APCperformX
APCperformX is an advanced process control performance monitoring solution designed to continuously evaluate the health and effectiveness of APC and DMC systems. It provides engineering and operations teams with clear visibility into controller performance, constraint utilization, variable behavior, and factors limiting the value delivered by existing APC applications.
By continuously monitoring control performance and identifying degradation, APCperformX helps teams uncover underperforming controllers, evaluate operating constraints, and identify opportunities to recover and sustain APC benefits over time.
Salient Features
Client Benefits
Maximize Existing APC Investment
Continuously evaluate APC performance to help plants sustain and recover value from existing control applications without immediately investing in new control infrastructure.
Improve Controller Performance
Identify degraded or underperforming controllers and highlight factors preventing APC applications from operating effectively.
Increase Constraint Visibility
Understand which operating constraints and variables are limiting controller performance and optimization opportunities.
Support Higher Throughput & Stable Operations
Improve visibility into APC performance to support more consistent control, effective constraint management, and improved plant operation.
Dashboard & Snapshots
![Solution configuration [Defining the Objective: Maximize Production, Minimize Utility]:](https://ingenerox.ai/wp-content/uploads/2025/05/Picture3-3.png)
![Solution configuration [Defining cases of interest – Multiple cases can also be added]:](https://ingenerox.ai/wp-content/uploads/2025/05/Picture4-3.png)
Case Studies
Development of Soft Sensor to predict the C5 contents in Debutaniser column Overhead:
Background
In modern petrochemical operations, maintaining product specifications within tight limits is critical for both quality assurance and process efficiency. One of the key challenges faced by a leading chemical plant was the need for real-time prediction and monitoring of C5 content in the overhead stream of the debutanizer column — a crucial step to ensure product specification compliance and optimize operations.
Challenge
Traditional laboratory testing methods for measuring C5 content introduced significant time delays, making real-time adjustments difficult. The plant required a fast, accurate, and reliable solution to continuously monitor C5 levels, allowing operators to take timely corrective actions and avoid off-spec products.
Solution with AnalyticX
Using AnalyticX, the engineering team was able to develop a soft sensor — a machine learning-based predictive model — specifically designed to estimate the C5 content in the debutanizer overhead stream in real time.
Key steps included:
- Seamless ingestion of historical operational data into AnalyticX without any coding requirements.
- Applying statistical analysis to identify key process variables influencing C5 concentrations.
- Rapid development and training of a machine learning model tailored to predict C5 content with high accuracy.
- Deployment of the predictive model into live operations for real-time product spec monitoring.
Results
- Enhanced Product Monitoring:
Operators now have a real-time view of the predicted C5 content, significantly reducing reliance on delayed lab measurements. - Improved Process Control:
By closely tracking C5 levels, the plant was able to make timely adjustments to operational parameters, ensuring consistent product quality. - Reduced Off-Spec Production:
Real-time insights helped minimize off-spec batches, leading to material savings and reduced reprocessing costs.
Key Takeaways
- AnalyticX enabled the rapid development of a soft sensor customized for critical KPI monitoring.
