Project Services

Spiro provides expert support for the deployment and maintenance of advanced control applications and real-time optimizers, tailored to meet the client’s needs. By leveraging agile methodologies and extensive industry experience, Spiro ensures reduced project risks, lower costs, and successful outcomes across a range of control and optimisation applications.

Project Services

Spiro provides expert support for the deployment and maintenance of advanced control applications and real-time optimizers, tailored to meet the client’s needs. By leveraging agile methodologies and extensive industry experience, Spiro ensures reduced project risks, lower costs, and successful outcomes across a range of control and optimisation applications.

Advanced process control & optimisation services

We provide a range of services from fully installed solutions, to process control trouble-shooting, control systems design and implementation. To help you deliver successful projects and rigorous risk management, we use a mix of creative thinking, expert judgement and experience.

Maintaining

Multivariable controllers and optimizers require ongoing maintenance to maintain the benefits achieved during initial setup. Over time, changes in the plant or process, personnel turnover, and instrumentation faults can degrade application performance, resulting in reduced benefits and diminished service quality. Even when the service factor remains high, neglected control applications may lead to panel operators restricting manipulated variables, causing significant inefficiencies.

Spiro’s engineering team can support the client by assisting with regular maintenance tasks, including identifying issues, making tuning adjustments, and performing minor modifications, such as adding new controlled or manipulated variables. We ensure all relevant documentation is kept up to date as part of our comprehensive support services. Additionally, we offer regular health reports that provide key management insights into application performance.

Revamping

When significant changes are made to a process unit—such as replacing a furnace or altering the number of trays in a column—the existing Model Predictive Control (MPC) system or optimiser will require a thorough revamp. This often involves conducting a full or partial step test campaign to ensure that the benefits of the application are maintained at post-audit levels.

Spiro’s engineers will collaborate with the client’s team to define the updated control structure, perform the necessary step tests, and update and recommission the existing MPC controller and optimiser. Our extensive expertise guarantees a high standard of support throughout the project. All relevant documentation will be meticulously updated, and refresher training for engineers and operators can be provided if needed.

Migrating

The migration of an existing MPC or optimisation application to a different software is often portrayed by vendors as a straightforward process involving the transfer of models and tuning parameters. However, this “cut and paste” approach overlooks the unique characteristics of each software. Simply replicating the existing setup is unlikely to achieve satisfactory performance, especially for highly customised systems.

Successful migration requires an experienced team capable of leveraging the features of the new software and effectively transferring all customisations. Spiro engineers can assist the client team in selecting the most suitable software and seamlessly migrating the existing applications to the chosen platform. Additionally, Spiro can aid in integrating new MPC controllers into an existing Real-Time Optimisation (RTO) structure.

Building

With extensive experience across a wide range of projects in the refining and petrochemical industries, Spiro is well-positioned to assist in identifying and justifying opportunities for new advanced control and optimisation applications. These opportunities can range from implementing advanced control systems on smaller process units like compressors or fired heaters to deploying more comprehensive optimisation solutions.

Spiro’s engineers will work closely with the client to define the design of the new application, perform the necessary step tests and model identification, and commission the application. Our team’s deep expertise ensures high-quality support at every stage. Comprehensive documentation will be provided throughout the project.

Agile Projects

Drawing from our substantial expertise in software product development, Spiro has gained valuable insights into the advantages of agile methodologies and the scrum approach to project execution. We have recognised the benefits of integrating these techniques into our application deployment projects. By merging the crucial elements of effective advanced control and optimisation project deployment with scrum methodologies, our agile approach to project management and application deployment aims to reduce project risks and costs while ensuring successful project outcomes.