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Press Releases

News Releases

2003

  • Five-fold increase in productivity (December 2003)
  • A 'class act' can dramatically improve plant profitability (December 2003)
  • Process Control Consultant In A Box (October 2003)
  • Manage Plant Performance In Real Time (September 2003)
  • Automatic Logging of PID Changes, Plant-Wide (June 2003)
  • Eliminate Cycling in Your Plant (May 2003)
  • Quickly Setup Your Plant For Performance Monitoring (April 2003)
  • Loop Performance Monitor Mines Knowledge From Your Historian (March 2003)



  • Five-fold increase in productivity (December 2003)

    A world scale chemical plant has seen a 5-fold increase in productivity, due to adopting a software program created by globally-acknowledged experts at a Wisconsin company. This remarkable saving was one of several such achievements that resulted in ExperTune Inc receiving a Problem Solver award from Plant Services magazine.

    According to this respected publication: "A major multinational chemical processor with tens of thousands of instruments and valves is receiving the benefits of five times the manpower by using PlantTriage performance monitoring software. The system also helps double the life of the company's valves."

    Plant Services (www.plantservices.com) continues: "By looking at the most important areas listed in the "Biggest Payback Loop" list, the same maintenance people can oversee 10 times as many controllers as before, since the controllers are prioritized based on importance to the business."

    President of ExperTune John Gerry, says: "Our latest technology, PlantTriage, is a plant-wide performance monitor that has successfully saved millions of dollars in improved performance for the process industries."

    He adds: "Now is the time, when the global economy shows signs of a resurgence, to ensure that every plant is reliable, efficient, and fine-tuned to deliver the last ounce of profitability."

    Last month, ExperTune announced a 'master class' that is being made available to engineers worldwide. Expert instructors are teaching techniques that achieve practical results, and are designed to produce major gains in days, not weeks or months."

    Mr Gerry notes: "The company wins awards for its software because its suite of optimization tools is designed solely to increase the efficiency of processes, and PlantTriage is designed to monitor and assess the entire plant, to ensure optimal operation and profitability."

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    A 'class act' can dramatically improve plant profitability (December 2003)

    In a typical plant, more than 75% of assets are tied to control systems, says the CEO of Wisconsin-based ExperTune, John Gerry. Launching a 'master class' that will be available to engineers worldwide, Mr Gerry said: "Almost every factory engineer is fully familiar with the operation of process plants, but needs some knowledge of the finer points in order to get the plant to run like an Indianapolis winner."

    "ExperTune's master classes are designed to teach engineers how to track the performance of plant assets, to identify process and equipment problems, pinpoint operational inconsistencies, and then remedy the problems found."

    He continued: "When economic conditions are tight, and markets are fiercely competitive, boards of directors want to direct resources to the areas of the plant where the greatest economic gains are possible. Our experts are now available to teach engineers to use performance monitoring technology to direct resources to the areas of the plant where they are needed most."

    Mr Gerry added: "Any CEO who has any doubt about the vast scope for improvement in the process industries should have been at a recent seminar held by Fisher Controls, an Emerson company."

    At the seminar, Director of PlantWeb sales, Joe Herink, said: "Emerson Asset Optimization, Honeywell Hi-Spec, and Aspen Tech all agree that process optimization benefits cannot be realized unless the control valves are doing their job. As many as 80% of the process loops today do not reduce process variability, and the control valve is the leading culprit."

    Key performance indicators

    ExperTune's hands-on classes teach engineers to identify the key performance indicators (KPIs) in various areas in the plant. Students learn about commonplace KPIs, how to benchmark a process, how to identify process and equipment problems, and how to pinpoint operational problems.

    Mr Gerry, an award winner at this year's ISA conference, explained that the classes are aimed at teaching techniques that achieve practical results. All instructors have years of practical hands-on experience in plants, he said, and engineers are invited to bring specific problems to be discussed during the seminar.

    He added: "The company's full suite of optimization tools are designed to increase the efficiency of processes, and PlantTriage is designed to monitor and assess the entire plant, to ensure optimal operation."

    "Now is the time, when the global economy shows signs of a resurgence, to ensure that your plant is reliable, efficient, and fine-tuned to deliver the last ounce of profitability. ExperTune's global master classes are designed to produce major gains in days, not weeks or months."

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    Process Control Consultant In A Box (October 2003)

    Engineers around the world are now able to overcome many of the difficult problems that beset process plants in industries as diverse as refining and pulp mills.

    This new expert system, the Control Consultant, launched by Wisconsin-based ExperTune as an integral part of its flagship product, PlantTriage.

    The new system was developed in conjunction with the world-renowned process control expert, Greg Shinskey, who is the author of numerous books and has lectured extensively over the past 50 years on literally thousands of control applications.

    ExperTune has captured the know-how of Mr Shinskey in the Control Consultant to allow any engineer to tap into and gain the benefit from his experience. The company saw a need for this 'distilled expertise' after working with many of its 6,000+ clients to solve various tuning and analysis problems.

    Founder and president of ExperTune, John Gerry, said: "Many of our clients have very subtle and often misleading symptoms from their automation systems, and often don't have enough time to solve many of the problems found in operating plants."

    He added: "We developed the Control Consultant to assist them in getting the right answers as fast as possible, and tests have shown that it is invaluable for engineers and managers seeking to wring the last drop of profit out of plants of all ages and types."

    Mr Gerry explained that PlantTriage is a plant-wide performance monitor that has successfully saved millions of dollars in improved performance for the process industries.

    "The company's full suite of optimization tools are designed to increase the efficiency of processes, and PlantTriage is designed to monitor and assess the entire plant, to ensure optimal operation," he said.

    This month (October), at the ISA conference in Houston, John Gerry received the Douglas H. Annin Award "in recognition of the contributions to the development of a PID tuning engine and its commercial applications."

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    Manage Plant Performance In Real Time (September 2003)

    ExperTune has released a Web-based presentation that outlines methods for managing the performance of process plants in real-time to get "huge increases in performance and productivity." The presentation describes a set of tools required to achieve real-time performance management.

    CEO of the Wisconsin company, John Gerry, explained: "First, software is required to continually monitor all plant areas, and continually assess the performance of these areas."

    He continued: "After talking to engineers in many industries, we recognized that the areas of biggest opportunity must be pinpointed by software. They told us they wanted tools that are integrated to easily drill-down, diagnose, troubleshoot and repair the problems found in these areas. Further, that the tools allow tracking of the performance over time accessible to all personnel."

    Mr. Gerry added: "So that is exactly what we have now provided. We have incorporated the needs and wants of engineers in the process industries and other areas of manufacturing, and incorporated the proven concepts we have generated during almost two decades of providing practical help to engineers."

    The genial CEO explained that, for 17 years, ExperTune had been creating award winning optimization software that runs in thousands of plants worldwide. The latest presentation outlines how to enhance and simplify the ongoing maintenance of the entire control system infrastructure.

    ExperTune's full suite of optimisation tools are designed to increase the efficiency of processes. Its PlantTriage monitors and assesses the entire plant, ensuring optimal operation. The company's analysis tools include simulation, modeling, robustness, linearization, valve wear analysis, pH linearizer, time series analysis, multivariable, statistical, frequency response, and PID tuning tools.

    The presentation is available free at http://www.expertune.com/present.asp?name=realtime
    - or from the presentation page at ExperTune.com:
    http://www.expertune.com/LearnCast.aspx

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    Automatic Logging of PID Changes, Plant-Wide (June 2003)

    When operators, engineers or technicians make many adjustments in one area, this indicates a problem in that area. Without an effective documentation system, changes are not communicated. This further exacerbates problems in the area.

    ExperTune's new version of PlantTriage automatically logs changes to PID tuning values across the plant. PlantTriage records these PID change events for every controller. Users can correlate the events and add notes.

    A spokesman for the Wisconsin-based company, Tom Kinney, says: "This change management system provides a consistent plant-wide method for viewing PID tuning change logs. Changes are easily accessible to anyone in the plant through their browser. Users can correlate performance changes with tuning changes."

    Users view PID change events in their web browser. The browser interface includes a notes section for explaining the purpose of change. Tuning changes are automatically logged and recorded for every controller in the plant. Spurious events (quick experiments) are automatically ignored. The log is sortable by date, controller tag, author of the change, parameter values etc. The log can be organized on a per user basis for various plant areas or process types. For example, a user could view the log for individual unit operations, specific controller types (only flow loops) or the entire plant. Users through their browser can also log other maintenance activities or process changes occurring in the plant.

    For 15 years, ExperTune has created award winning optimization software that runs in thousands of plants world-wide. Now, this automatic change management system allows users plants to effectively document and communicate PID and other loop changes. With this addition PlantTriage further enhances and simplifies the ongoing maintenance of the entire control system infrastructure.

    ExperTune's full suite of optimization tools are designed to increase the efficiency of processes. Its PlantTriage monitors and assesses the entire plant, ensuring optimal operation. The company's analysis includes simulation, modeling, robustness, linearization, valve wear analysis, pH linearizer, time series analysis, multivariable, statistical, frequency response and PID tuning tools.

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    Eliminate Cycling in Your Plant (May 2003)

    Remove cycling in a plant and the entire operation will improve. ExperTune has released this web-based presentation that outlines methods for eliminating cycling in process plants.

    The presentation is available at no-charge, anytime, anywhere via:

       http://www.expertune.com/present.asp?name=derivative

    Or from the presentation page at ExperTune.com:

       http://www.expertune.com/LearnCast.aspx

    The most typical cause of cycling in process plants is from valve stiction or hysteresis. Aggressive tuning, non-linearities, and loop interactions are also other causes. The first step in removing cycling is identifying the cause.

    ExperTune's full suite of optimization tools are designed to increase the efficiency of your process. ExperTune's PlantTriage monitors and assesses the entire plant, assuring optimal operation. ExperTune's analysis includes simulation, modeling, robustness, linearization, valve wear analysis, pH linearizer, time series analysis, multivariable, statistical, frequency response and PID tuning tools.

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    Quickly Setup Your Plant For Performance Monitoring (April 2003)

    ExperTune's newest development is a bulk database import for setting up an entire plant for monitoring and assessment in PlantTriage ™. PlantTriage continually monitors the plant and assesses its performance. Areas with the greatest need are prioritized for maintenance and engineering.

    The initial challenge in monitoring and assessing an entire plant, is setting up the addresses for all the instruments and controllers. John Gerry of ExperTune says, "PlantTriage makes this easy by using a smart wizard-based bulk import. The wizard (Patent Pending) has intelligence about specific control systems so that it polls the control system for most of the data it needs."

    The result is that PlantTriage imports, from your database, only the information necessary for the wizard to get started. It then reads as much information as possible directly from the process control computer. Optionally, the user could enter the addresses in Excel and direct PlantTriage to use Excel. Once setup, PlantTriage will monitor and assess every control loop in the plant, assuring optimal plant operation.

    ExperTune's full suite of optimization tools are designed to increase the efficiency of your process. ExperTune's PlantTriage monitors and assesses the entire plant, assuring optimal operation. ExperTune's analysis includes simulation, modeling, robustness, linearization, valve wear analysis, pH linearizer, time series analysis, multivariable, statistical, frequency response and PID tuning tools.

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    Loop Performance Monitor Mines Knowledge From Your Historian (March 2003)

    ExperTune's PlantTriage now will monitor the performance of your control loops directly from your plant Historian. PlantTriage's new OPC HDA makes this possible. Interfaces to these historians:

    • OSI PI Historian
    • Honeywell PHD
    • AspenTech InfoPlus.21
    • Invensys AIM*Historian
    • Any historian supporting OPC HDA

    HDA stands for Historical Data Access and is a new standard from the OPC Foundation.

    PlantTriage assesses the plant data from the historian, prioritizing process control loops in order of biggest payback. PlantTriage focuses efforts on those loops that will have the greatest economic impact. Applying PlantTriage results in a steady and continuous improvement in the product quality, costs, throughput, and waste reduction in process plants.

    The OPC HDA connection is simple and elegant, allowing control engineers to view past data and apply PlantTriage tools to diagnose, tune, linearize and decouple the problems found. These tools increase the effectiveness of maintenance and engineering personnel by a factor of 5 to 10 since they can optimize the process quickly and systematically with award winning tools.

    PlantTriage is ExperTune's loop monitoring package that prioritizes loops for process control engineers. With PlantTriage and the same maintenance people the plant has now, performance will improve since maintenance will be focused on the areas that will make the biggest difference. And PlantTriage includes the tools to optimize those areas. PlantTriage results in predictive, reliability centered maintenance. PlantTriage maximizes profit improvement without adding brick and mortar or personnel.

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