Controller Performance Assessment Service

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			Process plants contain hundreds or thousands of controllers, and proper monitoring and maintenance of controller performance can significantly improve plant production efficiency, productivity, and stability. However, it is reported that in process plants, more than 60% of controllers do not perform at expected levels. Keeping large numbers of controllers at optimum performance is not an easy task, but with improvement of controller performance, plant owners can typically:
			Increase plant throughput by 2-5% Reduce variability of product quality by 30% Reduce utility consumption by 5-10% Increase yields of valuable products by 2-5% Reduce valve maintenance costs Realize stable, safe and efficient process plant operation
			Traditional controllers such as PID controllers may have a relatively wide range of variance around the actual setpoint. For example, if process fluid temperature must be kept at least 100˚C at all times, a controller with wider variance may need a setpoint of 102˚C to maintain minimum required temperature. However, using a more advanced controller with a narrower range of variance, a setpoint of 100.5˚C might suffice. Lowering controller setpoints can save a large amount of energy. Thus, use of more advanced controllers can substantially improve plant efficiency as illustrated in the following figure.



			Improvement of Process Controller Performance
			To help plant owners improve process controller performance, JGC offers the following basic and advanced services:

			Basic Service:
			Analyze normal operation data and identify which control loops show bad performance Identify potential causes of bad performance, e.g. bad tuning parameters, bad calibration or maintenance (e.g. valve stick), interaction of process variables, disturbances, etc. Suggest potential counter-measures according to tuning objectives Suggest the best controller tuning parameters according to tuning objectives, and conduct on-site tuning support

			Advanced Service:
			In addition to basic service, tuning of PID controllers, and calibration of instruments, JGC offers the following solutions if further effort is required to improve control loop performance:
			PID-based Enhanced Regulatory Control loops, such as feed-forward, decoupling control. Model Predictive controller

			Related URLs
			Predictive Control for Reactor (PCR) / Predictive Functional Control (PFC)


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