SIMATIC Advanced Process Control

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.

Automate procedures. Standardize execution.

SIMATIC APC Procedure Automation transforms operating procedures and operational knowledge into structured, executable workflows. It empowers your team by turning individual expertise into a shared digital asset, ensuring every operator can perform at their best. Combine operator guidance with automated execution to reduce variability, retain valuable operational knowledge, and move closer toward autonomous operations.

Model
Structure procedures according to the ISA-106 plant hierarchy, from plant areas and units down to equipment and devices. State machines represent current and target operating conditions, while executable procedures define the actions and conditions required to move safely between them.

Guide

Support operators through an intuitive Web UI. Select target states and procedures, monitor plant conditions and active transitions, and approve, pause, or intervene when required. Transparent execution keeps operators informed and in control.

Automate
Automate suitable procedure steps based on defined plant states and process conditions. Verify that the intended state has actually been reached before continuing, enabling consistent and reliable execution of start-ups, shut-downs, load and grade changes, operating-mode transitions, disturbance recovery, and other operating procedures.

Integrate
Apply procedures across different control environments with a DCS-agnostic solution. SIMATIC APC works with different DCSs while enabling particularly efficient integration with Siemens control systems.