Abstract: A system and method for detecting malfunctions in control valves is disclosed. The system comprises a test unit that is capable of being coupled to a feedback controller that is coupled to a control valve. From the feedback controller the test unit obtains process variable data and output data associated with the control valve. A test unit controller in the test unit 1) forms a data pattern from the process variable data and output data associated with the control valve, and 2) compares the data pattern with a diagnostic data pattern of a valve malfunction or valve fault. When the data pattern matches the diagnostic data pattern of the valve fault, the test unit controller determines that the control valve is experiencing a valve fault. The system and method of the present invention does not require the control valve to be taken out of operation during the diagnostic testing.

Abstract: Systems and methods of operating the same are introduced for populating and using lookup tables with process facility control systems and models of the same. An exemplary computer system for use with a process facility having a plurality of associated processes, and includes both a memory and a processor. The memory is capable of maintaining (i) a data structure having a plurality of accessible fields and (ii) a model of at least a portion of the plurality of associated processes. The model may include a mathematical representation of at least a portion of the at least one process, defining certain relationships among inputs and outputs of the at least one process. The processor is capable of populating ones of the plurality of accessible fields of the data structure using the model iteratively with a range of possible values of the at least one measurable characteristic.