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why APC is underutilised in practice
APC AI Digital

Why APC Underperforms - in Practice

Filippo Trivella |

Advanced Process Control is supposed to deliver efficiency, throughput, and stability—so why is so much of it sitting idle?

operator in control room at night with plan views

The APC Paradox

Advanced Process Control (APC) has long been marketed as one of the most powerful levers for improving refinery and petrochemical performance: stabilize operations, push units closer to safe limits, and optimize energy. Yet across the industry, a paradox persists—30–50% of APC controllers are underused or switched off. The result: a large share of the investment in advanced control generates little return.

“Controllers don’t go idle because they fail technically. They go idle because they fail socially.”

Misconceptions About APC Underperformance

When APC underdelivers, the reflex is to blame technical issues:

  • Outdated models

  • Poor tuning

  • Missed constraints

These exist, but they’re rarely the main culprit. In most sites, APC fundamentals are sound. The real breakdown happens after commissioning, once day-to-day ownership shifts to the control room and adoption challenges begin.

The Real Reasons APC Underperforms

  1. Operator trust gaps

    If controller moves feel opaque or “unexpected,” operators override. Trust, once lost, is hard to rebuild.

  2. The “black box” effect

    APC executes optimizations without explaining why. Engineers may follow the logic; frontline operators are left guessing.

  3. Training gaps and turnover

    Staff rotation erodes know-how. New operators inherit systems they don’t fully understand and keep them in manual.

  4. Misaligned incentives

    If optimization and online time aren’t reflected in KPIs and routines, “just keep it running” becomes the default.

“If people don’t understand what APC is doing, they won’t let it do it.”

Consequences of Idle APC

  • Lost throughput: Without stabilization, units run conservatively—leaving margin on the table daily.

  • Higher energy consumption: More variability drives extra steam, fuel, and power; a few percentage points at refinery scale equals millions annually (and avoidable CO₂).

  • Stretched ROI: Projects costing $300k–$1M pay back in 6–18 months if kept online; idle systems push payback indefinitely and erode confidence in digital initiatives.

Lessons from the Control Room

Case: Underutilization

A distillation APC was disabled after moves were deemed “unexpected.” Six months later, it was effectively forgotten—lost throughput, higher energy, zero ROI.

Case: Adoption success

A refinery baked in operator engagement: short daily debriefs explained controller actions in plain language. Result: >95% continuous usage and measurable margin gains.

Takeaway: The difference wasn’t technology—it was communication and trust.

How to Break the Cycle

  1. Make APC transparent

    Show not just what the controller is doing, but why—in plain, operating-language tied to current constraints and objectives.

  2. Institutionalize short, frequent training

    Ten-minute refreshers per shift keep knowledge alive through turnover and build confidence.

  3. Align incentives with usage and outcomes

    Track online time and impact (throughput/energy/quality) so APC performance matters to the team.

  4. Bring context to the math

    Combine APC signals with engineering knowledge and SOPs so recommendations reflect real-world priorities, not just model objectives.

“The future of APC isn’t more algorithms—it’s explainability and trust.”

Why This Matters Now

  • Tighter margins make efficiency gains critical.

  • Sustainability pressure means wasted energy directly undermines CO₂ targets.

  • Generational turnover risks losing decades of operator wisdom unless it’s captured and shared.

In this environment, idle APC isn’t just missed potential—it’s a competitive risk.

The Road Ahead: From APC to Transparent Optimization

Operators don’t resist optimization; they resist optimization they do not understand. Looking ahead, it is essential to create an explainable, conversational layer for APC that:

- Explains optimization decisions in clear, operator-focused language

- Connects every recommendation directly to operational constraints and established procedures

- Preserves and shares operating knowledge for new team members

- Enables operators to see not just what the controller is doing, but the rationale behind every action

“The value of APC isn’t in being installed—it’s in being used.”

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