Finding The Sweet Spot in the Paper Mill

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2 Finding The Sweet Spot in the Paper Mill Presented by Kristi Kobetich, Port Townsend Paper Corporation Rob Chandler, Casne Engineering Inc 2

3 Agenda Introductions Background: History, Challenges, and Goals Centerline Proof of Concept Simplified Architecture The Results Next Steps 3

4 Casne Engineering, Inc OSIsoft Integration Partner Professional Engineering Control Systems Technology Integration Support desk services Utilities, Process Industries, Data Centers 30+ year track record 4

5 Port Townsend Paper Corporation Overview Located in Port Townsend, WA 280 employees Produce unbleached Kraft paper, containerboard & market pulp 300,000 tons per year 5

6 Port Townsend Paper Corporation Products & Markets Kraft pulp & paper Containerboard Specialty products Blend of both virgin and recycled fibers Northwest softwood chips and sawdust Sister facility Crown Packaging in British Columbia 6

7 Process 7

8 Our PI System PI Enterprise Server 5000 Tags Advanced Server Pack Data Access Pack PI Bailey Infi90 Interface to BAILEY DCS (PM#1, Pulp Mil) PI OPC Interface to METSO DCS (PM#2, OCC) PI OPC Interface to DeltaV DCS (Boiler) PI ProcessBook and PI DataLink (70 users) PI SQC Client PI Profile View 8

9 PM1 HOMEPAGE Click on links below to navigate through PI ProcessBooks and Reports Some of these links are in protected folders. Unless you have the proper permissions, you may not be able to open these files. MILL ADMINISTRATIVE Pulp Mill Status Sheet Paper Machine Schedules Paper Machine Summaries & Downtime Reports Paper QC & Shipping Specifications #1 PAPER MACHINE No 1 Paper Machine Key Trends No 1 Paper Machine Process Flow Diagram LINKS SW ITC HBOARD PULP MILL SWITCHBOARD Switchboard PI ProcessBook Displays Used for Process Visualization Copyright 2002 Process Group, Technical Services 9

10 Product Quality Challenges Variation in raw material from batch to batch Multitude of machine setting changes between paper grades Variation in operator judgment Long periods of time between similar product runs 10

11 Centerline Proof of Concept Goals Streamline QC data entry Single source for quality and process targets Get process information into the hands of the operators Improve visibility & access to historical process information Timely access to past quality and performance data Quick and easy comparison of real time production data to historical performance data Ability to communicate reasons for off-spec events 11

12 Solution Two Applications Data Entry Application Collection of quality test results Uploading into the PI System Process Dashboard Displaying current and historic Process, Quality & Economic Information compared to targets Provide access to Action Trees & Event Notes 12

13 QC Data Entry via the PI System Used to send quality data to PI for long term storage and use Microsoft Excel + PI DataLink = Operator familiarity Utilizes existing software licenses Simple, flexible, maintainable solution 13

14 Process Dashboard Used by operators and managers Merge Data Streams Quality Process Economic One-click Access to: Operator notes Quality Centerline charts Action trees (future) 14

15 Mullen.. Centerline Charts B40 Discovery Kraft 2/18/11 7:24:00 2/18/11 9:20:00 2/18/11 11:26:00 Run Time Target MIN Data from PI Server brought into Excel Charts Quick and easy access to quality information for same-grade runs 15

16 /18/11 7:21:01 2/18/11 7:34:17 2/18/11 7:49:57 2/18/11 8:05:32 2/18/11 8:20:00 2/18/11 8:42:30 2/18/11 8:58:59 2/18/11 9:17:26 2/18/11 9:20:40 2/18/11 9:21:37 2/18/11 9:46:07 2/18/11 10:18:00 2/18/11 10:18:57 2/18/11 11:13: B40 Discovery Kraft 2/18/11 11:26:30 2/18/11 11:26:59 Run Time 2/18/11 11:32:10 2/18/11 11:55:55 2/18/11 12:03:26 2/18/11 12:22:30 2/18/11 12:23:19 2/18/11 12:32:33 2/18/11 12:52:50 2/18/11 13:16:24 2/18/11 13:56:19 2/18/11 13:57:19 MIN Centerline Charts Quick and easy access to Process data over time for a specific product grade Color Coded for Identifying Run Conditions Excel charts for consistent interface and easy use within reports 16

17 Simplified Architecture Simple = Better Flexible User Familiarity Cost Effective Maintainable 17

18 Results Goals met Streamlined QC data entry Real time monitor for machine parameters and quality performance compared to targets Improved visibility & access to historical process information Timely access to past quality and performance data Quick and easy comparison of real time production data to historical performance data Ability to communicate reasons for off-spec events 18

19 Results Tangible Benefits Implementation is ongoing Reduced product rejection rate Standardized operating conditions Improved communications amongst operators Better understanding of off-spec events 19

20 Next Steps Complete implementation Operator hands on training in classroom Utilize operator input to develop Action Trees and Centerline Targets Expand Economics tab Develop system for continuous updates 20

21 Future Plans Integrate ABB Quality Management System with PI System Implement PI SQC Investigate PI Profile View Investigating Virtualizing our future upgrade to then PI 2010 architecture 21

22 Questions Contact information ROB CHANDLER Senior Software Integrator NE 38 th Place, Ste. 205 Kirkland, WA (425) Direct: (425)

23 Thank you

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