Engineer-to-engineer writing on closed-loop system identification, PID tuning, APC and MPC maintenance, and control-loop monitoring — straight from the desks that tune the loops. No hype, just the control math that holds up on the DCS.
Artificial intelligence has moved from the research lab into the plant control room, but the transition is less dramatic than the marketing suggests. AI is entering the control room through a mix of…
PID TuningEvery drying course covers the drying curve. Constant-rate period, critical moisture content, falling-rate period — three concepts, one graph, dozens of exam questions. What most courses skip is the…
MonitoringThe Control Room Is No Longer an Island For most of the history of industrial automation, process control systems operated in isolation. The DCS ran on a closed, proprietary network. The PLC had no…
APC & MPCThe Problem Hidden Behind Quiet Alarms Most plant managers operate with reasonable confidence that their control system is performing. The DCS overview is green, setpoints are being tracked, and…
TrainingThe Hidden Challenge of Multi-Plant Operations Managing process control across multiple plant sites is not simply a matter of scale - it is a matter of consistency. In most multi-site operations,…
APC & MPCIntroduction In 2026, industrial decarbonization has moved beyond voluntary sustainability reports and ESG scorecards. New regulatory frameworks — including the EU's updated Energy Efficiency…
TrainingThe Hiring Challenge No One Talks About You invest significant time and resources into finding the right candidate - only to discover that strong academic credentials do not always translate into…
PID TuningMost control loop oscillations do not announce themselves. They build gradually — a slightly wider PV swing here, a busier controller output there — until one day an operator notices product going…
System IdentificationPiControl Solutions LLC PID tuning technology in PITOPS software is able to work with data considered bad, poor data quality, oscillating or closed loop with PID controllers in auto or cascade modes.…
PID TuningIn modern industrial process control environments, the performance of PID control loops directly impacts product quality, plant safety, and energy efficiency. Despite advances in automation…
APC & MPCClassical methods like gain scheduling, feedforward control, and self-tuning controllers solve many industrial variability problems effectively. But some processes are too complex, too tightly…
PID TuningIndustrial processes rarely behave as textbook models suggest. Raw materials arrive with varying compositions, ambient conditions fluctuate, equipment degrades, and operating points shift.…
TrainingImagine driving a car where the accelerator responds too slowly, the brakes overreact, and the steering wheel constantly oscillates left and right. You would never feel comfortable or safe. In…
Case StudiesProcess control optimization is no longer a luxury; it is a strategic imperative. With global competition intensifying and margins shrinking, industrial facilities are discovering that properly tuned…
APC & MPCIn the modern control room, we measure almost everything in real-time: flow, temperature, pressure, level. But the one thing that matters most— Product Quality —is often the one thing we cannot see…
APC & MPCIn the world of continuous processing, whether is it polymers, petrochemicals, or specialty refining, steady-state operation is straightforward. The real challenge, and the real danger to your profit…
APC & MPCIn the oil, gas, and petrochemical industries, excessive steam consumption and unnecessary flaring are often accepted as the unavoidable "cost of doing business." However, in an era of tightening…
MonitoringIn the hierarchy of process control problems, the control valve is often the "usual suspect" and for good reason. Industry studies consistently show that over 30% of control valves in operation…
MonitoringIndustrial facilities lose critical efficiency and profitability every month—often without realizing where the losses occur. Control loops drift subtly out of specification, equipment deteriorates…
APC & MPCThe process control industry faces a critical talent crisis. An aging workforce approaching retirement, increasing competition from tech sectors, and increasingly complex automation systems create a…
APC & MPCChemical plants operate at the intersection of complex multivariable interactions, stringent product specifications, and economic optimization demands. One critical decision often determines whether…
APC & MPCAs 2025 ends and industries prepare for the innovations of 2026, process automation trends for manufacturing plants keeps moving beyond the boundaries of the traditional control room. Leading plants…
APC & MPCCOLUMBO – New MPC inside PLC PiControl Solutions LLC is pleased to offer a brand new release of multivariable model predictive controller, called COLUMBO, a full-blown competitor for Aspen DMC,…
MonitoringSmart Simulator provides Smart Savings PiControl Solutions LLC has developed CO 2 absorption simulator software.It is a state-of-the-art chemical process simulator using CO 2 absorption column model…
APC & MPCIn the United States, industries such as chemicals, petrochemicals, oil refining, and power generation are continually seeking ways to maximize efficiency and productivity. One crucial method for…
APC & MPCIn complex industrial operations, maintaining consistent performance and efficiency often hinges on the smooth and precise operation of PID and advanced process controllers (APCs). With growing…
APC & MPCPiControl has developed unique closed-loop, multivariable, time-domain-based technology that will help you improve control and maximize plant profits even if you have MPC model predictive control or…
APC & MPCThe chemical industry, petrochemical industry, oil and gas and other manufacturing processes are full of distillation columns. The chemical distillation process to separate various components is a…
MonitoringIn today’s highly automated industrial environments, the demand for precision, efficiency, and safety is paramount. Process control systems, integral to industries like chemical processing, oil and…
MonitoringIn the ever-evolving landscape of industrial automation, maintaining optimal performance of process control systems is paramount for efficiency, safety, and profitability. As industrial plants grow…
APC & MPCAs the chemical industry continues to evolve, the role of process control is becoming increasingly pivotal. Advanced process control systems, real-time monitoring technologies, and sophisticated…
MonitoringIn today's competitive industrial landscape, maintaining optimal control over plant operations is more crucial than ever. The key to achieving this lies in effective monitoring and optimization of…
TrainingIn the dynamic landscape of industrial process control, achieving optimal control of complex processes remains a paramount challenge. From chemical plants to refineries and beyond, the ability to…
APC & MPCAmidst the buzz surrounding Artificial Intelligence (AI), machine learning stands out as a pivotal branch of artificial intelligence, empowering computer systems to enhance their performance by…
PID TuningIn the world of industrial automation, process control is the cornerstone that ensures operations run smoothly and efficiently. At the heart of process control lies the critical task of tuning, a…
MonitoringIn the ever-evolving landscape of industrial automation, the control system serves as the nerve centre of operations. It ensures efficiency, safety, and precision in controlling machinery and…
PID TuningIntroduction In today's rapidly evolving industrial landscape, the choice between Programmable Logic Controllers (PLC) and Distributed Control Systems (DCS) plays a crucial role in optimizing…
APC & MPCIntroduction In the ever-evolving landscape of industrial automation, staying ahead of the competition is crucial for any business to remain competitive. Process control technology is at the heart…
APC & MPCIntroduction Process control is a critical aspect of the pharmaceutical and chemical industries. It plays a pivotal role in ensuring product quality, safety, and efficiency while also complying with…
System IdentificationEffective process control implementation is vital for organizations to ensure operational excellence and maximize productivity. In this blog, we will discuss best practices to consider when…
MonitoringImplementing process control strategies can present various challenges that organizations need to address to ensure successful implementation. In this blog, we will discuss common challenges and…
APC & MPCAdvanced Process Control (APC) refers to the use of sophisticated control algorithms, process models, and optimization techniques in order to improve the performance of industrial processes. It goes…
Case StudiesHow Leading Cement Plants Are Utilizing Advanced Software Solutions Modern cement industry way of doing things is very different from the past ones. Technological advancements enabled cement plants…
PID TuningAl-based fully automatic PID auto tuning software PiControl Solution LLC’s SuperTune software is the most advanced AI-based PID tuning software (artificial intelligence based PID tuning software) in…
APC & MPCReduce Carbon Dioxide CO2 emissions, Run Plants Efficiently, Increase Production Rates and Maximize Profits with Power New Advanced Process Control (APC) in DCS or PLC PiControl Solutions LLC is an…
Watch the video → Welcome to the latest video from PiControl Solutions on practical Industrial System Identification and Process Control as we continue with a series of short, practical, and useful…
Watch the video → Welcome to the new video from PiControl Solutions on practical industrial system identification and process control as we continue with a series of short, practical, and useful…
Watch the video → Welcome to the fifth video from PiControl Solutions on practical Industrial System Identification and Process Control as we continue with a series of short, practical, and useful…
Watch the video → Welcome to the fourth video from PiControl Solutions on practical Industrial System Identification and Process Control as we continue with a series of short, practical, and useful…
APC & MPCCNRL continues to use PiControl’s PITOPS PID tuning software for entire plant-wide application. PITOPS PID tuning software is integrated with APC design (advanced process control design) and MPC…
Watch the video → Welcome to the first educational video from PiControl Solutions on practical Industrial System Identification andProcess Control. Identification of process models is often needed…
Watch the video → Welcome to the third video from PiControl Solutions on practical Industrial System Identification and Process Control as we continue with a series of short, practical, and useful…
APC & MPCIn recent times, most olefins plants crack ethane that is more readily available than a few decades ago. Olefins plants built during the 1970s to 1990s were often more complex. The olefins plants…
Watch the video → Welcome to our second video from PiControl Solutions on practical Industrial System Identification and Process Control as we continue with a series of short, practical, and useful…
APC & MPCTypically, urea is manufactured by reacting liquid ammonia and carbon in an autoclave, where ammonium carbamate is formed. Ammonium carbamate is dehydrated in the synthesis reactor to molten urea.…
APC & MPCA typical modern ammonia-producing plant first converts natural gas, liquified petroleum gas, or petroleum naphtha into gaseous hydrogen. Starting with a feedstock heavy in methane as a main…
System IdentificationPiControl Solutions LLC engineers were special guests on The Automation Blog podcast ( https://theautomationblog.com/picontrol-pid-loop-tuning/ ), presenting PITOPS: the latest process control…
System IdentificationAdvanced Process Control in Chemical Plants Advanced Process Control (APC) is now commonly used in most chemical plants. APC consists of math and logic algorithms that reside in a DCS or PLC or on a…
System IdentificationPiControl Solutions LLC, a leader in industrial process control software, services, consulting and training has been contracted by a large USA based LNG producer for the closed-loop analysis of LNG…
APC & MPCBeware of Model Predictive Control (MPC) and Distributed Control System (DCS) companies trying to sell you expensive software that you do not need. We live in a world full of products and services.…
MonitoringPiControl Solutions LLC has successfully created automated process control performance and KPI reporting system for Canadian Natural Resources (CNRL). High level management, process engineers and…
APC & MPCMany MPCs (model predictive control) systems fail to deliver the promised and expected benefits : Many MPC (model predictive control) systems start with a lot of excitement, hope and expectations.…
MonitoringPiControl Solutions LLC in cooperation with Etairon LLC and Transpara LLC has successfully upgraded functionality of APROMON (Online PID/APC Loop Control Quality and Performance Monitoring Software).…
APC & MPCPiControl Solutions LLC just successfully completed a DCS-based APC (advanced process control) at South Hampton Resources chemical plant in Silsbee, Texas. PiControl's PITOPS software for…
System IdentificationSecond order transfer functions are not very common in chemical plants and oil refineries but they do exist and make up about 5% of all control loops. About 70% of all industrial processes can be…
System IdentificationManufacturing Technology Insights Magazine evaluation panel has shortlisted PiControl Solutions LLC to feature as one of the "Top 10 Chemical Tech Solution Providers 2021". The pallet of PiControl…
TrainingPiControl is a leader in developing and selling process simulators for laboratories and chemical plants. PiControl possesses a distillation simulator. The distillation simulator is a real-time…
System IdentificationPiControl's PITOPS software is the most modern, best software for tuning PID control loops. PITOPS has advanced PID tuning functionality not available in any other PID tuning software from any other…
APC & MPCPiControl Solutions LLC, a major international process control software, APC - advanced process control, MPC - model predictive control and process control training company is pleased to announce…
System IdentificationYou and your team worked hard for six months, completed an MPC project successfully. A few months later, many CVs (controlled variables) are oscillatory and looks like below: You do not have the time…
APC & MPCIn this blog we will explain the basis for choosing DCS-based Advanced Process Control (APC) over Model Predictive Control (MPC). PiControl has extensive skills and experience in making a judicious…
PID TuningFigure1 :Typical process control issues Since the beginning of the 20th century the field of process automation and process control optimization has become increasingly important in all manufacturing…
TrainingBased on the initiative of Louisiana Tech University Department of Chemical Engineering and its cooperation, PiControl Solutions has developed and it is pleased to announce novel, modern and powerful…
APC & MPCModel Predictive Control (MPC) technology, such as: DMC (Dynamic Matrix Control), RMPCT (Robust Model Predictive Control Technology), PredictPro, Connoisseur and other Model Predictive Control (MPC)…
System IdentificationCollege and university professors do an excellent job in covering theoretical aspects of system identification, primary process control design, and PID control loop tuning methods. However practical…
System IdentificationPiControl Solutions LLC is in talks with EMERSON USA for possible alliance on process control, PID control loop tuning and advanced process control (APC) and PID control loop monitoring software and…
PID TuningAbstract Since the 1980’s the field of process control has become increasingly important in chemical and petrochemical plants, oil refineries and other manufacturing units. The widely used and still…
PID TuningView original source for this content – www.prnewswire.com The “Global PID Loop Tuning Software Market 2018-2022” report has been added to ResearchAndMarkets.com’s offering. The global PID loop…
APC & MPCIncrease Plant Profits by Process Monitoring and Optimization Any factory or chemical plant has anywhere from about 10 to as many as several 1000 PID control loops. If PID tuning parameters are not…
PID TuningPID Tuning in Chemical Plants PID Tuning Optimization helps chemical plants to run better, more smoothly, increases production rate and plant profits. This can result in 2-4% profits, sometimes as…
APC & MPCPiControl Solutions LLC, an industrial process control software and technology company has APC (Advanced Process Control) technology for improving operation and profits in Polyester Fiber plants.…
PID TuningTwo Boeing 737 Max 8 airplanes crashed in less than six months. How is this possible in today’s day and age when safety and training procedures have been matured and perfected over several decades?…
APC & MPCDCS or PLC in the modern control room in a chemical plant Distributed Control Systems (DCS) are almost in every plant now. In smaller plants there are Programmable Logic Controllers (PLC). With…
APC & MPCPiControl Solutions is a worldwide industry leader and a great to learn practically and effectively about the Process control system which is needed in the modern control room environment. Receiving…
APC & MPCPhase 1: Benefits estimation The first step when implementing an Advanced Process Control (APC) strategy is to understand what process units or parts of the units are good candidates for learning the…
APC & MPCCompanies that have implemented successful Advanced Process Control (APC) projects suggest they’ve done just that and even better. Whether its new drivers, process controllers, or economic issues…
PID Tuning“PID auto-tuning” or “PID self-tuning” controllers are designed to simplify matters by choosing their own PID tuning parameters based on some sort of automated analysis of the controlled process’s…
APC & MPCWith the increase in processor power, the number of modern Advanced Process Control (APC) algorithms available to users has reached a level where everyone should apply them if there is an opportunity…
APC & MPCThe chemicals market is very competitive, volatile, and fast-paced. To maintain a strong market position, companies need to look harder and deeper into their equipment, production, and operations to…
PID TuningPiControl presented a paper on PID tuning software, PID tuning training, closed-loop transfer function system identification and advanced process control at the ACHEMA conference in Frankfurt. The…
PID TuningPiControl is pleased to announce the release of the latest PID tuning simulator and PID tuning calculation/optimization software SIMCET version 9.2. Now with almost 100 real-time examples from all…
APC & MPCMPC Maintenance for DMC/RMPCT- COLUMBO (Closed-Loop Universal Multivariable Optimizer) PiControl is pleased to release brand new software and technology for 2018. A unique new product called COLUMBO…
APC & MPCNow all plant DCSs and PLCs can easily create Excel files containing PV, OP and SP data from PID controllers or CVs and MVs from DMC or RMPCT controllers. PITOPS can analyze this data quickly and…
System IdentificationPITOPS PID Tuning software from PiControl Solutions LLC is the only software tool in the world capable of the following functions: Identify multiple open loop transfer functions with completely…
TrainingPiControl is proud to announce the release of the PID Tuning Training Simulator SIMCET version 8.2 SIMCET converts your computer into a DCS/PLC style real PID controller. The new SIMCET has over 80…
PID TuningThis is one of the latest reviews from an industrial process control professional, praising and recommending PiControl Solutions process control training, PID tuning training, and OPC training. We…
System IdentificationThe Value of PID Tuning, CLPM, and System Identification Software PID tuning optimization, monitoring, and advanced process control are increasingly important today. Many plants do not use software…
PID TuningPITOPS PID tuning, APC design, and system identification software use the latest technology along with modern and powerful tools in professional control rooms and colleges. PITOPS has the following…
MonitoringAPROMON, an advanced CLPM monitoring software, monitors all PID loops in any manufacturing plant with a DCS or PLC. APROMON is compact, simple yet powerful. It can monitor 10-5000 PID loops using…
MonitoringThe Importance of CLPM Software A plant can have 10-5000 PID control loops and no human can possibly monitor so many PID loops all the time. With time, control quality can deteriorate due to aging…
PID TuningPiControl Solution LLC’s is pleased to announce the successful winning of PID Tuning Software project and also corporate training for all process control engineers and technicians at a major bauxite…
Watch the video → PiControl Solutions LLC is pleased to announce that PITOPS software for PID tuning and transfer function identification was selected by a DCS vendor and DCS consulting company.…
PID TuningPiControl Solutions LLC is a worldwide leader in providing process control training on PID tuning, primary control, and advanced process control. We provide DCS and PLC training too including…
PID TuningTwo or more PID loops interacting and “fighting” can be a menacing and challenging problem. Many control engineers have struggled unsuccessfully because of PID loop interactions. PITOPS PID tuning…
PID TuningAs a business owner, you’re always looking for ways that you can improve your company and save on costs. Perhaps you’ve already made a number of changes to improve, but aren’t seeing the results you…
TrainingYou spend a lot of time looking for, interviewing, and hiring the right candidate for the job so, why should you have to spend more money on staff training? That’s a good question. If you look at it…
PID TuningPiControl’s SIMCET and PITOPS software converts your computer into a real-time PID simulator and PID tuning optimizer. SIMCET behaves as if you are working on real PIDs in a real plant. Build…
APC & MPCWe are pleased to announce the recent release of our modern and updated PID Tuning and Advanced Process Control (APC) courses using brand new Vimeo video-based life-like format. The sessions are…
PID TuningHave you heard about PID tuning and wondered if it can help your business? In this post, we’ll break down exactly would PID tuning is and explain how it is helpful to your business. PID Tuning…
APC & MPCPiControl Solutions LLC, a worldwide leader in software development, training and consulting on PID tuning, primary process control and advanced process control (APC) is pleased to announce the…
APC & MPCPiControl Solutions is pleased to announce upgraded online training courses on practical industrial process control. Now you can access the training 24/7 and with experienced live instructors…
APC & MPCPiControl is a worldwide leader on practical industrial process control training. Student install software on their own computers and convert the computer into a DCS/PLC where they can build and tune…
PID TuningPiControl Solutions LLC offers FREE PID tuning software for trial and evaluation. You get 30 days of free use. The software tunes PID controllers, identifies transfer functions in the time domain and…
System IdentificationPiControl has novel modern technology for identifying open loop transfer functions with completely closed-loop data with PID controllers in cascade or auto mode. No step tests are required and all…
System IdentificationHere at PiControl Solutions, we offer the best solution for PID tuning software. Whatever industry you’re in, our software will serve your needs. The industries we serve include: Alcohol Air…
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