Real-time Monitoring

Monitoring Monitoring and statistical analysis of the performance and KPI of the control loops
Evaluation help to master their operations at all times and achieve lean management.

Performance Evaluation

In view of the control loop operation, the system will automatically detect and assess
all loop running condition of the period, and output assessment and diagnosis
report, so as to carry out proactive maintenance in the early stage, conduct control
loop batch management in time, and improve operation efficiency.

Intelligent Diagnosis

Intelligent diagnosis and optimization advice will be provided for the typical loop
problems. It helps process engineers to define loop problems in time, get speciality
Optimization Diagnosis advice, so as to avoid unnecessary shutdown and maintenance.

PID Tuning

Based on the process data, it can automatically identify and select the effective data
Life-cycle Control Loop Performance Optimization
segments for IMC-PID parameter setting without any interference on site. The
interactive setting strategy based on data and model can greatly reduce the
threshold of using the software, and improve the tuning efficiency.
Overview Functional Architecture
Proportional-Integral-Derivative (PID) control is the most widely used control
The optimization of control loop performance is carried out in 4 steps:
algorithm in the process manufacturing industry. Its simplicity and robustness make
Evaluation: Based on defined performance KPI, evaluate the performance of each
it an ideal tool for the process industry. It is widely available across many platforms Benefits
close loop.
such as DCS, PLC, RTU, etc.
Diagnosis: Diagnose the bad actor(s) that cause the deterioration of loop
The PID control algorithm is very robust and is able to tolerate significant changes in performance, the sensor, the actuator or the controller issues.
the process dynamics, however it is still necessary to maintenance the PID controller Optimization: Optimize PID parameters based on identified process dynamic model.
loop performance. The process dynamics changes with different operation modes Monitoring: Monitor all the loop performance in real-time.
and aging equipment, especially in modern industrial complex where there are Improve the automation rate Reduce the alarm rate
and plant stability and operator workload
hundreds and thousands of control loops, simple and complex. Keeping all the loops
in peak performance can become a time consuming task.
Life-cycle Control Loop Performance Optimization
SUPCON dOps Control Loop Performance Optimization Application is designed to
Real-time Performance Intelligent
support the process and/or automation engineer optimize the PID control loops at PID Tuning
Monitoring Evaluation Diagnosis

peak performance. The application comes with intelligent analysis, diagnostic, and Control stability Automatic batch Valve viscosity Offline parameter
state information evaluation analysis tuning

expert advise on corrective actions to address the identified bad actors. Alarm/operation Comprehensive Loop vibration Interactive online
frequency evaluation grading detection tuning
Reduce excursion Enhance production excellence
Real-time Multiple types Coupling situation Speciality tuning of key process variables
loop display of reports display library

Units comparison Operation & maintenance Tuning results

Key loop push
assessment diagnosis and suggestion analysis

Advanced control platform/Standard Loop information real-time/relational

data services database

DCS PLC Other Data Source

Success Story
An Olefin Plant Control Loop Performance Optimization Project Comparison of overall loop performance of one unit before and after:

The project scope covers evaluation and diagnosis of 873 loops, PID tunning of 540 Before application, a large number of loops were in open loop, and the excellent rate
loops and performance optimization of 41 complex loop groups. After applying dOps of loops was only 29.6%
Control Loop Performance Optimization Application, the operation stability is
significantly improved to around 99%, the alarm frequency is reduced by 50%, and the
manual operation frequency is reduced by 80%.

873 540 41
complex loops groups
loops evaluation & diagnosis loops parameters tunning
optimization

99% 50%↓ 80%↓

operation stability alarm frequency manual operation frequency

Comparison of single loop performance before and after:

After application, the unit’s automation control was significantly improved, the
Before tuning, the control loop deviation is about 2%. stability rate increased to 99%, and the excellent & good loops rate reached to 93.18%.

After tuning, the control loop deviation is greatly reduced to 0.4%.

Control Loop performance

Optimization Application
for peak performance of your control assets

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