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



The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by Control Engineering subscribers. Vote now (if qualified)!
The System Integrator Giants program lists the top 100 system integrators among companies listed in CFE Media's Global System Integrator Database.
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
This eGuide illustrates solutions, applications and benefits of machine vision systems.
Learn how to increase device reliability in harsh environments and decrease unplanned system downtime.
This eGuide contains a series of articles and videos that considers theoretical and practical; immediate needs and a look into the future.
HMI effectiveness; Distributed I/O; Engineers' Choice Award finalists; System Integrator advice; Inside Machines
Women in engineering; Engineering Leaders Under 40; PID benefits and drawbacks; Ladder logic; Cloud computing
Robotic integration and cloud connections; SCADA and cybersecurity; Motor efficiency standards; Open- and closed-loop control; Augmented reality
Programmable logic controllers (PLCs) represent the logic (decision) part of the control loop of sense, decide, and actuate. As we know, PLCs aren’t the only option for making decisions in a control loop, but they are likely why you’re here.
This digital report explains how motion control advances and solutions can help with machine control, automated control on assembly lines, integration of robotics and automation, and machine safety.
This article collection contains several articles on how advancements in vision system designs, computing power, algorithms, optics, and communications are making machine vision more cost effective than ever before.

Find and connect with the most suitable service provider for your unique application. Start searching the Global System Integrator Database Now!

Control room technology innovation; Practical approaches to corrosion protection; Pipeline regulator revises quality programs
Cloud, mobility, and remote operations; SCADA and contextual mobility; Custom UPS empowering a secure pipeline
Infrastructure for natural gas expansion; Artificial lift methods; Disruptive technology and fugitive gas emissions
Automation Engineer; Wood Group
System Integrator; Cross Integrated Systems Group
Jose S. Vasquez, Jr.
Fire & Life Safety Engineer; Technip USA Inc.
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me