Client Background
BCPL operates complex petrochemical plants handling polymerization processes, cracking furnaces, and gas handling systems.
Challenge
- High energy consumption in cracking units
- Inconsistent polymer grade quality
- Limited operator understanding of process variables (PV) & control loops
- Need for deeper knowledge of DCS (Distributed Control Systems)
Y&Now Intervention
Y&Now built a Process Engineering & DCS Mastery Program:
- Ethylene & propylene cracking process deep dive
- Furnace temperature profiling
- PID loops & control philosophy
- Heat exchanger fouling detection
- DCS alarm classification and response
- Polymer grade switching procedures
- Emergency shutdown (ESD) logic
Implementation
- 60-day intensive technical bootcamp
- DCS simulators replicating plant conditions
- Virtual reality (VR) safety walk-throughs
Results
- Furnace efficiency improved by 12%
- Polymer grade consistency improved across shifts
- Operators demonstrated 40% faster ESD response time
- Energy savings translated into significant cost reductions
Client Feedback
“Y&Now demonstrated unmatched process engineering depth. They delivered what global consultants do—at local relevance.”
