Abstract: Systems and methods for adaptively tuning a Proportional, Integral and Derivative (PID) controller in a zero order industrial process are provided. A method and system can involve receiving input data at one or more inputs of the PID controller and generating output data at one or more outputs of the PID controller in response to processing the input data. Error(s) associated with the controller are determined based on an analysis of a measured parameter with respect to a desired setpoint. The measured parameter may be indicated in the output data. Adaptive gain may be applied to the PID controller in response to the absolute value of the controller error both exceeding a deadband and increasing. Additionally, normal gain, which is lower than the adaptive gain, may be applied to the PID controller in response to the absolute value of the controller error either being below the deadband or decreasing.

Abstract: Systems and methods for providing operator variation analysis for an industrial operation are disclosed herein. In one aspect of this disclosure, a method for providing operator variation analysis includes processing input data received from one or more data sources to identify steady state process data relating to the industrial operation and selecting one or more types of data in the steady state process data to cluster for operator variation analysis. The one or more types of data are clustered using one or more data clustering techniques, and the clustered one or more types of data are analyzed to identify a best operator of a plurality of operators responsible for managing the industrial operation. Information is analyzed to determine if one or more gaps exist in the economic operation of the industrial operation due to operator variability between the best operator and other operators.

Abstract: Systems and methods for addressing gaps in an industrial operation due to operator variability are disclosed herein. In one aspect of this disclosure, a method for addressing gaps in an industrial operation due to operator variability includes processing input data received from one or more data sources to identify a best operator of a plurality of operators responsible for managing the industrial operation, and determining if one or more gaps exist in the economic operation of the industrial operation due to operator variability between the best operator and operators other than the best operator. Identified gaps may be analyzed to determine if relevant characteristics associated with the gaps justify at least one solution for addressing the gaps for the particular industrial operation. At least one solution may be identified and mapped to the gaps in some instances.

Abstract: Systems and methods for benchmarking operator performance for an industrial operation are disclosed herein. In one aspect of this disclosure, a method for benchmarking operator performance for an industrial operation includes receiving input data relating to the industrial operation from one or more data sources, and processing the input data to measure operator effectiveness and build a data repository for benchmarking/analytics. The data repository may include information relating to the measured operator effectiveness, for example. Biggest contributors of operator variability may be identified based on an analysis of the data repository, and one or more actions may be taken to reduce or eliminate the biggest contributors of operator variability.

Abstract: Systems and methods for providing operator variation analysis for an industrial operation are disclosed herein. In one aspect of this disclosure, a method for providing operator variation analysis includes processing input data received from one or more data sources to identify transient or non-steady state process data relating to the industrial operation and selecting one or more types of data in the transient or non-steady state process data to cluster for operator variation analysis. The one or more types of data are clustered using one or more data clustering techniques, and the clustered one or more types of data are analyzed to identify a best operator of a plurality of operators responsible for managing the industrial operation. Information is analyzed to determine if one or more gaps exist in the economic operation of the industrial operation due to operator variability between the best operator and other operators.

Abstract: Systems and methods for adaptively tuning a Proportional, Integral and Derivative (PID) controller in a zero order industrial process are provided. A method and system can involve receiving input data at one or more inputs of the PID controller and generating output data at one or more outputs of the PID controller in response to processing the input data. Error(s) associated with the controller are determined based on an analysis of a measured parameter with respect to a desired setpoint. The measured parameter may be indicated in the output data. Adaptive gain may be applied to the PID controller in response to the absolute value of the controller error both exceeding a deadband and increasing. Additionally, normal gain, which is lower than the adaptive gain, may be applied to the PID controller in response to the absolute value of the controller error either being below the deadband or decreasing.

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.