Carry out control-system improvements without the need for step tests

The article explains that optimizing control-system architecture can boost production, but traditional step tests are often impractical or disruptive. It highlights PITOPS, a specialized platform that enables stepless multivariable closed-loop system identification and the detection/isolation of unmeasured process effects, allowing control-system improvements without intrusive step testing.

What strategies or tools have you used to retune or redesign control loops when step tests aren’t feasible, and how did you validate the changes safely?