Enhanced Process Control with PID Loop Monitoring
Interstates partnered with a consumer packaged goods client to address significant issues in their packaging line, particularly the inconsistent dispensing of products into bottles. Our solution involved providing a virtual machine running PID Loop Monitoring software, which collects real-time process data from a programmable logic controller (PLC). This data is monitored, and alerts are generated based on predefined analytical baselines.
The PID Loop Monitoring system was implemented in one area of the client’s plant, covering seven packing lines. This solution collects data such as pump speed, frequency, and setpoints, providing insights into how the PID Loop is performing. Process engineers and maintenance technicians receive alerts, enabling them to make informed adjustments without being physically present on the line.
Achieving Real Results
Improve visibility.
Make smarter, data-backed decisions.
Provide historical records and real-time alerts.
Make informed adjustments.
Challenges
- Limited visibility into loop performance: The client could not see how their PID loops were performing across different products on their packaging lines. Unplanned variations in product output required adjustments to ensure the optimal performance of pumps and tanks. The client’s main goal was to gain a deeper understanding of these variations and to troubleshoot issues more effectively.
- Troubling inconsistencies in product output: There were significant issues with the client’s product dispensing machine. Inconsistent amounts of product were ending up in bottles, but the client didn’t have a straightforward way to know if their adjustments were helping the situation or making it worse.
- Operators needed real-time monitoring and alerts: Alarms were only sent when a severity level had been reached where the loop was performing way outside its acceptable operating conditions. The operators needed data-filled dashboards and quick alerts that would help them make effective changes and get quicker feedback on adjustments. The client also needed a new private VLAN within their Operational Technology space to ensure secure, reliable communication between the server and PLC network.
Solution
Interstates proposed and implemented the PID Loop Monitoring system, which includes data collection, visualization, and alerting capabilities. The tool was customized with slight modifications to limits and thresholds to eliminate false alarms and fine-tune the performance for the client’s specific loops.
A PID loop is crucial for maintaining stable and reliable process variables. In this case, it ensures consistent product dispensing by adjusting control variables to meet setpoints. Control loops are the interface between equipment and process, and their stability directly impacts equipment reliability and operational performance.
The PID Loop Monitoring tool collects data points every second, including process, control, and setpoint variables. Additional metadata, such as pump speed, frequency, and tank levels, are also recorded. This comprehensive data collection allows for real-time analysis and historical trend visualization, enabling the client to understand the performance of their PID loops over time.
The tool buffers data in five-minute windows, allowing for detailed analysis of loop performance against setpoints. This helps identify state changes and other variables, ensuring that the PID loops operate within defined parameters and alert operators when deviations occur. Integrating seamlessly with the plant’s existing PLC systems using standard communication protocols like OPC (Open Platform Communications), our solution can also communicate using protocols such as TCP/IP and Modbus TCP, ensuring compatibility with various industrial systems.
Return on Investment
Since implementing the solution, the client has seen significant improvements in visibility and is equipped to make smarter, data-backed decisions. The PID Loop Monitoring tool has become vital to their daily operations, providing historical records and real-time alerts. This data-driven approach has enabled the client to make informed adjustments, leading to more consistent product quality and operational efficiency.
One notable example is the client’s ability to track a pump’s R-Factor, which measures pump performance. Adjustments to setpoints based on product viscosity have also improved efficiency. The client uses dashboards to monitor loop performance, allowing quick feedback and better decision-making.
The tool has also been used as a data source for data scientists, who explore deeper leading indicators of loop performance and apply machine learning principles to optimize operations. This has led to quicker feedback on adjustments, improving overall efficiency.