Hierarchical Scheduling and Utility Disturbance Management in the Process Industry

This thesis deals with control of production at large-scale process industrial sites in the presence of disturbances. The main focus is on disturbances in the supply of utilities such as steam, cooling water and electricity. A general method for reducing the revenue loss due to disturbances in utilities is introduced, which may provide both proactive and reactive disturbance management strategies. Utility availability and area availability are introduced as performance indicators. These measures are used to obtain quick estimations of the revenue losses related to each utility. To obtain reactive strategies for utility disturbance management, a simple model of how utilities affect production in an area, and how utilities are shared between areas, is introduced. The modeling approach is utilized to formulate the production control problem at disturbances in utilities as an optimization problem. Measurement data are used to obtain empirical models of utility disturbances at an industrial site, which may be used as input to the optimization. Since production control closely relates to production scheduling, the integration of production scheduling based on orders and forecasts with production control at disturbances in utilities is studied in the final part of the thesis.