SIMATIC Advanced Process Control

Minimizing fluctuations – for optimal performance

PID controllers aim to maintain processes at defined set-points. However, external disturbances can cause fluctuations, preventing controllers from consistently keeping the process at the set-point, which is essential for stable operation. Our SIMATIC APC optimizes PID controller parameters to minimize these fluctuations and achieve optimal performance.

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Ensuring superior process stability and efficiency

Traditional PID tuning often falls short in stabilizing complex processes, especially when multiple PID loops interact and disturb each other. Model Predictive Control (MPC) addresses this issue by identifying models that link manipulated variables to controlled variables. MPC optimizes process operations to achieve consistent production and cost -effective performance. The benefits comprise, e. g., minimum transition times, reduced fluctuations, optimal flexible operation. I. e. MPC combines control and optimization. It can adjust set-points or replace PID controllers entirely, ensuring superior process stability and efficiency. Linear MPC (LMPC) uses linear models derived from plant data.

We offer LMPC technologies embedded in process control systems like SIMATIC PCS7, particularly suited for applications with high availability requirements, as well as control system-agnostic solutions that interface with any control system via standard interfaces.

Increasing resilience to change and optimizing responsiveness

While LMPC is well suited for controlling processes that need to remain stable around an operating point, it often falls short when the process is operated in a wider range of operating conditions, when the process admits highly nonlinear behaviour, or in case of processes with larger operational variability. This holds for batch processes, in particular. Even in some cases where LMPC is effective, it can fail to deliver the maximum benefits. In these cases, Nonlinear Model Predictive Control (NMPC) can be used. We offer technologies for NMPC to ensure that process control remains optimized over a wide operating range. This makes processes more resilient to change, optimizes responsiveness and makes processes more autonomous by taking responsibility for complex transitions which would typically require experienced operators. Our APC suite comprises NMPC technologies based on physics-based models and data-driven models.

Meeting production requirements at the lowest possible cost

PID loops and Model Predictive Controls work to keep a process steady at the specified set-points – but who decides what those set-points should be? Often, these come from operators using their experience or making trial-and-error changes, and this requires deep process expertise and can be time consuming. With process conditions constantly changing, SIMATIC APC uses Real-Time Optimization to detect steady operation, provide reconciled estimates of current plant operation and performance KPIs and determine the optimal set-points for the control system to meet production requirements at the lowest possible cost.

Maintaining operation with minimal human intervention

In the ever-evolving industrial landscape, maintaining efficient and reliable plant operations is paramount. SIMATIC APC is here to transform the way you manage your processes, ensuring safety, reliability, and efficiency with minimal human intervention. Embrace the future of plant operations with our APC suite procedural automation.

Availability

Benefit from high availability and optimal performance by combining advanced state-based control with sequence-based control. SIMATIC APC offers a procedural automation system that enhances plant operations up to autonomy with closed-loop AI, taking care of complex procedures such as plant start-up, shut-down, major transitions, and failure state recovery.

Reliability

Turn optimized process operations into efficient performance – with cost-effective and adaptable outcomes. Leverage the enhanced safety provided by procedural automation and model predictive control to minimize human error and ensure the safe execution of complex procedures. Reliable operations achieve consistent and reproducible results, reducing unplanned events.

Stability

Apply best practices in managing plant states and transitions by adhering to proven ISA-106 and ISA-88 standards. With dynamic alarm management and automation, your facility stays in automatic mode for startup, shutdown, and abnormal situations, maintaining operational boundaries and avoiding alarms and trips. When a trip occurs, the units coordinate their response to minimize operator interventions.