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Best Practices of Effective Process Control Implementation

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Effective process control implementation is vital for organizations to ensure operational excellence and maximize productivity. In this blog, we will discuss best practices to consider when implementing process control strategies.

  • Define Clear Objectives and Key Performance Indicators (KPIs):

Objectives of the process control implementation need to be clearly defined, such as reducing variability, improving quality, or optimizing resource utilization. Relevant KPIs for measuring the progress and effectiveness of the implemented process control strategies need to be identified and established.

  • Engage Cross-Functional Collaboration:

Stakeholders from different departments, including operations, engineering, maintenance, and quality assurance, should be involved in the process control implementation. Effective communication and collaboration among team members will ensure alignment and smooth execution of project.

  • Conduct Thorough Process Analysis:

Performing a comprehensive analysis of the process dynamics, variables, and interdependencies will allow understanding the underlying behavior and requirements. Critical control points, process constraints, and potential sources of variability or inefficiency must be identified.

Select Appropriate Control Techniques:

Most suitable control techniques based on the process dynamics and control objectives should be applied. Options include PID control, model predictive control (MPC), advanced AI-based control algorithms, or undervalued but powerful approach of advance process control (APC) developed inside distributed control system (DCS). Finally, after implementation, control algorithms need to be validated and properly tuned tomaximize their performance. In this case having excellent process system identification, PID tuning, PLC or DCS based APC or even MPC maintenance technology should be of a great fit. Using PiControl Solutions technology called PITOPS you can benefit a lot. This technology is all in once: it can do complete closed-loop system identification, MPC model improvements, PID tuning and help to design and mathematically optimize PLC or DCS based APCs.

  • Implement Continuous Performance Monitoring and Alarm Systems:

Reliable and robust sensors and measurement devices must be implemented in order to capture process variables accurately and in real-time.Process performance needs to be continuously monitored using established KPIs (data analysis, deviation detection, identification of areas for improvement). Statistical process control (SPC) techniques have proven to be very useful tool for identifying trends, patterns, and root causes of process variations. In this case process control monitoring and diagnostics technology, like APROMON from PiControl Solutions, should play important role.  APROMON can give you continuous process control, measurement sensor and final control element (in 90% of industry we are talking about control valves) performance diagnostics. Also, they can give you ideas where your bottlenecks, interaction and main process control problems are. Based on monitoring technology corrective and preventive actions can be easily implemented when necessary.

Also, effective alarm management system that prioritizes alarms, minimizes false alarms, and provides timely and actionable information to operators will be important to ensure operator reaction when needed.

  • Invest in Training and Skill Development:

Comprehensive training for operators and employees involved in process control must be conducted to ensure their understanding of the implemented strategies and their roles. Encouraging ongoing skill development and knowledge sharing will result in keeping up with advancements in process control technologies and methodologies.

Implementing effective process control requires a systematic approach and adherence to best practices. By defining clear objectives, promoting cross-functional collaboration, conducting thorough process analysis, selecting appropriate control techniques, and emphasizing continuous monitoring and improvement, organizations can enhance their process control capabilities and achieve desired operational outcomes. By signing in Institute of Automation and Process Control (www.AIAPC.org) each operator, engineer or technician can easily get all above practical process control knowledge and experience by using industrial process control simulation and optimization technology during the training.

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