Conclusion:
PID controllers tuning is a very important aspect in today’s process industries. Having poorly tuned controllers will result for manufacturing plants to miss the opportunity of achieving additional 2 - 7 % capacity enhancement. Most control engineers and operators still use the old-fashion methods for PID tuning.  These methods are slow, imprecise and never allows the plant to run with maximum possible efficiency.  Only few people use PID tuning software because most of them are expensive, complex and limited for practical use. Therefore, unfortunately only fewer than 20 % of all plants worldwide are precisely tuned. Keeping the limitations in mind, appropriate methods must be used to identify the optimum PID tuning parameters. Market studies show that properly designed and optimally tuned process control strategies can increase a plant’s throughput anywhere by 2-10 %, equivalent to few hundreds of thousands of dollars to several millions. PITOPS is a practical and a low-cost comprehensive system identification and process control software which enables the control engineer to identify the optimal PID tuning parameters without any hiccup to the plant operations. It allows process units to be run closer to their hard limits without risking their safety which raises the production average of the plant.
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