7 things noncontrol people should know about control engineers

A few basic differences between control engineers and others in the plant can hinder progress toward optimization. Start a conversation to improve communications and controls. See examples and career advice. Send a link to these seven things other people should know about control engineers, so they understand.


In the photo, inoLECT of Baton Rouge is training powerhouse operators on new 50-in. touchscreens. What’s under the hood? It integrates seven systems from five vendors, all with a common interface. Courtesy: Byte SizeIt is no wonder "others" do not understand how to interact with control professionals. Control engineers may well be the least understood group in our society today. The U.S. government has more than 50 job codes for IT professionals but NONE for control engineers. Alaska does not offer a Professional Engineering License in control. Are control engineers part of chemical or process? Are they electrical or instrumentation? Having enjoyed over 35 years in this fulfilling arena, allow me to offer seven things "others" should know about this chosen profession.

1. Process engineering is steady-state; control engineering is real-time.

Process engineers pick setpoints and targets: 85 tons of wood chips plus 20,000 gal of chemical at a specific temperature for a certain length of time yields pulp with predictable properties. Control engineers, on the other hand, do not care about chemistry. Control cares about transfer functions and response times of the elements affecting the reaction: if the valve moves, how fast does the process change and by how much? If a different chemical is used by the process folks, odds are a least one response time will change and the loop will need to be retuned.

Process engineering is NOT control engineering. Do not assume a process engineer will succeed as a control engineer. Example: A chemical company was simultaneously setting both production and quality records on its most profitable product. A manager with a process engineering background decided a control valve was moving "too much." He ordered the valve to be locked down at its average position. He hoped to make an additional $200-500 per month on increased sales of a by-product. When the control engineer questioned the impact of the change, he was told he was being territorial, and perhaps had a personality conflict. Over the control engineer's objection the change was implemented.

Rejects increased dramatically, often changing with the ambient temperature. Within a month this once most profitable product was losing over $10,000 per day! The control engineer pointed to the change in the control strategy and the corresponding start of the problem and asked to run a simple and most basic trial with absolutely no risk: Put the original control back.

Process engineers and research scientists dismissed the idea since average temperatures, pressures, etc., remained the same (but those variables were swinging constantly). The requested trial was specifically forbidden. It was stated emphatically, "The control was NOT the source of the problem." The control engineer was excluded from the biweekly meetings on the problem. The problem continued for 6 months. Every time the product was scheduled to run, they doubled management presence around the clock (with no effect on the rejects). Finally, the plant ran for 3 days with 100% rejects. Marketing decided to discontinue sale of the product at the end of the quarter. At that point the control engineer went directly to the plant manager, pleaded his case, and then ran the trial. The problem immediately disappeared. Process engineers (even PhDs and scientists) are not necessarily control engineers.

2. Computer geeks are not control experts.

This is an easy mistake to make. The control people live in a world of human-machine interfaces (HMIs) and "block-ware," using a PC interface. Many people with process control on their business card are not control engineers. A control engineer can calculate the flow through a relief valve. A control engineer knows the effect of load swings versus source swings on the design and tuning of a control loop. A true control engineer will not spend a week trying to tune a simple flow loop while standing next to a check-valve that is mounted backward in the line.

If you know of or are a computer whiz in a control position, welcome to a fabulous field. Please start learning control. There are many sources of control training available, and this training will pay huge dividends. Every company can benefit greatly by getting this control training for employees who need it.

3. Physics rules.

While driving down the road, if the back of your car passes the front of your car, you are unstable and in trouble; the back should not go faster than the front. Likewise, the control cannot go faster than the process. Put a loop in manual and give the valve a step-change. If the process shows no change for 2 minutes and then gradually rises over the next 30 seconds until it stabilizes, you cannot use that control for disturbances that occur faster than 2 minutes. Increasing gain and decreasing poll-time will not speed up the process response. When the process response is too slow, the loop must be reengineered. Relocate sensors, find sensors with faster response, use feed-forward controls, and discover other process relationships to predict control. This is the very heart of a good control engineer. This is the type of situation where process and computer folks have problems acting like a control engineer.

4. Senior control experts know things they do not teach in school.

Good control strategy beats more expensive instrumentation. This statement may upset some, but it is another example of where a true control expert can perform where others will fail. Consider consistency, density, or temperature control. Putting a $45,000 transmitter on the main flow to directly drive the valve on the controlled flow (sweetener or dilution) is standard practice from virtually every major engineering company. It is very simple, and it is very wrong. This is the loop requiring retuning repeatedly for years and years with no success. Why? The process variable deviation may occur due to an incoming change (such as an inlet temperature change), or a header pressure change may cause a change in the controlled flow, or a production rate change may necessitate a step change in controlled flow.

Each of the three error sources requires different tuning. One size does not fit all. In fact the main control (correcting for a change in inlet value) is production rate dependent: what works at a high production rate oscillates at a low rate, and what works at a low production rate is too slow at a high rate. Control will always be poor. Instead, take a simple $600 sensor but add an orifice plate/differential pressure (DP) transmitter on the sweetener/dilution line, and things improve. Flow control on the control line eliminates flow errors due to any header pressure changes. Ratio that flow to the main product flow and production rate errors disappear, and tuning the main variable is no longer rate dependent. Now control the ratio setpoint with the consistency, density, or temperature sensor, and you have a very simple to tune, robust control that will outperform the expensive instrument. Senior control experts know this; I haven't heard of a school that teaches it.

SEE more, next page.

<< First < Previous 1 2 Next > Last >>

Oleg , LA, United States, 05/06/14 03:21 PM:

1. Yes
2. Yes
3. Yes
4. Yes
5. Yes
6. Yes
7. Yes

You speak for many of us.
ED , Brittish Columbia, Canada, 05/06/14 05:39 PM:

Good article. We as Controls Engineers go on and on about not being recognized for what we can contribute. Part of it is that most folks don't uinderstand what we do. What we do seems like black magic done with a black box. I for one would really appreciate the opportunity to develop an truly state of the art control system using bus systems everywhere, advanced multivariable controls, wireless and programmed using IEC61131 languages where ever they fit best. Just can't seem to get anyone to take the chance as they are too risk adverse to completely buying in to new technology. What we could do if they let us would be amazing.
jian , China, 05/06/14 08:25 PM:

very useful to me
JOHN , KS, United States, 05/07/14 04:15 PM:

Sounds like Control Engineers also require street sense.

This simple truth can be said in many ways.
Meshack , Non-US/Not Applicable, Kenya, 05/09/14 10:37 PM:

Anonymous , 05/10/14 06:50 AM:

Well Written! Thanks for your experiences shared...and for your courage to take it to the plant manager!
Anonymous , 05/10/14 10:36 PM:

Some of the descriptions you made fit to a process control engineer, please don't forget that there are more than just one kind of controls engineers.
WILLIAM , MI, United States, 05/10/14 10:42 PM:

Definitely written by somebody who understands controls very well. I work very hard at being able to communicate with non-controls people because they can get things done for me, and also maybe they can learn to understand what is happening in a system.
PARISS , CA, United States, 05/11/14 01:05 AM:

A control system is considered to be any system which exists for the purpose of regulating or controlling the flow of energy, information, money, or other quantities in some desired fashion.
WALTER , Alberta, Canada, 05/14/14 02:59 PM:

Wrt. #5, How to pick a PCS. I tell them that buying a PCS is like getting married: 1) You will not know the answers to the most important questions until it is too late. 2) Never base the final decision on price. 3) Be aware of the local reputation.
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
2015 Top Plant: Phoenix Contact, Middletown, Pa.; 2015 Best Practices: Automation, Electrical Safety, Electrical Systems, Pneumatics, Material Handling, Mechanical Systems
A cool solution: Collaboration, chemistry leads to foundry coat product development; See the 2015 Product of the Year Finalists
Raising the standard: What's new with NFPA 70E; A global view of manufacturing; Maintenance data; Fit bearings properly
Special report: U.S. natural gas; LNG transport technologies evolve to meet market demand; Understanding new methane regulations; Predictive maintenance for gas pipeline compressors
Cyber security cost-efficient for industrial control systems; Extracting full value from operational data; Managing cyber security risks
Drilling for Big Data: Managing the flow of information; Big data drilldown series: Challenge and opportunity; OT to IT: Creating a circle of improvement; Industry loses best workers, again
Migrating industrial networks; Tracking HMI advances; Making the right automation changes
Understanding transfer switch operation; Coordinating protective devices; Analyzing NEC 2014 changes; Cooling data centers
Upgrading secondary control systems; Keeping enclosures conditioned; Diagnostics increase equipment uptime; Mechatronics simplifies machine design

Annual Salary Survey

After almost a decade of uncertainty, the confidence of plant floor managers is soaring. Even with a number of challenges and while implementing new technologies, there is a renewed sense of optimism among plant managers about their business and their future.

The respondents to the 2014 Plant Engineering Salary Survey come from throughout the U.S. and serve a variety of industries, but they are uniform in their optimism about manufacturing. This year’s survey found 79% consider manufacturing a secure career. That’s up from 75% in 2013 and significantly higher than the 63% figure when Plant Engineering first started asking that question a decade ago.

Read more: 2014 Salary Survey: Confidence rises amid the challenges

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
This article collection contains several articles on the vital role that compressed air plays in manufacturing plants.