PiControl Solutions

Process Control Optimization

Request More InFo

Process Control Optimization: Maximize Plant Efficiency and Product Quality

Process control optimization is a critical aspect of industrial operation, encompassing a wide range of techniques and technologies aimed at maximizing plant efficiency, ensuring consistent product quality, and promoting control reliability. In today's competitive business landscape, the need for optimization and cost-effectiveness has never been greater. PITOPS, SUPERTUNE, and COLUMBO, play a pivotal role in achieving these process control and plant optimization goals.

What are their main process control optimization principles?

  1. Control System Enhancement: The heart and soul of process control optimization is the refinement of base layer and advanced control loops. It involves the adjustment of control parameters, such as proportional, integral, and derivative (PID) settings, and many other advanced process control (APC) parameters to get desired response or action of a process. PITOPS specializes in multi-objective PID tuning, PLC or a DCS-based advanced process control (APC) design and optimization, and base-layer and advanced process control (APC) simulation, where it provides an advanced approach to control system enhancement. It is also capable to improve very quickly and far more accurate the performance of a model predictive control (MPC) system, such as: PACE from Yokogawa, RMPCT from Honeywell, SMOC from Shell, DMC from AspenTech, and many others. PITOPS can work with any PLC, DCS or a MPC industrial system and can provide powerful benefits and optimization results in a remarkable short period of time, all in time domain, many times even without and plant time-consuming and intrusive perturbations.
  2. Dynamic Modeling: Understanding the dynamic behavior of a process is crucial for effective control and its optimization. This involves identifying and quantifying the response of the process to changes in one or more inputs. Dynamic models can be used for PID tuning, advanced process control (APC) design and optimization inside of PLC or a DCS, for model predictive control (MPC) improvement and maintenance, and for building real-time process control simulation platform for testing and training. COLUMBO, as truly multivariable completely closed-loop system identification technology, is mainly focused on model predictive control (MPC) model improvement where it ensures dynamic model accuracy, all in time domain. It can identify accurate open-loop process models based on completely closed-loop model predictive control (MPC) performance behavior (while model predictive control (MPC) is ON and running) without the need for conducting any kind of plant time-consuming and many times intrusive step-test, or turning OFF the model predictive control (MPC) system and causing and plant perturbations. COLUMBO can work with any worldwide model predictive control (MPC) system, such as: PACE from Yokogawa, RMPCT from Honeywell, SMOC from Shell, DMC from AspenTech, and many others.
  3. Data-Driven Insights: Today, plant data plays a pivotal role in any process control optimization. Advanced data analysis techniques, including machine learning and artificial intelligence, can uncover hidden patterns and correlations within the data. This information is used to make informed decisions for process improvement. SUPERTUNE utilizes AI-based PID auto-tuning for precise control and data-driven insights. It can optimize and tune tens and hundreds of PID control loops simultaneously on the fly without any need to change the mode of any PID control loop from Cascade to Auto, or from Auto to Manual, again all in time domain. With SUPERTUNE any kind of PID control loops and processes can be tuned and optimized, such as: ramped or integrating and also self-regulating processes, PID control loops in all Modes (Manual, Auto, Cascade and Program) without any need for one or more plant time-consuming and many times intrusive step-test. It is truly real-time auto-adaptive and autotuning technology.

Benefits of Process Control Optimization

  1. Improved Efficiency: PITOPS allows you to fine-tune control systems, reducing energy consumption and lowering production costs. With its advanced features, it produces and gains efficiency that can positively impact your bottom line.
  2. Consistent Product Quality: Process control optimization ensures that processes are tightly controlled, resulting in consistent product quality. Variability is minimized, reducing the likelihood of defects, and ensuring that products meet predefined specifications.
  3. Resource Conservation: Efficient processes are synonymous with resource conservation. PITOPS and COLUMBO, enable you to minimize waste, optimize resource utilization, and operate in an environmentally responsible manner.
  4. Reduced Downtime: Our products provide proactive optimization to identify and address potential issues before they lead to equipment failures or production stoppages. This preventive approach significantly reduces costly downtime and maintenance expenses.
  5. Safety Enhancement: Precise control over processes enhances safety. Accidents and incidents are less likely to occur when processes are consistently operating within predefined safety parameters and under optimal conditions.
  6. Competitive Advantage: In rapidly changing markets, the ability to adapt quickly is a competitive edge. SUPERTUNE ensures swift responses to shifts in demand, helping you stay agile and competitive.

Explore Our Products

Process control optimization is a vital discipline that empowers organizations to streamline their operations, reduce costs, maintain high-quality product output, and ensure system reliability. By applying advanced control techniques, dynamic modeling, and data-driven insights through our products, businesses can stay ahead in the dynamic industrial landscape. This approach is not just about making operations more efficient, but also about creating a sustainable, environmentally responsible, and competitive future.

Schedule A Demo