PlantESP Loop Performance Monitoring

by Control Station, Inc.

Plant-wide monitoring and diagnostic solution for optimizing Mechanical, Controller, and Process performance.

Solution Overview

Right now roughly 65% of your facility’s regulatory control systems are underperforming. They are wasting energy and feedstock, and they are negatively impacting both product quality and plant safety. With 100s if not 1,000s of control loops at a typical production facility, engineering and operations staff are hard pressed to identify those control loops that have degraded let alone to isolate the associated root-causes.

Proactive identification and correction of control loop performance issues using PlantESP has been proven to consistently improve plant performance from increases in production throughput and product quality to decreases in energy consumption and unplanned downtime. PlantESP provides the enhanced awareness and advanced diagnostics needed by production staff to keep a facility’s expansive regulatory control systems running optimally. PlantESP’s intuitive design makes it easy to use, and its customizable reports keep all stakeholders informed from operations and engineering to plant and corporate management.

Solution Approach

PlantESP makes it easy to optimize plant-wide control loop performance. PlantESP keeps a constant watch for performance issues and it equips production staff with timely notification of changes affecting regulatory control. PlantESP applies a select portfolio of KPIs and diagnostic tools to uncover insights that other technologies overlook. It recommends appropriate corrective actions and accelerates the resolution of performance issues. With the insight to see issues and the tools to fix them, PlantESP empowers production staff to continuously improve production performance.

By leveraging Asset Framework and utilizing OSIsoft’s AF SDK, PlantESP makes it easy to connect with the PI System and to optimize plant-wide performance. PlantESP automatically reads the Asset Framework hierarchy and quickly locates elements associated with a production facility’s numerous PID control loops. With the help of Asset Framework PlantESP allows for seamless and rapid integration with the PI System.



  • KPIs for mechanical, controller, and process
  • Advanced forensic tools for root-cause analysis
  • Auto-benchmarking of plant-wide loop performance
  • Prioritization of loops based on importance
  • Customizable alerting and reporting utilities


  • Install: Integrate with PI System using the PI System Development Technologies
  • Discover: Remain aware of performance issues
  • Analyze: Examine metrics to enhance insight
  • Isolate: Pinpoint the associated root-causes
  • Recommend: Review suggestions for corrective action
  • Optimize: Implement PID tuning recommendations
  • Document: Capture and report plant performance

PI System Requirements

PI System version 3.4.390 or later, PSA Server

Solution Type

Advanced Analytics, Control Loop Monitoring


  • Chemical & Petrochemical
  • Mining, Metallurgy & Material
  • Oil & Gas
  • Pharmaceuticals & Life Sciences
  • Power Generation
  • Pulp and Paper
  • Water & Wastewater
  • Discrete Manufacturing
  • Engineering Services
  • Food & Beverages

Business Impacts

Optimize Processes, Evaluate Quality, Increase Asset Health & Uptime, Improve Energy Efficiencies


Applications for the PI System

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