Metris Control Performance Assessment (CPA) is an essential step to reaching an autonomous plant. The app continuously monitors standard PID controls and Advanced Process Controls (APCs) 24/7, providing more than 50 KPIs per control loop — covering Variability, Average Error, Automatic Mode Time, Output Saturation, IAE (Integral of Absolute Error), Setpoint Crossings, Output Travel, Reversals, and Process Capability (Cp/Cpk). Both absolute and normalized KPIs are calculated, enabling cross-loop and cross-area comparison regardless of engineering units or process type.

CPA identifies loops with the highest process variability, exposes hidden process upsets, detects instrumentation and final control element issues through wear indicators such as Travel and Reversals, and recommends best actions to restore loop performance. All events — PID gain changes, mode changes, setpoint changes, and output changes — are logged and searchable, providing a complete audit trail per loop.

Results are visualized through color-coded Treemaps, dynamic Pivot Tables, Aggregated Performance views, and detailed Loop Detail Displays with control charts, histograms, and statistical KPIs. Kanban integration delivers automatic notifications when KPI thresholds are crossed. Multi-plant operations can be consolidated in a single view using Metris All-in-one Platform Enterprise. Integration with third-party systems — Power BI, SAP, MS Teams — is available via API.

The integrated PID Tuner module provides a complete loop optimization workflow: engineers capture open-loop bump test data, model the process (First Order, Second Order, or Integrator), simulate multiple tuning techniques with adjustable Lambda control, and evaluate performance statistics — overshoot, rise time, settling time, IAE, and output travel — before uploading optimized gains to the DCS. Tank level loops can be modeled analytically from physical parameters without bump testing.

The solution is offered as a stand-alone product or as part of Metris OPP (Process Optimization or Autonomous Operations) agreements. Real-world results include a 30% reduction in Standard Deviation and Total Error on a Super Heater cascade, yielding approximately €1,500,000 in annual savings through stable turbine operation and maximized energy production.