Control Talk Blog

Checklist for Level Control Tips

The maximum level controller gain for stability is one or two orders of magnitude higher than expected. The main limit to how high you can go in controller gain is often measurement noise and control objective.

Checklist for pH Control Tips

pH is the most common analytical measurement. pH is important for product purity and environmental compliance. The most stringent pH control requirements occur in bioreactors for biopharmaceuticals where a deviation of 0.05 pH can cause a noticeable degradation in mammalian cell growth rate and product formation rate.

Checklist for Batch Optimization

Batch processing is a critical part of many high value added biological and chemical processes. Batch processes are capable of higher conversions than continuous processes because there is no discharge flow until the batch is deemed complete.

Checklist for Flow Feed-Forward Control

Flow feed-forward control is the most utilized and underutilized advanced regulatory control technique. Proper implementation involves the use of ratio control and cascade control. Processes can be started up and moved quickly to new operating points by achieving a new flow ratio.  Temperature and composition loops have a particular ratio...

Checklist for Batch Reactor Temperature Control

Tight reactor temperature control enables the optimization of capacity and yield. What happens upfront in the reaction sets the stage for downstream processing and what ultimately ends up in the final product. Generally, increasing reactor temperature will increase reaction rate (capacity) but if the temperature is too high, side reactions...

Checklist for Cascade Control

Cascade control is an effective way of providing better feedback and feedforward control. The peak error in the primary loop can be reduced by more than an order of magnitude for disturbances originating in the secondary loop.

Checklist for a Virtual Plant

What is the most effective type of simulation? What is the fidelity needed? How can you automatically increase fidelity? How can you help operators deal with abnormal situations? How can you have a laboratory that behaves like the real plant to learn how the process responds, demonstrate creative control solutions, and quantify the benefits?

Deadband and Resolution Limit Cycle Causes and Fixes

Deadband and resolution cause sustained equal amplitude oscillations called limit cycles that cannot be eliminated by controller tuning. A resolution limit causes limit cycles if there is integrating action at just one point in the control loop either in the process (e.g. level), positioner, or the process controller (e.g. PID).

Where Do Process Dynamics Come From?

Do you lie awake at night wondering what the source of process dynamics is? Do you wonder why temperature and composition controllers tend to oscillate at low production rates and low levels? Are you perplexed why some controllers need a lambda factor of 2 and others need a lambda factor...

Checklist for Loop Analysis by Trend Charts

Humans have an incredible capability to see and analyze patterns. The setup of the data historian and trend chart can either hide or enable the recognition of essential patterns. The check list can help you identify the root cause of poor loop performance and a potential solution.