Papermaker s experience with State-of-the-Art t th AtAutomation ti Keith Masters, ABB PaperCon 211 Page 2696
Presentation Topics Typical business case for Automation Investment Case History Experience - Best Practice Implementation - Asset Effectiveness - Optimization Results Prediction Challenge PaperCon 211 Page 2697
Business Case for Automation Investment Opportunity for Results increase with reduction in variation Limit Value ($) PaperCon 211 Page 2698
State-of-the-Art Automation Control information Trend information Maintenance History for the control Description of proper control action Diagnostic information provided by intelligent process measurement devices Alarms associated with the variable Interlock information Mill Automation Computers Mill Maintenance Computers Mill Engineering Computers PaperCon 211 Page 2699
Best Practice Implementation How the user sees the information Alarm Mechanical Drawing Standard d Operating Procedure Live Video PaperCon 211 Page 27
Asset Effectiveness Product Documentation Diagnostic Information Condition Information Configuration Operating Information PaperCon 211 Page 271
Alarm Analysis Top 2 Alarms Active alarms, time in seconds Top 2 longest in alarm state Distribution of alarm priority PaperCon 211 Page 272
Optimization Module Tasks Module Reporting Data Access Machine Testing Visualization Analysis KPI COV as a percent of total 1 8 6 4 2 CD Fingerprint: Weight and Moisture Decade 1 Decade 2 Decade 3 Decade 4 Decade 5 Decade 6 weight moisture Product Steady State Variability Return on Investment Performance Benchmark Summary of Findings Recommendations Implementation Plan Poor regulation Cyclic response Offset from setpoint Good regulation Process Input Stability History Transient Response Slow response Fast response Actual Calculated Product Unique Requirements Diagnostics Complete Profile 3 2 1-1 -2-3 -4-5 -6-7 5 1 15 2 25 3 35 4 45 5 55 6 65 Zones Current Potential Sigma Standard Efficient PaperCon 211 Page 273
Optimization Areas Grade Change Speed Change / Speed Optimization i Sheet Break Recovery Historical Data Mechanical Vibration Rotational DCS Process and Control MD Process and Control CD Process and Control Lab Testing Data Collection PaperCon 211 Page 274
Stock Delivery System Pulp Handling Mechanical Condition Vibration Surges Pulsations Stock Prep Dilute Stock Circuit Headbox and Former 3hrs to 2 m 2 m to 2 m 2 m to 1 s 1 s to 1 s 1 s to.1 s.1 s to.1s.1hz1h.1hz1hz 1Hz.1Hz 1Hz.1Hz 1Hz 1.Hz 1.HzHz 1. Hz PaperCon 211 Page 275
e Diagnostic Capabilities Evaluates: On control Performance of: Total Head, Thick Stock Flow, Thick Stock Consistency, Machine Chest Level Provides information on: Controllable Energy Mechanical Pulsations of vibrations Benchmark of machine stability Stock Approach Stability Poor regulation Offset from setpoint COV as a percent of total 1 8 6 4 2 Product Variability CD Fingerprint: Weight and Moisture Decade 1 Decade 2 Decade 3 Decade 4 Decade 5 COV Weight = 5.17 COV Moisture = 36.45 Decade 6 History (VPA) weight moisture Evaluates: Cyclic content of Weight and Moisture in: Cross Direction and Machine Direction from High Frequency up 5Hz down to Low Frequency of 5 hours. Machine Response Cyclic response Slow response Provides information on: Start up time Grade Change recovery Disturbance reduction Sheet break recovery Responsiveness Provides information on: Controllable Energy Stock Approach performance Tuning Quality Oscillation sources Good regulation Profile 3 2 1-1 -2-3 -4-5 -6-7 Profiling Capability Actual Sigma Calculated Fast response Evaluates: Automatic and Manual mode operation of: Weight, Moisture, and Total Head. 5 1 15 2 25 3 35 4 45 5 55 6 65 Zones Current Potential Evaluates: On control Performance and model for: Weight, Moisture, and Caliper Provides information on: Will CD control improve the profile? Is current CD control optimized? PaperCon 211 Page 276
PM Module: Stock Stability Index Indicates the stability of the Stock approach system. A high index suggests problems related to: process, control, mixing, etc. Comparison 7 6 5 4 3 2 1 Fiber Stability Index Total = 7.8261 Total Head Chest Level Stock Flow 135 13 8 7 6 19 Total Head Chest Level Stock Flow185 Consistency 18 4.2 1 2 3 4 Total Head.1115 Chest Level 7.444999 Stock Flow 1.9641 Consistency 1.411 Co onsistency 4.1 Fiber Stability Trends Points = 1681 Product Variability Fiber Line Stability Poor regulation Offset from setpoint Good regulation Profi l e 3 2 1-1 -2-3 -4-5 -6-7 COV as a percent of total 1 8 6 4 2 CD Fingerprint: Weight and Moisture Decade 1 Decade 2 Decade 3 Decade 4 Decade 5 COV Weight = 5.17 COV Moisture = 36.45 Decade 6 Profiling Capability Actual vs. Calc. Profiles for 1 inch Zones Actual Sigma Calculated weight moisture 5 1 15 2 25 3 35 4 45 5 55 6 65 Zones Current Potential Machine Response Cyclic response Slow response Fast response 25 5 75 1 125 15 175 raw data Raw Data Trend (~5 hours) shows that chest level impacts consistency and stock flow. Index points to Machine chest level as the primary problem PaperCon 211 Page 277
Sp 25 2 15 1 5-5 -1-15 -2-25 Size Steam Prediction Error 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 Grade Change # Current New Transition Fingerprint: Paper Machine Provides information on: Quality measurements during grade change limiting process measurements Transition Time Transition time (min) Evaluates: Quantify grade change time for 3 to 6 grade changes 1 Evaluates: Control response during and after grade change eed Reel Steam Reel Moist Stock Weight 7 65 6 55 18 17 4 2 4 3 18 16 Reel Steam start Reel Moist start Spe eed start Stock start Weight start Reel Steam stop Stock stop peed stop Control Response Basis Weight and Reel Moisture Weight stop Reel Moist stop Time (min) 8 6 4 2 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 Grade Change # History % Moist Error Moisture Response Reel Moisture Max/Min Deviation 1 8 6 4 2 1 4 7 1 13 16 19 22 25 28 31 34 37 4-2 Max Min Sheet Break Provides information on: upstream and reel moisture response during grade change Upstream and reel moisture response to headbox changes PSI Error Consistency Sp 14 4.2 4.1 Consistency start Consistency stop -4 Grade Change # 5 66.67 83.33 1 116.67 133.33 15 166.67 25% Provides information on: Level 1 PID response Level 2 control response Evaluates: Grade change level 1 setpoint prediction Prediction Error 2% 15% 1% 5% % Reel Steam Size Steam Setpoint Prediction Evaluates: Moisture response during grade changes Provides information on: Level 1 steam pressure setpoint prediction Level 1 stock flow prediction PaperCon 211 Page 278
Grade Change Time: KPI Tracking Grade Change Times Average grade change time: 42.5 min to 32.3 min! 24% improvement Time Sheet Break Time (min) 12 1 8 6 4 2 Average Average 1 6 11 16 21 26 31 36 Grade Change # Before After 4 sheet breaks before corrective action. None observed after corrective action taken. Desired Limit 1 min per grade change production increase! 3 hour per month of extra production from reduced sheet breaks! PaperCon 211 Page 279
Results Prediction 1 to 3 % Efficiency improvements are realized by maximizing saleable production at planned production rates. Theoretical Production Time Planned Production Time Planned Down Time Planning Factor (Pf) Gross Operating Time Unplanned down Time Losses Process not running No stock on wire Availability Factor (A) Net Operating Time Speed Losses Below target speed Breaks & Short Outages Stock on the wire Performance Factor (P) Valuable Operating Time Quality Losses Does not meet spec Often referred to as: Broke, off grade, rejects Quality Factor (Q) Generalized model for evaluating efficiency PaperCon 211 Page 271
Paper Industry Typical Values 1 9 8 7 6 5 4 3 2 1 Availability Efficiency World Class Average Poor Typical values all grades Parameter Availability (Uptime) Overall Machine Efficiency % % All Grades Average 89.88 82.7 Survey Range - all grades Low 83.3 73. High 96.2 92.3 Recommended guideline for good Availability Overall Machine operation Parameter (Uptime) Efficiency % % Bleach Board Guidelines 93 84 Medium Guidelines 94 91 Fine Paper Guidelines 93 87 Fluff Pulp Guidelines 95 92 Linerboard Guidelines 94 91 Market Pulp Guidelines 95 94 Source: Tappi Typical Pulp and Paper Mill Performance PaperCon 211 Page 2711
3,1 t/ /d 176 Non-mill factors 2,9 t/ /d 167 Planned downtime 7,2 % 1,3 t/ /d 2,3 t/ /d 77 13 Unplanned maintenance downtime Downtime for other reasons 4,2 t/ /d 24 Web break Gap Analysis Example 16,6 % Speed losses 22,5 t/d Speed losses due to grades 8,5 t/d Trim waste,6 t/d 3 % Other waste 5 t/d Production Line Efficiency-% = Production efficiency % x 1 % production efficiency Gross Operating Efficiency Net Operati ing Efficiency (Gross Operation Time/Available time)% OR Efficiency-% = (1- A - P - Q)% 15 t/d Net Operating time 797 hours Available Production time 8584 hours Calendar Time 876 hours PaperCon 211 Page 2712
Visibility Tools help sustain performance PaperCon 211 Page 2713
Case History Experience Benefit Papermakers using these Capabilities today are Experiencing 1 to 3 % Efficiency Improvement Optimize Utilize PaperCon 211 Page 2714
Challenge As we consider the various types of information in the mill computer systems, our challenge is to consider how we can better leverage this information to improve mill operations. PaperCon 211 Page 2715
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