Incatools blog

Did you know a DCS can change your PID equation?

Posted by Edwin Weetink on Apr 7, 2021 10:23:16 AM

Every DCS has its own set of PID loop equations.  A Honeywell Experion DCS features 5 different equations and an Emerson Delta-V DCS can even offer 7 equations. Each equation implies a different formulation of the PID control algorithm. So, each equation might require different tuning parameters to obtain the same or similar closed-loop behaviour. Many control engineers ignore the equation type of a PID loop. Even if you have tuned many different loops, you might not be able to obtain the desired closed-loop performance if you don’t have the right equation selected.

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Topics: PID tuning, Plant performance

Comparison of different tuning methods with INCA Aptitune

Posted by Kamalnayan Singh on Mar 15, 2021 11:39:10 AM

The tuning of Proportional-Integral-Derivative (PID) can be considered a mix of art and science. It's an art where one needs to use their judgment and experience to understand the controller’s behavior. The science of tuning comes into the picture where one uses open-loop mathematical models and different techniques to derive the tuning parameters. The “Art” of tuning helps to understand the how’s and why’s of the process, and the “Science” of tuning provides a roadmap for tuning.

The performance of any PID controller depends on tuning parameters, i.e., gain, integral time, and derivative time that is set in. The tuning parameters are a function of process types, functionality expected from the PID loop, i.e., variance reduction or setpoint tracking, and type of the PID loop.

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Topics: PID tuning methods

APC: 5 benefits of Advanced Process Control you can generate in your plant - starting this year

Posted by Christiaan Moons on Feb 24, 2021 5:17:56 PM

Advanced Process Control (APC) carries a raft of benefits. Any competent control engineer can list at least a dozen. That list will often contain only quantitative benefits - emphasizing production yields, feedstock flows, product qualities and the like. There are however also other benefits to advanced process control - benefits less strictly numeric, but nonetheless with a huge impact on operating efficiency.

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Topics: Advanced Process Control

PID tuning: A low cost way to boost process performance

Posted by Christiaan Moons on Feb 8, 2021 4:41:32 PM

As a production manager, you have one main goal: optimal and stable operations. You need to reach your production targets while taking care of the plant’s efficiency and safety. Optimal functioning of the entire production process in its broadest sense — achieving objectives for safety, quality, quantity, costs, environmental impact and reliability — is your responsibility. A low cost way t boost process performance therefore may seem like the holy grail.

In this blog, we'll describe 6 ways how PID Tuning boosts plant performance. Are you curious about this holy grail yet?

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Topics: PID tuning, Plant performance

Boiler Steam Drum Level Control Strategies

Posted by Rohit Anantulwar on Jan 18, 2021 4:00:35 PM

Steam drum is a vital part of boiler system in chemical industries. Proper and safe functioning of boiler depends on various parameters such as level of steam drum, flow of feedwater and flow of steam. The pressure, temperature and level of boiler system cannot be regulated directly but depends on the feed-water flow. The pressure or temperature in a boiler system can be maintained by controlling the flow of fuel and air whereas the level can be maintained by regulating the flow of feed water. The purpose of drum level controller is to keep the level at desired value, optimal interface level requires between steam and water within the steam drum. It is essential that the level of liquid must be low enough to assure that there is appropriate separation between steam and water and high enough to guarantee that the water exists in every steam generating tube. 


In this blog we will show the 3 most common drum level control schemes and what tuning strategy you should adopt for every strategy.


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Topics: PID tuning, PID tuning methods

How LANXESS Belgium improves control with IPCOS process control tools

Posted by Christiaan Moons on Jan 18, 2021 12:13:13 PM

Leading specialty chemicals company, Lanxess Belgium, noticed the plant wasn’t working at its full potential. Many controllers were underperforming and in manual mode. Due to lack of time, the control engineers ran aground to complete optimization. Read in this blog what benefits they gained by using the INCATools software, or download the case study to discover the process and results.

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Topics: PID tuning, Advanced Process Control

7 reasons to get INCATools PID Tuning software

Posted by Christiaan Moons on Jan 12, 2021 1:52:50 PM

When PID tuning it is done right, it can provide significant benefits to your plant. A little help from PID tuning software can help tremendously to get your tuning on track. You can find many free PID tuning software downloads on the internet, or you can find a free PID tuner in your DCS. Nevertheless, are numerous companies that provide PID software licences at a fair price. But, why would you pay for a PID tuning software licence when you can do somewhat the same with the free versions? 

The answer is simple, the most critical PID loops in your plant will get left behind when you use free PID tuning software. The freeware will stand in the way of optimization and receiving the full ROI of your plant.

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Topics: PID tuning, PID software

PID control Equations: Do you know the difference?

Posted by Christiaan Moons on Jan 4, 2021 11:44:21 AM

The principle of PID is very simple. Three subsets (P, I, D) of one equation that each have their own task. Nevertheless, the PID formula in your DCS/PLC can have many forms. The most common equations are the series and parallel equation. In this blog we'll show you that it's extremely important to know the different formulas to tune your controller. 

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Topics: PID tuning, PID control equations

How PID tuning impacts furnace control in plants

Posted by Didac Recio on Dec 8, 2020 10:37:45 AM

What if you could increase your return on investment, safety, and overall plant efficiency with just one optimization? Furnace control is often disregarded as furnaces are considered as subunits that are not important to optimize. However, one cannot underestimate the impact of the furnace performance on the overall unit. In this blog, we'll explain what the consequences of bad furnace control are, what the results of optimization will be and how to tune your furnace correctly.

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Topics: PID tuning

On demand webinar: Sustained Control Performance Monitoring

Posted by Michiel Huizer on Nov 17, 2020 12:58:38 PM

Bringing PID control performance to the highest level is a challenge, but keeping the performance high is a different game. In this blog, you’ll read reasons for degrading PID control performance and the various ways in which our customers take on the challenge of sustaining control performance monitoring. You’ll also read what to expect from the webinar “PID sustained control performance”: how to get to a high control performance monitoring and how to keep the performance up, including some practical cases.

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Topics: PID tuning, Plant performance