Incatools blog

How to configure an MPC controller with INCA Architect

Posted by Leon Ariaans on Aug 4, 2022 9:55:36 AM

Once installed, INCA MPC has proven to generate sustained benefits for operating companies. To configure INCA MPC, you need to take several steps: choose the targets and constraints, determine the controller structure, set up the communication between the controller and the process, and tune the controller… After the first version of the controller, updates will be needed later. These updates range from tweaking a tuning parameter to adding extra variables to the controller and updating the targets. All these steps must be executed carefully. The iterations involved in finding mistakes slow down the project’s progress. 

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Topics: Advanced Process Control

Advanced Configuration with INCA Architect

Posted by Leon Ariaans on Aug 4, 2022 9:55:29 AM

An earlier blog described how INCA Architect makes configuring an INCA MPC application easy by automating tasks, grouping related information and continuously monitoring the consistency and validity of the configuration.

But what if your situation is non-standard? Can you also use the INCA tools in that case? Can you verify the correct behavior of your configuration before going online? This blog discusses how the combination of INCA MPC and INCA Architect gives you all the tools to tackle these cases too!

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Topics: Advanced Process Control

Non-minimum Phase PID Control

Posted by Rohit Anantulwar on Sep 28, 2021 12:41:18 PM

Non-minimum phase systems are difficult to understand and even difficult to tune manually. The understanding of non-minimum phase system and control strategies explain in this blog.

The response of a non-minimum phase system to a step input has an "undershoot". This means, if the output was initially zero and the steady-state output is positive, the output becomes negative before changing direction and converging to its positive steady-state value.These systemsare difficult to control due towaiting time until the initial undershoot for a positive gain system or overshoot for a negative gain system.

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Topics: PID tuning

Hydrogen: Do you want to reduce the venting inside your refinery?

Posted by Akash Gupta on Sep 28, 2021 12:29:35 PM


Hydrogen is one of the key raw materials used in the refinery. It is used in various process units: Hydrocracker, Aromatic plants, to name a few. Since the process is dynamic, the demand for H2 keeps on varying, and excess is vented out either to fuel gas or to flare to control the Header pressure. The good news is that the venting of the H2 can be reduced. In some cases, it can be reduced to close to zero.

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Topics: PID tuning

How to approach a PID tuning project in a phased way

Posted by Julian Vidal on Aug 17, 2021 9:02:21 AM

Many operations managers face a challenge to maintain all PID loops on their plant in good working order. Plant safety may be at stake in some cases if some of these PID loops are kept in manual mode. Poor PID tuning may also contribute towards degradation in plant performance, leading to unstable operation and, eventually, reduced profitability. Operations managers need to create a culture of continuous PID performance monitoring and improvement, ensuring safe and optimal plant performance. How do you embark on this journey, and what are the best practices?

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Topics: PID tuning

How to keep PID loops optimal

Posted by Julian Vidal on Aug 9, 2021 4:50:50 PM

Large processing facilities such as Refineries and Chemical plants spend money on technology to enhance process performance. Metrics are typically put in place to measure how well the technology is performing, and control engineers are required to report on these metrics regularly. There are thousands of PID loops on a typical refinery; what strategy should you use to identify poor performers and then rectify the issues?
How do you ensure that the reported metrics provide your management a full and clear picture of PID loop performance?

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Topics: PID tuning

How to Successfully Configure and Tune a Split Range PID Control Strategy and Not Die Trying

Posted by Julian Vidal on Jul 13, 2021 11:21:56 AM

A split range control strategy uses software or hardware-based splitter and two or more final control elements to control a process variable. Split range strategies can be found in different applications across process industries: temperature control with heating/cooling media, large and small valves installed in parallel, pressure control with a vent valve, etc. 

Usually, split range applications are tricky and time-consuming, and you should know what I’m talking about as a process control engineer

Oscillations over the entire range of operation and across the split point, typically improperly selected at 50%, are common in real operation. 

In this blog, we will discuss the usual problems you might face when configuring and tuning a split range strategy and the possible and practical solutions to overcome it.

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Topics: PID tuning

3 ways to find out more about INCATools

Posted by Christiaan Moons on Jul 12, 2021 1:21:51 PM

We often don't have the time to sift through information on new products, especially when under pressure to find solutions for ongoing problems. To help you discover INCATools AptiTune, we've compiled a list of options to choose from to fit your busy schedule.

INCATools is a suite of process control tools that contains some of the most powerful PID tuning instruments on the market. INCATools AptiTune is the tool to be used to tune ALL your PID controllers: the easy, the tough, the non-interacting and the interacting ones.

To learn more about INCATools AptiTune, you can download a demo version of the software or request a live demo with one of our Control experts.

 

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Topics: PID tuning software

Temperature Control for Batch Reactors in your industry

Posted by Julian Vidal on Jul 6, 2021 4:36:58 PM

Batch reactors are used to produce a variety of products in all sectors of process industries, especially in the pharmaceutical, specialty chemicals, wastewater treatment and the beverage sector. The flexibility to use the same equipment to produce different products sometimes makes batch reactor difficult to control. If we add to this the integrating/runaway process response, suboptimal PID control loop tuning, poor control loop elements performance, and an inappropriate process and control design,we might have the perfect recipe for disaster. If you want to learn more about obtaining optimal batch reactor temperature control, keep reading the blog.

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Topics: PID tuning

PID tuning example: tuning for closed loops

Posted by Edwin Weetink on Jun 29, 2021 1:17:33 PM

There are many critical PID loops in an operating plant. Operations managers typically like to minimise changes on tuning parameters on such PID loops, quite often maintaining the status quo, even if improvements are possible or desirable. The performance of such PID loops could be optimised if they could be inserted in manual mode followed by moving the output a few times, collecting data, and calculating PID tuning using PID tuning software. Unfortunately, operations managers may not allow you to insert this critical loop in manual, so how can you calculate PID tuning parameters for such a loop while maintaining it in closed-loop mode? In this PID tuning example, we’ll show the best practices and pitfalls.

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Topics: PID tuning