What optimisation delivers in practice.
Running is not the same as controlling well. A controller that is not optimally tuned costs wear, alarms, manual intervention and margin to the trip limit every day, even when nobody seems bothered by it. Below you can see how big that difference was, calculated from the trend data from before and after.
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Drum level control, from drum level to feedwater pump
A drum level, a feedwater valve and pumps moving up and down in the same rhythm. Now within a band half as wide, with 62% less valve movement.
See the result- −49% Level variation
- −95% Large level deviations
- −62% Valve movement
- −50% Flow variation
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NOₓ trim controller, SCR ammonia dosing
A controller that corrected more than 40 times per hour and consistently came out too high. Now closer to the setpoint, with half as much correcting.
See the result- −49% Spread around setpoint
- −71% Time well above setpoint
- −49% Controller output movement
- −14% Ammonia slip
Do you know what your controllers are quietly costing you?
The only way to know what there is to gain is to look at your data. We do that in the free PID Performance Scan, and it starts with a no-obligation introduction.