Enhancing Paper Mill Performance through Advanced Diagnostics Services Dr. BS Babji Process Automation Division ABB India Ltd, Bangalore IPPTA Zonal Seminar on Best Maintenance Practices in Pulp and Paper Mill to Improve Profitability 17 th & 18 th July, 2014

Outline Introduction Advanced Performance Diagnostics Platform Control Loop Performance Improvement Services Summary 7/3/20152

Introduction Reliable and consistent equipment are needed to Reduce energy consumption Minimize downtime Optimal use of raw material DCS, QCS and Drives are important assets of a paper mill Traditional Maintenance methods are inadequate Need Maintenance strategies that are: Proactive and Predictive Quick and timely resolution of issues Cost effective Advanced Diagnostics Services are available to address such maintenance needs of Pulp and Paper mills. 7/3/20153

Advanced Diagnostics Services Methodology Diagnose Measure performance gap ROI Estimation Prepare action plan Implement Apply corrective actions Improve Performance Sustain Manage Performance gap Diagnose Implement Condition monitoring Pro-Active, not Re-Active Measure and Reduce Performance Gap and sustain it through the plant life cycle 7/3/20154 Mill performance decreases over a period of time

Advanced Service Delivery Platform QCS Drives DCS Service Expert s Performance Applications Equipment Process Local Users Secure Remote Connection Advanced Performance Diagnostics Platform Features: Automatic data collection and analysis Multiple Applications DCS Control Loops QCS Drives Archiving of the information Benchmarking Planning maintenance schedules Remote Connectivity 7/3/20155

Control Loops Performance PID Controller Important assets in a pulp and paper mill Includes both hardware and software PID Controllers are designed to:  Regulate the process  Reduce product quality variations  Improve operations However, it is observed that PID Loops :  are not being maintained  are standing in the way of production and performance. Manual Operation Output Out of range Increasing Variability Improving process 35% 15% 30% 25% Simple PID utilization 7/3/20156

Control Loops Perfromance Deterioration Change in process characteristics Process behavior changes with time as compared to original design. Plants are modified, debottlenecked or added with new equipment Equipment fouling, varying plant loads, seasonal changes Operations Operator do not operate some loops in their design mode of operation due to various reasons Control valve problems Hysteresis, stiction, nonlinear characteristics and Valve sizing PID Tuning parameters Many times default parameters are used Parameters unchanged after initial commissioning 7/3/20157

Loop Performance Diagnosis example : oscillating loops F FC cycling load tight tuning Oscillation could be due to: Controller is tuned too aggressively Control valve is affected by stiction upstream system oscillation generating a disturbance on the loop. Valve stiction 7/3/20158

Benefits of Process Variability Reduction Increased process variability leads to Quality problems Increased operating costs 7/3/20159

Control Loops Performance Assessment Few Control Loops Easy to evaluate Many Control Loops Time consuming to collect data and analyze it to find the problems Impractical to find with simple tools Hard to interpret dependencies between control loops Challenge to handle Increasing complexity of automation With less technical resources Need a systematic and automated method with suitable tools. 7/3/201510

Control Loops Maintenance: Performance Diagnosis Diagnose issues related to Control, Process and Signal Conditioning 7/3/201511

Control Loops Maintenance: Performance Diagnosis Error Dead Band Offset Slow Control 7/3/ Over Control

Control Output SaturationControl Valve Sizing Valve stiction Control Valve Leakage Control Loops Maintenance: Performance Diagnosis 7/3/201513

Control Loops Maintenance: Performance Diagnosis Measurement Out of range Excessive Noise Persistent Disturbances Stepout 7/3/201514

7/3/ Control Loops Maintenance: Implementation Examples Prioritized Control Loops tuning Instrumentation calibration or repair Control Loop Configuration Enhancements Valve and positioner repair Base tuning prior to APC Projects Investigation of Root Cause Disturbances Original Tuning (Unstable) New Tuning Manual Operation Original Tuning (Unstable) New Tuning Manual Operation Original Tuning (Unstable) New Tuning Manual Operation

7/3/ Control Loops Maintenance: Sustain Scan Automatic data collection and diagnosis at scheduled intervals Implement the corrections Periodic detailed analysis of the diagnosis results for process improvements Track Continuous monitoring of key Performance Indices ( KPIs) Send notification automatically to concerned managers Advanced Diagnostics Platform for SCAN and TRACK activities DrivesQCS DCS User Defined Access QCS Expert Drives Expert DCS Expert Remote Service Local Remote Secure Access Continuous Diagnostics

Control Loops Maintenance: Benefits Shifting of the targets for Moisture & Basis Weight results in Fiber and energy savings. 7/3/201517

Control Loops Maintenance: Benefits Reduced response time after tuning results in faster recovery after sheet breaks grade changes start ups. This results in increased production and reduced broke. 7/3/201518

Summary Proactive and predictive maintenance strategies meet the challenges of reliability and consistency of equipment in pulp and paper mills.. Service methodology of ‘Diagnose, Implement and Sustain ‘ helps in reducing the downtime and improve the performance of assets in a mill. Innovative service delivery platforms with sophisticated software tools are available for continuous automatic data collection and analysis to diagnose the problems in DCS, QCS and Drives.. Control Loops are important assets in a pulp and paper mill and their performance deteriorate over a period of time due to changes in process characteristics, wear and tear, controller tuning, seasonal changes etc Control Loop Performance Diagnostics & improvement services help in Improving product quality, increasing the thruput reducing energy consumption 7/3/201519

Thank You 7/3/201520