Case Study: Enhancing Reliability and Reducing Failures with Controller Consultant
Overview.
A major industrial operator faced persistent issues with rapidly failing valve stems and controllers. Despite investing in specialised 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:
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Rapid Component Failures: Valve stems and controllers were failing at an alarming rate, leading to frequent shutdowns and costly repairs.
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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.
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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:
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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.
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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.
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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 OpMode provided BP with crucial insights into the health of the choke valve, leading to significant potential savings:
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Binary Tag for Operational Mode: The results from OpMode were simplified into a binary tag that indicated whether the choke valve was operating within the "normal" or "good" operational mode. This allowed engineers to quickly assess the valve's condition.
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Gradual Deviation from Normal Operation: Over time, the choke valve was observed to deviate more frequently from the "good" operational mode, signalling a deterioration in its performance. This deviation was consistently detected by OpMode, providing early warnings well before the decision to replace the valve was made in late 2018.
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Preventative Maintenance Planning: By alerting engineers to the gradual degradation, OpMode could have facilitated better planning for maintenance and potential shutdowns, helping to avoid unplanned interruptions and saving BP millions of pounds.
The Controller Consultant UI makes it easy to track the condition of controller configuration
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.