Process and controller performance monitoring: overview with industrial applications

Complex processes depend on regulatory control systems to operate. Changes made to the sensor system and the process itself as well as the natural degradation over time of the equipment may cause some controllers' and process performance to suffer. Since there are hundreds of controllers in most complex processes, it is virtually impossible to monitor their performance manually. This work reviews the state-of the-art in controller performance monitoring including both feedforward and feedback control. The experiences of the DuPont Company in the deployment of a system for performance monitoring are presented. Information as to how such a monitoring system is implemented in the operation of a chemical process and examples of its operation are included. Copyright (C) 2003 John Wiley Sons, Ltd.