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Implementation and Performance Monitoring of Control Systems

On a plant with 1000 PID control loops, how many man-hours would be required to check that all are being used and working well? And what would the findings be? In the paper industry in the early 1990's, one author suggested that 20% would be working well. A decade later, a multi-national chemical company monitored 14,000 loops across nine sites and reported that 59% were good or excellent, the rest could be improved. Control loops are usually maintained on complaint, not on data-based condition monitoring.

Construction of the Comalco Alumina Refinery (CAR) commenced in 2002. By this time a number of software products had become commercially available, which automatically monitor control loops and report on their performance, identifying those which are in need of attention. CAR chose to install automatic loop performance monitoring and, when first alumina was shipped in November 2004, 490 priority controllers had been identified and configured into the system.

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Details:
Whitepaper (727 KB , PDF)
Author: Matrikon Inc.

Description:
Matrikon™ Control Performance Monitor Whitepaper.