Process diagnostic platform targets plant performance and profitability

PlantESP from Control Station actively monitors regulatory controllers and simplifies root-cause analysis.

11/06/2012


Control Station has announced the addition of new and advanced process diagnostic capabilities to the Company’s PlantESP solution platform. The enhancements expand PlantESP’s existing root-cause analysis capabilities and targets the 5% of production lost by process manufacturers due to poorly performing regulatory control systems.

Advanced diagnostics were recently extended with the introduction of an intuitive cross-correlation analysis capability. The new feature characterizes the interaction among and between PID control loops within a production facility’s regulatory control environment. Analysis is presented in an interactive matrix and it characterizes loop relationships as either leading or lagging. Combined with spectral analysis and other diagnostic tools, PlantESP provides users with a comprehensive toolkit for quickly and systematically correcting control-related issues that impact plant profitability.

“Process manufacturers lose 5% of their production value annually due to correctable control and asset reliability issues,” noted Rick Bontatibus, Control Station’s vice president of global sales. “That represents nearly $500 billion on a global basis. Whether in terms of controller performance or asset reliability, PlantESP is making it easier for manufacturers to realize their full potential.”

PlantESP helps process manufacturers reclaim significant economic losses associated with underperforming control systems and unplanned equipment failures. The platform’s loop performance monitoring module isolates the root-cause of controller performance issues which result in unnecessary energy consumption, production waste, and reduced output. 

The company contends that with hundreds or even thousands of PID controllers at a typical production facility, the task of maintaining effective and efficient control can be overwhelming. Maintaining control has become increasingly challenging due to reduced plant staffing levels.

PlantESP addresses the challenges of diminished staffing levels and increased market expectations. Specifically, the platform’s loop performance monitoring module actively monitors control loops on a plant-wide basis and identifies PIDs that require service. PlantESP provides timely alerts and reports that target the unique information needs of operations staff and plant management. With advanced diagnostic tools such as cross-correlation and recommendations for corrective action, PlantESP equips users with guidance for resolving control-related issues quickly and for maintaining optimal production levels.

The PlantESP platform was originally launched in 2010 with a focus on PID controller performance. The loop performance monitoring module has been noted both for its intuitive design and for its contributions to improved plant-wide control. PlantESP was extended in 2011 with the introduction of the predictive analytics model, an innovative asset management tool that provides advance warning of equipment failure. Combined, the loop performance monitoring and predictive analytics capabilities address the growing need among process manufacturers for technologies that deliver reliable and actionable information.

www.controlstation.com

Control Station

Edited by Peter Welander, pwelander@cfemedia.com



No comments
The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
Each year, a panel of Control Engineering editors and industry expert judges select the System Integrator of the Year Award winners.
Control Engineering Leaders Under 40 identifies and gives recognition to young engineers who...
Learn more about methods used to ensure that the integration between the safety system and the process control...
Adding industrial toughness and reliability to Ethernet eGuide
Technological advances like multiple-in-multiple-out (MIMO) transmitting and receiving
Virtualization advice: 4 ways splitting servers can help manufacturing; Efficient motion controls; Fill the brain drain; Learn from the HART Plant of the Year
Two sides to process safety: Combining human and technical factors in your program; Preparing HMI graphics for migrations; Mechatronics and safety; Engineers' Choice Awards
Detecting security breaches: Forensic invenstigations depend on knowing your networks inside and out; Wireless workers; Opening robotic control; Product exclusive: Robust encoders
The Ask Control Engineering blog covers all aspects of automation, including motors, drives, sensors, motion control, machine control, and embedded systems.
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
News and comments from Control Engineering process industries editor, Peter Welander.
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
This is a blog from the trenches – written by engineers who are implementing and upgrading control systems every day across every industry.
Anthony Baker is a fictitious aggregation of experts from Callisto Integration, providing manufacturing consulting and systems integration.
Integrator Guide

Integrator Guide

Search the online Automation Integrator Guide
 

Create New Listing

Visit the System Integrators page to view past winners of Control Engineering's System Integrator of the Year Award and learn how to enter the competition. You will also find more information on system integrators and Control System Integrators Association.

Case Study Database

Case Study Database

Get more exposure for your case study by uploading it to the Control Engineering case study database, where end-users can identify relevant solutions and explore what the experts are doing to effectively implement a variety of technology and productivity related projects.

These case studies provide examples of how knowledgeable solution providers have used technology, processes and people to create effective and successful implementations in real-world situations. Case studies can be completed by filling out a simple online form where you can outline the project title, abstract, and full story in 1500 words or less; upload photos, videos and a logo.

Click here to visit the Case Study Database and upload your case study.