Continuous Control Loop Indicator for Industrial KPI Monitoring
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Solution Overview
Problem
In large industrial facilities with hundreds or thousands of control loops, it is difficult to determine which loops are experiencing problems, especially when issues in one loop affect others, due to the complexity of monitoring multiple Key Performance Indicators (KPIs) and the qualitative nature of existing generalized indices.
Innovation Solution
A generalized continuous performance indicator (CPI) tool is implemented, providing a quantitative measure of control loop performance on a continuous scale, with color gradient visualization to simplify monitoring and enable early warning of performance degradation, allowing for pre-emptive actions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple Key Performance Indicators (KPIs) are monitored for each control loop, then comprehensive performance assessment is improved, but monitoring complexity and difficulty increase
Solution Approach 1:
The patent combines multiple discrete KPIs (such as stability, offset, variability, and other performance metrics) into a single aggregated performance indicator. This consolidation maintains comprehensive performance assessment by incorporating all relevant KPIs while simplifying the monitoring interface to display one unified metric, thereby resolving the contradiction between comprehensive assessment and monitoring complexity
Solution Approach 2:
The aggregated performance indicator serves multiple functions simultaneously: it integrates multiple KPIs, provides a single comprehensive metric, enables easy comparison across loops, and supports both detailed and high-level monitoring needs. This multi-functionality allows the system to maintain assessment comprehensiveness while simplifying the monitoring interface
2Loss of information
If numerous KPIs are monitored across all control loops, then performance monitoring completeness is improved, but operator ability to identify problematic loops deteriorates
Solution Approach 1:
The patent implements a hierarchical monitoring structure where control loops are grouped into areas, and areas are grouped into units, with aggregated performance indicators calculated at each level. This segmentation allows operators to navigate from high-level unit summaries down to specific loop details only when needed, maintaining information completeness while improving problem identification efficiency
Solution Approach 2:
Multiple KPIs are merged into a single aggregated performance indicator that captures the overall health of each loop. This consolidation preserves all performance information within the aggregated metric while presenting a simplified view that makes it easy for operators to quickly identify which loops require attention
3Ease of operation
If discrete performance ratings are used for control loops, then simplicity of interpretation is improved, but continuity of performance tracking deteriorates
Solution Approach 1:
The patent transitions from discrete performance ratings (such as poor/fair/good/excellent categories) to a continuous performance indicator that provides granular numerical values. This parameter change enables precise performance tracking and comparison while maintaining interpretability through standardized scaling and reference points, thereby achieving both continuity and simplicity
Data Source
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AI summary
A method includes, using at least one processing device (210), obtaining (1105) multiple diagnostic indicators associated with at least a portion of an industrial process system and combining (1110-1125) the diagnostic indicators to form a generalized indicator. Each diagnostic indicator has a value, and the generalized indicator is associated with a position on a continuous scale (410, 600, 1000, 1010). The continuous scale could include a color gradient, and the method could include displaying (1130) the generalized indicator along the color gradient with a color based on its position. Multiple generalized indicators associated with multiple portions of the process system could be displayed within a torus or circle (800, 900), and different portions (805-820, 905-915) of the torus or circle can be associated with different portions of the process system. Different concentric tori or circles (905-915) could be associated with different periods of time, and at least one concentric torus or circle could identify a predicted behavior of the process system.