Apparatus and method for identifying impacts and causes of variability or control giveaway on model-based controller performance

An apparatus comprising:

• at least one interface configured to receive data identifying values of one or more controlled variables associated with an industrial process controller;
• and
• at least one processor configured to:
• identify periods when at least one of the one or more controlled variables has been moved to an associated limit by the controller;
• for each identified period, (i) identify a standard deviation of predicted values over the identified period for the associated controlled variable and (ii) determine a control giveaway value for the associated controlled variable over the identified period based on the standard deviation of predicted values, the control giveaway value is indicative of an offset between the associated controlled variable's average value and the associated limit;
• identify variances in the one or more controlled variables using the control giveaway values;
• and
• generate a graphical display identifying one or more impacts or causes for at least some of the variances.

A non-transitory computer readable medium containing instructions that when executed cause at least one processing device to:

• obtain data identifying values of one or more controlled variables associated with an industrial process controller configured to operate the one or more control variables at respectively associated limits;
• identify periods when at least one of the one or more controlled variables has been moved to an associated limit by the controller;
• for each identified period, (i) identify a standard deviation of predicted values over the identified period for the associated controlled variable and (ii) determine a control giveaway value for the associated controlled variable over the identified period based on the standard deviation of predicted values, the control giveaway value is indicative of an offset between the associated controlled variable's average value and the associated limit;
• identify variances in the one or more controlled variables using the control giveaway values;
• and
• generate a graphical display identifying one or more impacts or causes for at least some of the variances.