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KNOW YOUR LOOP BEFORE YOU ATTEMPT TO TUNE YOUR LOOP – PART 2

In the last article for this topic, we discussed the importance of field data collection and the importance of a methodical approach to PID tuning. I introduced the concept of the bump test and that its results would help guide the steps and equations used in proper tuning. Here I will explore that concept in greater detail. At ECS we use a visual tool for data collection in every instance. The tool may be part of a controller suite, or it may be stand-alone but, in any case, it is imperative to capture accurate information about the performance of your system before planning and then programming a solution.

In the interest of time, this article will focus on tuning concepts for self-regulating loops as they make up the majority of applications in the industrial field. A common example of this type of loop is a flow control which varies flow through a pipe via either variable speed control on a pump or a position-controlled valve. In this example, the flow can be adjusted by speed adjustment of the pump or position of a valve and the result of the change ordered from the controller is stable and is generally fast and repeatable.

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Innovative Tools for the Evolving Systems Integrator

The personnel challenges facing virtually every industry over the last few years have been nothing short of astonishing. Proper candidates have become increasingly difficult to court and bring on board. New staff in key roles are tasked to accomplish more with fewer floor operators and technology is increasingly leveraged to close the resulting gaps. This is not unique in history although it may seem that way due to the current media deluge surrounding business intelligence and general-purpose visibility software that makes life easier, smarter, and generally more efficient.

Industrial software is again playing a leading role in the current intelligence revolution. Inductive Automation didn’t invent floor supervisory (SCADA) software, nor did they invent the first responsive, general-purpose web software. However, their current offerings certainly do marry these concepts together in a way that hasn’t existed in industry before. Since 2010 their award-winning Vision Module has enhanced the experiences of factory floor users everywhere, easily connecting complex factory controllers to databases, alarm and reporting systems, and intuitive visualization tools. This product is robust, proven, and works very well for users “inside the industrial network” of many facilities. Today this is coupled with the newer Perspective Module which is an equally powerful tool for use in mobile-responsive applications. For situations where a user may be “outside the industrial network” or simply need to utilize a variety of hardware platforms like PCs, phones, or tablets, Perspective provides an ideal solution.

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ECS Solutions and Inductive Automation Deliver Solutions for Latin America

At ECS Solutions, Inc., (ECS) we’re seeing a change in how the Latin American market is approaching manufacturing operations. The region is one that has traditionally addressed challenges by adding personnel in almost any situation. This mentality is evolving in the face of a rapidly growing population and the associated demands for things like regionally processed food and beverage products. Increasingly, companies are using technology to streamline operations.

As is usually the case, the correct solutions lie with partners who have the right staff and the right tools. At ECS we believe that we can deliver both via our team and with products offered by Inductive Automation. ECS is chiefly focused on batch industries, and this has led us to decades of success in delivering solutions in industries like food processing. Our team now includes multiple native Spanish-speaking personnel, several of whom reside within the Latin region in places like Columbia and Venezuela. From initial project discussions, we can provide personnel with deep expertise to explore options with clients in their native tongue. Execution of projects occurs under project management from our personnel within the region along with local strategic partners and backend support from our home office and elsewhere. The client experience is with genuine, local ECS subject matter experts and project managers.

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Know Your Loop Before You Attempt to Tune Your Loop

PID (proportional, integral, derivative) control algorithms are probably the most commonly used process control strategies in the industry. PID controllers or code are used to optimize process control, providing the means to ensure product stability and company profitability. These functions exist in small but powerful standalone controllers and as part of the instruction set of most modern large-scale programmable controllers. The code within PID controllers is frequently used in tandem with other control functions to create both simple and complex control systems.

PID control has existed for decades and there are many tools available to help implement and tune systems. Thus, this is generally easy to deploy in most situations. Straightforward methods exist to bring most processes into some degree of control. Higher-order analysis and techniques are needed for more complex control loops, products, or systems. Other factors must be considered like upstream and downstream operations and energy consumption. Furthermore, safety and regulatory items must be examined as well as these control loops and associated equipment do not exist in a vacuum. Volumes have been written about detailed techniques for tuning loops so this article will cover only basics in preparation for a later piece on the tuning of atypical loops.

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ECS Proud to Support T.R.E.K.

ECS Solutions is always looking to support programs that encourage young people to explore the engineering and manufacturing industries. A strong workforce starts with exposure to these important fields long before college. This summer we are proud to be a sponsor for the T.R.E.K. Summer Experience.

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ECS & Ignition Deliver for AmeriQual

Success in many industries is the product of preparation and opportunity. Agility is frequently the lubricant that enables businesses to adapt and win a project or contract. This is especially true in private-label food manufacturing. “The people, processes, and equipment must be able to adapt to ever-changing market demands,” says Wes Blankenberger, Vice President of Operations & Maintenance for AmeriQual Group, LLC, in Evansville, IN (AmeriQual). Brand owners must beat their competition to market and the best way to do that is frequently via a capable private labeling partner. Much like brand owners leverage private label manufacturers, the manufacturing plants themselves leverage partners to assemble existing and new equipment into functional processing systems, often on aggressive timelines.

Similar traits and situations define success inside of the control system integration space. Much like private label manufacturing, clients call upon these firms because of their known ability to deliver in specialized market segments. They’re well-trained and typically gainfully employed by clients where they excel. Rarely are they entirely idle but their mix of professionals at different levels and specialties allows them to apply staff, often on short notice, to applications. Their highly trained teams can tackle projects or parts of projects large and small, often in concert with their teammates or outside firms.

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High Performance Rubber Batching by ECS

ECS Solutions, Inc (ECS) recently used its extensive batch experience and dynamic company structure to help a major Southeast US rubber manufacturer realize and achieve project success. The end client had an existing semi-automated batch and mixing operation and had recently commissioned a project to duplicate this line’s operation with a new mix room, ingredient systems, and rubber mixer. They employed a powerhouse electrical contractor to connect all the new equipment and make it operate as a single system and this was largely successful. However, as the project moved through its lifecycle, the team realized that sophisticated batch operations would require specialized talents that were missing from the initial project team.

A quick web search for batch expertise within the region quickly pointed to ECS. It’s rare that ECS assets are idle, waiting for project work to arrive, and that was true in this case. Fortunately, the electrical contractor was a proven operator who had the situation in check with respect to major control equipment, general electrical planning, and installation, so ECS was able to apply only batch-specific resources and a slim project management umbrella. The ECS team quickly mobilized and took control of the batch portion of the project.

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Native Spanish Speakers Drive Results at ECS

ECS Solutions (ECS) continually evolves to respond to the needs of our clients. In many cases, this is evident in the form of new services or specialized training and certifications to address changing technology. Another area where we have placed considerable emphasis over the last decade is diversity within the ranks of the ECS team. Specifically, we have placed marked effort into growing the number of our native Spanish-speaking teammates.

According to the US Department of Labor, the overall composition of Hispanic workers grew from 8.5% in 1990 to 18% in 2020. They project that this will be over 21% of the overall workforce by 2030. In 2020 Hispanic workers already made up more than 25% of the total workforce in six states including key agricultural locations like California, Arizona, Texas, and Florida. The Bureau of Labor Statistics states that the number of Hispanic workers in management jobs more than doubled to over 10% today from just over 5% in 2000.

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ECS is thrilled to be named “One of Indiana’s Best Places to Work” again!

ECS is thrilled to be named “One of Indiana’s Best Places to Work” for the fourth year in a row!

A multitude of industries from across the state are represented on the 2023 Best Places to Work in Indiana list – with a total of 125 Hoosier businesses recognized, including nearly 40 newcomers from last year. This marks the 18^th edition of the Indiana Chamber of Commerce initiative.

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PlantPAx Objects for Chemical Processor

ECS Solutions, Inc. (ECS) recently executed an increasingly rare upgrade for a midwestern chemical processor. The application was rare in that the facility and its controls were neither a brand new, greenfield design nor an upgrade from existing, controller-based automation. This grain processor utilizes volatile hexane in their oil extraction operations so the facility has classified locations throughout. Thus, the legacy control system leveraged pneumatic integration, and hard-wired, and hard-plumbed control loops. That system served them admirably for years and was left in place until this was replaced with a modern electrical system at the direction of ECS.

To facilitate a clean project that could be adopted easily by seasoned operators, ECS built the automation using Rockwell Automation ControlLogix hardware and PlantPAx objects for the code. The robust library of process objects made the code generation very straightforward, and the controller code coupled seamlessly to the Rockwell FactoryTalk View SE SCADA. ECS’ high-performance HMI design focused on a simple, flatter overall concept that leveraged color and animation effectively to drive efficient user interaction. Information from code easily passes to the newly deployed FT Historian system, sharing the same information to the long-term storage.

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