Instrument Calibration & PID Loop Tuning

Accurate instruments and well-tuned loops are the difference between a process that runs smoothly and one that constantly needs attention. Complete Controls Services, LLC (CCS) provides on-site instrument calibration and PID loop tuning for transmitters, analyzers, control valves and the control systems they serve. Calibration services can be scheduled quarterly, biannually or annually, along with start-up calibration on new instruments. CCS is based in Blair, Nebraska, emphasizes the Midwest and serves customers throughout the United States.

Our Calibration Services

On-Site Instrument Calibration

We calibrate instruments where they are installed, checking and adjusting pressure, level, flow, temperature and analytical measurements so your control system is working from accurate data.

Scheduled Calibration Programs

Calibration can be scheduled quarterly, biannually or annually, depending on your equipment, process and requirements. A regular schedule helps catch drift before it affects operations.

Start-Up Calibration

We calibrate instruments during startup of new or modified systems so the process starts on accurate measurements.

Your Equipment or Ours

CCS can perform calibrations with our own certified equipment or using customer provided equipment. Offering this service allows us to provide complete turn-key services on projects.

Calibration with Combustion Tuning

For burner applications, calibrations are recommended to be performed in conjunction with efficiency tuning. Accurate O2, pressure and flow measurements keep a tuned burner performing as intended. See combustion tuning.

Our Loop Tuning Services

PID Loop Tuning

Poorly tuned loops oscillate, respond slowly or fight each other. We tune PID loops for pressure, level, flow, temperature and combustion control so they respond quickly and settle smoothly.

Control Valve and Final Element Checks

A loop can't be tuned around a sticking valve or a worn actuator. We check control valves, positioners and actuators as part of loop tuning and recommend repairs when needed.

Documentation

We record what we found and what we adjusted, so you have a record of as-found and as-left conditions and tuning changes.

Instruments and Systems

• Pressure, differential pressure and level transmitters

• Flow and temperature instruments

• Combustion and flue gas analyzers

• Control valves, positioners and actuators

• Loops on Allen Bradley (Rockwell Automation), Siemens, Schneider, Fanuc, Keyence, Pro-face, C-more and other PLC, DCS and SCADA systems

Applications

Boilers, burners, deaerators, HRSGs, heaters, dryers, cooling towers, chillers, pump and process skids, air and steam systems, and water treatment systems.

Why Calibration and Tuning Go Together

Calibration alone can't fix a poorly tuned loop, and tuning alone can't fix an inaccurate instrument. When transmitters read correctly and loops respond correctly, the result is steadier pressure, level, temperature and flow, fewer alarms and less operator intervention. That's why we approach calibration and loop tuning as one service, and why we check the final elements, such as valves and actuators, along the way.

Why Choose CCS for Calibration and Loop Tuning

• Turn-key service. Calibration, loop tuning, instrumentation, programming and combustion tuning from one company.

• Flexible calibration equipment: ours or yours.

• Controls expertise to fix the logic and loop issues calibration alone can't solve.

• Technician-founded in 2017.

• Midwest-based, nationwide service from Blair, NE.

Related CCS Services

• Instrumentation: Installation, repair, configuration and troubleshooting of process and boiler instruments.

• Combustion Tuning: Analyzer-based burner tuning for efficiency and performance on boilers, dryers, HRSGs and heaters.

• DCS Integration: Distributed control system design, configuration and migration, small to large.

• Field Service: On-site troubleshooting, commissioning and startup support.

• Emissions Tuning: NOx and CO focused burner tuning and combustion testing with documented before-and-after readings.

Calibration & Loop Tuning FAQ

How often should instruments be calibrated?

Common schedules are quarterly, biannually or annually. The right interval depends on the instrument, process and any requirements you must meet.

Do you calibrate on-site?

Yes. We perform calibration at your facility, using our own certified equipment or customer provided equipment.

Why tune loops after calibration?

Calibration makes sure measurements are accurate; loop tuning makes sure the control system responds correctly to those measurements. Together they improve stability.

Should calibration be paired with burner tuning?

Yes. For burner applications, we recommend calibration in conjunction with efficiency tuning.

Schedule Calibration or Loop Tuning

Call Complete Controls Services at (833) CCS-AUTOMATION ((833) 227-2886), Monday–Friday, 7:30 AM–4:30 PM, or reach us through our contact page.