How to Keep Advanced Process Controls (APCs) Operational Longer than 24?Months, 2021 TAPPICon Live (21TAPL)

The Process Controls Committee of TAPPI, in its role to help guide the industry towards the use of operational data and information to achieve better overall productivity and quality of products, is undertaking a study to address the fact that currently over 50% of all Advanced Process Control systems (APCs) get turned off within 24‐months. The goal of this paper will be to explore the background on this prevalent issue throughout industry, document source references on the magnitude of the issue and offer frank assessments on how to prevent APCs from getting turned off in the first place. In most instances, these APCs are multi‐million‐dollar investments with key EBITDA drivers of chemical, labor and / or energy savings in a facility. Initially, these APC projects are well received in that they offer sizable Cost Reduction opportunities for the facility. Normally, start‐ups go well, and early indications are that the projects are considered a success. However, there are tell‐tale signs that most APC projects display, which are often ignored, but can alert management that the APC project(s) are in danger months before they are turned off. This paper will explore what those tell‐tale signs are and what steps can be taken to address those issues to essentially keep the APCs running well and successfully delivering on the original benefits for years into the future. 

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