GNPK Control Loop

Performance Monitoring
Technical Principles and
Guidelines

Prepared by: Engr. George Pio G. Aclan

 1. TECHNICAL BACKGROUND

Process control is an engineering discipline for maintaining the output of a specific

process within a desired range and regulates the dynamics of the production process to
ensure safe and efficient production.
A control loop is the fundamental building block of industrial control systems. It consists
of all the physical components and control functions necessary to automatically adjust the
value of a measured process variable (PV) to equal the value of a desired setpoint (SP). It
includes the process sensor, the controller algorithm, and the final control element, all of
which are required for automatic control as illustrated in Figure 1.

Figure 1. Feedback control loop

Majority of the control loops are installed and tuned usually in a rush during the
commissioning phase, and as such might never reach their design potential. Even if they
initially perform well, it usually deteriorates over the lifetime of the plant because of the
aging of the equipment and process dynamic changes as shown in figure 2.
Power plant control systems, in specific, must perform well to obtain maximum
efficiency, reliability, regulatory compliance and safety. Poorly performing controls can
cause operational difficulties such as boiler oscillations, increased heat rate, accelerated
equipment wear, increased emissions, slower ramp rates, reduced generation capacity,
steam temperature excursions and unit trips following upsets. To maintain the optimum
plant performance, the control loops should always be tuned for maximum productivity.

Prepared by: Engr. George Pio G. Aclan

 This can be achieved only by monitoring loop performance and taking the appropriate
corrective actions when poor performance is detected.

Figure 2. Typical performance decay of an industrial process control

Control performance monitoring provides a solution to monitor the performance of an

enterprise fleet (GNPower Kauswagan Ltd.) of process control loops, to detect and
identify underperforming control loops and to help diagnose control loop problems. It is
therefore essential to manage the performance of control loops as valuable assets in an
industrial enterprise facility (GNPower Kauswagan Ltd.) that should be continuously
monitored and optimized.

Prepared by: Engr. George Pio G. Aclan

 2. TECHNICAL APPROACH

2.1 OBJECTIVES

The following should be the core functions of the control loop performance monitoring
program:

a. Collection of process data for analysis

b. Assessment of the dynamic performance of control loops
c. Represent loop performance with a set of metrics
d. Present loop performance in reports

Figure 3 illustrates the basic steps in control loop performance monitoring.

Asses loop
Define Control
Collect data performance and Report Results
Loops
calculate metrics

Figure 3. Basic steps in control loop performance monitoring

2.2 CONTROL LOOPS

There are numerous process control loops in GNPower Kauswagan Ltd Co power station.
We will focus on the performance of the following:

a. Boiler Controls
b. Turbine Controls

2.2.1 Boiler Control Loops

a. Boiler Master
b. Fuel Master
c. Air Master
d. Drum Level
e. Furnace Pressure
f. Main Steam Temperature
g. Reheat Steam Temperature

Prepared by: Engr. George Pio G. Aclan

 h. HP Bypass
i. LP Bypass
j. Hot PA Flow

2.2.2 Turbine Control Loops

a. Load control loop

b. Pressure control loop
c. Speed control loop

2.3 DATA COLLECTION

To monitor the performance of the system, we need to access the process data that is
sampled sufficiently fast to capture the loop dynamics. Data will be collected from the
historian servers or trends from the DCS into a time series for all the identified control
loop in the power station. To ensure the accuracy of the calculations, the recommended
rate for data collection is every 5 seconds or every 1 second.

2.4. CALCULATIONS

Loop performance should be assessed from various perspectives. The measures described
in this section has the advantage that they are easy to apply to real systems. The
following metrics, to name a few, will be used to assess the performance of GNPK’s
control loops:

a. Percentage of the time that the controller is in auto or manual mode

b. Controller responsiveness to setpoint changes and disturbances
c. Loop oscillation
d. Percentage of time the controller output is at its limits
e. Standard deviation in error

Prepared by: Engr. George Pio G. Aclan

 2.4.1 Percentage Auto

This indicates the percentage of the samples of good quality within the sampling period
for which the control mode used was Auto. Mathematically,

𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒔𝒂𝒎𝒑𝒍𝒆𝒔 𝑨𝒖𝒕𝒐 𝑴𝒐𝒅𝒆

% 𝑨𝒖𝒕𝒐 = 𝒙 𝟏𝟎𝟎%
𝑻𝒐𝒕𝒂𝒍 𝒏𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝑺𝒂𝒎𝒑𝒍𝒆𝒔

2.4.2 Percentage Manual

This indicates the percentage of the samples of good quality within the sampling period
for which the control mode used was Manual. Mathematically,

𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒔𝒂𝒎𝒑𝒍𝒆𝒔 𝑴𝒂𝒏𝒖𝒂𝒍 𝑴𝒐𝒅𝒆

%𝑴𝒂𝒏𝒖𝒂𝒍 = 𝒙 𝟏𝟎𝟎%
𝑻𝒐𝒕𝒂𝒍 𝒏𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝑺𝒂𝒎𝒑𝒍𝒆𝒔

2.4.3 Percentage Auto LL Exceeded

This indicates the percentage of percentage of the samples for which the control mode
was set to auto and that the PV was below the lower SP limit.

𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝑺𝒂𝒎𝒑𝒍𝒆𝒔 𝑨𝒖𝒕𝒐 𝒂𝒏𝒅 𝑷𝑽<𝑳𝒐𝒘𝒆𝒓 𝑺𝑷 𝑳𝒊𝒎𝒊𝒕

% 𝑳𝑳 𝑬𝒙𝒄𝒆𝒆𝒅𝒆𝒅 = 𝒙 𝟏𝟎𝟎%
𝑻𝒐𝒕𝒂𝒍 𝒏𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝑺𝒂𝒎𝒑𝒍𝒆𝒔
2.4.3 Percentage Auto UL Exceeded

This indicates the percentage of percentage of the samples for which the control mode
was set to auto and that the PV was above the lower SP limit.

𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝑺𝒂𝒎𝒑𝒍𝒆𝒔 𝑨𝒖𝒕𝒐 𝒂𝒏𝒅 𝑷𝑽<𝑳𝒐𝒘𝒆𝒓 𝑺𝑷 𝑳𝒊𝒎𝒊𝒕

%𝑼𝑳 𝑬𝒙𝒄𝒆𝒆𝒅𝒆𝒅 = 𝒙 𝟏𝟎𝟎%
𝑻𝒐𝒕𝒂𝒍 𝒏𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝑺𝒂𝒎𝒑𝒍𝒆𝒔

2.4.4 Total Limits Exceeded

This indicates the total percentage of time that the loop operated out of the limit.
Mathematically,

𝑻𝒐𝒕𝒂𝒍 𝑳𝒊𝒎𝒊𝒕𝒔 𝑬𝒙𝒄𝒆𝒆𝒅𝒆𝒅 (%) = %𝑳𝑳 𝑬𝒙𝒄𝒆𝒆𝒅𝒆𝒅 + %𝑼𝑳 𝑬𝒙𝒄𝒆𝒆𝒅𝒆𝒅

Prepared by: Engr. George Pio G. Aclan

 2.4.5 Percentage Controller Output

This indicates the average MV value (expressed as percentage). Mathematically,

∑(𝑴𝒂𝒏𝒊𝒑𝒖𝒍𝒂𝒕𝒆𝒅 𝑽𝒂𝒓𝒊𝒂𝒃𝒍𝒆)
𝑷𝒆𝒓𝒄𝒆𝒏𝒕𝒂𝒈𝒆 𝑪𝒐𝒏𝒕𝒓𝒐𝒍𝒍𝒆𝒓 𝑶𝒖𝒕𝒑𝒖𝒕 =
𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝑺𝒂𝒎𝒑𝒍𝒆𝒔

2.4.6 Movement Index

The movement index gives the sum of all changes of the MV, divided by 100.
Mathematically,

∑ 𝑀𝑉𝑅𝑂𝐶
𝑴𝒐𝒗𝒆𝒎𝒆𝒏𝒕 𝑰𝒏𝒅𝒆𝒙 =
𝟏𝟎𝟎
Where:

𝑴𝑽𝑹𝑶𝑪 = 𝑴𝑽𝑪𝒖𝒓𝒓𝒆𝒏𝒕 − 𝑴𝑽𝑷𝒓𝒆𝒗𝒊𝒐𝒖𝒔

2.4.7 Total MV Movement

This is an indication of the absolute sum of all changes made in the MV. The closer the
value for this variable is to zero, the closer the MV is to staying at a constant value.
Mathematically,

𝑻𝒐𝒕𝒂𝒍 𝑴𝑽 𝑴𝒐𝒗𝒆𝒎𝒆𝒏𝒕 = 𝑨𝒗𝒆𝒓𝒂𝒈𝒆 (𝑴𝒐𝒗𝒆𝒎𝒆𝒏𝒕 𝑰𝒏𝒅𝒆𝒙)

2.4.8 Control Amplitude

The control amplitude gives the sum of all changes of the MV, divided by the number of
samples. Mathematically,

∑ 𝑴𝑽𝑹𝑶𝑪
𝑪𝒐𝒏𝒕𝒓𝒐𝒍 𝑨𝒎𝒑𝒍𝒊𝒕𝒖𝒅𝒆 =
𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒔𝒂𝒎𝒑𝒍𝒆𝒔

2.4.9 Average MV Change (%)

The average percentage change in the MV between samples. Mathematically,

𝑨𝒗𝒆𝒓𝒂𝒈𝒆 𝑴𝑽 𝑪𝒉𝒂𝒏𝒈𝒆 = 𝑨𝒗𝒆𝒓𝒂𝒈𝒆 (𝑪𝒐𝒏𝒕𝒓𝒐𝒍 𝑨𝒎𝒑𝒍𝒊𝒕𝒖𝒅𝒆)

Prepared by: Engr. George Pio G. Aclan

 2.4.10 MV Oscillation Count

This calculates the number of times that the MV oscillates over the reporting period. In
equation form,

𝑪𝑶𝑼𝑵𝑻 (𝑴𝑽 𝑫𝒊𝒓𝒆𝒄𝒕𝒊𝒐𝒏 𝑪𝒉𝒂𝒏𝒈𝒆)

𝑴𝑽 𝑶𝒔𝒄𝒊𝒍𝒍𝒂𝒕𝒊𝒐𝒏 𝑪𝒐𝒖𝒏𝒕 =
𝟐

2.4.11 Reversal Amplitude

This calculates the sum of all the changes in the MV relative to the number of times the
MV changes direction. In equation form,

∑ 𝑴𝑽𝑹𝑶𝑪
𝑹𝒆𝒗𝒆𝒓𝒔𝒂𝒍 𝑨𝒎𝒑𝒍𝒊𝒕𝒖𝒅𝒆 =
𝑪𝑶𝑼𝑵𝑻 (𝑴𝑽 𝑫𝒊𝒓𝒆𝒄𝒕𝒊𝒐𝒏 𝑪𝒉𝒂𝒏𝒈𝒆)

2.4.12 Average Oscillation Amplitude

The average percentage change in the MV before changing direction. Mathematically,

𝑨𝒗𝒆𝒓𝒂𝒈𝒆 𝑶𝒔𝒄𝒊𝒍𝒍𝒂𝒕𝒊𝒐𝒏 𝑨𝒎𝒑𝒍𝒊𝒕𝒖𝒅𝒆 = 𝑨𝒗𝒆𝒓𝒂𝒈𝒆 (𝑹𝒆𝒗𝒆𝒓𝒔𝒂𝒍 𝑨𝒎𝒑𝒍𝒊𝒕𝒖𝒅𝒆)

2.4.13 Percentage MV Saturation

This indicates the percentage of samples where the MV is saturated. The MV is

considered saturated when it is at 0% or at 100%. In equation form,

𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝑺𝒂𝒎𝒑𝒍𝒆𝒔𝑴𝑽 𝒊𝒔 𝟎% 𝒐𝒓 𝟏𝟎𝟎%

𝑷𝒆𝒓𝒄𝒆𝒏𝒕𝒂𝒈𝒆 𝑴𝑽 𝑺𝒂𝒕𝒖𝒓𝒂𝒕𝒊𝒐𝒏 = 𝒙 𝟏𝟎𝟎%
𝑻𝒐𝒕𝒂𝒍 𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝑺𝒂𝒎𝒑𝒍𝒆𝒔

2.4.14 MV Saturation

This indicates the percentage of the reporting window for which the controller output is
saturated. Mathematically,

𝑴𝑽 𝑺𝒂𝒕𝒖𝒓𝒂𝒕𝒊𝒐𝒏 = 𝑨𝒗𝒆𝒓𝒂𝒈𝒆 (𝑷𝒆𝒓𝒄𝒆𝒏𝒕𝒂𝒈𝒆 𝑴𝑽 𝑺𝒂𝒕𝒖𝒓𝒂𝒕𝒊𝒐𝒏)

Prepared by: Engr. George Pio G. Aclan

 2.4.15 Percentage not Utilized

This indicates the percentage of samples where the loop not being utilized.
Mathematically,

𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒔𝒂𝒎𝒑𝒍𝒆𝒔𝑴𝑽 𝒊𝒔 𝟎%,𝟏𝟎𝟎% 𝒐𝒓 𝑴𝒂𝒏𝒖𝒂𝒍

𝑷𝒆𝒓𝒄𝒆𝒏𝒕𝒂𝒈𝒆 𝒏𝒐𝒕 𝑼𝒕𝒊𝒍𝒊𝒛𝒆𝒅 =
𝑻𝒐𝒕𝒂𝒍 𝒏𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒔𝒂𝒎𝒑𝒍𝒆𝒔

2.4.16 Duration not Utilized

This indicates the percentage of the reporting window for which the loop is not in use.
Mathematically,

𝑫𝒖𝒓𝒂𝒕𝒊𝒐𝒏 𝒏𝒐𝒕 𝑼𝒕𝒊𝒍𝒊𝒛𝒆𝒅 = 𝑨𝒗𝒆𝒓𝒂𝒈𝒆(𝑷𝒆𝒓𝒄𝒆𝒏𝒕𝒂𝒈𝒆 𝒏𝒐𝒕 𝑼𝒕𝒊𝒍𝒊𝒛𝒆𝒅)

2.4.17 Percentage Limits Exceeded

This indicates the total percentage of time that the system is in auto or manual modes
where the upper or lower limits for those modes have been exceeded.

𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝑺𝒂𝒎𝒑𝒍𝒆𝒔𝑨𝒖𝒕𝒐_𝑴𝒂𝒏𝒖𝒂_𝑳𝒊𝒎𝒊𝒕𝒔_𝑬𝒙𝒄𝒆𝒆𝒅𝒆𝒅
𝑷𝒆𝒓𝒄𝒆𝒏𝒕𝒂𝒈𝒆 𝑳𝒊𝒎𝒊𝒕𝒔 𝑬𝒙𝒄𝒆𝒆𝒅𝒆𝒅 =
𝑻𝒐𝒕𝒂𝒍 𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝑺𝒂𝒎𝒑𝒍𝒆𝒔𝑨𝒖𝒕𝒐_𝑴𝒂𝒏𝒖𝒂𝒍

2.4.18 Average PV Limits Exceeded

This indicates the average of the percentage of time the PV exceeded the upper or lower
limits.

𝑨𝒗𝒆𝒓𝒂𝒈𝒆 𝑷𝑽 𝑳𝒊𝒎𝒊𝒕𝒔 𝑬𝒙𝒄𝒆𝒆𝒅𝒆𝒅 = 𝑨𝒗𝒆𝒓𝒂𝒈𝒆 ( 𝑷𝒆𝒓𝒄𝒆𝒏𝒕𝒂𝒈𝒆 𝑳𝒊𝒎𝒊𝒕𝒔 𝑬𝒙𝒄𝒆𝒆𝒅𝒆𝒅)

2.4.19 PV Variance

This gives the variance of all PV samples of good quality over the reporting period.

∑(𝑷𝑽 𝑺𝒂𝒎𝒑𝒍𝒆 − 𝑷𝑽 𝑨𝒗𝒆𝒓𝒂𝒈𝒆)𝟐

𝑷𝑽 𝑽𝒂𝒓𝒊𝒂𝒏𝒄𝒆 =
𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝑷𝑽 𝑺𝒂𝒎𝒑𝒍𝒆𝒔

Prepared by: Engr. George Pio G. Aclan

 2.4.20 PV Variance (%)

This value is a measure of the average deviation of the PV from the average PV. This is
the average value of the PV Variance.

𝑷𝑽 𝑽𝒂𝒓𝒊𝒂𝒏𝒄𝒆 (%) = 𝑨𝒗𝒆𝒓𝒂𝒈𝒆 (𝑷𝑽 𝑽𝒂𝒓𝒊𝒂𝒏𝒄𝒆)

2.4.21 PV Variability

This gives a ratio which is a measure of the standard deviation relative to the PV sample
average.

(𝑷𝑽 𝑺𝒕𝒂𝒏𝒅𝒂𝒓𝒅 𝑫𝒆𝒗𝒊𝒂𝒕𝒊𝒐𝒏) × 𝟐𝟎𝟎

𝑷𝑽 𝑽𝒂𝒓𝒊𝒂𝒃𝒊𝒍𝒊𝒕𝒚 =
|𝑷𝑽 𝑨𝒗𝒆𝒓𝒂𝒈𝒆|

2.4.22 Integrated Sum

This gives the sum of the absolute values of all PV Error (PV-SP).

𝑰𝒏𝒕𝒆𝒈𝒓𝒂𝒕𝒆𝒅 𝑺𝒖𝒎 = ∑(|𝑷𝑽 − 𝑺𝑷|)

2.4.23 Integrated Error

This value indicates the percentage time the process has spent out of limits. This is the
sum of the integrated sum calculations.

𝑰𝒏𝒕𝒆𝒈𝒓𝒂𝒕𝒆𝒅 𝑬𝒓𝒓𝒐𝒓 = ∑(𝑰𝒏𝒕𝒆𝒈𝒓𝒂𝒕𝒆𝒅 𝑺𝒖𝒎)

2.4.24 PV Error Average

This gives the average of all PV Error (PV-SP).

∑(𝑷𝑽 − 𝑺𝑷)
𝑷𝑽 𝑬𝒓𝒓𝒐𝒓 𝑨𝒗𝒆𝒓𝒂𝒈𝒆 =
𝑻𝒐𝒕𝒂𝒍 𝒏𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝑺𝒂𝒎𝒑𝒍𝒆𝒔

2.4.25 Average Error

This value indicates the average tag error. Error is the difference between process
variable and setpoint. This is the average value of the PV Error Average KPI.

𝑨𝒗𝒆𝒓𝒂𝒈𝒆 𝑬𝒓𝒓𝒐𝒓 = 𝑨𝒗𝒆𝒓𝒂𝒈𝒆 (𝑷𝑽 𝑬𝒓𝒓𝒐𝒓 𝑨𝒗𝒆𝒓𝒂𝒈𝒆)

Prepared by: Engr. George Pio G. Aclan

 2.4.26 PV Error Absolute Average

This gives the average of the absolute values of all PV error samples.

∑|𝑷𝑽 − 𝑺𝑷|
𝑷𝑽 𝑬𝒓𝒓𝒐𝒓 𝑨𝒃𝒔𝒐𝒍𝒖𝒕𝒆 𝑨𝒗𝒆𝒓𝒂𝒈𝒆 =
𝑻𝒐𝒕𝒂𝒍 𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝑷𝑽 𝑬𝒓𝒓𝒐𝒓 𝑺𝒂𝒎𝒑𝒍𝒆𝒔

2.4.27 Average Absolute Error

This value indicates the average absolute value of the error.

𝐀𝐯𝐞𝐫𝐚𝐠𝐞 𝐀𝐛𝐬𝐨𝐥𝐮𝐭𝐞 𝐄𝐫𝐫𝐨𝐫 = 𝐀𝐯𝐞𝐫𝐚𝐠𝐞 (𝐏𝐕 𝐄𝐫𝐫𝐨𝐫 𝐀𝐛𝐬𝐨𝐥𝐮𝐭𝐞 𝐀𝐯𝐞𝐫𝐚𝐠𝐞)

2.4.28 PV Error Standard Deviation

This gives the standard deviation of all PV error.

𝟐
√∑((𝑷𝑽𝑬𝒓𝒓𝒐𝒓 − 𝑷𝑽 𝑬𝒓𝒓𝒐𝒓 𝑨𝒗𝒆𝒓𝒂𝒈𝒆)𝟐 )
𝑷𝑽 𝑬𝒓𝒓𝒐𝒓 𝑺𝒕𝒂𝒏𝒅𝒂𝒓𝒅 𝑫𝒆𝒗𝒊𝒂𝒕𝒊𝒐𝒏 =
𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝑷𝑽 𝑬𝒓𝒓𝒐𝒓 𝑺𝒂𝒎𝒑𝒍𝒆𝒔

2.5 REPORTING

Once the various metrics of control loop performance have been calculated, they should
be combined into a single report representing the overall as well as the individual control
loop health. In this way, the performance of loops can be observed and that loops
requiring attention are easy to find. Process control engineers and technicians can use the
diagnosis to decide on the appropriate type of corrective action such as tuning or
mechanical maintenance. Two types of reports will be generated: the fleet report and the
loop report.

Prepared by: Engr. George Pio G. Aclan

 2.5.1 Fleet Report

The fleet report provides a summary of all loops in the defined system for the selected
time period. The report contains the following information:

a. Control loop performance table.

Loop % Auto % Manual % Limits Exceeded

Sample Sample Sample Sample

Table 1. Control loop performance table

2.5.2 Loop Report

The loop report provides a systematic approach to optimizing the performance of a

control loop by monitoring the loop performance and providing diagnostic data about the
loop. The report contains various charts and tables that help in assessing the performance
of a control loop.

The loop report contains the following charts:

a. Process variable performance chart.

b. Manipulated variable distribution chart.
c. Error distribution chart.

Also, the loop report contains the following tables:

a. Control mode summary table.

b. Process variable performance table.
c. Error statistics table.

2.5.2.1 Process Variable Performance Chart

The process variable performance chart helps in analyzing the trend of the process
variable against the setpoint.

The chart contains the following axes:

 X- axis: represents the time period

Prepared by: Engr. George Pio G. Aclan

  Y-axis: represents the PV and SP values

The trend of each value over the selected time period appears as a line chart, which helps
us understand the magnitude of change at a specific time stamp. The following trend lines
are plotted on the chart:

Trend Line Description

PV A chart representing the trend of PV over the time period selected
SP A chart representing the trend of SP over the time period selected.

Based on the values plotted on the chart, we can identify performance issues in the
process control loop. The following table lists a few scenarios that may appear in the
chart and what each scenario indicates about the loop performance:

What you See Interpretation Suggested Action

The trend of the PV values
is centered around the trend
of the SP values
The trend of the PV values
exceeds the upper and
lower limits
Process is under control None. Maintain the
parameter settings.
Process is not under Tune the control loop to
control reduce the process
variation

2.5.2.2 Manipulated Variable Distribution Chart

The manipulated variable distribution chart is a histogram that helps us analyze the
efficiency of a control element and evaluate the suitability of the element of the process.

A control element receives the output signal from the controller and controls the
operating conditions such as flow, pressure temperature and liquid level in response to
the signal. The manipulated variable is a percentage measure of the value at which the
control element is functioning.

The chart contains the following axes:

Prepared by: Engr. George Pio G. Aclan

  Y axis: represents the value of the MV in percentage
 X-axis: represents the count of samples of the MV

The histogram represents the count of samples that the control element was set to at each
percentage value, and not the length of time the element remained at each value.

Chart 2. Manipulated Variable Distribution Chart

Based on the values plotted on the chart, we can identify performance issues in the
controller. The following table provide few scenarios that may appear in the chart and
what each scenario indicates regarding the controller performance.

What you see Interpretation Required Action

< 6% or > 95% If majority of the samples are Install a different type of control
in these values, it indicates element, either a larger one or a
the control element is smaller one that is suitable and
operating very low or very energy and cost effective.
high saturation level and that
the element is oversized or
undersized.

Prepared by: Engr. George Pio G. Aclan

 6% - 30% Indicates that the control Monitor the control element for
element is operating close to signs of asset fatigue.
its lower saturation level
71% - 95% Indicates that the control
element is operating close to
its higher saturation level.
31% - 70% The controller is operating at None. This is the ideal value.
the desired capacity. More
samples in this range indicate
that the controller is well
designed.

2.5.2.3 The Error Distribution Chart

The error distribution chart displays a histogram that represents the distribution of the
amount of time the controller operated at each error value. Controller error is calculated
as the difference between the values, PV and SP. The chart contains the following axes:

 X-axis: represents the controller error.

 Y-axis: represents the samples for which the controller was operating at the error
value.

Prepared by: Engr. George Pio G. Aclan

 Chart 3. Error Distribution Chart

Based on the values plotted on the chart, we can identify performance issues in the
controller. The following table provides a few scenarios that may appear in the chart and
what each scenario indicates regarding the controller performance.

What you see Interpretation Required Action

If error is 5% The error is out of the Tune PID to control the PV so
above the ideal acceptable limits that it functions within the
value defined process limits.
If the error is The error is at acceptable limits None.
within 5% of the
ideal value
Oscillating Possible friction exists in Check the functioning of the
distribution of control element control element. Tune the PID
histogram controller parameters.

2.5.2.4 Control Mode Summary Table

The control mode summary table helps us assess the performance of the control loop
based on the percentage of time the loop operated in each control mode. The table
contains a row for each of the following control modes:

 Manual
 Auto

The table contains the following information for each control mode:

Column Name Description

Duration (%) Indicates the percentage of time the control loop
operated in each control mode. This is the average value
of the percentage (control mode) KPI.

Prepared by: Engr. George Pio G. Aclan

 Lower Limit Exceeded (%)
Upper Limit Exceeded (%)
Total Limits Exceeded (%)
Indicates the percentage of time the loop operated below
the lower limit. This is the average value of the
Percentage (control mode) LL Exceeded KPI.
Indicates the percentage of time the loop operated above
the upper limit. This is the average value of the
Percentage (control mode) UL Exceeded KPI.
Indicates the total percentage of time that the loop
operated out of limit. This value is calculated as the sum
of the Lower Limit Exceeded (%) and Upper Limit
Exceeded (%) values.

2.5.2.5 The Controller Performance Table

The controller performance table helps us analyze the performance of the control element
using a range of KPIs. It contains the following information.

KPI Interpretation Required Action

Manipulated The average value of the
Variable (%) control variable, expressed as a
percentage.
• < 5%: Indicates that the
control element is operating at
a very low saturation level and
that the element is oversized.
• 5 - 30%: Indicates that the
control element is operating
close to its lower saturation
level.
• 30 - 70%: Indicates that the
control element is operating at
If the variable is not in the ideal
range, install a different type of
controller. Depending on the
variable value, install either a
larger controller that is more
suitable for the process, or a
smaller one that is more energy-
efficient and cost-effective.

Prepared by: Engr. George Pio G. Aclan

 its optimal value. This is the
ideal value for the variable.
• 70 - 95%: Indicates that the
control element is operating
close to its higher saturation
level.
• > 95%: Indicates that the
control element is operating at
a very high saturation level and
that the element is undersized.
This is the average value of the
Percentage Controller Output
KPI.
Total MV An indication of the absolute Investigate and optimize the size
Movement sum of all changes made in the of the control system.
MV. The closer the value for
this variable is to zero, the
closer the MV is to staying at a
constant value. You can use
this statistic to help you keep
the PV operating within
process limits. This is the
average value of the Movement
Index KPI.
Average MV The average percentage change Investigate and optimize the size
Change [%] in the MV between samples. of the
The closer the value for control system.
this variable is to zero, the
closer the MV is to staying at a
constant value. This is the
average value of the Control

Prepared by: Engr. George Pio G. Aclan

 Amplitude KPI.
Oscillation Count The number of times that the Add a better filter to the control
[#] MV changes direction. This system.
indicates the level of noise
in the system. The closer this
value is to zero, the less noise
there is in the system. All data
is taken into account for this
statistic, regardless of the
quality. This is the average
value of the MV Oscillation
Count KPI.
Average The average percentage change Investigate and optimize the
oscillation in the MV before changing control
amplitude [%] direction. element.
• 0: The closer this value is to
zero, the closer the MV is to
staying at a constant value.
• <5% Indicates a good control
system.
• > 5%: Indicates a possibility
of damage or failure, but must
be viewed in conjunction with
the number of controller
oscillations.
This is the average value of the
Reversal
Amplitude KPI.
MV Saturation The percentage of the reporting Investigate for a possibility of an
[%] window for which the undersized or oversized control
controller output is element,

Prepared by: Engr. George Pio G. Aclan

 saturated. The controller output a malfunctioning control
is considered saturated when element, or
the MV has a value of 0 other causes for MV saturation,
(the lower limit for controller and
output saturation) or 100 (the optimize the control element.
upper limit for controller
output saturation). The closer
this is to zero, the more likely
it is that the control element is
appropriately sized and
functioning correctly.
This is the average value of the
Percentage MV Saturation
KPI.
Duration Not The percentage of the reporting If the percentage of time not
Utilized [%] window for which the loop is utilized is
not in use. The loop is too high this can be for either or
considered to be not in use if it both of the following reasons:
is in manual mode or if the • The loop spends a large
controller output is saturated. proportion of time in manual
The controller output is mode. Investigate the
considered saturated when the reasons for that behavior.
MV has a value of 0 (the lower • Investigate for a possibility of
limit for controller output an undersized or oversized
saturation) or 100 (the upper control element, a
limit for controller output malfunctioning control
saturation). The closer this is to element, or other causes for MV
zero, the more likely it is saturation, and optimize the
that the loop is in a mode other control element.
than manual and the control

Prepared by: Engr. George Pio G. Aclan

 element is appropriately sized
and functioning correctly.
This is the average value of the
Percentage Not Utilized KPI.

2.5.2.6 The PV Performance Table

The process variable performance table helps us analyze the performance of the process
variable based on values as specified in the following table.

Column Name Interpretation

Average PV Limits This value is an average of the percentage of time the
exceeded PV exceeded the upper or lower limits.
This is the average value of the Percentage Limits
Exceeded KPI.
PV Variance [%] This value is a measure of the average deviation of the
PV from the average PV, expressed as a percentage of
the reporting window span.
This is the average value of the PV Variance KPI.
PV Variability This value is an averaged measure of how spread or
closely clustered the PV data set is, expressed as a
percentage.
This is the average value of the PV Variability KPI.

2.5.2.7 The Error Statistics Table

The error statistics table contains the statistics that indicate the extent at which the
process variable deviates from the setpoint. The table contains the following values:

Measured variable Interpretation

Integrated Error This value indicates the percentage time the process has spent

Prepared by: Engr. George Pio G. Aclan

 out of limits. If there is a substantial integrated error,
investigate the functioning of the PV, and tune the system to
maintain the PV within the defined limits.
This is the sum of the Integrated Sum KPI values for the
window.
Average Error This value indicates the average tag error. Tag error is the
difference between process variable and set point, expressed as
a percentage.
This is the average value of the PV Error Average KPI.
Average Absolute This value indicates the average absolute value of the tag error.
Error This is the average value of the PV Error Absolute Average
KPI.
PV Error Standard This value indicates the standard deviation of the tag error,
Deviation where the tag error is the difference between process variable
and set point, expressed as a percentage.
This is the average value of the PV Error Standard Deviation
KPI.

Prepared by: Engr. George Pio G. Aclan