PID Control & Tuning

Optimal PID control: the basis for improved plant performance

Ready to improve processes? Base layer control is where you start. Minimize oscillations, maximize quality – in one loop or a whole plant.

Run you plant in full automatic mode closer to the constraints

Optimal base layer control starts with a good control design. First bring process and control know-how together in the best control design for your plant. Then tune all the PID loops such that every single loop in your plant is in auto mode and keeps all your process parameters at the desired setpoint 24/7. This will result in less operator interventions, less alarms, more stable operation and more benefits.

Reduce process variations

Reduce process variations

Optimal base layer control means less variations of temperatures, pressures, flows and levels. This will result in less alarms.

Higher automation level- more safety

Higher automation level: more safety

More and better automatic control result in less operator interventions, less operator stress and a reduction of the human errors. This will increase plant safety.

Reduced emissions due to optimal control

Reduced emissions due to optimal control

With optimal base layer controls it is possible to reduce the excess air in furnaces, reduce the over consumption of energy. This has a significant impact on emissions.

Stabilize a complete unit with optimal base layer controls

IPCOS reviews and optimizes your base layers controls. This can be for a few loops to your complete site. Our scope of work consists of reviewing and finding the root cause for the bad performing loops. Sub optimal performance can be due to instrumentation or actuator issues, bad tuning or even a bad control design.

IPCOS Case Study

PID Tuning for Gas Processing facility Al-Khafji Joint Operations (KJO) in Saudi Arabia

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Stabilize a complete unit: PID Tuning gas plant
PID tuning: Optimal boiler control gives lower emissions

Optimal boiler control gives lower emissions

No need to keep operating a boiler at a high oxygen excess when the PID controllers are doing what they need to do: keep your boiler stable under all circumstances

IPCOS Case Study

Coal Fluidised Bed Steam Generator – PID Tuning

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The ultimate process stability is created with an optimal design and tuning

The base-layer control project, carried out by IPCOS, allowed the client
to operate the steam generator more stably, which not only increase steam delivery at a higher rate but also saves treatment chemicals and reduces material stress due to large variations on the combustion side.

IPCOS Case Study

Baselayer Controls Assesment and optimization of waste Incinerators

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Create process stability with base-layer control assessment and optimization

End-to-end value


 Benefits by designing a reformer duty controller and applying optimal tuning.


Annual savings at with optimal base layer control on a visbreaker


Variability reduction with PID control design and tuning

1-8 weeks

Average payback times for base layer control projects

Other services


Advanced Process Control

APC systems maintain your operation at the optimal operating point. APC improves product yield, maximizes throughput, increases your plant’s efficiency under varying feedstock quality and operating conditions.


Alarm Management

Benchmark your alarm situation and then develop an alarm management philosophy document tailored from best-practice templates with buy-in from process engineers, operators, and controls staff.

Real-time monitoring and optimization of wells and facilities

Real-time Optimization

Generate benefits on top of an advanced process control application, by capturing the non-linearities of the process and determining the most optimal operating point, in closed loop.



Build by process control engineers for engineers in the industry. INCATOOLS has all you need to tune ALL your loops. INCATOOLS has all the tools to build a complete MPC system and maintain it for many years.

Ask IPCOS what PID control and tuning can do for your processes

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