Tips for New Process Automation Folks

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

Greg McMillan — Fri, 17 May 2013 14:00:19 GMT

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)

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

Greg McMillan — Thu, 16 May 2013 00:34:12 GMT

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)

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

Greg McMillan — Fri, 10 May 2013 14:00:54 GMT

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)

A Unified Approach to PID Control Steps 12-16 Tips

Greg McMillan — Thu, 09 May 2013 21:30:43 GMT

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)

A Unified Approach to PID Control Steps 6-11 Tips

Greg McMillan — Fri, 03 May 2013 20:43:23 GMT

Tip #68: Find the Best Valve Location

Greg McMillan — Fri, 03 May 2013 15:05:36 GMT

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)

A Unified Approach to PID Control Steps 1-5 Tips

Greg McMillan — Fri, 26 Apr 2013 16:39:47 GMT

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)

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

Greg McMillan — Fri, 26 Apr 2013 14:00:33 GMT

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)

How to Improve Setpoint Response Tips

Greg McMillan — Fri, 19 Apr 2013 21:16:07 GMT

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)

Tip #67: Find the Best Measurement Location

Greg McMillan — Fri, 19 Apr 2013 14:00:15 GMT

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)

Tip #32: General Project Management Tips

Greg McMillan — Fri, 12 Apr 2013 14:00:44 GMT

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)

How to Avoid a Common PID Tuning Mistake Tips

Greg McMillan — Thu, 11 Apr 2013 19:25:31 GMT

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)

Steps to Better Process Control Tips (Part 2)

Greg McMillan — Fri, 05 Apr 2013 18:56:08 GMT

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)

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

Greg McMillan — Fri, 05 Apr 2013 14:00:27 GMT

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)

Tip #31: Project Management Is Really Risk Management

Greg McMillan — Fri, 29 Mar 2013 17:59:38 GMT

As a project manager I am responsible for a myriad of activities, but if I consider them in aggregate I realize that they are just different manifestations of the same thing: my job as a project manager is to recognize risk and manage it. Concept: Successful...(read more)