Set-point manipulation approach towards online performance improvement in existing process control loops

The majority of current industrial process control systems are based on PID control. However, in many of these systems, once the initial setup has been carried out, it is difficult to implement subsequent continuous improvements on the control performance without shutting down the production and disarming the overall system to retrofit alternative controllers. These measures to integrate additional instruments for allowing such flexibility incur heavy costs in terms of time and resources. In this paper, we propose an approach towards achieving the control adaptations which cannot be achieved easily with an existing closed-architectural system. The approach leverages on a set-point manipulation mechanism which allows a virtual modification of the closed-architectural system. In this way, process performance of existing plants can be continuously improved without the need to continuously alter the existing closed loop system. The implementation of the proposed configuration is illustrated with respect to a PID controller although the framework proposed is amenable to higher order controller as well. Simulation examples and experimental results are furnished to show the motivation for such an approach and the improved performance achievable with the proposed approach.