It is generally agreed that less than 80% of modulating control loops are satisfactorily handled by conventional PID controllers even if well-tuned. The remainder are not well-managed by conventional controllers and may be responsive to some form of model-based advanced (modern) control. This is particularly the case where a process requires the monitoring and control of more than one variable using multiple loops which may result in undesirable interactions.
Costec Systems has developed an advanced model-predictive (look-ahead), controller concept that can be broadly applied to optimize the control of disparate smaller scale processes or components. The controller structure is standard and requires only the configuration of the model of the process or component for implementation.
The controller can be implemented on a current generation industrial PC or PLC for integration with an existing process control system or as a discrete installation on a plant component.
Controllers have been developed and tested for:
- The control of superheated steam temperatures in a large power generating station boiler plant and,
- the coordinated control of ground product flow and temperature in ubiquitous vertical spindle coal pulverizing (PF) mills found in power generating plants and large process plant energy supply facilities.
- The PF mill controller has wider potential application to crushing and ore preparation mills, such as SAG and tube mills, used in the mining, metal processing and cement manufacturing industries.
Other applications under development include the control of multi-effect evaporators.
Where PID control loops cannot be effectively deployed the whole process inevitably runs below optimum resulting in output below design capacity and increased maintenance costs due to premature equipment wear, replacement and unscheduled outages.
Successful implementation of advanced control in place of sub-optimal PID loops can optimize both plant design throughput capacity and economic performance.
Services:
Advanced Control