Paper Automation Service CEU - Optimization Service - EN - RevUK

Paper Automation Service Central Europe Optimization Service
ABB Group Paper Automation Service CEU Optimization Service_EN_RevC 2009-04-28 | Slide 1
Optimization Service Service Level and Plant Areas
Optimization Service Development of Plant Performance
Optimization
Maintenance and Service
Application Service
r f ec na m o r e P
Project Phase
without Service
System Availability
Time
Optimization Service Phases

Diagnose Implement Sustain
Diagnose

Measure process Detailed scope with defined objectives Forecast performance
Service
Sustain
Implement

Implement
Improve performance Apply corrective actions

1
Sustain

Diagnose
Maintain performance Preventative maintenance Monitor machine index
Optimization Service Analysis
Every Optimization begins with an analysis
Process
Pulsation Vibration Study
Stock Approach
Paper Machine Fingerprint
Transition
Boiler
Color
Optimization Service Phase 1: Diagnose - Paper Machine Fingerprint

Fiber Line Stability
Power (variance)[e-2]
Provides information on: Controllable energy Mechanical pulsations of vibrations Process disturbances Benchmark of machine stability
Product Variability
0.200 0.175 0.150 0.125 0.100 0.075 0.050 0.025 0.000
Provides information on: Control behavior (disturbance reduction, responsiveness) Grade change recovery Sheet break recovery
-4 10
-3 10 -2 10 Frequency (Cycle/Time)
-1 10
Machine Response
VPA
Profiling Capability
A c t u a l v s . C a 7c . P r o f i l e s f o r l
A ctu a l 7 7 7 7 -7 -7 Profile -7 -7 -7
in c h Z o n e s
C a l c u l a te d
Provides information on: Stock approach performance Controllable energy and tuning quality Oscillation sources
Sigma
-7 -7 7 7 77 77 77 77 77
77 Zo n es
77
Current
77
77
77
Potential
77
77
Provides information on: Potential of CD controls CD disturbances CD control quality and tuning Mapping problems
Paper Machine Fingerprint Module 1: VPA Variance Partition Analysis

Paper Machine Fingerprint Module 1: VPA

As an initial analysis of the Paper Machine Fingerprint, QCS reel reports of the last 3 month are reviewed. The results show an overview about the process variances during the last quarter.
MDS
MDL
CD
TOT

This analysis allows conclusions about possible causes of process variation an potentially useful methods for further analysis.
MDS
(Machine Direction Short Term Variation) Variance in machine direction with periods between 0.1 und 60 seconds.
TOT (Total Variation)

Variance over all collected measurements
MDL (Machine Direction Long Term Variation) Variance in machine direction with periods above 60 seconds.
CD
(Cross Direction Variation) Variance in cross direction.

The following limits and distributions are valid for the evaluation of the variances. They can be seen as ideal target values.
Variance Short (MDS) in % of Total Variance (TOT)
70%
Total 2 Sigma (TOT) in % of the average Basis Weight Conditioned Weight Moisture Caliper Ash < 1.7% < 1,5% < 10% < 1% < 4,5% Variance Long (MDL) in % of Total Variance (TOT)
10%
Variance Cross Direction (CD) in % of Total Variance (TOT)
20%

VPA results:
Average 105 100 95 90 3.1 2.6 2 Sigma 2.1 1.6 1.1 0.6 0.1 01.03.2008 12.03.2008
VPA Average [TB Berichte:PM 1 Sorte XYZ:Atro]

CD MDL
MDS
TOT
Comparison over machines and grades Trend displays Bar charts with target regions
24.03.2008
02.04.2008 Reel Time Stamp 29.04.2008 20.04.2008
11.05.2008
21.05.2008
Sorte A Sorte B
Sorte C
Sorte D
Sorte A Sorte B Sorte C Sorte D
0.200
0.175
0.150
0.125
0.100
0.075
0.050
0.025
0.000 10 -4 10 -3 Frequency (Cycle/Time) 10 -2 10 -1
Paper Machine Fingerprint Module 2: Product Variability


Because of continuous production conditions process variations show up frequently in machine direction.
R a w D a ta
M T 7_ O p e r M e a s _ g .M e a s u r e m e n t 7 P R 7_ g .M e a s u r e m e n t 7 6 66 , 7 77 , 6 66 , 7 77 , 6 66 , 7 77 , 7 77 , 7 77 , 7 77 , 7777 6666 7777 7777 7777 7777 S a m p le N u m b e r , T s = 7 7777 77777 , T o t a l S a m p7 s =7 7 7 le 7 77777 77777 77777 A p p lic a t io n _ P M7 M D 7 .M T 7 7 7 P R 7_ fb .P ID _ O p e r S P 7 _ T a r g e t_ g

The frequencies can be assigned to different frequency bands.
Slow Loops tau>20 sec
Fast Loops tau<20 sec
Vibrations Mechanical Conditions Surges Pulsations
Stock Prep Dilute Stock Circuit Headbox / Former
Decade 1 3hrs to 20 m 0.0001

Decade 2 20 m to 2 m 0.01
Decade 3 2 m to 10 s 0.1
Decade 4 10 s to 1 s 1.0
Decade 5 1 s to 0.1 s
Decade 6 0.1 s to 0.01 s 10.0 100.0
0.001
Frequency [Cycles/Second]

Raw data are logged in 3 steps

AGP 400 2 kHz 200 Hz 5sec. TBM from QCS 5s
1. 2000 Samples/sec. 410000 points 3.4 minutes at 3 positions
2. 200 Samples/sec. 410000 points 34 minutes at one position
3. 5 Sekunden Samples. ber ca. 8 hours In scan mode

High frequency data will be collected directly from the frame via Datalogger AGP400.
Additional process data can be logged

The collected data will be compared and analyzed in different ways

R a w D a ta
M 7 7 _ O p e rM e a s _ g .M e a s u re m e n t T P R 7 _ g .M e a s u re m e n t 7 6 66 , 7 77 , 6 66 , A p p l ic a t i7 n _ P7M 7 M D7 7 . M T o P R 7 _ fb .P ID _ O p e r S P 7 _ T a rg e t_ g
M 7 77 k P o w e r S p e c t r u m C o m p a r7i, s77 n O o
6 66 , 7 77 , 7 77 , 7 77 , 7 77 , 7777 6666 7777 7777 7777 7777 7777 77777 77777 S a m p l e N u m b e r , T s = , T o t a l S7a 7 p7le 7 =7 7 m s 77777 77777
6 666 . 7 777 .
MO777 Mk MO777 Dk
A frequency analysis (FFT) determines frequencies contained in the signals and localizes causes of disturbances.
MO777 Tk
6 666 . 7 777 . 6 66 . 7 77 . 6 66 . 7 77 . 7 777 .
7 777 .
7 777 .
-7 77 -7 77 7 7 77 77 F r e q u e n c y ( C y c le /T im e ) 7 77

As a result an index-based diagram of the variances divided into 6 decades is compiled

Weight 40 35 30 Moisture
QCS Potentials
DCS Potentials
Mechanical Potentials
Comparison
25 20 15 10 5 0
Weight Moisture
CD Decade 1 18.2127838 3.3569510 4.2681885 1.1965742
Decade 2 1.3546985 1.4669303
Decade 3 6.5347900 5.4170699
Decade 4 Decade 5 Decade 6 8.4648914 21.9569969 40.1188774 34.6394196 38.3444977 14.6673136
CD
MDL
MDS
Paper Machine Fingerprint Module 3: Machine Response


Based on bump tests of the QCS controls in Manual and Auto time constants are determined and compared. The relation between Manual and Auto represents an index that indicates the performance of the control. A Value of 1.5 is the target based on experience.
Bump in Auto
- Setpoint - Measurement
Bump in Manual

Results of the machine response analysis:
Comparison of the responses in Manual and Auto
14 12 Index
Target
Additional findings:
10 8 6 4 2 0 Moisture Total Head Weight Target: <1.5; Actual: 12.7; 6.0; 2.8
Wrong process model parameters in the QCS Improvements with or without feed-forward controls Bad control parameters in QCS Performance of DCS loops (Level 1)
Paper Machine Fingerprint Module 4: Profile Capability


The controllable frequencies and with that a residual goal plot are determined from the raw profiles with Fourier analysis (FFT)
Raw Profile Plot
Sigma
Current
P r o f i l e : M o7is 7u r e , 7 t 6. 6 6. 6 6. 6 6. 6 66 . Power (variance)[e-7] 6. 6 6. 6 66 . 6. 6 77 . 7. 77 7. 77 7 77 .
P o w e r S p e c tru m
C y c le s
Potential
Residual Profile Plot
7. 77 7 77 . 7. 77 7 77 . F r e q u e n c y ( C y c le / L e n g th )
7. 77
7. 77

Additional possible findings from machine response module:
Edge problems (deckle waves, wire curls, edge flows) Global and local mapping issues Model mismatch Tuning issues (I versus PI) Actuator tracking problems Influences from wire and felt cleaning Startup or sheet break recovery issues Grade dependent CD tuning etc.
Paper Machine Fingerprint Module 5: Fiber Line Stability


The machine chest is the interface between stock approach and machine Process variances in this area are directly affecting paper quality
Stock Approach
Paper Machine
Machine Chest

The following controls and measurements are analyzed:

Headbox
Machine Chest
Total Head
White Water 1
Stock Flow
Stock Valve
Consistency
Fan Pump
Level Machine Schest

The difference between Measurement and Setpoint is calculated. The error is accumulated. Based on the scaling of the measurement an index is calculated.
Error

Big Index
Small Index

The indices are compared with their limits Optimization potentials are revealed
Total Head Level Schest Stock Flow Consistency
0.40 0.35 Comparison[e-2] 0.30 0.25 0.20 0.15 0.10 0.05 0.00
1 0.0299000 2 0.0997000 3 0.2298000 4
Limit
0.4104000
Paper Machine Fingerprint Summary

Results of the Paper Machine Fingerprints:
Product Variability
0.200 0.175 0.150 0.125
Daily detailed report of the accomplished analysis Index-based summary of KPIs Summary of critical areas Implementation plan improve the machine performance Return on investment (ROI) forecasts
0.100 0.075 0.050 0.025 0.000 -4 10 -3 10 Frequency (Cycle/Time) 10 -2 -1 10
Machine Response
VPA
Profiling Capability
A c t u a l v s . C a 7 . P r o fi l e s f o r lc
A c tu a l 7 7 7 7 -7 -7 Profile -7 -7 -7 -7 -7 7 7 77 77 77 77 77 77 Zones 77 77 77 77 77 77
in c h Z o n e s
C a l c u l a te d
Sigma
Current
Potential
Optimization Service Phase 2: Implement

Implementation of the proposed changes from the five analysis modules, e.g.:

Control tuning for MD and/or CD Adaption and extension of control strategies Grade-dependent tuning setup Assignment of detected frequencies to the process environment in order to find causes of product variability Change of setpoint targets after reduction of the product variability in order to increase production and reduce energy consumption

Typical savings for different paper machines: Mill Medium Fine Writing Newsprint Tissue Towel Pulp Investment 65k 95k 20k 70k 75k 120k Annual Savings 325k 610k 250k 650k 560k 2,270k Ratio 5 to 1 6.4 to 1 12.5 to 1 9.3 to 1 7.5 to 1 18.9 to 1
Average
74k
778k
10.5 to 1
Every Dollar invested in the reduction of product variability results in a return of 5 to 10 times.

Example for proposed improvements for a medium mill:
Target shift: Weight
A 0.1lb shift in basis weight can be made. This results in savings of $116.500. A 0.1% moisture target shift (i.e. 8.9 to 9.0) can be made. If speed limited the savings would be $40.600. A 5 min improvement after a break and less breaks represent $264.300 in savings. Improvement in quality results in savings of $4,180.
Target shift: Moisture
Sheet break recovery, number of breaks and faster startup
Reduced rejects and customer returns
Total benefits
If the recommendations are followed, the savings as a result of the project will be $425.580.
Optimization Service Phase 3: Sustain

Goal: Sustain the reached performance improvements

Adapt service procedures Change operation strategy Remote monitoring Optimization

Implement Sustain Phase Continuous Improvement
MaintenanceUtilization
Availability
Optimization Service Phase 3: Sustain

Combination of Optimization Service and Remote Service to continuously remote monitor important performance indices (KPI)
Remote
Local
OPC SQL
Product Variability Stock Approach Stability

Power (variance)[e-2] 0.200 0.175 0.150 0.125 0.100 0.075 0.050 0.025 0.000
KPI KPI KPI KPI KPI
-4 10
-3 10 -2 10 Frequency (Cycle/Time)
-1 10
RDS
Machine Response
Product Variability Machine Response Profile Capability VPA Analyis
VPA
Profile Capability
A c t u a l v s . C a l7 . P r o f i l e s f o r c in ch Z o n es
A c tu a l 7 7 7 7 -7 -7 Profile -7 -7 -7 -7 -7 7 7 77 77 77 77 77 77 Z o ne s 77 77 77 77 77 77 C a lc u la te d
Sigma
Current
Potential
Optimization Services European Network

Pool of specialists available for OS in Europe
Luciano Bianchi Manager OS South 1
Fabien Laleuf Manager OS South 2
Robert Steinhauser Manager OS Central
John Fraser Manager OS UK
Magnus Vestberg Manager OS North
Michele Strepparola Business Driver South 1
Tadeuz Romanowski Business Driver South 2
Uwe Beekhuis Business Driver Central
Paul Kelly Business Driver UK
Jonas Warnqvist Business Driver North + OS Network Coordinator
Marco Nieri Alessandro Camoirano Dario Fenini Michele Strepparola
Christophe Miclo JC Benedic (Color Control) P.Beuste & D.Trouche
Andreas Zehnpfund Andr Rppnack Cees Funcke Uwe Beekhuis
Paul Kelly Joe Bell (Ireland) Patrick Laweless (Ireland)
Jonas Warnqvist Jonas Berggren Carl-Magnus Tjeder Niclas Alfsvg Hans Lundberg John-Helge Askeland Kent Norman Pontus Johnsson Nicklas Ljungberg
Italy MEA
France Spain Portugal North Africa
Germany Belgium Netherlands Austria Switzerland Chech Rep. Slovakia Slovenia Hungary Poland South
U.K.
Sweden Norway Denmark Finland Poland North Russia
Jonas Warnqvist team leader.


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Paper Automation Service Central Europe Optimization Service

Optimization Service Service Level and Plant Areas

Optimization Service Development of Plant Performance

Optimization Service Phases

Measure process Detailed scope with defined objectives Forecast performance

Improve performance Apply corrective actions

Maintain performance Preventative maintenance Monitor machine index

Optimization Service Analysis

Every Optimization begins with an analysis

Pulsation Vibration Study

Paper Machine Fingerprint

Optimization Service Phase 1: Diagnose - Paper Machine Fingerprint

Fiber Line Stability

Paper Machine Fingerprint Module 1: VPA Variance Partition Analysis

Paper Machine Fingerprint Module 1: VPA

Paper Machine Fingerprint Module 1: VPA

TOT (Total Variation)

Paper Machine Fingerprint Module 1: VPA

Paper Machine Fingerprint Module 1: VPA

VPA Average [TB Berichte:PM 1 Sorte XYZ:Atro]

02.04.2008 Reel Time Stamp 29.04.2008 20.04.2008

Sorte A Sorte B Sorte C Sorte D

0.000 10 -4 10 -3 Frequency (Cycle/Time) 10 -2 10 -1

Paper Machine Fingerprint Module 2: Product Variability

Paper Machine Fingerprint Module 2: Product Variability

Paper Machine Fingerprint Module 2: Product Variability

The frequencies can be assigned to different frequency bands.

Slow Loops tau>20 sec

Fast Loops tau<20 sec

Vibrations Mechanical Conditions Surges Pulsations

Stock Prep Dilute Stock Circuit Headbox / Former

Decade 1 3hrs to 20 m 0.0001

Decade 6 0.1 s to 0.01 s 10.0 100.0

Paper Machine Fingerprint Module 2: Product Variability

Raw data are logged in 3 steps

1. 2000 Samples/sec. 410000 points 3.4 minutes at 3 positions

2. 200 Samples/sec. 410000 points 34 minutes at one position

3. 5 Sekunden Samples. ber ca. 8 hours In scan mode

Paper Machine Fingerprint Module 2: Product Variability

Additional process data can be logged

Paper Machine Fingerprint Module 2: Product Variability

The collected data will be compared and analyzed in different ways

6 666 . 7 777 . 6 66 . 7 77 . 6 66 . 7 77 . 7 777 .

Paper Machine Fingerprint Module 2: Product Variability

As a result an index-based diagram of the variances divided into 6 decades is compiled

CD Decade 1 18.2127838 3.3569510 4.2681885 1.1965742

Decade 2 1.3546985 1.4669303

Decade 3 6.5347900 5.4170699

Decade 4 Decade 5 Decade 6 8.4648914 21.9569969 40.1188774 34.6394196 38.3444977 14.6673136

Paper Machine Fingerprint Module 3: Machine Response

Paper Machine Fingerprint Module 3: Machine Response

Paper Machine Fingerprint Module 3: Machine Response

Results of the machine response analysis:

Comparison of the responses in Manual and Auto

Paper Machine Fingerprint Module 4: Profile Capability

Paper Machine Fingerprint Module 4: Profile Capability

Raw Profile Plot

P r o f i l e : M o7is 7u r e , 7 t 6. 6 6. 6 6. 6 6. 6 66 . Power (variance)[e-7] 6. 6 6. 6 66 . 6. 6 77 . 7. 77 7. 77 7 77 .

Residual Profile Plot

Paper Machine Fingerprint Module 4: Profile Capability

Additional possible findings from machine response module:

Paper Machine Fingerprint Module 5: Fiber Line Stability

Paper Machine Fingerprint Module 5: Fiber Line Stability