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Process Control Optimization Process Control Optimization

Are your control loops operating at their full potential?

Research has shown that in most plants, two out of three of all the control loops are underperforming. Top Quartile performers focus their investments on improving control loop performance.

Typical gains are:

  • 4-8% increase in throughput
  • 5-10% reduction in energy costs
  • 40-80% reduction in quality variations
  • 1-5% increase in equipment availability

Fact - A survey of 5,000 control loops has revealed:

  • Only 1 in 5 loops are Well Tuned

  • 1 in 6 loops have Default Tuning 

  • 1 in 3 loops have Suspect Tuning

Who are we?

Lakeside has a dedicated process optimization team with over 60 years of experience

This team has worked in a wide range of industries including:
  • Power & Steam generation
  • Nuclear
  • Food and beverage
  • Specialty chemicals
  • Petrochemical
  • Pulp & Paper
  • Pharmaceutical
  • Water and wastewater
  • Mining
  • Steel
  • Manufacturing

Their in-depth expertise in processescontrol strategiesinstrumentation, and modern loop tuning techniques will help you become a Top Quartile Performer.

Your Road Map to Becoming a Top Quartile Performer

With our Optimization Experts, Lakeside will successfully guide you on your optimization journey. We’ve simplified this journey into 4 easy stages:
  1. Lakeside Tuning Index
  2. Discovery Phase
  3. Recommendations and Optimization
  4. Monitor and Assess

Step 1: Lakeside Tuning Index (LTI)

The LTI will benchmark the current parameters in your DCS against the industry average.  This is the first step in the optimization journey.

The LTI is a proprietary database tool which provides a high-level assessment of the current PID tuning in your control system. Your LTI is compared to almost 5000 other control loops; your results are benchmarked to the overall industry average.

How is the LTI generated?

The LTI is generated using our proven methodology.  We extract the data directly from your DCS database to ensure the data is relevant. We do a comprehensive review of the tuning (and other key parameters) of each control loop, and rate them as  "good," "questionable," or "suspect". 

The LTI will also analyze other parameters associated with your control loops such as:
  1. Excessive PV filtering indicating potential measurement issue
  2. Non-linear PID features indicating potential valve related issues
  3. Default Tuning
  4. Duplicated tuning
  5. Use of Derivative
  6. Slow scan rates
  7. Excessive Gain
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Generating your LTI dashboard is a FREE SERVICE

Step 2: Discovery Phase

The onsite discovery phase is the next step in the journey, where our experts take the results of the LTI and do a deeper dive into your process. Your LTI dashboard will outline the key focus areas for immediate improvements and provides a guideline for the onsite Discovery Phase. 

Process data will be collected, analyzed and compiled in a comprehensive report that will detail recommendations for improvement and, where possible, the potential ROI for each recommendation.

Step 3: Recommendations & Optimization

A series of recommendations will come out of the Discovery stage.  

A series of recommendations will come out of the Discovery stage.  

These recommendations will cover:
  • Process modifications
  • Control Strategy modifications
  • Instrumentation Repair/Replacement
  • Loop tuning

Process modifications

Processes are often designed from mass/energy balance point of view; process dynamics and control loop interactions are rarely considered.  Modifying the piping or the process can improve the efficiency of the controllers while maintaining the overall mass and energy balance.

Control Strategy Modifications

Modifying the control strategy can reduce control loop interactions and improve process stability.

FACT - 30% of control related issues involve a poorly functioning control valve!

Instrumentation Repair/Replacement

Instrumentation must be properly specified, installed and maintained.  A control loop is only as effective as its primary elements.  Faulty or poorly performing control valves are a large source of process variations and present some of the greatest opportunities.  Moreover, improperly installed transmitters can lead to control loop underperformance.

FACT: 1 in 3 control loops have 'suspect' tuning.

Loop Tuning

Only 1 in 5 control loops are properly tuned.  Improperly tuned control loops will not reduce process variations effectively and potentially even increase process variability.

Lakeside offers courses on proper loop tuning techniques, CLICK HERE for more information.

Step 4: Monitor & Assess

Degradation of control loop performance can be slow and insidious. Once a control related problem has been detected and identified, it has been occurring for a long time.

Degradation of control loop performance can be slow and insidious. Once a control related problem has been detected and identified, it has been occurring for a long time.

This phase will monitor your control assets on a periodic basis and track their performance.  Top Quartile performers use this predictive monitoring program to ensure maximum performance from their control loops.

Remote Monitoring

Remote access to your DCS is a safe and cost-efficient solution to monitor the ongoing performance of your control loops.
Automatic Control Loop Performance Monitoring

Automatic Control Loop Performance Monitoring

For our DeltaV customers, an additional monitoring step can be incorporated by applying a continuous loop performance package called DeltaV Insight. This program will continuously monitor certain dynamic aspects of selected control loops. It will provide several metrics including the following:
  1. Percentage of time the control loop is not in its normal mode
  2. Variability
  3. High process oscillations
  4. Tuning
If you're interested in transforming your data into actionable knowledge, get in touch with an expert today! 
Talk to one of our experts in this field