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Here are Some Little Known Facts About Process Controllers
Control loops CAN be tuned accurately to provide the best possible operation of your facility!

The quality of loop tuning CAN be measured to provide preventative maintenance information and reducing down time!

Sluggish response to system needs, such as AGC, cost companies thousands of dollars each year due to missed opportunities!

  1. 30% of installed controllers operate in manual only!
  2. 65% of loops operating in auto actually have less variation while in manual!
  3. 80% of control loops are badly tuned!
  4. 25% of installed controllers have the factory default settings in place.
  5. Loop performance declines at a rate of about 50% every 6 months. 
  6. Without maintenance, in one year 75% of the performance is lost.

Loops operating in manual lead to operator error and lost revenue!

References
1 & 2 Ender, D,. B., Control Engineering (September 1993), 180-190
3 & 4 Van Overschee, P. and De Moore, B. Preprints Proc. PID '00: IFAC
          Workshop on digital control (Terrassa, Spain, 2000), 687-692
5 & 6 ISA - InTECH 01 January 2004 - Emond, Martin
                 "The performance of control loops declines over time"