There are many ways a plant’s process control system can be optimised, but regardless of the method used, as time goes by, the parameters that once worked so well might not be working anymore. This happens because of constant changes in the production facility, with some changes impacting the process’ ability to meet its objective. This creates a need for the process control systems parameters to be verified or updated on a regular basis.
The objectives of an automatic control system are to regulate the process to meet the final product specifications and minimise waste production and energy consumption, hence lowering the environmental impact of the process and maximising the production rate, while ensuring safe operation. Because operating as close as possible to these maximum or minimum objectives are most profitable.
We all know how a small, trivial thing can escalate and turn into a big problem. A tiny decimal point can make all the difference. Consequently, it’s important to know what can go wrong if even a small variable is set incorrectly, and of course how to detect if there are any potential problems that can develop within our control system.