paper automation service ceu - optimization service_en_revuk
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Optimization ServiceService Level and Plant Areas, Enjoy!TRANSCRIPT
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 1
Paper Automation Service Central Europe
Optimization Service
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 2
Optimization ServiceService Level and Plant Areas
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 3
Optimization ServiceDevelopment of Plant Performance
without Service
Time
Per
form
ance
ProjectPhase
Optimization
Maintenance and Service
Application Service
System Availability
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 4
Optimization ServicePhases
Diagnose
Measure process
Detailed scope with defined objectives
Forecast performance
Implement
Improve performance
Apply corrective actions
Sustain
Maintain performance
Preventative maintenance
Monitor machine index
Sustain
Implement
Diagnose
Service
1
2
3Diagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 5
Optimization ServiceAnalysis
Every Optimization begins with an analysis
Paper MachineFingerprint
PulsationVibration
Study
StockApproach
Transition
Color
Process
Boiler
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 6
Optimization ServicePhase 1: Diagnose - Paper Machine Fingerprint
MachineResponse
ProductVariability
Fiber LineStability
Provides information on:• Control behavior (disturbance reduction, responsiveness)• Grade change recovery• Sheet break recovery
Provides information on:• Controllable energy• Mechanical pulsations of vibrations• Process disturbances• Benchmark of machine stability
Provides information on:• Stock approach performance• Controllable energy and tuning quality• Oscillation sources
Provides information on: • Potential of CD controls• CD disturbances • CD control quality and tuning• Mapping problems
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0 5 10 15 20 25 30 35 40 45 50 55 60 65
Actual vs. Calc. Profiles for 1 inch Zones
Pro
file
Zones
Actual Calculated
ProfilingCapability
Sig
ma
Current Potential
0.000
0.025
0.050
0.075
0.100
0.125
0.150
0.175
0.200
10-4 10-3 10-2 10-1
Pow
er (
varia
nce)
[e-2
]
Frequency (Cycle/Time)
VPA
Diagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 7
Paper Machine FingerprintModule 1: VPA Variance Partition Analysis
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 8
Paper Machine FingerprintModule 1: VPA
TOTCDMDLMDS
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.
Diagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 9
Paper Machine FingerprintModule 1: VPA
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.
MDL(Machine Direction Long Term Variation)Variance in machine direction with periods
above 60 seconds.
CD(Cross Direction Variation)Variance in cross direction.
TOT(Total Variation)
Variance over all collected measurements
Diagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 10
Paper Machine FingerprintModule 1: VPA
The following limits and distributions are valid for the evaluation of the variances. They can be seen as ideal target values.
Total 2 Sigma (TOT)in % of the average
20%
Variance Cross Direction (CD) in % of Total Variance (TOT)
10%
Variance Long (MDL) in % of Total Variance (TOT)
70%
Variance Short (MDS) in % of Total Variance (TOT)
Basis Weight < 1.7%Conditioned Weight < 1,5%Moisture < 10%Caliper < 1%Ash < 4,5%
Diagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 11
Paper Machine FingerprintModule 1: VPA
VPA results:
Comparison over machines and grades
Trend displays
Bar charts with target regions
90
95
100
105
0.1
0.6
1.1
1.6
2.1
2.6
3.1
01.03.2008 12.03.2008 24.03.2008 02.04.2008 20.04.2008 29.04.2008 11.05.2008 21.05.2008
VPA Average [TB Berichte:PM 1 Sorte XYZ:Atro]
2 S
igm
a
Reel Time Stamp
Average CD MDL MDS TOT
Sorte A
Sorte B
Sorte C
Sorte D
Sorte ASorte B
Sorte DSorte C
Diagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 12
Paper Machine FingerprintModule 2: Product Variability
0.000
0.025
0.050
0.075
0.100
0.125
0.150
0.175
0.200
10 -4 10 -3 10 -2 10 -1
Pow
er (
varia
nce)
[e-2
]
Frequency (Cycle/Time)
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 13
Paper Machine FingerprintModule 2: Product Variability
Because of continuous production conditions process variations show up frequently in machine direction.
6,50
6,75
7,00
7,25
1,60
1,65
1,70
1,75
1,80
9300 9400 9500 9600 9700 9800 9900 10000 10100 10200 10300
Raw Data
Sample Number, Ts = 5 , Total Samples = 11787
MT01_OperMeas_g.Measurement Application_PM5MD01.MT01_Target_g
PR01_g.Measurement PR01_fb.PID_OperSP
Diagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 14
Paper Machine FingerprintModule 2: Product Variability
The frequencies can be assigned to different frequency bands.
Slow Loopstau>20 sec Fast Loops
tau<20 secMechanicalConditions
Vibrations
Surges
Pulsations
Dilute Stock Circuit
Headbox / Former
StockPrep
0.0001 0.001 0.01 0.1 1.0 10.0 100.0
Frequency [Cycles/Second]
Decade 51 s to 0.1 s
Decade 60.1 s to 0.01 s
Decade 410 s to 1 s
Decade 32 m to 10 s
Decade 13hrs to 20 m
Decade 220 m to 2 m
Diagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 15
Paper Machine FingerprintModule 2: Product Variability
Raw data are logged in 3 steps
1.2000 Samples/sec.
410000 points3.4 minutes
at 3 positions
2.200 Samples/sec.
410000 points34 minutes
at one position
3.5 Sekunden Samples.
Über ca. 8 hoursIn scan mode
2 kHz 200 Hz 5 s
AGP 400 5sec. TBM from QCS
Diagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 16
Paper Machine FingerprintModule 2: Product Variability
High frequency data will be collected directly from the frame via Datalogger AGP400™.
Additional process data can be logged
Diagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 17
Paper Machine FingerprintModule 2: Product Variability
The collected data will be compared and analyzed in different ways
6,50
6,75
7,00
7,25
1,60
1,65
1,70
1,75
1,80
9300 9400 9500 9600 9700 9800 9900 10000 10100 10200 10300
Raw Data
Sample Number, Ts = 5 , Total Samples = 11787
MT01_OperMeas_g.Measurement Application_PM5MD01.MT01_Target_g
PR01_g.Measurement PR01_fb.PID_OperSP
0.000
0.025
0.050
0.075
0.00
0.01
0.02
0.03
0.000
0.025
0.050
10-2 10-1 100 101 102
MO11 1k Power Spectrum Comparison
MO
11 T
1kM
O11
M1k
MO
11 D
1k
Frequency (Cycle/Time)
A frequency analysis (FFT) determines frequencies contained in the signals and localizes causes of disturbances.
Diagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 18
Paper Machine FingerprintModule 2: Product Variability
0
5
10
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25
30
35
40
Com
paris
on
CD Decade 1 Decade 2 Decade 3 Decade 4 Decade 5 Decade 6
Weight Moisture
Weight 18.2127838 3.3569510 1.3546985 6.5347900 8.4648914 21.9569969 40.1188774Moisture 4.2681885 1.1965742 1.4669303 5.4170699 34.6394196 38.3444977 14.6673136
QCSPotentials
DCSPotentials
MechanicalPotentials
MDSMDLCD
As a result an index-based diagram of the variances divided into 6 decades is compiled
Diagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 19
Paper Machine FingerprintModule 3: Machine Response
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 20
Paper Machine FingerprintModule 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.
- Setpoint - Measurement
Bump in Manual
- Setpoint - Measurement
Bump in AutoDiagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 21
Paper Machine FingerprintModule 3: Machine Response
Results of the machine response analysis:
Comparison of the responses in Manual and Auto
Additional findings:
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)
Diagnose
Implement
Sustain
0
2
4
6
8
10
12
14
Moisture Total Head WeightTarget: <1.5; Actual: 12.7; 6.0; 2.8
Ind
ex
Target
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 22
Paper Machine FingerprintModule 4: Profile Capability
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 23
Paper Machine FingerprintModule 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
Residual Profile Plot
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0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09
Power SpectrumProfile: Moisture, 300 Cycles
Pow
er (v
aria
nce)
[e-2
]
Frequency (Cycle/Length)
Sig
ma
Current Potential
Diagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 24
Paper Machine FingerprintModule 4: Profile Capability
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.
Diagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 25
Paper Machine FingerprintModule 5: Fiber Line Stability
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 26
Paper Machine FingerprintModule 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
Paper MachineStock Approach
Machine Chest
Diagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 27
Paper Machine FingerprintModule 5: Fiber Line Stability
The following controls and measurements are analyzed:
Stock Flow
Consistency
LevelMachine Schest
TotalHead
Machine Chest
Stock Valve Fan Pump
White Water 1
Headbox
Diagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 28
Paper Machine FingerprintModule 5: Fiber Line Stability
The difference between Measurement and Setpoint is calculated. The error is accumulated. Based on the scaling of the measurement an index is calculated.
Error- Setpoint - Measurement
Diagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 29
Paper Machine FingerprintModule 5: Fiber Line Stability
Big Index
- Setpoint - Measurement
Small Index
- Setpoint - Measurement
Diagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 30
Paper Machine FingerprintModule 5: Fiber Line Stability
Limit
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
Co
mp
aris
on
[e-2
]
1 2 3 40.0299000
0.09970000.2298000
0.4104000
Total Head Level Schest Stock Flow Consistency
The indices are compared with their limits
Optimization potentials are revealed
Diagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 31
Paper Machine FingerprintSummary
Results of the Paper Machine Fingerprints:
Daily detailed report of the accomplished analysis
Index-based summary of KPI‘s
Summary of critical areas
Implementation plan improve the machine performance
Return on investment (ROI) forecasts
MachineResponse
ProductVariability
Fiber LineStability
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0
1
2
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0 5 10 15 20 25 30 35 40 45 50 55 60 65
Actual vs. Calc. Profiles for 1 inch Zones
Pro
file
Zones
Actual Calculated
ProfilingCapability
Sig
ma
Current Potential
0.000
0.025
0.050
0.075
0.100
0.125
0.150
0.175
0.200
10-4 10-3 10-2 10-1
Pow
er (
vari
ance
)[e-
2]
Frequency (Cycle/Time)
VPA
Diagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 32
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
Diagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 33
Optimization Service Phase 2: Implement
Typical savings for different paper machines:
Every Dollar invested in the reduction of product variability results in a return of 5 to 10 times.
Mill Investment Annual Savings
Ratio
Medium 65k 325k 5 to 1
Fine Writing 95k 610k 6.4 to 1
Newsprint 20k 250k 12.5 to 1
Tissue 70k 650k 9.3 to 1
Towel 75k 560k 7.5 to 1
Pulp 120k 2,270k 18.9 to 1
Average 74k 778k 10.5 to 1
Diagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 34
Optimization Service Phase 2: Implement
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.
Target shift: Moisture
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.
Sheet break recovery, number of breaks and faster startup
A 5 min improvement after a break and less breaks represent $264.300 in savings.
Reduced rejects and customer returns
Improvement in quality results in savings of $4,180.
Total benefits
If the recommendations are followed, the savings as a result of the project will be $425.580.
Diagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 35
Goal: Sustain the reached performance improvements
Adapt service procedures
Change operation strategy
Remote monitoring
Optimization Service Phase 3: Sustain
Availability
Optimization
Maintenance
Continuous Improvement
Sustain PhaseImplement
Utilization
Diagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 36
Optimization Service Phase 3: Sustain
Remote
Fiber Line Stability
Product Variability
Machine Response
Profile Capability
VPA Analyis
KPI
KPI
KPI
KPI
KPI
Local
RD
S
OPCSQL
MachineResponse
ProductVariability
Stock ApproachStability
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0
1
2
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0 5 10 15 20 25 30 35 40 45 50 55 60 65
Actual vs. Calc. Profiles for 1 inch Zones
Pro
file
Zones
Actual Calculated
ProfileCapability
Sig
ma
Current Potential
0.0000.025
0.050
0.075
0.100
0.125
0.150
0.175
0.200
10-4 10-3 10-2 10-1
Pow
er (
vari
ance
)[e-
2]
Frequency (Cycle/Time)
VPA
Combination of Optimization Service and Remote Service to continuously remote monitor important performance indices (KPI)
Diagnose
Implement
Sustain
© ABB Group Paper Automation Service CEU – Optimization Service_EN_RevC2009-04-28 | Slide 37
Optimization Services European Network
Robert SteinhauserManager
OS Central
Magnus VestbergManagerOS North
Jonas WarnqvistBusiness Driver
North+
OS NetworkCoordinator
Uwe BeekhuisBusiness Driver
Central
Fabien LaleufManager
OS South 2
Paul KellyBusiness Driver
UK
John FraserManagerOS UK
FranceSpainPortugalNorth Africa
GermanyBelgiumNetherlandsAustriaSwitzerlandChech Rep.SlovakiaSloveniaHungaryPoland South U.K.
SwedenNorwayDenmarkFinlandPoland NorthRussia
Pool of specialists available for OS in Europe
Luciano BianchiManager
OS South 1
ItalyMEA
Tadeuz RomanowskiBusiness Driver
South 2
Michele StrepparolaBusiness Driver
South 1
Andreas Zehnpfund
André RöppnackJonas Warnqvist
Jonas Berggren
Carl-Magnus Tjeder
Niclas Alfsvåg
Hans Lundberg
Pontus Johnsson
Nicklas Ljungberg
Kent Norman
John-Helge Askeland
Paul Kelly
Joe Bell (Ireland)
Christophe MicloMarco Nieri
Alessandro Camoirano
Dario Fenini
Michele Strepparola
Cees Funcke Patrick Laweless (Ireland)
Jonas Warnqvist team leader.
JC Benedic (Color Control)
P.Beuste & D.Trouche Uwe Beekhuis