Controller Consultant

£POA

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What Does Controller Consultant do?

Controller Consultant helps you understand how best to manage your controllers. Do your controllers require tuning? Are they over-tuned? Are they in manual (disabled)?

Controller Consultant can:

• Find controllers automatically so you don't need that expensive configuration report
• Automatically find controllers that are left in manual
• Highlight over-tuned controller which may lead to excessive wear

What's New?

View our release notes to find out about recent updates to this app.

Release Notes

Case Study: Enhancing Reliability Failures with Controller Consultant

Client: Maersk

Overview

A major industrial operator faced persistent issues with rapidly failing valve stems and controllers. Despite investing in specialized software designed to monitor these components, the client struggled for years to configure the system effectively and eventually abandoned it. Seeking a solution, the client implemented Intelligent Plant’s Controller Consultant tool. Within weeks, Controller Consultant identified the root cause of the failures and provided actionable insights that significantly improved the reliability of control loops and valve systems. This proactive approach led to fewer shutdowns and reduced losses, ensuring smoother and more efficient operations.

Challenges

The client encountered several significant challenges in their operations:

• Rapid Component Failures: Valve stems and controllers were failing at an alarming rate, leading to frequent shutdowns and costly repairs.
• Ineffective Monitoring Solutions: Previous attempts to monitor and address these issues using purchased software were unsuccessful. The client spent years trying to configure the software without success, ultimately giving up on it.
• Need for Timely and Accurate Diagnostics: The client required a tool that could quickly diagnose the issues and provide actionable insights to prevent further failures.

Solution

Intelligent Plant’s Controller Consultant was deployed to address these challenges. The tool’s ability to quickly configure itself and provide immediate feedback proved crucial in resolving the issues.

Key Elements of the Solution:

• Automated Initial Setup: Unlike the previous monitoring solution, Controller Consultant was designed to automatically configure itself, allowing the client to start receiving feedback within weeks of deployment.
• Identification of Harsh Control Loops: The tool quickly identified that the control loops were being managed too aggressively, which was contributing to the rapid wear and tear on valve stems and controllers.
• Actionable Feedback: Controller Consultant provided clear recommendations to the client on how to de-tune the controllers, reducing the stress on components and preventing unnecessary failures.

Results and Impact

The implementation of Controller Consultant led to significant improvements in the client’s operations:

• Rapid Problem Identification: Within weeks of deploying Controller Consultant, the client was able to pinpoint that the harsh control loop settings were the primary cause of the rapid failures.
• Reduction in Component Wear: By de-tuning the controllers as recommended, the client reduced the wear on valve stems and controllers, leading to more reliable operation and fewer component failures.
• Improved Communication and Justification: Controller Consultant not only provided technical insights but also helped the client communicate these findings to the broader business. This facilitated the justification and approval of necessary changes to control loop settings.
• Decreased Shutdowns and Losses: The improved reliability of the control loops and valves meant fewer shutdowns due to failing components, leading to significant cost savings and increased production efficiency.

Conclusion

The deployment of Controller Consultant transformed the client’s approach to managing their control systems, turning a persistent problem into an opportunity for improvement. By quickly diagnosing the issues and providing actionable recommendations, Controller Consultant enabled the client to make informed decisions that enhanced the reliability of their operations.

This case study highlights the importance of effective monitoring and diagnostics in industrial settings. Intelligent Plant’s Controller Consultant not only identified the root cause of rapid component failures but also empowered the client to implement changes that led to lasting improvements. The result was a more reliable operation, fewer unplanned shutdowns, and a more efficient and cost-effective production process.