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2005




ExperTune And IPCOS Form Partnership For Delivering Plant Performance Solutions

Alternate Title: ExperTune And IPCOS Create Partnership For Plant Performance Solutions

 

Hartland, Wisconsin (United States), Leuven (Belgium), 12 December 2005

ExperTune Inc and IPCOS have signed an agreement to provide best-in-class performance supervision and process optimization solutions for Europe, the Middle East and North Africa.  The combination of IPCOS consultants applying ExperTune's best-in-class software will benefit many processing plants in the region.  IPCOS has more than 200 man-years experience in advanced control applications.  ExperTune's software consistently wins awards for innovation and optimization.

"The combination of expert talent, leveraged with best-in-class software, has been proven to accelerate optimization efforts. Process plants using IPCOS services together with ExperTune software can expect to see these benefits directly on the bottom line, including energy savings, quality improvement, and production rate increases," says John Gerry, President and founder of ExperTune, Inc.

Christiaan Moons, Managing Director of IPCOS, adds "IPCOS has chosen ExperTune because of their proven solution for plant performance supervision. Plant Performance Supervision Systems are indispensable for the industry to be competitive in the market. Especially in the case of Advanced Control, it is crucial that the control system is performing well before implementing Advanced Control. PlantTriage® makes a perfect fit with the services and software solutions IPCOS already delivers to the industry."

Services offered through this partnership include:

  • Process Plant Dynamic Optimization
  • Sales & Installation of ExperTune PlantTriage®
  • Identification and ranking of highest-priority problems
  • Solving Problems and Quantifying Benefits
  • Training, from Overview to In-Depth training, always with a hands-on approach

John Gerry continued, "We are very excited that process plants in Europe, the Middle East, and Northern Africa will be better able to step-up their optimization efforts. When two strong teams come together, we are able to push the optimization envelope even further than before."

About ExperTune: ExperTune is the company behind PlantTriage®, an enterprise-wide, performance supervision system that pinpoints opportunities for maximum economic benefit. ExperTune can be found online at http://www.expertune.com.

About IPCOS: IPCOS provides Advanced Process Control (APC) and plant optimization solutions (software and services) for the Chemical, Glass, Power and Oil & Gas industry. IPCOS can be found online at http://www.ipcos.com/en

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Finding the Most Important Plant Upsets

ALTERNATE TITLE: Find the Most Important Process Upsets with Oscillation Significance

PlantTriage now shows the impact that cyclic upsets have on your plant's performance. PlantTriage's new "Oscillation Significance" identifies cycling problems in a plant, and ranks them according to importance.

Oscillatory upsets are always a problem. They cause energy losses, lower product quality, and reduced equipment life. Oscillation Significance uses a combination of statistical and frequency-domain information to calculate a single, meaningful measure of significance for each process parameter. Drill-down reporting ranks every process parameter in the plant by Oscillation Significance.

John Gerry, President of ExperTune, says "Our customers have asked for more tools to make use of the enormous warehouse of information within PlantTriage. With Oscillation Significance, you can look at a single number and evaluate a very complex cycling problem."

John Gerry continued "Using traditional approaches, solving oscillation problems may take days or weeks. Now, in minutes, you can have a prioritized assessment of the cycling for every part of the process."

PlantTriage Oscillation Detection analyzes every process variable in a system, looking for patterns of cyclical behavior. It then identifies the source of oscillation to be valve problems, tuning, or load disturbances. Oscillation Significance further refines these assessments by using a combination of loop variability, oscillation detection, and percent of power by frequency. The resulting measure of oscillation detection can be ranked directly, or in combination with economic criteria. A list of process parameters ranked by oscillation significance is then displayed in a drill-down report.

About ExperTune: For 19 years, ExperTune has created award-winning optimization software that runs in thousands of plants world-wide. PlantTriage Performance Supervision Software oversees the optimization of an entire plant. PlantTriage optimizes the entire process, including instrumentation, controllers, and valves. ExperTune's full suite of optimization tools is designed to increase the efficiency of processes. 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. ExperTune is a member of the OPC Foundation. For more information, set your browser to http://www.expertune.com.

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PID Tuning Translator Eases Conversion to New Control System (August 2005)

ExperTune's PID Tuning Translator easily converts PID tuning from one industrial PID controller to another. It converts PID values from any of over 490 different industrial PID controllers to the new system.

For example, when migrating from a PLC to a DCS, the PID tuning parameters are converted directly to the proper units and time bases for the algorithm choice. This maintains the established dynamic performance of the control loop.

John Gerry, President of ExperTune said "Customers have loudly requested the ability to quickly transfer PID settings when upgrading to a new control system. The Translator does that, saving time and avoiding human error".

John Gerry continued, "On a typical DCS conversion project, loop re-tuning can take days, or even weeks. With PID Tuning Translator, all loops retain their basis of performance, and are converted in just hours."

The software converts PID settings from any DCS, controller, or PLC to any other DCS, controller or PLC. In addition to the included 490 PID algorithms, you can customize your own combinations. Many manufacturers have several different PID algorithms available, and the software also converts between different algorithm types within a single manufacturer's controller.

About ExperTune:

For 19 years, ExperTune has created award winning optimization software that runs in thousands of plants world-wide. ExperTune's full suite of optimization tools is designed to increase the efficiency of processes. One of ExperTune's products is PlantTriage which is a Performance Supervision System for 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. ExperTune is a member of the OPC Foundation. For more information, set your browser to http://www.expertune.com.

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ExperTune and TiPS Form Partnership to Integrate Best-in-Class Plant Performance and Alarm Management Tools (July 2005)

ExperTune and TiPS® Form Partnership to Integrate Best-in-Class Plant Performance and Alarm Management Tools

Alarm Management and Performance Monitoring have until now, been independent software applications. TiPS and ExperTune have leveraged their respective expertise to develop a combined solution that offers even more targeted insight into opportunities to improve plant performance and gain competitive advantage.

ExperTune and TiPS have consistently demonstrated leadership in their respective markets through 15-plus years of operation; ExperTune in the area of performance monitoring and PID optimization, and TiPS in the area of process alarm management.

Contact us for more information about how this partnership will help you improve operations and plant performance.

About ExperTune: ExperTune is the company behind PlantTriage®, an enterprise-wide, performance monitoring and diagnostic system that pinpoints opportunities where maximum economic impact to operations can be realized. ExperTune can be found online at http://www.expertune.com.

About TiPS: TiPS develops and distributes LogMateAMS®, an advanced alarm management software package and provides the highest quality of services available from any vendor in the alarm management field. With the largest alarm management specific customer base in the industry, TiPS provides an unequaled resource for alarm management software and services. TiPS can be found online at http://www.tipsweb.com.

ExperTune home page | Information request form




Visual Mapping Gives Performance View of Entire Plant (June 2005)

PlantTriage latest release includes Visual Performance Mapping. It shows the performance of thousands of assets on one browser screen.

With a glance, the Visual Performance Map allows management, engineering, and maintenance to determine how the plant is performing, and where effort is needed for improvement. By drilling down into an asset, engineering and maintenance can view complete diagnosis of problems.

The Visual Performance Maps include several layers of drill-down. Users can zoom-in on specific plants within the site, and specific unit operations within a plant. Then further drill down into specific loops for detailed diagnosis.

All of the assets on the map are spaced into one congruent area. Each asset is represented by both size and color of a rectangle. The larger the size, the more important the asset. The brighter the color, the more opportunity there is to make improvements. For example, bright asset represents a large opportunity for improvement.

PlantTriage continues its industry leading innovation by linking Visual Performance Mapping with biggest payback and historical performance at a glance.

About ExperTune: For 19 years, ExperTune has created award winning optimization software that runs in thousands of plants world-wide. ExperTune's full suite of optimization tools is designed to increase the efficiency of processes. One of ExperTune's products is PlantTriage which is an automatic diagnostic system for 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. ExperTune is a member of the OPC Foundation.

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New PlantTriage Measures Profit and Performance in Real-time (April 2005)

ExperTune's new release of PlantTriage assesses the performance of batch processes. It pinpoints areas where improvements can increase yields, throughput, and decrease turnaround times. Once the areas are identified, specific analysis recommendations are made to improve the control of the batch process.

PlantTriage prioritizes areas for improvement, so personnel are focused on the most profitable areas. It also directs engineers to the product codes where the greatest profit improvements can be made.

A new equation builder allows assessments of batches to be synchronized to periods within a batch when the control loops are operating. This eliminates erroneous assessments of data during batch filling, emptying, heat-up or other irrelevant times

PlantTriage automatically performs 46 assessments on every controller on each batch process. Assessment and diagnosis include detecting oscillations, non-intrusive field instrument diagnosis, controller performance, interaction detection, process modeling, and control system availability. It connects to automation control systems via industry standard OPC or OPC HDA.

For 19 years, ExperTune has created award winning optimization software that runs in thousands of plants world-wide. ExperTune's full suite of optimization tools is designed to increase the efficiency of processes. PlantTriage is an automatic diagnostic system for 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.

ExperTune home page | Information request form




Performance Improvement for Batch Processes (March 2005)

ExperTune's new release of PlantTriage assesses the performance of batch processes. It pinpoints areas where improvements can increase yields, throughput, and decrease turnaround times. Once the areas are identified, specific analysis recommendations are made to improve the control of the batch process.

PlantTriage prioritizes areas for improvement, so personnel are focused on the most profitable areas. It also directs engineers to the product codes where the greatest profit improvements can be made.

A new equation builder allows assessments of batches to be synchronized to periods within a batch when the control loops are operating. This eliminates erroneous assessments of data during batch filling, emptying, heat-up or other irrelevant times

PlantTriage automatically performs 46 assessments on every controller on each batch process. Assessment and diagnosis include detecting oscillations, non-intrusive field instrument diagnosis, controller performance, interaction detection, process modeling, and control system availability. It connects to automation control systems via industry standard OPC or OPC HDA.

For 19 years, ExperTune has created award winning optimization software that runs in thousands of plants world-wide. ExperTune's full suite of optimization tools is designed to increase the efficiency of processes. PlantTriage is an automatic diagnostic system for 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.

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ExperTune home page | Information request form




Engineers Alerted to Abnormal Conditions Before they Affect Plant Performance (February 2005)

ExperTune's new version of PlantTriage automatically sends technicians and engineers an email if a controller or process area behaves abnormally. PlantTriage detects problems well before they show up as an operator alarm. Now the PlantTriage alert email will announce the potential problem in good time for it to be fixed. Shut-downs are avoided. Product quality is increased and production becomes more efficient.

PlantTriage alerts are easy to set up from a desktop browser. For example, engineers may want to be alerted when a critical controller or an entire unit operation is underperforming. Or they may wish to be alerted if a number of controllers in a certain area start to oscillate. Plant managers may wish to know if the variability of a critical process variable increases. Alerts are fully flexible. Any user can choose any assessment of any loop or unit operation.

PlantTriage includes a browser alert summary window which shows which alerts are outstanding for which user, now and at any time in the past. This makes sure that the alert is not overlooked until the underlying problem is diagnosed and fixed. For documentation purposes there is a browser-based log of when alerts occurred and returned to normal.

For 19 years, ExperTune has created award winning optimization software that runs in thousands of plants world-wide. ExperTune's full suite of optimization tools are designed to increase the efficiency of processes. PlantTriage is an automatic diagnostic system for 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.

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ExperTune home page | Information request form




ExperTune's New Wizard Guides Engineers to Best Level Control (January 2005)

ExperTune has released a new software wizard to help process engineers optimize the control strategy of level control loops in all types of process vessels. The wizard uses the design experience of Greg Shinskey.

Level loops present a unique challenge to process control since the control objective varies widely, from tight level control in reactors to averaging level control in surge tanks.

Whatever the performance requirement, whether it be a complex application like a hot vapor by-pass, or a simple surge tank, the new ExperTune Level Wizard guides engineers through choosing and implementing the best level loop control strategy for each individual need. The wizard:

  1. Identifies the goals for the level loop
  2. Chooses the level control strategy that matches the plant's goals
  3. Finds the best P, PI, or PID parameters to meet those goals
  4. Provides built-in user guidance (see figure below).

The wizard pays for itself quickly by:

  • Forcing the controls to adhere to the operational objectives, maximizing profits
  • Maximizing surge usage for smoother response to upsets, keeping critical quality variables on target
  • Savings in cost, better quality, safer operations, increased throughput, and more consistent quality

ExperTune Level Wizard optimizes level loops with the following level control goals:

  • Fast and accurate control of level to setpoint, with and without derivative control action. The result is the fastest possible recovery back to setpoint in the face of upsets.
  • Averaging level, where the purpose of the tank is a surge vessel to smooth flow upsets. In this case, the vessel is used to reduce the effects of upstream disturbances. The goal is that one unit feeding a second should disturb the second as little as possible.
    • Averaging level with P action only - level is floating, maximizing the use of the surge vessel to smooth flow upsets.
    • Averaging level with P and I action - level floats and slowly returns to setpoint.

Averaging level techniques may use tank volume. Using simple test data, the ExperTune Level Control Wizard automatically determines tank volume and controller settings.

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