How Do I Tune a Level Controller?

Level controllers present challenges that are different from others. Although their presence is significant they lag behind Flow controllers in their overall share of the typical production facility’s process control landscape. Unlike other processes such as Temperature, Pressure and Flow, Level control loops demonstrate different dynamics, they don’t play by the same rules as the non-integrating (also known as self-regulating) types. And although best-practices for modeling and tuning Level loops are similar they involve nuances that can hamper a less experienced practitioner.

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Why Are Control Loops Operated in Manual Mode?

Why do manufacturers automate production? Why do they spend millions each year on new equipment and software? Those questions are pretty straight forward, and the answers seem obvious. Clearly automation allows manufacturers to improve the control of complex and business-critical processes. Surely automation reduces the cost of operation by enhancing production output while reducing production-related waste. But if that’s the case, then why do staff at automated facilities choose to operate production in any mode other than “auto”?

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