PITOPS
Multivariable closed-loop system identification and PID tuning software. PITOPS identifies SISO and MIMO transfer functions for up to 50 inputs × 50 outputs from normal closed-loop operating data in the time domain — no bump tests required.
Process control software is industrial optimization software that improves the performance of PID controllers, advanced process control strategies, and control-loop monitoring — closed-loop system identification, PID auto-tuning, MPC model identification, and real-time monitoring, all in the time domain and connecting to any DCS or PLC via OPC.
Most plants already run a DCS, PLC, or SCADA system — the performance problem is not the control system itself. It is that 60–80% of PID loops are poorly tuned, MPC models degrade silently, and oscillations cost money every day until someone tunes them out. Across 16+ industrial sectors and 40+ countries, engineers use PiControl to reduce variability by 30–70%, recover 5–15% in energy losses on affected loops, and typically pay back the software cost within 3–6 months.
Optimization, monitoring & diagnostics, simulation, and OPC communication — every product built on the same closed-loop, time-domain methodology and connecting to any DCS or PLC via OPC.
Multivariable closed-loop system identification and PID tuning software. PITOPS identifies SISO and MIMO transfer functions for up to 50 inputs × 50 outputs from normal closed-loop operating data in the time domain — no bump tests required.
Automatic online PID auto-tuning software that recalculates controller parameters every 1–5 minutes based on real-time process dynamics — running continuously inside the DCS or PLC, adapting to fouling, catalyst aging, and feed drift.
Closed-loop MPC model identification software that extracts accurate multivariable transfer functions from existing MPC data without removing the controller from automatic mode — to refresh degraded MPC models.
Online control loop monitoring software. APROMON tracks PID and APC performance, detects oscillations, identifies sticking valves, and diagnoses tuning degradation in real time — ranking hundreds of loops by economic loss.
High-speed industrial data logging software capturing PV, setpoint, and controller-output trends at sub-second resolution for tuning analysis, post-mortem investigation, and root-cause troubleshooting.
Laboratory information management system for process plants. PiLims captures lab analyses, tracks sample chains, and correlates lab results to real-time process data.
Real-time PID tuning simulator with 20+ pre-built process simulations covering flow, temperature, pressure, level and composition loops, plus a testing-and-grading module used for PID tuning certification.
Styrene monomer plant DCS simulator — a full plant-scale dynamic simulator with PCS 7 control-room interface for operator training, alarm-response practice, and APC strategy validation.
Continuous distillation column dynamic simulator capturing tray hydraulics, reboiler and condenser response, and feed composition disturbances.
Batch distillation column simulator modelling reflux drum behaviour, cut transitions, and end-point determination for specialty and pharma plants.
Azeotropic batch distillation simulator — a lighter-footprint version focused on azeotropic separations and entrainer-based distillation.
Absorption column simulator modelling gas-liquid absorption dynamics for amine systems, scrubbing, and acid-gas removal.
Tubular reactor simulator modelling plug-flow dynamics for cracking, polymerization, and other tubular reaction systems.
Continuously stirred tank reactor simulator — will model residence-time distribution, heat-removal limits, and exothermic reaction stability.
Flow controller in heat exchanger simulator capturing flow-loop dynamics with realistic valve characteristics and pump curves.
Level controller in vertical tank simulator modelling integrating-process behaviour and cascade level-flow control.
Temperature controller for heat exchangers simulator capturing dead-time-dominated thermal dynamics.
Closed-loop heat transfer simulator — will add cascade temperature control, secondary-loop dynamics, and disturbance rejection.
Heat exchanger network simulator modelling multi-unit networks with cross-coupling between hot and cold streams.
Pressure drop simulator capturing dynamics across piping, control valves, and process equipment.
Pump system simulator modelling centrifugal and positive-displacement pump dynamics with realistic curves and cavitation behaviour.
Agitation effect simulator modelling mixing time, blend uniformity, and impeller-driven flow patterns in stirred vessels.
OPC communication bridge software. PiBridge is a dual OPC client bridge connecting two OPC servers across different networks, protocols, or sites — transparent data exchange without proprietary middleware. OPC-DA and OPC-UA compatible.
Simulation OPC server with an embedded real-time PID control loop. PiOPCServer generates test data and validates OPC client connectivity for development, integration testing, and software demonstrations.
PID controllers account for over 95% of all industrial control loops, and 60–80% of those loops are poorly tuned at any given time. PiControl solves this in four specific ways.
PiControl extracts true multivariable process models from 4–24 hours of normal closed-loop operating data — no bump tests, no open-loop step changes, no production disruption.
All PiControl software identifies in the time domain rather than the frequency domain — capturing dead time, nonlinearities, and multivariable interactions that frequency-domain methods routinely miss.
Compatible with every major DCS and PLC via OPC-DA and OPC-UA — Honeywell Experion, Emerson DeltaV, Yokogawa CENTUM VP, ABB, Siemens PCS 7, Rockwell PlantPAx, Schneider EcoStruxure. No vendor lock-in.
The only independent vendor offering optimization, monitoring, and simulation software alongside expert consulting services and 30+ training courses — all on the same closed-loop, time-domain methodology.
PiControl optimizes industrial process control systems across refining, petrochemical, LNG, power, pharma, cement, and 10+ more sectors — the closed-loop, time-domain methodology stays constant across all of them.
Definitions, DCS/PLC compatibility, cost, and how it differs from SCADA.
PiControl process control software runs in plants operated by the world's largest industrial companies across refining, petrochemicals, power, polymers, specialty chemicals, and semiconductor manufacturing — including Shell, ExxonMobil, Chevron, BP, Intel, Corning, LG Chem, Praxair, Sipchem, Atlas Copco, and 200+ facilities in 40+ countries.
Available worldwide — 40+ countries served and every major DCS or PLC supported via OPC. Choose the path that matches where you are today.