INDUSPHERE CONTROLS

AUTOMATION. CONTROL. OPTIMIZATION.

Services

We design, program, and optimize industrial automation systems – DCS and PLCs – to improve reliability, efficiency, and safety of process plants.

InduSphere Controls Services - Service 1 - Programming and integration of industrial automation and process control systems on DCS/PLCs
  • Relays, VFDs and Soft Starters: GE, Eaton, ABB, Schneider
  • DCS: Emerson DeltaV, ABB 800xA,
  • PLCs: Rockwell, ABB, Siemens, Schneider, IDEC
  • IEC Languages: FBD, SFC, IL, LD, and ST
  • HMI/SCADA: Graphics and alarm rationalization
  • Commissioning: Testing, troubleshooting, and redlining

Industrial Automation

We build robust control logic and HMIs for continuous and batch processes – tested, documented, and ready for operations.

InduSphere Controls Services - Service 2 | Supervisory and Advanced Process Control
  • Plantwide PID audit and model-based tuning
  • Constraint control, feed-forward, gain scheduling
  • APC (MPC and Fuzzy) and real time optimization (LP, NLP, QP) for critical circuits (e.g., mills, flotation, dewatering, distillation columns, boilers)
  • Data Analysis and Visualization: Advanced Statistical and Machine Learning techniques

Advanced Process Control

Stabilize variability, increase throughput and recovery, while decreasing costs with disciplined tuning and advanced control strategies.

InduSphere Controls Services - Service 3 | Upgrades and Migrations for process plants and operations.
  • Controller & I/O migration
  • network segmentation
  • Virtualization, patching, backup & disaster recover

Upgrades & Migrations

Modernize legacy systems with minimal downtime and clear rollback plans.

Technical Expertise

InduSphere Controls CPU Icon | DCS, PLCs, and automation and process control platforms for Process Plants and Industrial Operations

Core Platforms

Emerson DeltaV, ABB 800xA, ABB S+ Metso OCS-4D, Yokogawa PACE, Honeywell FORGE, Allen-Bradley RSLogix 500/5000, Siemens TIA Portal, ABB Automation Builder

InduSphere Controls Coding Icon | IEC Paradigms for Process Plant Automation and Control

IEC Paradigms

Function Block Diagram, Ladder Logic, Sequential Flow Diagram, Structured Text, Instruction List, Python

InduSphere Controls Programming Icons | Programming Languages for Process Plant Automation, Control, and Optimization

Programming Languages

Python, VBA, SQL, Batch Scripts, PowerShell, Network Shell

InduSphere Controls Network Icons | Communication Protocols for Processing Plant Automation and Control

Communication Protocols

OPC UA/DA/HDA, Modbus TCP/RTU, Profibus, Ethernet TCP/IP

InduSphere Controls Chart Icons | Advanced Process Control Strategies for optimized industrial operation

Control Strategies

Cascade, Feedforward, Split-Range, Override, Smith Predictor, Kalman Filter, MPC, Fuzzy, IMC, PID

InduSphere Controls OT Icons | Networking and Cybersecurity for reliable plant operation

OT Hardware & Cybersecurity

Managed Switches, Routers, Firewalls, Hosts, Servers, Backup & Failover, Virtualization (Hyper-V, VRTX), VLANs

Featured Projects

ntrols Services - Project 1 | Grinding Circuit APC optimization.

Furnace Temperature Control

Increased stability and improved disturbance rejection due to composition change.

  • Cascade control of temperature to duty to fuel flow
  • Pressure, temperature, and density compensation
  • Mitigated temperature swings due to upsets.

Flotation Supervisory Control

Improved rougher circuit recovery (+1 % Cu, +3 % Au).

  • Multi-tier cascade, MPC, and Fuzzy Control
  • FrothSense velocity feedback
  • Real-time optimization
ntrols Services - Project 2 | Optimizing flotation circuit in mining industy
InduSphere Controls Services - Project 3 | Industrial OT and Cybersecurity upgrades

OT System Upgrade & Virtualization

Managed DeltaV upgrades, virtualized servers and network, reduced hardware footprint by 40 %.

  • Controller & I/O migration to SX/PK
  • VLAN architecture redesign
  • Managed switch and router configuration
  • OT cybersecurity improvements

Technologies & Tools

DCS Platforms

Emerson DeltaV, ABB 800xA, ABB S+

APC Platforms

DeltaV MPC, Yokogawa PACE, Metso OCS-4D, Honeywell FORGE, GEKKO

PLCs

ABB, Rockwell, Siemens, Schneider, IDEC, Beckhoff

Data Analysis and machine learning

Modeling (MLR, RF, DT, ANN), clustering and dimensionality reduction (PCA), and explainability (SHAP, feature importance), Statistical analysis (ANOVA, OLS) and time-series methods (ACF/PACF)

System Identification

Kalman Filter, Non-Parametric (ML, ARX, ARMAX, FIR/Step Response, Laguerre), Parametric (n-th order ODE)

Optimization Techniques

LP, NLP, QP

Data Acquisition, Visualization, and Reporting

dataPARC PARCview, CS LoggerNet, Aveva Data Hub, PI and PI servers, SQL servers and databases (DeltaV, LIMS), and VBA and batch codes for automated reporting.

Communication Protocols

OPC UA/DA/HDA, Modbus TCP/RTU, Profibus, Ethernet TCP/IP

Programming

Python, VBA, SQL

Servers / Virtualization

Hyper-V, VRTX, VMs, VLANs

Diagnostics Tools

ProfiTrace, CommBricks, Fluke

Cybersecurity

User access policies, Network segmentation, Network Address Translation (NAT), VLANs

OS Environments

Windows Server 2016-2019, Windows 10-11, Debian, Ubuntu

Database Systems

SQL Server 2016, ODBC

Control Languages

SFC, FBD, ST, LD, IL

OT Hardware

Controllers, Switches, Routers, IO Cards, Virtual IO Cards, Serial Cards

Industries

  • Mining & Mineral Processing
  • Oil & Gas / Refining / Petrochemicals
  • Pulp & Paper / Water Treatment

Let’s Optimize Your Process

Contact InduSphere Controls’ team for tailored DCS and APC solutions designed for reliability, precision, and measurable results.

Schedule a Consultation