Metso Automation Services

Transcription

1 Metso Automation Services

2 At your service This booklet is designed to give you an overview of Metso s modular automation service portfolio. Ranging from managed to individual technical services, our portfolio is designed to deliver the solutions that make the biggest difference to your production and business profitability as a whole. We ensure your business objectives are met by: Offering our personal commitment to resolving customer issues Using intelligent tools that focus activity on the areas where the optimal business return can be obtained Providing highly skilled service teams that follow Metso standards worldwide to guarantee high-quality results Thank you for your custom. The Metso Automation Services team

3 Contents Introduction Managed services Business solutions Automation services Case studies Our presence

4 Our service team Committed to safety: Our goal is zero accidents. Closer to you: Our service technicians and engineers are located wherever they are needed to best support your business needs. Excellence: Global competence management ensures our service experts have world-class skills and follow a common methodology wherever they are in the world. A global network: Your personal Metso team is supported by a global network of service centers and experts. Personal commitment: Our world-class service is provided by individuals who are passionately dedicated to their customers and their needs.

5 Metso service agreements Agreed service levels: Clearly defined performance targets and responsibilities. Transparent pricing: Clear visibility and control of service costs over the service agreement period. Close working relationships: The closer we work together, the more effectively we can fulfill your objectives. Increased service scope: Service agreements allow a broader range of services to be offered to you locally.

6 Metso Automation Services portfolio Managed services Take responsibility for business areas Business solutions Improve business performance Automation services Solve technical and process issues

7 Metso Automation Services Managed services

8 Improving operations and cutting costs Full responsibility: Metso takes full responsibility for a defined business area for example, device management or for maintenance of all QCS on site. Shared objectives: Your business objectives in terms of key performance indicators are our goals. Our charges are linked to how we perform against these objectives. Managed services Business solutions and services Tailored: We build managed services to meet your exact business needs using business solutions and services as building blocks.

9 Metso Automation Services Business solutions

10 Helping you meet your goals Customized: Tailored to meet your individual needs. Intelligent: Focused effort when and where needed delivers superior results and value for money. Business solutions Customer requirements Lifecycle: Maximizes your return throughout the lifecycle. Plant availability Process performance Risk control Broad scope: From field devices to process controls and plant management systems. Proven: Built around tried and tested Metso products and services. Services and products

11 Business solutions Plant availability Maximize production and minimize costs Process performance Improve performance using less resources Risk control Achieve results by reducing risks Customer care Intelligent maintenance Intelligent shutdown Device management Performance monitoring Process optimization Control performance Lifecycle management Safety and security Environment Competence Lifecycle management

12 Plant availability Customer care Value proposition: When you need to restore production, Metso is on call to help minimize disruption to your business. Solution: We tailor a support package that will help you meet your system availability targets The response times can be chosen to meet your operational requirements and budget We offer a remote support option which allows remote diagnosis of issues and, where possible, remote resolution We provide a network of highly experienced product and process experts We provide highly skilled local engineers and technicians to implement solutions Customer care Installed base audit On-call service Remote connection Response time for emergency service visit Service visit Repairs Spare parts

13 Plant availability Intelligent maintenance Value proposition: Higher system availability and significantly reduced maintenance costs can be delivered by concentrating maintenance resources to where they are needed most. Solution: We analyze your system and identify the criticality of each element We develop a maintenance plan based on criticality We carry out condition analysis wherever possible to determine wear and the need for maintenance actions Where condition analysis is not possible, we carry out preventive maintenance We carry out high-quality repairs and refurbishments to return equipment to peak condition Where it is more efficient for service delivery, we put resident engineers on site Intelligent maintenance Intelligent planning and execution Installed base audit Criticality analysis Maintenance plan Condition analysis Preventive maintenance Repairs Modernization and upgrades

14 Plant availability Intelligent shutdown Value proposition: We offer a single shutdown package designed to minimize shutdown time and costs by targeting maintenance only to devices which require it. Solution: We analyze your devices in advance and identify any maintenance that can be done outside the shutdown We carry out condition analysis to identify devices showing signs of wear or failure We develop a maintenance plan identifying the devices not requiring maintenance, those that require maintenance without removal and those that need to be removed We order any spare parts that are definitely required We provide a service container storing spare parts and tools that may be required We ensure in advance you have the right information, the correct number of people and the right skill sets to implement the identified repairs Intelligent shutdown Intelligent planning and shutdown Installed base audit Pre-screen shutdown list Condition analysis Repairs Service container Startup supervision

15 Plant availability Device management Value proposition: Optimizes your spare parts inventory to reduce costs while ensuring critical spare parts are available to quickly get your process fully operational following a failure. Solution: We work together with you to identify your spare parts requirements We analyze your plant and build a stocking strategy based on products, budget and availability targets We remove obsolete or unnecessary stock from the inventory We transfer stock to Metso premises (if required) and disassemble spare parts into their components We train your staff on the new spare parts process We provide day-to-day inventory management according to the stocking strategy providing spare parts and restocking as needed Device management Criticality analysis Installed base audit Inventory audit Lifecycle plan Stocking strategy Inventory setup Inventory management

16 Plant availability Lifecycle management Value proposition: We minimize the total cost of ownership for your plant while maximizing production efficiency. By managing the upgrade of hardware and software, we maximize the life of equipment, minimize maintenance costs, and improve the accuracy of process controls. Solution: We work with you to understand your production and investment objectives We develop with you a lifecycle plan We upgrade hardware and/or software to prevent reliability from falling and/or maintenance costs from rising We integrate maintenance and upgrades to minimize total cost of ownership We propose hardware and software upgrades when performance improvements would enhance production and result in a short investment payback time Lifecycle management Installed base audit Lifecycle plan Modernization and upgrades

17 Process performance Performance monitoring Value proposition: The solution allows plant personnel to optimize production by identifying areas where process performance can be improved. The solution compares process performance against historical data, expected performance and, where available, the performance of similar processes. Solution: We carry out a performance audit of your processes and provide the results and proposed corrective actions We monitor process performance to provide early warnings of process issues and to identify production bottlenecks We provide a monitoring and reporting solution to manage plant production and emissions Performance monitoring Management and results reporting Operations monitoring Process monitoring Controls monitoring Machine and device monitoring

18 Process performance Process optimization Value proposition: Minimizes the resources required to deliver a target production yield and quality by optimizing complete production processes. Production gains are sustained in the long term by continually monitoring and optimizing processes. Solution: We continuously monitor your processes to detect production variability We provide recommendations on how to increase production efficiency by reducing production variability and running the process closer to its optimum operating point We sustain and improve performance over time so that you continue to maintain production efficiency as your production and processes change Process optimization Pulp optimization Paper optimization Power optimization

19 Process performance Pulp process optimization Services for pulp producers A set of optimization services to reduce costs, improve yield, enhance quality and reduce environmental impact. Debottlenecking Continuous/batch cooking optimization Brown stock washing optimization Bleaching optimization Evaporator optimization Recovery boiler optimization Sootblowing optimization Causticizing optimization Lime kiln optimization

20 Process performance Paper process optimization Services for paper producers A set of optimization services to reduce costs, improve yield, enhance quality and reduce environmental impact. Debottlenecking Mill-wide brightness optimization Recycled fiber optimization Mechanical fiber optimization Stock preparation optimization Paper and tissue machine optimization

21 Process performance Power process optimization Services for power producers A set of optimization services to reduce costs, improve power production and reduce environmental impact. Combustion optimization Steam network optimization District heating network optimization Energy management solutions

22 Process performance Control performance Value proposition: Minimizes the required production resources and increases production stability by identifying incorrectly functioning controls, finding the root causes and recommending corrective action. Solution: We monitor your controls for sub-optimal performance and emerging device issues (for example, sticking valves) We tune control loop parameters to optimize control performance We provide maintenance recommendations to improve performance, and implement these actions together with the customer where applicable We sustain performance improvements over time Control performance Management and results reporting Root cause analysis Instrument and valve analysis Manage corrective actions Performance improvement Control strategy consulting

23 Process performance Lifecycle management Value proposition: We minimize the total cost of ownership for your plant while maximizing production efficiency. By managing the upgrade of hardware and software, we maximize the life of equipment, minimize maintenance costs and improve the accuracy of process controls. Solution: We work with you to understand your production and investment objectives We develop with you a lifecycle plan We propose hardware and software upgrades when performance improvements would enhance production and result in a short investment payback time We upgrade hardware and/or software to prevent reliability from falling and/or maintenance costs from rising We integrate maintenance and upgrades to minimize total cost of ownership Lifecycle management Installed base audit Lifecycle plan Modernization and upgrades

24 Risk control Safety and security Value proposition: Helps create a safer and more secure working and production environment, ensures that the plant complies with health and safety regulations, and protects key systems and data from malicious attack. Solution: We support you during the periodic inspection of the safety-related system by helping with test arrangements and preparing necessary documentation We work with you to understand your security requirements and what they mean for your automation systems Our security audit identifies any automation system information security issues We manage your network security to secure against external threats to the production control systems We manage your Metso DNA system security to protect production control systems against attack Safety and security Safety instrumented system (HIMA) audit Security audit Safety followup service

25 Risk control Environment Value proposition: Ensures environmental regulatory compliance to reduce the risk of enforcement action. Ensures that systems are in place to minimize the environmental impact of the production process. Solution: We ensure you have the necessary environmental monitoring systems in place We monitor the environmental impact of production processes (for example, leaks, emissions, water pollution) We identify sources of environmental pollution and identify corrective actions We provide other business solutions that optimize devices, controls and processes in order to deliver the agreed environmental target Environment Environmental monitoring system audit Environmental upgrade Environmental monitoring

26 Risk control Competence Value proposition: Ensures that your team always has the correct skills and know-how to operate and maintain Metso equipment and processes so that production efficiency is maximized and business risks are minimized. Solution: We regularly audit how you use your installed systems to pinpoint areas where you could get more value We work with you to identify skills and competence gaps in your organization which would help you extract more value We build with you a skills development plan specifying the required training We deliver the identified training either using predefined courses or by building a customized course to meet your exact needs Competence Management and results reporting Competence review Development planning Standard training Customized training

27 Metso Automation Services Automation services

28 Automation services Service Bleaching optimization Brown stock washing optimization Causticizing optimization Combustion optimization Competence review Condition analysis Continuous/batch cooking optimization Control strategy consulting Controls monitoring Criticality analysis Customized training Description Reduces final pulp brightness variability and ensures the efficient use of bleaching chemicals. Maintains the desired weak black liquor solids and minimizes chemical losses in the process. Increases quality and strength of white liquor, enhances lime mud solids to the lime kiln and reduces process plugging by overliming. Stabilizes and optimizes the combustion process to minimize flue gas emissions (for example, SO 2, NOx) and to improve combustion efficiency in fluidized bed boilers. We evaluate in conjunction with you and each individual team member their competences. We monitor the process and/or process devices to extract performance data. A number of monitoring options are available from visual inspection to automated data collection tools depending upon the capabilities of the equipment being monitored. Reduces kappa variability and optimizes the sub-process. We propose new or upgraded controls to improve process performance. We provide a control loop monitoring system along with its support and maintenance. We classify devices and equipment into different criticality categories depending on their process importance. We work with you to define a customized training package and then deliver the training.

29 Automation services Service Debottlenecking Development planning District heating network optimization Energy management solutions Environmental monitoring Environmental monitoring system audit Environmental upgrade Evaporator optimization Fuel power compensator Description Identifies process bottlenecks which have a cascading impact on the next process, and sometimes on the whole unit. Identifying and solving these bottlenecks defines the operational economics of the whole mill. We identify competence gaps and build development plans identifying training to take your team members to the required competence level. Enables accurate control of district heating water temperature, network pressures and pressure differentials to minimize heat losses and pumping losses while ensuring heat availability to all customers. Optimize production plans, fuel contracts and outage schedules and enable informed trading in electricity exchange. We monitor the environment for pollution from a plant/process and report the results. An audit of the environmental control systems makes sure that the necessary elements of environmental monitoring (for example, water, air emissions and soil monitoring) are in place. We implement upgrades to ensure that the necessary elements of environmental monitoring are in place. Maintains desired dry solids content profile over the evaporation train by coordinating the feed-, mediumand strong-liquor dry solids controls. Compensates for fuel quality variations and fuel feeding upsets to enable better combustion and utilization of lower quality fuels.

30 Automation services Service Installed base audit Instrument and valve analysis Intelligent planning and execution Intelligent planning and shutdown Inventory audit Inventory management Inventory setup Lifecycle plan Lime kiln optimization Machine and device monitoring Maintenance plan Description We identify and record in the agreed system(s) the accurate installed base information. We identify field devices (for example, valve) issues and recommend corrective actions. We provide project management covering planning and execution for the intelligent maintenance solution. We provide project management covering planning and execution for the intelligent shutdown solution. We identify and record in the agreed system(s) the accurate spare parts information. We carry out day-to-day spare parts storage and management. This covers delivering spare parts according to pre-defined response times, restocking according to the stocking strategy, and removing obsolete stock. We remove obsolete stock, transfer stock, disassemble it into components, and carry out process training with customer staff. We produce and keep up to date a plan identifying when a specific device, hardware or software should be upgraded in order to meet customer requirements for availability and/or performance. Manages the lime kiln process in order to reduce lime quality variability and implement a target shift. We provide a monitoring system to monitor the performance of field devices and machines, along with the associated support and maintenance. The plan continuously defines the maintenance program for devices and equipment according to the device or equipment type and its criticality.

31 Automation services Service Manage corrective actions Management and results reporting Mechanical fiber optimization Mill-wide brightness optimization Modernization and upgrades On-call service Operations monitoring Paper and tissue machine optimization Performance improvement Pre-screen shutdown list Description We manage the implementation of correction actions by Metso and/or third parties. We provide project management and results reporting for a solution. Optimizes pulp quality and process production. Coordinates brightness agents and unites the pulp and papermaking process. We change field devices, system hardware and/or software to a newer variant. Modernization is when the change results in no increase in functionality. An upgrade is when the change results in an increase in functionality. We provide easily accessible technical support that helps customers to resolve any issues regarding automation systems or field devices. We provide a monitoring system to monitor the overall performance of operations. Optimizes the paper/tissue machine process. Our skilled engineers tune control loop parameters to optimize control performance. Our staff identifies which devices can be maintained outside a shutdown.

32 Automation services Service Preventive maintenance Process monitoring Recovery boiler optimization Recycled fiber optimization Remote connection Repairs Resident engineer Response time for emergency service visit Root cause analysis Safety followup service Safety instrumented system (HIMA) audit Security audit Description Execution of preventive maintenance tasks according to the maintenance plans. Provides timely and accurate information on the development of process performance KPIs. Manages the combustion process for both the firing of black liquor and the combustion air. Coordinates the pulping, bleaching and flotation processes, decreases brightness and ash variability, and improves the deinking process. We remotely diagnose and, where possible, solve system and/or equipment issues. We repair and recondition automation and instrumentation devices (for example, valves, DCS units). This includes what was previously called Intelligent Valve Repair. We offer an on-site expert to provide continuous local expertise as part of a service agreement. We put in place resources to deliver a specified response time. Our experts find the root cause of control and process issues and propose a solution. We ensure that the plant automation systems are secure from external threats and viruses. We provide safety logic application support and consulting (for example, for turbines). Identifies any automation system information security issues.

33 Automation services Service Service container Service visit Sootblowing optimization Spare parts Standard training Startup supervision Steam network optimization Stock preparation optimization Stocking strategy Technical visit Description We provide for a shutdown a customized container of spare parts and tools that may be required during a shutdown or turnaround. An engineer visits your site to carry out emergency corrective action. Intelligent sootblowing optimizes the process to clean only the areas where it is needed. We provide replacement spare parts for Metso products. We provide a number of standard training courses. We provide on-site troubleshooting support to ensure a smooth production start-up after a shutdown. Optimizes steam and electricity production and utilization of compensating process resources in varying CHP production to ensure better steam pressure control, optimize electricity generation, minimize steam venting and optimize the fuel mix. Optimizes the stock preparation process. We continuously update the spare part stocking strategy based on targets and device lifecycles. Our service experts carry out a visual inspection of devices and their environment for shutdown or maintenance planning.

34 Metso Automation Services Case studies

35 Plant availability Intelligent maintenance improves maintenance efficiency without compromising quality Background: Braskem is the largest petrochemical company in South America and 5 th largest in the world Braskem s Triunfo plant produces more than 1,200 Kt per year of ethylene and other hydrocarbons Target was to maintain equipment availability and improve maintenance efficiency to bring down maintenance costs Solution: Intelligent maintenance business solution implemented to analyze internal and external condition of valves, schedule maintenance based on condition and carry out high-quality repairs. Results: 36% saving in maintenance costs Only 24% of valves required removal for maintenance Job safety increased Improved environmental compliance Our customer s view: Not only have we saved in maintenance and inventory costs, but we have also increased the reliability and the performance of our field equipment. Nelzo Luiz Neto da Silva, Maintenance Coordinator, Braskem Triunfo

36 Plant availability Device management solution reduces inventory costs and capital expenditure Background: The world s leading producer of nickel and palladium The Harjavalta plant produces nickel salts for the European market Target was to reduce inventory costs and space needed and ensure spare parts inventory aligned to installed base Solution: Device management business solution implemented to audit spare parts stock and the process, identify surplus inventory and reduce the number of models in use over time. Results: 71% reduction in customer inventory in 2 years Spare part equipment coverage up from 40% to 90% Significant reduction in material costs 100% on-time delivery Our customer s view: Agreements are made between companies, but genuine cooperation and teamwork is built around people. Mikko Marjakoski, Chief of maintenance, Harjavalta plant

37 Plant availability Intelligent shutdown reduces shutdown costs and time by focusing effort where needed Background: CMPC is the largest Chilean pulp company and the world s 5 th largest pulp supplier The Santa Fe Mill near Nascimento produces bleached eucalyptus pulp with two fiber lines Target was to maintain valve availability while reducing maintenance costs and resources Solution: Intelligent shutdown business solution implemented to analyze valve condition in advance and remove only under-performing valves for high-quality repair. Results: Less than 20% of the control valves needed removal for service 70% drop in maintenance costs compared to sister line where all critical valves were taken out (reduced scaffolding, construction, inspection and repair costs) Maintained target availability for valves Our customer s view: Maintenance costs optimization of control valves, based on predictive maintenance philosophy, allows us to allocate resources to other important maintenance activities at the mill. Javier Gonzalez, Electrical and Instrumentation Superintendent, CMPC Santa Fe Mill

38 Plant availability Lifecycle management optimizes system performance and total cost of ownership Background: Major SC publication paper producer Target was to upgrade the DCS system selectively to maximize lifetime of the system, improve the return on investment, maintain availability targets and system security and minimize maintenance and service costs Solution: Lifecycle management business solution implemented to upgrade automation systems to coincide with a jointly agreed lifecycle plan. Results: System uptime improved by 10 hours per year System and application engineering change costs reduced by 20% Our customer s view: Laakirchen mill has dealt with issues of automation asset obsolescence and lifecycle management. We have invested in new technologies and applications that improve reliability and serviceability while, at the same time, reducing costs and improving papermaking performance. Siegfried Schober, Automation Project Manager, SCA Laakirchen

39 Process performance Power process optimization saves unnecessary investments Background: ABPP is a joint venture between a number of US power companies The Grant Town plant has two circulating fluidized bed boilers generating 80 MW and a 3 rd party control system Target was to benchmark plant performance for measurement purposes, improve performance and lower production costs Solution: Power process optimization solution implemented. Results: 7% reduction in limestone usage By reducing limestone injected with the fuel and average SO 2 levels, the plant avoided having to install a post-combustion flue gas treatment system estimated to cost $12 million Our customer s view: Our business has to include optimization of our processes to ensure that we are operating as efficiently as possible. Every dollar that I invest in bettering our plant must ensure that I achieve that high return on investment. Metso meets our expectations of efficient, lowcost operation. Steve Friend, Plant Manager, American Bituminous Power Partners

40 Process performance Reduced variability leads to massive cost savings Background: One of the largest pulp producers in Brazil Target was to stabilize pulp quality and kappa variation, improve pulp yield and lower costs per ton Solution: Continuous cooking optimization, a pulp optimization service within the process optimization business solution, was implemented. Results: Kappa variability reduced by as much as 93% Yield increase resulting in annual savings of up to $900,000 Our customer s view: Working together, we got very good results which were much better than expected and which have been maintained. Hamilton Brandão, Fiberline Coordinator, Cenibra

41 Process performance Tighter process control combats rising energy and raw material costs Background: SABIC is one of the world s largest chemicals, fertilizers, plastics and metals producers with annual sales of $75 billion SABIC Innovative Plastics (SABIC-IP) produces a variety of plastics for OEMs in the automotive and computer electronic markets Target was to stabilize plant processes to reduce energy and maintenance costs Results: Annual energy savings of $1 million Oscillating loops reduced from 40% to 16% Loops unable to hold setpoint reduced from 12% to 2% Our customer s view: By tightening this upstream control and optimizing the hydrogen process, we are able to save over $1 million per year in energy consumption. Keith Phillips, Control Engineer, SABIC-IP Solution: Control performance business solution Metso ExperTune PlantTriage implemented and consultancy provided.

42 Risk control Doing better business by being a better business Background: A principal bioenergy producer and the world s leading peat company Target was to address the public perception around the impact of peat extraction on the environment by implementing a monitoring solution that increased information transparency Solution: Environment business solution implemented. Results: Transparency of water quality information improved Company is able to better manage its environmental footprint Our customer s view: Metso s service package provides us with a more comprehensive, transparent and real-time solution for parallel use with the monitoring method used currently. In addition, it supports our previous commitment of including all peatlands in our emissions monitoring. Pasi Koivisto, Business Area Director, Vapo Peat Products

43 A selection of our customers Oil, gas and biofuels Industrial gas Pulp and paper Power Chemicals Metals Mining and construction Food

44 Our presence closer to you Our presence today Service personnel 30+ Countries 55+ Automation service hubs 35+ Service centers Full solution and service portfolio available Core solution and service portfolio available

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46 E9021_EN_01 12/2013 Product names in this brochure are all trademarks of Metso Automation Inc. Metso Automation Inc.