We are proven experts in the field of regulatory controls. Through our PIControl Solutions division (http://www.picontrolsolutions.com), we offer a suite of packages that are aimed at providing the total solution for base regulatory controls. As can be imagined, building the software suit required many years of experience, dedication and expertise and education in the area of process controls. We will combine our efforts to provide the optimal solution for each loop.

Not all multi-variable problems require MPC and we are proven leaders in making this statement true. We will analyze your system and develop the simplest solution for your needs and then help you implement them.

W have the following Process Controls Packages to enable us tackle your issues:

PITOPS: Pitops is abbreviation for Process Identification and Controller Tuning Optimizer Simulator. It is aimed at developing and commissioning supervisory and advanced control strategies in the DCS or PLC. Furthermore, Pitops tunes all PIDs from millisecond time frame to several hours of time constant - single/slave, cascade and constraint over-ride types. Pitops was created by a group of experienced process control engineers with years of control room experience on PID tuning, cascade or override PIDs, DCS-based advanced control strategies and MPC systems.

SIMCET: Simcet is a dynamic real-time simulation software for PID tuning in DCS and PLC. It provides the user with real plant-like environment on a PC platform. Simcet is designed to train, test, certify and qualify process control engineers, technicians and operators before allowing them to tune loops in the control room. Users see PV, PID output on the screen in real time. User can change SP, see the effect of tuning changes on control quality.

Production Rate Maximizer: Maximizing production rates and minimizing utilities is a common goal in most chemical plants. We have developed proprietary routines that can achieve the goal of production rate maximization in any production facility. This is an area in which we are at the lading edge.

Adaptive Advanced Control in DCS or PLC 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 host computer. These algorithms monitor process variables and move the plant towards the direction of increasing profit. Benefits of APC are increased production rates, reduced utilities, smoother and more automated plant operation.

Process Control Vision Solutions to New Challenges for the Chemical Process Control Industry7
The DCS (distributed control system) is now controlling almost each and every chemical plant and refinery all over the world. The rapid growth and modernization of industrial process control software and hardware has generated an explosive growth in the field of advanced process control. A rapidly increasing number of advanced applications are getting rolled out in the control rooms. The new age is also seeing many new and inexperienced process control engineers enter the control rooms. Despite the modern curricula in colleges and universities, fresh graduates are not fully equipped with all tools and knowledge required for immediately becoming an effective process control engineer in the control room environment. Furthermore, after 1-5 years, many control engineers get moved or promoted into other areas, management. As a result, new control engineers continue to enter the process control field. There is a growing need for fast and effective training for both new and experienced process control engineers and DCS technicians in the control room environment.

Advanced Process Control and Optimization Tools:
Process controls tools can be broadly classified into the following:
	Online Real-time Optimizers
	Multivariable Model-Predictive Controllers
	Expert Systems, Knowledge-based Systems, Rule-based Systems – Advisory Applications
	Fuzzy Controllers
	DCS-resident Advanced Controllers

	Slave and Cascade PID Controllers
	Constraint Override PID Controllers
	Feedforward Controllers
	Model-based Controllers using regressed, empirical or semi-empirical models
	Model-based Controllers using rigorous models fit to match real-plant data
	Dead-time Compensators

	PID tuning optimizations
	Setting the correct configuration options in the DCS
	Knowledge on when to use PID, multivariable controllers like DMC or DCS-resident model-based control schemes
	Use of transforms to linearize non-linear processes and dynamics
	Watching for process control performance change with time (heuristics) because of various reasons
	Savings Potential based on Primary Process Control functionality

Sign of primary control schemes in the DCS and the control system performance optimization can save annually:  
• US$50,000 to $300,000 in a small plant
• US$100,000 to $1000,000 in a medium sized plant
• US$1000,000 to $3000,000 in a large complex like an olefins plant or a refinery>  
   
These benefits are big, but most importantly, they are recurring benefits each year (not just one time). Expensive and more sophisticated advanced control and real-time optimizer projects using complex systems can also provide comparable monetary benefits as the ones listed above. The notable point is that primary control improvements (all inside the DCS) can be achieved far more quickly at a fractional cost and with high monetary savings as compared to complex and expensive control projects.

→ PID Control Opportunities:
Even in recent times, we find huge savings and other benefits opportunities by implementing various PID control schemes directly inside the DCS or PLC. Many view the PID as a simple, age-old algorithm and so do not use it to the fullest potential inside the DCS. We will implement or teach you novel, innovative techniques for the following:

• Primary control tuning optimization.
• Optimized constraint control.
• Model-based control using online analyzer feedback.
• Triple -cascades optimized for tighter control.
• Optimal and appropriate use of the derivative in special cases.
• Equipment local and area control optimization

With so many new control engineers coming into the control room every year, there is need for better, more effective training and tools for the control engineer in the control room environment.

A college degree in any of the engineering courses is good start for the control room environment, but these new people do not have the practical exposure to bring their talent abilities to the fullest potential.

Our PIControl Solution’s Simcet PID simulator allows the control engineer to work in real time on typical process control loops like no other tool in the market. From fast flow loops to medium fast pressure loops to temperatures to very slow loops like those controlling online analyzer variables, the new control engineer can tune on the PC as if he is working on the real plant. Since the engineer is working on the PC-based simulator, he or she can fearlessly make controller and tuning changes without any fear of driving loops unstable or causing any plant problems or shutdowns.

Unlike most competitor tools, PIControl Solution’s Simcet is a complete real time process control simulator. It starts to simulate process data in real time and continues to run as long as the user desires. Other tools are accelerated simulations - they start at time = 0 until a specific time and then stop. Simcet also allows the control engineer to take various tests and pass the skill requirements before he or she can be considered to be ready for tuning in the real control room environment.

The Pitops-TFI and PID software modules provide all the control room tools you will ever need for the control room environment. These tools provide all the power and the Process Control CBT provides the essential training for a new or experienced control engineer to come up with many new ideas and design, implement various new controllers.

It is amazing how much controller improvement can be made only by tightly correctly tuning something critical pressure, level and temperature PIDs. Only a systematic method as recommended and advocated by us shows that quick and easy path for the primary control improvements.

To make sure all the PID controllers work well, the new cutting edge tools Apromon and Tadpole provide all the monitoring necessary in the plant. Apromon is an online process control monitoring tool and Tadpole detects oscillations in the process. Both work as online and real-time, well-suited for the control room environment.

It is estimated that millions of dollars are still to be saved at various plants, all around the world. We expect our services and PIControl Solution’s tools - Pitops-TFI, Pitops-PID, Simcet, Process Control CBT, Apromon, Tadpole and the numerous additional tools and tutorials to set new, unprecedented standards for the control engineer for the years ahead.

→ Production Rate Control & Maximization
ARTCON can show you novel powerful techniques to maximize your plant production rate and increase profits. An entire production rate controller can be designed and implemented directly inside the existing DCS or PLC. PiControl Solutions's Pitops-TFI module identifies process dynamics precisely based on real plant data and then the Pitops-Control Simulator will calculate and optimize all controller parameters to be input into the DCS. This novel methodology helps to quickly and easily develop a complete process control simulation on any PC. This simulation can be shown to control room operators to gain approval on the control action and make sure that it matches with their experience and requirements.

The technique can use open-loop data, closed-loop data or a mixture of both. Data can be single-input or multiple input. PIControl's Pitops-TFI module is the only true multi-input (multivariable) dynamics identification software that can work with very short-time frame closed-loop data. The package is able to weed out the disturbances and noise and isolate the true process dynamics.

Implementing such production rate maximizers can easily increase a plant's production rate by 1% to 10%. Market studies and papers indicate that typically 2-5% increase rate can be expected in most chemical, petrochemical and refining processes. The same can apply to paper, pharmaceutical processes and related industry also.

A typical controller schematic is shown in the Figure below. 

 
Our approach saves you, the plant - significant amount of money by way of increased production rates. ARTCON services focus on delivering quality products to the industry at a very attractive price. We help the end user to maximize their ability to do the work on their own quickly and easily without the need for much contract and consulting fees which often are the major cost slice in process control or advanced control project. ARTCON can provide quality service by email/phone with help on controller configuration design, development, process dynamics identification and controller parameter optimization.

Before you initiate expensive projects using expensive consulting services and costly multivariable or model-predictive software, first contact Eta-etch Consulting for amazing low cost solution while delivering the fullest benefits potential.

Pushing against constraints to save money:
In most cases, a 2-10% increase in production rate because of better control is huge in terms of payback. In some cases, pushing against specific plant, process or equipment constraints can be a money-saving opportunity.

Your process may need to keep certain valves in fixed ranges for improved quality, in which case a multivariable valve monitoring advanced control application can be very appropriate. Or the process under optimal conditions may require certain temperatures to stay in a fixed operating zone.

The opportunities are endless for saving money both by maximizing rates or pushing against specific constraints. Contact ARTCON today and we will assist you in design very low-cost advanced control solutions right inside your very own existing DCS.