PID control & Tuning
IPCOS offers PID optimization services (tuning and, if required and beneficial, a full redesign of the control structures), as well as PID Tuning software. Optimal PID control results in more production at a lower cost with less operator interventions and alarms. It is also the foundation for building robust APC controllers.

In day to day operation PID controllers are
- Often in manual mode, or are put in manual during large disturbances
- Causing process oscillations due to bad tuning or sub-optimal control strategies
- Part of a control strategy that is copied from the old DCS or pneumatic controllers
- Tuned based on a time consuming trial and error approach. This can result in long startup times for grass root plants
- Tuned based on tuning rules like Ziegler-Nichols, Lambda and Kappa-Tau. These rules give reasonable results in many cases. Critical loops that have a direct effect on product quality, energy consumption or overal plant throughput, should be tuned based on real optimization. The difference in performance is significant
- Interacting with each other, posing a challenge to the control engineers to tune them correctly.

The benefits of optimal PID Control
- Reduced process oscillations resulting in less wear and tear of the equipment
- Less alarms
- Less operator interventions
- Less process interactions due to optimal control strategies
- The plant becomes APC-ready
- More efficient plant operations (higher production, less specific energy consumption, better quality control,…).
What defines the IPCOS’ PID Control solutions?
- Combine process know-how and control know-how
- A first time right approach
- We want to share share our experience by offering PID tuning training courses to our customers
- Look at the process. Not everything can be solved with PID tuning. E.g. bad actuators and instruments can have a large impact on the control loop performance. Tuning will not resolve this. IPCOS engineers will do the right triage of your control loops
- Covers all common DCS/PLC systems on the market
- Keep it simple. Optimal balance between benefits and complexity
- Focus on the tuning AND the control structures
- Usage of state of the art tuning tools (see INCA PID Tuner and INCA AptiTune).
Watch these webinars on PID Performances, Cascading loops, Interacting loops, PID tuning plant startup, the D in PID
Best practices
- Look beyond the controllers. Therefore, look at the process, the instruments, the actuators,..
- Use state of the art tuning tools
- Tune controllers based on engineering specifications that matter like max overshoot, minimum robustness, minimal settling times,….
- Document all the modifications in a clear way
- Thorough testing of the new control structures before the commissioning