Tips for New Process Automation Folks

Tip #17: You Can Never Have Too Much Messaging

2013-05-24T14:00:09Z

This is one of those tips that you cannot appreciate until you have worked on a control system that did NOT have adequate messaging programmed in it. Operators want to know what is going on, and system messaging is usually their only clue. Imagine running ...read more...(read more)

Tip #75: Use Wireless Transmitters for Diagnostics, Improvements, and Metrics

2013-05-17T14:00:19Z

In the 1970s, there was a concerted effort at the chemical company I worked for to provide extra process measurement connections throughout the plants for pressure and temperature measurement. These connections could be used as needed to help identify ...read more...(read more)

Fundamentals of Process Modeling for ISA Certification of Automation Professionals (CAP) Tips

2013-05-16T00:34:12Z

Here are the new sections on process modeling fundementals for the next edition of the Guide to the Automation Book of Knowledge that is the primary resource for the ISA Certification of Automation Professionals (CAP) Program. The following includes text ...read more...(read more)

Tip #21: Too Many Alarms Can Be Worse Than None at All

2013-05-10T14:00:54Z

At one time, I worked in a large continuous process plant that had alarms coming in constantly. The operators could hit the “Silence” button in their sleep. We had a case where a process flow was accidently diverted to the wrong tank, and it eventually ...read more...(read more)

A Unified Approach to PID Control Steps 12-16 Tips

2013-05-09T21:30:43Z

A unified approach to tuning has been found that enables a common and simplified method for setting PID tuning parameters. Key features can be used to eliminate the need for retuning to deal with different dynamics and objectives. Here are steps 12-16 ...read more...(read more)

A Unified Approach to PID Control Steps 6-11 Tips

2013-05-03T20:43:23Z

Tip #68: Find the Best Valve Location

2013-05-03T15:05:36Z

When I am in an instrument and valve repair shop, I see many more control valves than instruments, particularly with the advances in sensor technology, transmitter intelligence, and asset management systems. Valves are mechanical devices and as such require ...read more...(read more)

A Unified Approach to PID Control Steps 1-5 Tips

2013-04-26T16:39:47Z

A unified approach to PID Control has been found that enables a common and simplified method for setting PID tuning parameters. Key features can be used to eliminate the need for retuning to deal with different dynamics and objectives. Here are steps ...read more...(read more)

Tip #25: Make Sure the Coffee Is Strong and the Pot Brews Quickly on Start-up

2013-04-26T14:00:33Z

This may seem like a crazy tip, but there is a lot more truth in this statement than you might realize. It’s directed to management, but a young engineer may have reason and opportunity to encourage management to do this. Concept: Simple things like strong ...read more...(read more)

How to Improve Setpoint Response Tips

2013-04-19T21:16:07Z

A PID tuned for maximum disturbance rejection in a composition, temperature, and gas pressure loop will exhibit excessive overshoot in the setpoint response unless one of several PID features is used. The options are relatively easy to configure. Here ...read more...(read more)

Tip #67: Find the Best Measurement Location

2013-04-19T14:00:15Z

I became sensitized to the importance of measurement location when I found the easiest way to keep a pH electrode from fouling was to install it in a pipe with a flow velocity of 5 to 7 fps, preventing the usual 100× deterioration in the speed of response ...read more...(read more)

Tip #32: General Project Management Tips

2013-04-12T14:00:44Z

Over the years, I have learned a number of valuable tips, either the hard way or from my talented colleagues. Here are some points that will be extremely useful to any project manager. Concept: Successful project management requires a diverse skill set ...read more...(read more)

How to Avoid a Common PID Tuning Mistake Tips

2013-04-11T19:25:31Z

The process variable has slow decaying oscillations. Control theory text books indicate decreasing the PID gain should make the loop more stable. You decrease the PID gain. The oscillation gets worse. You decrease the gain again. The amplitude and the ...read more...(read more)

Steps to Better Process Control Tips (Part 2)

2013-04-05T18:56:08Z

We continue this series with the steps for designing control strategies. Simple rules of thumb will be offered for setting up cascade, composition, flow, level, pH, pressure, and temperature control systems. Examples of common unit operations will help ...read more...(read more)

Tip #63: Use Field Analyzers to Measure Key Component Concentrations

2013-04-05T14:00:27Z

When we did process control improvements in the 1980s and 1990s, the major limitation was the lack of a reliable field analyzer. None of the plants had field analyzers on raw materials. The specialty chemicals production units had very few field analyzers ...read more...(read more)