Control loop performance advisory tool

The method of 1, further comprising:

• comparing, by the computing device, the at least one current segment to the digital twin model by:
• applying differential evolution to the at least one current segment and/or the digital twin model of the pneumatically controlled valve system;
• identifying, by the computing device, a best proportional—integral—derivative (PID) outer loop control gain which reduces the severity of the stiction;
• and
• generating, by the computing device, instructions for the stiction control device to compensate for the stiction by applying the best PID outer loop control gain to a PID outer loop.

The method of 1, further comprising:

• comparing, by the computing device, the at least one current segment to the digital twin model;
• applying differential evolution to the at least one current segment and to the digital twin model of the pneumatically controlled valve system;
• identifying, by the computing device, a best proportional—integral—derivative (PID) inner loop control gain which reduces the severity of the stiction;
• and
• generating, by the computing device, instructions for the stiction control device to compensate for the stiction by applying the best PID inner loop control gain to a PID inner loop.

A stiction control system for compensating for stiction of an actuator of a controllable pneumatic valve, comprising:

• a proportional—integral—derivative (PID) controller configured to receive set-point values (SP) at a PID controller input and output control signals at a PID controller output (OP);
• a first switch connected to the PID controller output;
• a stiction compensator switchably connected to the PID controller output by the first switch and configured to receive the control signals;
• a controllable pneumatic valve input connected to the stiction compensator and switchably connected to the PID controller by the first switch;
• a vibration measurement device connected to an output of the controllable pneumatic valve, the vibration measurement device configured to generate electrical signals based on an oscillation of an actuator of the controllable pneumatic valve;
• a process measurement device connected at an input to the output of the controllable pneumatic valve and configured to output a process variable (PV) at a process output;
• a feedback loop connected between the process output and the PID controller input;
• a computing device connected to the stiction compensator, the computing device including circuitry and program instructions stored therein that, when executed by one or more processors, cause the one or more processors apply an artificial intelligence algorithm to the electrical signals of oscillation of the controllable pneumatic valve, wherein the artificial intelligence algorithm generates sets of stiction reduction values;
• and
• wherein the stiction compensator is configured to modify the control signals based on the stiction reduction values.

A non-transitory computer readable medium having instructions stored therein that, when executed by one or more processors, cause the one or more processors to perform a method for diagnosing stiction of an actuator of at least one control valve in a pneumatically controlled valve system, comprising:

• generating, in a computing device including circuitry and program instructions stored therein that are executed by one or more processors, a digital twin model of the pneumatically controlled valve system;
• receiving, by the computing device, at least one current segment of data signals from a process measurement device connected to the pneumatically controlled valve system;
• monitoring, by the computing device, operation of the pneumatic controlled valve system by comparing the at least one current segment to the digital twin model;
• detecting, by the computing device, stiction when an anomaly is detected between the at least one current segment and the digital twin model;
• determining, by the computing device, a severity of the stiction;
• generating, by the computing device, instructions for a stiction control device to generate control signals to be applied to the actuator to compensate for the severity of the stiction;
• and
• displaying, by the computing device, the digital twin model of the pneumatically controlled valve system with a representation of the severity of the stiction.