How Small Control System Tweaks Can Deliver Big Gains in Plant Reliability

When it comes to improving plant reliability, many Engineering Managers focus first on major equipment upgrades, large-scale CAPEX projects, or extensive system overhauls.

But in reality, some of the biggest reliability gains can come from small, targeted tweaks to existing control systems — if you know where to look.

At BIA Engineering Ltd, a key part of our work involves identifying exactly these opportunities.

Time and again, we’ve seen how a carefully designed control logic adjustment, a minor parameter tuning, or a simple sequencing change can eliminate persistent process instability and extend equipment life — without the need for major capital expenditure.

Common Scenarios

Here are just a few examples of small tweaks that can drive big results:

1. Improved Sequencing Logic

One energy plant we supported was experiencing frequent equipment trips during process transitions.

By adjusting the sequencing logic to better manage interlocks and timing between subsystems, we eliminated the trips entirely — improving uptime and reducing operator workload.

2. Tuning of PID Loops

We often encounter poorly tuned control loops that cause valves to hunt or oscillate.

In one case, a simple retuning of a critical temperature control loop led to much smoother process behaviour — reducing wear on both the valve and the downstream equipment.

3. Better Alarm Management

In another facility, operators were drowning in nuisance alarms — masking the signals that really mattered.

By implementing smarter alarm logic and proper prioritisation, we gave operators a clearer picture of plant health — improving response times and reducing unnecessary interventions.

4. Restoration of ‘Temporary’ Commissioning Changes

It is surprisingly common to find temporary overrides or logic changes left in place after commissioning.

We routinely help clients identify and safely reverse these changes — restoring proper system behaviour and improving long-term reliability.

Why It Matters

Modern control systems are powerful — but small errors or suboptimal configurations can silently erode reliability and performance.

Left unaddressed, these issues cause:

• Increased wear and tear on equipment

• Process instability and inefficiency

• Increased operator workload and intervention

• Higher maintenance costs and more frequent downtime

By focusing on targeted control system optimisation, we help our clients achieve better plant outcomes with minimal disruption.

Our Approach

BIA Engineering Ltd provides:

• Expert control system reviews and diagnostics

• Targeted control logic optimisation

• Loop tuning and stability improvements

• Alarm rationalisation and management improvements

• Support for post-commissioning control system clean-up

Engineering solutions beyond expectations means knowing where small changes can deliver big value — and helping clients capture that value without unnecessary cost or disruption.

If your plant could benefit from a fresh set of eyes on its control system — we can help.