Process Control Performance Assessment

This book is a practical guide to the application of control benchmarking to real, complex, industrial processes. The variety of industrial case studies gives the benchmarking ideas presented a robust real-world attitude. The book deals with control engineering principles and economic and management aspects of benchmarking. It shows the reader how to avoid common problems in benchmarking and details the benefits of effective benchmarking.

Control Performance Management in Industrial Automation provides a coherent and self-contained treatment of a group of methods and applications of burgeoning importance to the detection and solution of problems with control loops that are vital in maintaining product quality, operational safety, and efficiency of material and energy consumption in the process industries. The monograph deals with all aspects of control performance management (CPM), from controller assessment (minimum-variance-control-based and advanced methods), to detection and diagnosis of control loop problems (process non-linearities, oscillations, actuator faults), to the improvement of control performance (maintenance, re-design of loop components, automatic controller re-tuning). It provides a contribution towards the development and application of completely self-contained and automatic methodologies in the field. Moreover, within this work, many CPM tools have been developed that goes far beyond available CPM packages. Control Performance Management in Industrial Automation: · presents a comprehensive review of control performance assessment methods; · develops methods and procedures for the detection and diagnosis of the root-causes of poor performance in complex control loops; · covers important issues that arise when applying these assessment and diagnosis methods; · recommends new approaches and techniques for the optimization of control loop performance based on the results of the control performance stage; and · offers illustrative examples and industrial case studies drawn from – chemicals, building, mining, pulp and paper, mineral and metal processing industries. This book will be of interest to academic and industrial staff working on control systems design, maintenance or optimisation in all process industries.

This book presents a comprehensive review of currently available Control Performance Assessment methods. It covers a broad range of classical and modern methods, with a main focus on assessment practice, and is intended to help practitioners learn and properly perform control assessment in the industrial reality. Further, it offers an educational guide for control engineers, who are currently in high demand in the industry. The book consists of three main parts. Firstly, a comprehensive review of available approaches is presented and discussed. The classical canon methods are extended with a discussion of nonlinear and complex alternative measures using non-Gaussian statistics, persistence and fractional calculations. Secondly, the methods’ applicability aspects are visualized with the aid of computer simulations, covering the most popular control philosophies used in the process industry. Lastly, a critical review of the methods discussed, on the basis of real-world industrial examples, rounds out the coverage.

The series Advances in Industrial Control aims to report and encourage technology transfer in control engineering. The rapid development of control technology has an impact on all areas of the control discipline. New theory, new controllers, actuators, sensors, new industrial processes, computer methods, new applications, new philosophies. . . , new challenges. Much of this development work resides in industrial reports, feasibility study papers and the reports of advanced collaborative projects. The series offers an opportunity for researchers to present an extended exposition of such new work in all aspects of industrial control for widerand rapid dissemination. Benchmarking is a technique first applied by Rank Xerox in the late 1970s for business processes. As a subject in the commercial arena, benchmarking thrives with, for example, a European Benchmarking Forum. It has taken rather longer for benchmarking to make the transfer to the technical domain and even now the subject is making a slow headway. Akey research step in this direction was taken by Harris (1989) who used minimum variance control as a benchmark for controller loop assessment. This contribution opened up the area and a significant specialist literature has now developed. Significant support for the methodologywas given by Honeywell who have controller assessment routines in their process control applications software; therefore, it is timely to welcome a (first) monograph on controller performance assessment by Biao Huang and Sirish Shah to the Advances in Industrial Control series.

Advanced Chemical Process Control Bridge the gap between theory and practice with this accessible guide Process control is an area of study which seeks to optimize industrial processes, applying different strategies and technologies as required to navigate the variety of processes and their many potential challenges. Though the body of chemical process control theory is robust, it is only in recent decades that it has been effectively integrated with industrial practice to form a flexible toolkit. The need for a guide to this integration of theory and practice has therefore never been more urgent. Advanced Chemical Process Control meets this need, making advanced chemical process control accessible and useful to chemical engineers with little grounding in the theoretical principles of the subject. It provides a basic introduction to the background and mathematics of control theory, before turning to the implementation of control principles in industrial contexts. The result is a bridge between the insights of control theory and the needs of engineers in plants, factories, research facilities, and beyond. Advanced Chemical Process Control readers will also find: Detailed overview of Control Performance Monitoring (CPM), Model Predictive Control (MPC), and more Discussion of the cost benefit analysis of improved control in particular jobs Authored by a leading international expert on chemical process control Advanced Chemical Process Control is essential for chemical and process engineers looking to develop a working knowledge of process control, as well as for students and graduates entering the chemical process control field.

Dr.-Ing. Hao Luo demonstrates the developments of advanced plug-and-play (PnP) process monitoring and control systems for industrial automation processes. With aid of the so-called Youla parameterization, a novel PnP process monitoring and control architecture (PnP-PMCA) with modularized components is proposed. To validate the developments, a case study on an industrial rolling mill benchmark is performed, and the real-time implementation on a laboratory brushless DC motor is presented.

Control Performance Management in Industrial Automation provides a coherent and self-contained treatment of a group of methods and applications of burgeoning importance to the detection and solution of problems with control loops that are vital in maintaining product quality, operational safety, and efficiency of material and energy consumption in the process industries. The monograph deals with all aspects of control performance management (CPM), from controller assessment (minimum-variance-control-based and advanced methods), to detection and diagnosis of control loop problems (process non-linearities, oscillations, actuator faults), to the improvement of control performance (maintenance, re-design of loop components, automatic controller re-tuning). It provides a contribution towards the development and application of completely self-contained and automatic methodologies in the field. Moreover, within this work, many CPM tools have been developed that goes far beyond available CPM packages. Control Performance Management in Industrial Automation: · presents a comprehensive review of control performance assessment methods; · develops methods and procedures for the detection and diagnosis of the root-causes of poor performance in complex control loops; · covers important issues that arise when applying these assessment and diagnosis methods; · recommends new approaches and techniques for the optimization of control loop performance based on the results of the control performance stage; and · offers illustrative examples and industrial case studies drawn from – chemicals, building, mining, pulp and paper, mineral and metal processing industries. This book will be of interest to academic and industrial staff working on control systems design, maintenance or optimisation in all process industries.

A typical design procedure for model predictive control or control performance monitoring consists of: 1. identification of a parametric or nonparametric model; 2. derivation of the output predictor from the model; 3. design of the control law or calculation of performance indices according to the predictor. Both design problems need an explicit model form and both require this three-step design procedure. Can this design procedure be simplified? Can an explicit model be avoided? With these questions in mind, the authors eliminate the first and second step of the above design procedure, a “data-driven” approach in the sense that no traditional parametric models are used; hence, the intermediate subspace matrices, which are obtained from the process data and otherwise identified as a first step in the subspace identification methods, are used directly for the designs. Without using an explicit model, the design procedure is simplified and the modelling error caused by parameterization is eliminated.