ExperTune

PlantTriage
PlantTriage’s latest enhancement, Root Cause Finder, employs advanced mathematical techniques to automatically identify the root causes of process upsets, without requiring any process models or other prior knowledge of the process. Upsets that start in one part of a plant are reflected in the data patterns observed in other parts of the plant. By evaluating the correlations among instrument readings throughout the entire manufacturing facility, and the time-shift from one correlation to the other, PlantTriage is able to determine the most likely sources of process variation. Root Cause Finder results, color-coded to show the extent and the time-lag of the cause, are displayed graphically, at the top of PlantTriage’s Process Interaction Map. Other affected process areas are also shown on the display.

PlantTriage
PlantTriage now provides real-time trending of process variables on a mobile phone’s browser, giving workers immediate access to control-room data, even when they are working out in the plant. The trending tools provide immediate information on process variables, setpoints, and controller outputs. Users can zoom, span, and scale the trends to see details, as well as browse through reports and dashboards that pinpoint instrument issues, valve issues, and tuning problems.

PlantTriage software
PlantTriage software allows tuning over 50 control loops per day. It identifies the loops to be tuned and indicates the best proportional-integral-derivative (PID) values, and performs before and after simulations to quickly confirm the settings. This real-time monitoring provides prioritized, focused advice via a standard web browser or automated e-mail, which allows users to perform simulations, fine-tune the controller, and generate loop documentation. The advice is based on the 40 years of experience of process control expert Greg Shinskey, whose analysis techniques and thought processes are made available to users via this sophisticated software interface. The system analyzes the problem as though it were Mr. Shinskey himself. Live links to detailed dashboards can be used to inspect all aspects of control loop performance. The new features link directly to the manufacturer’s active model capture technology (AMCT), which scans the plant 24 h/d looking for operator setpoint changes or output changes. From these normal operating data, the software models the process, finds new tuning constants, and shows the improvement. The PlantTriage server maintains a history of these process models and tuning values, as well as other control performance metrics.

ProcessApex
Based on the expert advice of Greg Shinskey and others, ProcessApex provides real-time advice for process unit operations. It handles unit operations from simple to complex. Individual process objects include common operations, such as heat exchangers, dryers and distillation columns. Each “smart” unit operation provides real-time performance metrics that address throughput, quality, reliability and cost. A direct link with the company’s PlantTriage system allows users to drill down into specific performance issues. Benchmarking tools help users to squeeze additional value from process performance information. This includes tools for benchmarking within and between similar unit operations over time. When used at a corporate level, the tools can help drive capital spending decisions, resolving questions like “Where should I add more production capacity?”

Plant Performance Supervision and Alarm Management Tools
Traditionally, alarm management and performance supervision have been independent software applications. Integrating these two applications is TiPS and ExperTune. These companies have leveraged their respective expertise to develop the next-generation manufacturing intelligence tool. Alarm performance metrics from LogMateAMS are used by PlantTriage in loop performance calculations, resulting in a more complete and accurate view of operations. Because PlantTriage and LogMateAMS use similar designs and are both thin-clients, the integration is seamless and users are still able to access all information through a web browser.