Continuous PID/APC/MPC monitoring
Tracks every PID loop, advanced process controller, and model predictive controller in the plant around the clock.
APROMON is online process control (PID/APC/MPC) and machine-condition quality and performance monitoring and diagnostics software from PiControl Solutions. Built on an AI-based algorithm, APROMON continuously monitors every PID control loop, advanced process controller (APC), and model predictive controller (MPC) in a plant, along with the control valves and measuring sensors those loops depend on, running automatically once connected to a DCS, PLC, or historian over OPC. See the full process control software range for how APROMON fits alongside PiControl's tuning and simulation products.
No engineer can manually review hundreds of PID loops every day. Loops degrade gradually — through equipment aging, feedstock changes, and process drift — until oscillation or poor control quality is quietly costing yield, energy, or throughput long before anyone notices on a trend screen. APROMON replaces manual loop review with a standing 0-100 grade on every loop, so engineers see which of hundreds of loops need attention today, and can send the worst of them to PID tuning consulting instead of guessing.
APROMON monitors PID control loops, advanced process controllers, and model predictive controllers continuously, so plants know which loops are degrading long before a scheduled loop audit would catch it. It connects to any DCS or PLC over OPC-DA or OPC-UA, requires no proprietary hardware, and scales from 10 to 5,000 monitored loops.
Tracks every PID loop, advanced process controller, and model predictive controller in the plant around the clock.
Scores each loop against 25+ control-quality and statistical criteria.
Flags oscillating loops early using spectral frequency distribution analysis.
Identifies sticking, degraded, or poorly sized valves before they cause chronic oscillation.
Surfaces noisy, drifting, or failing instrumentation feeding the loop.
Configurable real-time alerts plus daily engineer and management email reports.
Control room operators and process engineers use APROMON to see which of hundreds of loops need attention today, instead of checking trends one screen at a time. Daily gradeboard reports and real-time alerts turn loop review from a manual, best-effort task into a standing, automated one — and the worst loops can be routed straight to PiControl's PID tuning consulting team for a fix.
Maintenance teams use APROMON's control valve and measuring-sensor diagnostics to separate mechanical problems from tuning problems, turning reactive troubleshooting into a proactive work-order list. Plant managers use the plant-wide grade summary and management email reports to track control performance the same way they track other KPIs.
For the software plants use to fix the loops APROMON flags, see the full process control software range.
APROMON's feature set is built for one outcome: engineers who know exactly which loops are losing money, before a scheduled audit would ever find them.
Computes a 0-100 grade from more than 25 control-quality and statistical criteria for every PID loop, APC, and MPC.
Turns hundreds of loops into a ranked list, so engineers spend time on the loops that are actually losing money.
A spectral frequency distribution chart isolates oscillating loops and points toward their root cause.
Chronic oscillation is one of the most common — and most overlooked — sources of lost throughput and off-spec product.
Detects valve stiction, deadband, and other final-control-element problems from routine operating data.
Valve problems are a leading cause of loop oscillation; catching them early avoids re-tuning an otherwise healthy loop.
Flags noisy, drifting, or failing sensors feeding the control loop.
A bad measurement makes any tuning look bad; APROMON separates instrumentation problems from tuning problems.
Configurable real-time alerts plus daily reports ranking the worst-performing loops in the plant.
Problems get caught the day they start, not weeks later during the next scheduled loop audit.
Connects to any DCS, PLC, or historian via OPC-DA/OPC-UA in about half a day, with a 70-80-page manual.
Plants get their first gradeboard the next day, without a multi-week installation project.
In a plant running hundreds or thousands of PID loops, no engineer can review every loop every day. Loops don't fail all at once — they degrade gradually, as equipment ages, feedstock changes, and process conditions drift, until a loop that was tuned correctly years ago is quietly oscillating, fighting a stuck valve, or being fed by a failing sensor. PID controllers make up more than 95% of the control loops in most plants, so a monitoring gap here touches nearly every loop the plant runs.
Most plants that don't run continuous monitoring conduct a loop tuning survey once every one to three years. Between surveys, individual loops can quietly degrade for months, sometimes years, unnoticed.
DCS and PLC alarms trigger on process deviation, not on loop performance. A poorly tuned or oscillating loop can run for months without ever tripping a hard alarm.
Spreadsheet-based loop checks that work for 20 loops break down at 200 or 2,000. No engineering team can eyeball every trend, every day, across the whole plant.
APROMON removes the structural problem: continuous automated grading, oscillation and valve diagnostics, and alerting and reporting that surface degrading loops the day they start drifting, not at the next scheduled audit. For plants that want loops fixed, not just diagnosed, PiControl's PID tuning consulting team re-tunes the loops APROMON flags.
APROMON is the diagnostic layer of PiControl's process control software suite: it finds the loops that need work, and the products below fix them.
When APROMON flags a degrading loop, engineers use PITOPS for closed-loop system identification and PID/APC tuning to re-tune it correctly the first time, instead of guessing at new gains.
For loops APROMON shows drifting repeatedly under changing conditions, SUPERTUNE online PID auto-tuning runs fully automatic, auto-adaptive re-tuning inside the DCS or PLC.
When a flagged loop needs deeper investigation, PiLogger high-speed data logging captures PV, setpoint, and controller-output trends at sub-second resolution for root-cause analysis of the oscillation APROMON detected.
Plants across every sector PiControl serves run APROMON to catch degrading loops early — each industry runs different processes, but the same oscillation, valve, and sensor problems erode performance everywhere.
APROMON is part of the software suite behind PiControl's track record: 10,000+ PID loops tuned and 50+ MPCs re-stabilized across 200+ industrial facilities since 2005, on-site and remote, worldwide. Plants running APROMON typically see payback within a few weeks to a year, and recurring annual savings in the $200K-$2 million range from loops caught and fixed before they cost yield or throughput. Read more in our customer success stories.
Request the APROMON installer, brochure, and licensing details for your plant.
See APROMON grade a live set of loops in real time and watch it flag an oscillating loop or a sticking valve. A PiControl engineer will demonstrate the gradeboard, diagnostics, and alerting against data relevant to your plant, and scope a deployment for your DCS or PLC.