APC Revamp | Revoluen Technology

Targeting Opportunity, Delivering Value

Targeted For Plants Facing Challenges Likes...

A well-executed APC revamp typically delivers..

A well-executed APC revamp typically delivers..

Have APC commissioned more than 3–5 years ago
Experience frequent controller drop-outs or low utilization
Have changed feeds, equipment, or operating strategy
Are targeting higher throughput or tighter energy KPIs
Want to restore ROI on existing APC investments

Start your apc audit

A well-executed APC revamp typically delivers..

A well-executed APC revamp typically delivers..

A well-executed APC revamp typically delivers..

Higher throughput and improved margins
Lower energy consumption and emissions
Better catalyst and equipment health
Reduced controller downtime
More stable unit operations across varying feeds
Stronger operator trust and adoption

Our Delivery Approach

Performance Audit

Model Re-identification

Strategy Re-alignment

A structured review of the existing controller and its impact on plant KPIs:

Constraint management
MV movement and smoothness
Model quality checks
Controller utilization pattern
Change since commissioning (process changes, instrumentation drift, new bottlenecks)

Strategy Re-alignment

Model Re-identification

Strategy Re-alignment

Controllers are updated to reflect:

New optimization targets (throughput, energy, yields)
What has changed in the unit (equipment revamps, instrumentation, constraints)
Revised limits and prioritization
Updated push strategies and optimization handles

Model Re-identification

Model Re-identification

APC Rebuild - Tuning & Validation

Renewed and high-quality process models using:

Updated step-testing strategy tailored to current operating modes
Model recalibration with closed loop steps OR Fresh plant tests when necessary
Robust data selection and noise filtering

APC Rebuild - Tuning & Validation

APC Rebuild - Tuning & Validation

APC Rebuild - Tuning & Validation

A complete rebuild of the APC application where needed:

MV/CV reconfiguration
Constraint handling logic updates
MV tuning improvements
CV closed-loop validation
Full commissioning with operations alignment

Training & Operator Alignment

APC Rebuild - Tuning & Validation

Training & Operator Alignment

Successful revamps require adoption. We provide:

Shift-wise operator training
Updated SOPs and “controller handling cheat-sheets”
Acceptability criteria and on-shift support
Post-upgrade performance check