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      Chemical and other manufacturing plants can have anywhere from about 50 PID control loops (small plants) to over 4000 PID control        loops (large refineries and integrated petrochemical complexes). Primary process control loops can easily deteriorate over time,                instruments can fail, control valves can stick, operating conditions and process dynamics can change and cause problems in the                way of oscillations or poor and sluggish control.
      LeKa Control has got the technology and experience to analyze plant process control loops, instruments and control valves                          performance and suggest corrective or improvement actions. We can easily answer to questions: which PID control loops are                      oscillatory or too sluggish, which PID control loops can be transferred back to auto or cascade mode, which PID control loops                      interacts, which control valves are not working well or are moving excessively, which instruments are too noisy or have instrument            signal problems, and many other diagnostic questions which will help to address problems of PID control loops and associated                  equipment. This way, all plant process control loops and dedicated equipment performance can be improved. PID control loops can          be re-designed and continuously maintained, which in return will increase overall plant’s profit and reduce costs.

Using closed-or-open-loop Excel data generated from any DCS/PLC historian, LeKa Control can easily identify multivariable dynamic process models in time-domain and use them for what-if process and control analysis, primary process control design and PID tuning, and advanced process control (APC) parameter calculation.
Our modern system identification approach works well with completely oscillatory data obtained from control loops in auto or even in cascade (remote) mode. Also, it can work with fast control loops in milli/micro seconds time frame to very slow control loops settling in several hours. It does not need signal conditioning, data normalization or data whitening. Identified true dynamic process control models are completely isolated from process and instruments drifts and noises, and unmeasured process disturbances which are typically present in any plant.
LeKa Control can precisely tune single, slave or multiple cascade and other complex PID controllers in order to reduce/eliminate oscillations and improve their control quality and performance. The oscillation reduction will enable smoother but faster running of the plant with increased stability in all control loops. During PID control loops tuning we take into account the following control needs of each loop; typical setpoint change, pulse/ramp/sine disturbance change and/or desired output rate of change. Moreover, LeKa Control can mathematically calculate any advanced process control (APC) parameters, such as feedforward and/or any model-based control parameters.

The DCS and PLC advanced functionalities are still not fully utilized today. LeKa Control has extensive skills and expertise to evaluate and do advanced process control (APC) study and to make a judicious selection which plant is DCS-based APC (advanced process control) or model predictive control (MPC) resident. We have designed, implemented and started-up numerous DCS-based APC projects all over the world with success and safety. Our advanced process control technology can wholly be implemented inside any DCS/PLC system without a need for an external computer, communication and safety issues.
Unique and proven LeKa Control DCS-based APC (advanced process control) approach will provide significant cost savings, fast commissioning and project completion, and high benefits to any DCS-based APC plant resident. With DCS-based APC approach we can maximize production rate, minimize utilities, waste and off-spec products and reduce unplanned shut-downs, oscillations and control problems. LeKa Control ensures minimum 2 – 4% improvement in the plant’s operating efficiency and a 30 – 50% or more reduction in oscillation amplitudes due to PID tuning and optimization.
The DCS-based APC system will also include details about safe start-up, safety clamps and other guidelines to ensure success, safety and the achievement of the advanced process control (APC) goals and objectives. Data analysis for support and improvements can be conducted remotely very efficiently followed by changes on site.

LeKa Control provides design and integration of Siemens PLC (programmable logic controller), HMI (human machine interface) and SCADA (supervisory control and data acquisition) systems for automatic control of new laboratory and industrial systems or modernization and maintenance of existing ones.
We can also prepare preliminary and detailed automation design study for any laboratory and industrial process.
Inside of any automation project all equipment installation, testing, user training and continuous maintenance of the system within and beyond the warranty period is provided.
Knowledge and experience of LeKa Control engineers is gained in numerous laboratory and industrial automation projects present in pharmaceutical and polymer industries, research facilities, refineries power plants.