Greg McMillan

Author's details

Date registered: April 19, 2011

Biography

Gregory K. McMillan,CAP, is a retired Senior Fellow from Solutia/Monsanto where he worked in engineering technology on process control improvement. Greg was also an affiliate professor for Washington University in Saint Louis. Greg is an ISA Fellow and received the ISA "Kermit Fischer Environmental" Award for pH control in 1991, the Control Magazine "Engineer of the Year" Award for the Process Industry in 1994, was inducted into the Control "Process Automation Hall of Fame" in 2001, was honored by InTech Magazine in 2003 as one of the most influential innovators in automation, and received the ISA "Life Achievement Award" in 2010. Greg is the author of numerous books on process control, his most recent being Essentials of Modern Measurements and Final Elements for the Process Industry. Greg has been the monthly "Control Talk" columnist for Control magazine since 2002. Presently, Greg contracts as a consultant in DeltaV R&D via CDI Process & Industrial.

Latest posts

  1. Different but the Same — February 22, 2012
  2. Compressor Surge and Stall Detection and Prevention — January 26, 2012
  3. How to Succeed – Part 10 — January 19, 2012
  4. How to Succeed – Part 9 — January 12, 2012
  5. How to Succeed – Part 8 — January 5, 2012

Author's posts listings

Sep
08

Batch vs. Continuous Control and Optimization – Part 1

Feedback control systems play an important role in batch and continuous unit operations. What are the similarities and differences in the process response, tuning, control strategies, and advanced process control opportunities? What can continuous control specialists learn from batch control experts and vice versa? Is it possible there are some fundamental principles unifying our solutions …

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Sep
01

Chance of a Lifetime

We have the opportunity to hear the 3 most influential and knowledgeable technical leaders in industry give their assessment of the present state and future of our profession. This will be the first and most likely only time these guys will be sharing their knowledge at the same event, thus covering the complete spectrum of …

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Aug
25

Top Twelve Mistakes in pH System Design

The extreme capability of the pH measurement and the broad spectrum of applications and process conditions create exceptional requirements for electrode design, mixing uniformity, control valve precision, deadtime minimization, nonlinearity compensation, and control strategies. pH loops are often the most challenging loops in the plant. Slight deficiencies in the mechanical, piping, process, measurement, and control …

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Aug
18

Effect of Mechanical Design – Equipment

There are numerous examples where equipment design by not taking into consideration dynamics caused poor control. A good equipment design should reflect an understanding of how dynamics affect control loops and the efficiency and capacity of the production unit. Most advanced control opportunities arise from equipment deficiencies that become particularly evident as plants are pushed …

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Aug
11

Effect of Mechanical Design – UA

The product of the overall heat transfer coefficient and area (UA) determines the controllability of temperature processes. The deterioration of the UA is a particular concern for crystallization and polymerization processes. Frosting and fouling can decrease process efficiency and production rate even if the controllers are retuned. For exothermic reactors, a decrease in the UA …

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Aug
04

Effect of Mechanical Design – Pumps and Piping

The increasing emphasis on saving energy and capital costs can lead to pump and piping designs that inadvertently cause a severe loss of turndown in flow loops and a significant increase in noise , delay, and lag in temperature and pH loops. The deterioration in loop performance can create an insidious reduction in process efficiency …

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Jul
28

Effect of Mechanical Design – Mixing

Mixing changes the game. Mixing has a broad impact on disturbances, interactions, and noise. Mixing breaks paradigms on tuning, control, and performance. Mixing is at play in key unit operations offering incredible tightness of control and forgiveness of mistakes enabling exceptional product quality. I became sensitized to the role of mixing early in my career …

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Jul
21

Top Ten Limitations – Analyzers

Ultimately what we most need to know in each key process stream is the operating condition least measured; composition. We are largely flying blind. Neural networks and projections to latent structure technologies have proliferated because online and at-line analyzers are missing. Here is a look at the use of analyzers in the process industries.  Advanced process control (APC) …

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Jul
15

Top Ten Limitations – Setpoints

A loop is only as good as its setpoint. Most loops are not operating at the best setpoint for 9 major reasons. For sustainable manufacturing we need to understand and address these reasons to achieve better setpoints to reduce the energy, raw material, recycle, and waste and provide more flexible production while maintaining product quality. Reducing …

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Jul
07

Top Ten Limitations – Turndown

Plant turndown determines how effectively a production unit can minimize inventory and energy costs. As utility rates change with supply and demand, energy efficiency changes with weather, and product demand changes with customer shipments and downstream requirements, the need to be able to run at lower and lower rates becomes increasingly important. Temporarily shutting down a …

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