Basic Process Control Systems

Basic Process Control System (BPCS) is a system which handles process control and monitoring for a facility or piece of equipment. It takes inputs from sensors and process instrumentations to provide an output based on an approved design control strategy. The Basic Process Control System (BPCS) is responsible for the proper operation of the plant, and in many instances is used in the first layer of protection against unsafe conditions. A simple example of a basic process control loop is shown in the system shown below. A level transmitter (LT), a level controller (LC), and a control valve (LV) are used to control the liquid level in a process tank.

Basic Process Control System DiagramBasic Process Control Systems are designed to meet a wide range of industrial challenges related to system operation and monitoring. BPCS solutions offered by STI Automation include:

  • Process Control- The development of architectures, mechanisms, and algorithms to maintain a specific process within the desired range. Enables complex processes to be operated from a central location by the use of automation.
  • Operator Interface & Monitoring- Provides a central system interface for monitoring of process data and equipment operation via an operator console or HMI.
  • Real-Time & Historical Data- Provide operational information based real-time process data that is displayed locally for the operator

These systems can be designed for particular performance and economic improvement opportunities such as:

  • Reduced Variability- Improving system operation to produce a more consistent and quality product.
  • Increased Efficiency- Improving system efficiency can lower operational cost and increase production.
  • Improved Safety- Provide the first layer of protection against an unsafe condition to equipment and personnel by keeping a process or piece of equipment within a pre-set operating condition.
  • Improved Troubleshooting and System Diagnostics- Real-time alarm and event logging to shorten downtime due to troubleshooting and diagnostic activities.

Typical Applications:

  • Temperature Control Loops
  • Flow Control Loops
  • Level Control Loops
  • Pressure Control Loops
  • Multi-Variable & Advanced Control Loops
  • Feedforward Control
  • Feedback Controls
  • Cascade Control
  • Batch Control
  • Ratio Control
  • Selective Control


  • Chemical
  • Oil & Gas
  • Food & Beverage
  • Pharmaceutical
  • Water & Waste Water
  • Power

Products & Services

  • Electrical Engineering & Design
  • CAD Drawings & Supporting Documentation
  • Programming & Configuration
  • Fabrication & Functional Testing
  • Field Implementation & Commissioning
  • Replacement of Legacy Controls and Equipment
  • System Integration

Process Optimization & Efficiency Upgrades

  • Selection/design of suitable control, operating and monitoring instruments
  • Selection of suitable controllers and control algorithms
  • Optimization of the mode of operation by process simulation