimonials

Business cases, some examples:

• Optimization in a liquefaction of natural gas plant to increase production (Oil & Gas)
• Optimization and equipment performance validation in a refinery (Petrochemical)
• Optimization and troubleshooting at start-up (Petrochemical)
• Optimization of a chemical plant (Chemical)
• Optimization of a steam plant to reduce costs and improve performance (Energy, Pulp & Paper)
• Control strategies design for a cogeneration plant in a pulp mill (Energy, Pulp & Paper)
• Optimization of a deinked plant (Pulp & Paper)
• Training and tools in a mining plant (Mining & Metallurgy)
• Optimization of a mining processing plant (Mining & Metallurgy)

Gas Business Case

Atlantic Liquified Natural Gas Company
Atlantic Avenue
Point Fortin,
Trinidad & Tobago

Industry type: Liquefaction of Natural Gas, train 1

Top Control mandate
• Obtain the maximum from the process
• Increase production rate
• Improve stability and operation

Investment by Atlantic Liquified Natural Gas : 137 000 $us

Top Control intervention

• duration : 3 weeks

Top Control engineers met the production and operation teams to define their objectives and targets.
They then analyzed the processes, the control strategies, control schemes and operation approach.

Each unit was optimized accordingly to goals defined.

  • Control strategies
    • Optimization
    • New control strategies
  • Process optimization
  • Loops optimization;
    • Equipment;
    • Loop performance;
    • Loop tuning
  • Report, recommendations;
  • Training for operation, engineering and maintenance teams.

      Results
      Production increase : 1.5 %
      Benefits : 20 000 000$us/y

      Other improvements: production is more stable, operation is easier, personnel now have the tools to sustain the performance obtained.
      Other consequences: the same approach ahs been done with trains 2 and 3 and the same results were obtained.

      Refinery Business case

      Refinery on the West Coast in USA

      Industry type: Refinery

      Top Control mandate

      • Optimize regulatory control before adding MPC
      • Validate control strategies and equipment performance

      Investment by Refinery : 105 000 $us (service, design, tool)

      Top Control intervention
      • duration : 6 weeks

      Top Control engineers met the production and operation teams to define their objectives and targets.
      They then analyzed the processes, the control strategies, control schemes and operation approach. Control strategies were validated. Instruments and valves were tested during normal operation.

      •Loop tuning software
      • Control strategies
      • Process optimization
      • Loops optimization

      • Equipment
      • Loop performance
      • Loop tuning
    • Report, recommendations
    • Training for operation, engineering and maintenance teams.

      Results
      Benefits : Payback = 3.5 months

      Petrochemical business case

        Shanghai SECCO Petrochemical Co Ltd.
        Shanghai Chemical Industry Park
        Xihe Road, Shanghai 201507 China

         Industry type: Ethylene plant

        Top Control Mandate

      • Obtain the maximum from the process
      • Reduce oscillations and improve stability
      • Improve operation

        Investment by Shanghai SECCO : 77 000 $us

        Top Control intervention 

      • duration : 5 weeks

        Top Control engineers met the production and operation teams to define their objectives and targets.

        They then analyzed the processes, the control strategies, control schemes and operation approach.

        Each unit was optimized accordingly to goals defined.

      • Control strategies
        • Optimization
        • New control strategies
      • Process optimization
      • Loops optimization
        • Equipment
        • Loop performance
        • Loop tuning
      • Report, recommendations

        Results

        Production increase; stability and reliability improved.

        Benefits : undisclosed

         

        Chemical Business case:

        Uniboard (Div. Unires)
        970 Rue de l'Echo
        Val d'Or, Qc J9P 6L1

        Industry type: Chemical Plant (formaldehyde)

        Top Control mandate

        ·      Obtain the maximum from the process

        Investment by Unires : 19 000 $cdn

        Top Control intervention

        ·         duration : 15 weeks

        Top Control specialist met the production and operation teams to define their objectives and targets.

        They he analyzed the processes, the control strategies, control schemes and operation approach.

        Each unit was optimized accordingly to goals defined.

      • Control strategies
        • Optimization
        • New control strategies
      • Process optimization
      • Loops optimization
        • Equipment
        • Loop performance
        • Loop tuning
      • Report, recommendations
      • Training for operation, engineering and maintenance teams

        Results

        Production increase, stability, reliability. Variability has been reduced. Plant now runs in automatic.

         

        Energy Business

        SFK PATE S.E.N.C.
        C.P. 7100
        4000, chemin St-Eusèbe
        Saint-Félicien, QC G8K 2R6

        Industry type: Co-gen plant in a kraft pulp mill

        Top Control mandate

        ·         Reduce energy costs

        ·         Balance automatically electrical demand, electrical production, steam generation

        ·         Improve stability and operation

        Investment by SFK : 25 000 $cdn (service, design)

        Top Control intervention

        ·         duration : 3 weeks

        Top Control engineers met the production and operation teams to define their objectives and targets.

        They then analyzed the processes, the control strategies, control schemes and operation approach. Control strategies were designed to maximize benefits while respecting contract clauses (peak period, electricity consumption). Competitors suggested expensive and complex black boxes algorithms. We proposed to program everything with basic functions using their DCS.

        ·   Control strategies

        §   Fuel management

        §   Boiler management

        §   Optimization

        §   Electricity generation/Electricity consumption

        ·   Process optimization

        ·   Automation

        ·   Loops optimization

        §   Equipment

        §   Loop performance

        §   Loop tuning

        ·   Report, recommendations

        ·   Training for operation, engineering and maintenance teams.

        Results

        Benefits :                      Payback = 2 months

        They can now modify themselves goals and limits in their DCS.

        Pulp Mill Business Case

        SP Newsprint Co.
        709 Papermill road
        Dublin, GA 31027    
        U.S.A.

        Industry type: Pulp and Paper (Deinked plant)
        Top Control mandate
        • Reduce sheet breaks
        • Improve pulp quality
        • Improve stability and operation

        Investment by SP Newsprint : 12 000 $us

        Top Control intervention
        • duration : 1 week

        Top Control engineers met the production and operation teams to define their objectives and targets.
        They then analyzed the processes, the control strategies, control schemes and operation approach.
        Deinked plant was optimized accordingly to goals defined.

        • Control strategies
          • Optimization
          • New control strategies to maximize quality and limit production
        • Process optimization
        • Loops optimization
          • Equipment
          • Loop performance
          • Loop tuning
        • Report, recommendations

        Results
        Benefits :   Payback = 1 week
         

        Sheet breaks on paper machines have been reduced by 43% and these results have been verified again after 6 months.

        Mining processing plant Business case

        Xstrata Nickel - Mine Raglan
        Canada

        Industry type: Mining Processing Plant
        Top Control mandate

        • Obtain the maximum from the process
        • Increase production rate
        • Improve stability and operation
        • Improve personnel technical skills

        Investment by Xstrata : 219 000 $cdn

        Top Control intervention
        • duration : 15 weeks

        Top Control engineers met the production and operation teams to define their objectives and targets.
        They then analyzed the processes, the control strategies, control schemes and operation approach.
        Each unit was optimized accordingly to goals defined.

        • Control strategies
          • Optimization
          • New control strategies
        • Process optimization
        • Loops optimization
          • Equipment
          • Loop performance
          • Loop tuning
        • Report, recommendations
        • Training for operation, engineering and maintenance teams.

        Results

        Production increase, stability, reliability
        Benefits :   7 000 000$cdn/y recurrent