Control Talk Blog

Batch Optimization Recommendations Tips

Batch processes pose particular challenges for closed loop control and optimization due to inherent process nonlinearity and non-self-regulation. At the same time there are is a greater potential for increasing capacity in batch than in continuous processes. Solutions need to address the interrelationship between yield, capacity, quality, and repeatability.

Batch Optimization Perspective Tips

The highest value added products use batch operations. Batches can take days to complete and be worth millions of dollars. In many cases bad batches cannot be fixed downstream. Bad batches must be avoided. There are many techniques for making batches more repeatable and faster by better monitoring and control.

Auto Tuners and Adaptive Control Recommendations Tips

Software for auto tuning and adaptive control provide the opportunity to identify key loop dynamics besides providing a sound fundamental and automated basis for getting the best PID settings. Presented are uses of the knowledge gained and the setup of the automation system and testing/monitoring of PID performance to get...

Auto Tuners and Adaptive Control Perspective Tips

Automating any process can yield big improvements by eliminating human error and adding repeatability and predictability. The benefits are greatest when the best technology and practices are automated, the novice is protected against mistakes, and the specialist is enabled to capitalize on creativity and expertise.

Process Control Improvement Recommendations Tips

Here we look at how to make sure the measurement system is able to provide the analysis, metrics, and control needed for process control improvement. Also outlined is the opportunity sizing and assessment process, the use of statistical tools, the tracking down of the source of variability, and the finding...

Process Control Improvement Perspective Tips

The benefits from process control improvement originate from increases in process efficiency, flexibility, and capacity. Often, there is a tradeoff where an increase in flexibility or capacity is accompanied by a decrease in efficiency. Better measurements, process knowledge, online metrics, and an enhanced PID can provide a more intelligent and effective...

Compressor Surge and Stall Detection and Prevention Tips

A compressor going into stall is like jumping off a cliff with a bungee cord. If the bungee cord has no losses to dampen the oscillation, we have something akin to surge. A 0.5% drop in efficiency can occur for each surge cycle.

Startup, Career, and Mentor Humor Tips

How do you know when a startup has gone wrong, it is time to retire, your mentor is an endangered species and your mentor's book will become a college text? These and other questions you have not asked will be answered.

Advanced Regulatory Control Recommendations Tips

The power of the PID largely remains underutilized. Most of the options and parameters other than scale ranges and tuning settings remain at their defaults. Here we look how to tap into the incredible capability of the PID to minimize batch cycle time and start-up time and to maximize production...

Advanced Regulatory Control Perspective Tips

Advanced regulatory control seeks to incorporate knowledge of process dynamics, disturbances, constraints, and objectives to increase process efficiency and capacity. The PID power and flexibility enables an incredible spectrum of creative opportunities to achieve these goals.