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We offer services in optimization and troubleshooting, start-up assistance,
implementation startegies for ISO 9000 standards in instrumentation,
design support, process control design and training, as they relate to
optimization and maintenance of control systems.
To do so, our team first utilizes state-of-the-art tools coupled with vast
practical experience. They optimize control system perfotmances per the
plant's particular characteristics.
The tools permit the following:
1. Spectral analysis
2. Temporal analysis
3. Statistical analysis
4. Correlation analysis
5. Performance estimates
6. Tightness estimates
7. Simulations
ICS engineers have defined control startegies for complex and difficult-to-control
processes.
Our control technologies include:
1. model-based auto-tuning
2. process loop monitoring and diagnostic
3. model-based maultivariable control such as IMC (Internal Model Control),
CC (Co-ordinated Control) and MMC (Modular Multivariable Control).
4. Single PID
5. Multistage cascade
6. Multi-parameter PID
We can assisst in providing the following benefits through our process optimization
and tuning services:
1. Better yield
2. Uniform production within tolerances
3. Less production loss
4. Energy costs reduced
5. Productivity increase
6. Less wear and tear on equipment
7. Less production breakdowns
8. Less time for start-ups
To achieve the above, we use the following methods:
1. Quarter turn amplitude (Ziegler/Nichols)
2. Syrface minimization below the curve
3. Obtaining pre-determined overshoot
4. Critical overshoot
5. Lambda method
Examples of control loops designed, implemented and tuned by ICS, which require advanced functions beyond the classical PID are outlined below:
1. pH and chlorination control in water treatment
2. Moisture control on a paper machine system
3. Fermentation co-ordinated control
4. Reactor control in resin manufacturing
5. Furnace control in the glass industry
6. Moisture control in the food industry
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Samples of results obtained:
Natural gas furnace
Three loops analyzed, one actuator replaced, operation in automatic mode,
automated start-up, uniform production (product quality), stability, security,
profitability.
Secondary treatment
Before our involvment, there were frequent stops. Three 900-HP blowers that
started/stopped several times an hour. Twenty-nine loops analyzed, six valves
modified. After our involvment, no stoppages for three days, no useless start-ups,
treatment more effective.
pH loop
Before our involvment there were oscillations of 2 to 8. After our involvment the
oscillations of 6 to 6.4. Three loops analyzed, strategy modified, PLC program
modified.
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