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 run over 95% of all industrial control loops, and 60–80% of those loops are poorly tuned at any given time. The five capabilities below are what PiControl products do that competing process control software does not.
PiControl process control software builds a full multivariable process model from 4 to 24 hours of normal closed-loop operating data that your historian already collects. No bump tests, no open-loop step changes, no production disruption, and no request to operations for a test window.
Most PID tuning software tunes a loop once and leaves it to drift. SUPERTUNE process control software recalculates optimal controller parameters every 1 to 5 minutes against live process dynamics, so tuning holds as catalyst ages, exchangers foul, feed quality shifts, and throughput changes.
PiControl designs advanced process control that executes inside the DCS or PLC you already own. No external host computer, no middleware server, no proprietary hardware, and no annual platform fee for a box in a cabinet.
PiControl process control software simulates proposed tuning against the model identified from your own plant, then injects realistic disturbances to show how the loop will behave before a single parameter reaches the controller. Engineers validate on a desk, not on a running unit.
PiControl is the only independent process control software vendor delivering optimization, monitoring, and simulation software alongside expert consulting and a full training curriculum, all built on the same closed-loop, time-domain method. The engineer who tunes your plant uses the tool your team is trained on.
Process control software delivers different value in every sector, because every sector fails differently. A cement kiln oscillates. A polyethylene reactor loses grade transitions. An air separation unit vents product. Pick a sector to see the verified result from a PiControl deployment.
Also deployed in semiconductor manufacturing, pulp and paper, methanol production, copper smelting, and steel. A large international semiconductor manufacturer selected PiControl from four world-class competitors for a plant-wide control quality monitoring project.
View all success stories →Definitions, DCS/PLC compatibility, cost, and how it differs from SCADA.
Available worldwide — 40+ countries served and every major DCS or PLC supported via OPC. Choose the path that matches where you are today.
