Loop tuning is the process of adjusting a control loop to achieve the desired effects. A control loop is an industrial control system used in application machines that need constant control. It is a feedback process that strives to correct any differences between at the set point, and the measured variable. The measured variable may be higher or lower than the set point and controller implements corrective measures to return the variables to the set point. Loop tuning is a complicated process, but when done right it can increase product uniformity and enhance the control process. There are different ways for loop tuning. Lambda tuning is the standardized approach which uses Proportional-Integrative-Derivative (PID).
Loop tuning is mostly used in closed loop systems. Novaspect uses Lambda PID which uses a feedback control algorithm. The use of this algorithm cuts across various industries from oil and gas to metal and mining, power production, refining among others. PID controllers aim for a constant control loop that increases the process maintenance depending on the variable loop. Controllers enhance the running of the process. Lambda loop tuning system can be tested before final setting and implementation.
During the setting stage, a few steps need to be followed to ensure appropriate configuration.
Set what the controllers should achieve during the process. Definite tuning parameters to be used in the process should be stated. The usual process parameters include gain, dead time, a time constant, proportional band and integral.
Prioritize Loop Controls
Control loops should be setups for fast or slow implementation especially for interacting loops. When control loops are set on an equal level, they cannot achieve stability.
Place the controllers in manual mode and test the process for the output. Make changes in small percentages depending on how sensitive the process is until you achieve the desired output.
Calculating tuning Parameters
The parameters must be calculated to find out the parameters that optimize the output of the process. Engineers do the necessary calculations to be used in the loop tuning. An example of set parameters may be:
- Dead time: 1 minute 30 seconds
- Integral: 15 min/rep
- Proportional Band: 50
- Gain: 1
- Time constant: 7 minutes
Solve hardware challenges
The major hardware challenges that affect the effectiveness of the process are the type of valves used. The right valves should be put in place to increase efficiency and effectiveness.
This is just a confirmation process to check whether everything is running smoothly. Repeat testing should be approved by engineers before PID is finalized.
If the results of repeat testing are satisfactory, it’s time to finalize the setup process and go to live production.
Novaspect has a team of engineers and other qualified staffs who have vast experience with other control loops. We understand that control loops are crucial in ensuring the smooth running of your loop system. Novaspect will study your current loop system to capture all the vital data before upgrading to PID controls.
The new loop controls will improve the efficiency of the control process and increase product uniformity. Novaspect engineers will supervise the whole process to ensure a smooth transition. An improved loop tuning can be attained easily with the help of Novaspect professional team. Feel free to contact Novaspect for further details on loop tuning. We look forward to working with you.