The theoretically attainable performance of a petrochemical plant is closely aligned with the technology applied and the equipment installed during the design and construction of the plant. Achieving that potential performance is dependent upon proper operation of that equipment, which depends in part on the effectiveness of the plant’s control system. For decades, the industry has tried to close the gap between actual and potential plant performance with the application of advanced control. However, there are numerous opportunities to improve plant operation through the rectification of the basic regulatory control system. In fact, some of the benefit that is attributed to advanced control technology is often the result of correcting regulatory control problems during the implementation of an advanced control project.
Systematic methods can be used to identify problematic regulatory control loops. Once identified, straightforward techniques are available to troubleshoot several typical control system problems. These methods and techniques are described in this article.