Incatools blog

Low risk investment and guaranteed benefits with APC project

Posted by Christiaan Moons on May 17, 2021 5:02:01 PM

Every operations manager would like to improve the performance of their asset in a safe manner. You need to steer your plant operation through rapid business changes, and maintain products within the specified targets while always maintaining safe plant conditions. Further optimisation of your operation is not feasible with the current tools, and you know that Advanced Process Control (APC) has been successful in making further improvements in similar processes. How do you go about adopting APC for your facility?

 

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Topics: PID tuning

Do I have a PID Tuning Problem?

Posted by Christiaan Moons on May 11, 2021 9:07:08 AM

Engineers are often tasked with troubleshooting and resolving process performance issues. The feedback from operators could be statements such as “this PID loop does not work in Automatic” or “I am always getting alarms in this variable” or “this PID loop has never worked in Automatic”. Understanding how to tackle these issues efficiently and effectively requires a systematic approach along with a good PID tuning tool. This blog explains how to go about achieving success in resolving PID tuning issues.

 

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Topics: PID tuning

Tuning a buffer tank to absorb disturbances

Posted by Gustavo Müller on May 3, 2021 4:24:43 PM

Buffer tanks are built to provide smoother operation to the process, avoiding the propagation of disturbances on the inputs, e.g., temperature, composition, feed rate, to the downstream process. Aggressive tuning methods don't work for buffer tanks since you want to explore the largest volume possible to reduce the disturbances. In this blog, we will explain how you make a compromise with the correct tuning.

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Topics: PID tuning

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

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