Process control optimization involves adjusting the controls in a process in order to optimize certain sets of parameters while avoiding violating some constraint. The idea is to maximize control but at the same time keep all other associated specifications within their constraints. Process control optimization is usually aimed at reducing costs, increasing efficiency and maximizing output. Іt is an important quantative tool for decision making in industry.
A processing plant like oil refinery or a chemical plant typically has hundreds to thousands of devices called control loops. The loops are responsible for different parts of a process including maintaining flow, liquid level and temperature.
Іf a control loop isn’t properly designed or tuned, the process will run below its optimum. Consequently, more costs will be incurred to operate the process and the equipment will wear out fast. For the control loops to run maximally, it is important to identify and correct problems in the sensor and valve as well as tuning. Studies have shown that more than 35% of control loops in industry often have problems. Identifying the problems early enough may help keep process control at its optimum.