Minimizing variability and maximizing production

Posted on by Trident

What if you could fine-tune your control system to minimize variability and maximize production? There are hundreds of process loops in an ethanol plant that can be a significant source of variability. Taking the time to identify variability and determining if control loops are a contributor is often complex and time consuming.

Until now.

Trident Automation is offering a software module that works in conjunction with our Trident Workbench called LoopPAC©, Control Loop Performance Monitoring. LoopPAC© is a software program that quickly and accurately identifies control loops that are operating at less than optimal performance.

“Plant operations is often adjusting for variability, but it is typically hard to track down root cause in a system as complex as a biofuels refinery.” Jerry Wenzel, Chief Knowledge Officer for Trident said. “Control loops can be a significant contributor to that variability.  LoopPAC© is the tool to shine a light on that variability and help you resolve it.”

There are typically a lot of issues that LoopPAC© finds when you first run it.  The package helps you prioritize what it reports, and the first run results often are eye opening.  There is often “low hanging fruit”, opportunities for significant improvement without a huge effort or cost.  Long-term, because control loop performance often degrades over time due to things like control valve wear, LoopPAC© is able to significantly contribute to your preventative maintenance efforts.

LoopPAC© uses your plant’s existing data and automatically configures its database by identifying loops in your control system configuration. The package analyzes PV/SP deviation, valve travel and numerous other key indications of control loop health.  When one of those factors degrades LoopPAC© flags the loop as needing attention and reports it according to the priority level you place on that loop.

The benefits of LoopPAC© are:

  • Records and aggregates deviation between PV & set point, so you can control the ranges of your plant’s optimal operation.
  • Records the cumulative change in controller output. Excessive output changes are an indication of poor control loop performance and a major case of control valve failure. This allows operators to better monitor the wear and tear on plant hardware..
  • Tracks the time loops spend in manual. If operators are consistently putting a loop in manual, that is an indication the loop needs attention.
  • Organizes and reports loop problems in an easy to understand prioritized format. .

Control loops are a significant source of variability and keeping your plant at peak performance means increased profitability. LoopPAC© is the valuable tool needed to manage the production details that may be affecting your bottom line.

LoopPAC© is available as a module to Trident Workbench© Suite of products.

Contact Trident Automation for more information or a demonstration at [email protected].

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