Advanced process control (APC) software refers to a set of control strategies and algorithms used to help operate industrial processes more efficiently and optimize performance. APC software goes beyond basic control functions to leverage adaptive modeling, data analytics and machine learning for advanced automation and optimization capabilities.

APC software employs advanced control strategies like model predictive control (MPC), which uses process models and optimization techniques to calculate and implement optimal control moves that satisfy operating constraints. Other advanced strategies used include multivariable model predictive control (MVPC), which coordinates control of multiple process variables simultaneously.

Benefits of APC Software

APC software provides several key benefits to industrial processes:

Increased Capacity and Throughput

By more precisely controlling process variables like temperature, pressure and flow rates, APC software allows plants to operate closer to maximum capacity safely. This increases throughput while maintaining quality standards. For example, an oil refinery used APC to boost capacity by 4% without additional capital spending.

Improved Product Quality

Precise control of critical process variables helps maintain consistent, high-quality products. APC software can quickly detect and correct deviations to keep operations within tight specifications. This reduces rejects, reworks and off-spec product costs. One chemical plant reduced out-of-spec production by 30% using APC strategies.

Reduced Operational Costs

By optimizing operations, Advanced Process Control Software usage can cut energy, raw material and utility costs considerably. For instance, a power plant saved over $3 million annually in fuel costs after installing APC solutions to optimize boiler performance. Many plants see 5-15% reductions in variable costs like fuel and power.

Improved Stability and Safety

Advanced control strategies ensure smooth, stable operation even during upsets, disturbances or changing demand. This mitigates risks of process excursions, safety issues and unplanned shutdowns. APC stabilizes processes and allows safer operation nearer constraints than previously possible.

Predictive Maintenance Capabilities

APC software integrated with Industrial Internet of Things (IIoT) technologies can monitor equipment performance and predict potential failures. This enables condition-based and predictive maintenance strategies for improved asset reliability and uptime. Downtime costs are reduced considerably through such predictive maintenance.

How APC Software Works

Most modern APC solutions follow a modular architecture to handle different control tasks:

Modeling Module

This module develops first-principle or data-driven process models used by control strategies. Models simulate plant behavior under changing conditions. Models are regularly updated online using plant data.

Optimization Module

This module solves optimization problems formulated by model predictive control and other optimization-based advanced control strategies. It calculates optimal manipulated variable moves subject to operating constraints.

Control Module

This module implements optimal control moves sent by the optimization module on plant equipment like valves, pumps and heat exchangers via interfaces to distributed control systems (DCS). It also closes control loops.

Data Historian

Plant measurements and APC-related data like models, optimization information are recorded in a relational or non-relational database. This provides information for performance monitoring, maintenance strategies and continuous improvement.

User Interface

Engineers interact with the APC solution through interfaces to configure strategies, develop/edit models, visualize control performance, track key performance indicators and troubleshoot issues. Modern interfaces are role-based, web-based and mobile-enabled.

Implementing APC Projects

Successful APC projects require proper planning, preparation and change management:

Evaluate Processes and Opportunities

Audit current controls to ascertain processes suitable for APC and potential benefits. Develop business case factoring expected performance boosts and return on investment.

Develop Control Strategies and Algorithms

Detailed engineering work develops advanced control strategies matched to processes. Suitable modeling techniques are selected and algorithms coded. Simulations validate performance.

Integrate with DCS and Field Equipment

APC software is integrated with plant DCS/SCADA and field devices via standard interfaces. Projects address telemetry, networking and IT infrastructure requirements.

Train Operators and Engineers

Personnel are comprehensively trained on new APC system features, operation and troubleshooting. Their feedback aids continuous improvement.

Commission and Tune Strategies Online

Gradually transition control from existing to APC strategies through commissioning trials. Strategies are tuned using plant data for optimal integrated operation.

Monitor Performance Metrics

Benchmarks are set for key performance indicators. APC benefits are regularly tracked through performance reviews against targets for continuous enhancement.
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