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Improved Performance with Industrial Internet
Wolfgang SchüßlerSenior Technology Manager Industrial Internet EMEAValmet, Finland
Valmet’s competence
network
We want to become the most desired Industrial Internet partner for our customers
Valmet develops its
Industrial Internet
solutions building on the
unique combination of
process technology,
services and automation
Industrial Internet solutions
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Valmet has a long history in the digitalization of process industries
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1970Elmatic-100
system, electronic
instrumentation
1990’sPaperIQ, QCS
metsoDNA, Dynamic Network
of Applications
1980’sDamatic, the first Distributed Control
System (DCS)
Sensodec Condition Monitoring System
Damatic XD, modular second generation
DCS
2000’sMultivariable Model
Predictive Controls (MPC)
24/7 ProCenter for DCS/QCS
PaperIQ Select
2010’sMetso PQV
web inspection system
2015Valmet DNA
2015Valmet IQ
1960The Airmatic
a pneumatic
measurement and
control system
Distributing
controls &
gathering
performance data
Increasing
availability
Increasing
productivity
through
information
services
Embedded
intelligence &
advanced
information
Benchmarking and
best practice
sharing capability
5
Customer Benefits
Contents
Valmet Maintenance Pad
1
2
3
Energy Savings
Extended Roll cover Lifetime
3
Current Developments
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Case: Roll cover life time
Increased production efficiency
Case: Magazine paper machineHow to extend intervals between shut downs?
Issue: Calender rolls!
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Wear and vibration determines shut down interval
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How to address these kind of problems?Analytics as service from Valmet
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Preparation
Meeting
Discovery
WorkshopExecution of
results
Data
profiling
A N A L Y T I C A L D I S C O V E R Y
Customer
case(s)
Data either trough on-line connection or as a batch load with hard drive
What will be done with analytics ?Correlations and performance models – 15 parameters explains roll lifetime
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𝑅2 = 89, 2 %
Case: Office paper machineHow to run longer intervals?
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Customer target:
Planned shutdown interval
from 5 weeks to 6 weeks
Wear and vibration determines shut down interval
What can be answered by performance models ?
Performance modeling is a basis for giving advise
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Critical part lifetime (days)
0 5 10 15 20 25 30 35
How many running
days remaining?
Actual
Predicted
Can lifetime be
extended?
Lifetime with
alternative component?
Critical Vibration Level
10 days
5 days 5 days
13
Case: Energy Optimization
Significant savings in both steam and electricity through data analytics
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Energy savings through data analytics
14
Case: Fluting machine
Recycled fluting machineBasis weight 90-150 g/m2
Design speed 1 200 m/min
Trim width 6 660 mm
Start-up 2014
Same grade and production rate, but different steam consumption
(125gsm: 1,28 t/t vs 1,46 t/t)
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Vacuum element study-based running pointsOptimal forming section water removal based on dryer section steam consumption
Water removal MD profile in former should be tuned so that water removal amount of elements are as shown below (left
red circles 610, 580, 450 and 790 dm3/min with basis weight 125 g/m2 and production 45 t/h)
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Corrugating medium grade A105g/m2
Electricity consumption
reduction from 230 kWh/t
to 200 kWh/t
Steam consumption
reduction from 1,55 t/t to
1,25 t/t
Oct 2014 Feb 2015Oct 2014 Feb 2015
Significant savings in steam and electricity consumptionCase: Siam Kraft Industry PM16, Thailand
16% energy savings with
remote data analysis
Value 3 M€/a
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Valmet Maintenance PadCondition monitoring in the palm of your hand
Wireless industrial tablet identifies machinery
with potential problems that require scheduled
servicing and alerts to risk of breakdowns.
Tool for offline vibration measurement
Collects, measures and stores vibration signals
Route/off-route measurements
Touch-screen user interface for basic or
advanced analysis (database on Pad)
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Board Strength Model for SCT
• Model to predict SCT in order to
lower production costs
• Covers all grades
• Expected relationships were
identified:
• Specific energy increases strength
• Recycled fiber and broke lowers
strength
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KPI Monitoring and BenchmarkingValmet Industrial Internet
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Online Monitoring and Dashboard
Example: FormMaster remote monitoring
Breast roll shaker condition can be monitored remotely by Customer and
Valmet
Remote support from Valmet (process and software expertise)
Data collection for Valmet analyzes to improve equipment efficiency
Customer portal
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Cyber security for Industrial Internet
Cloud:
Role-based access control
Strong authentication for both customers
and internal Valmet users
All data encrypted in move and rest
Customer sees only his own data and
anonymized industry reference
• High level security cloud provider
Installation:
Security services for patches and updates
available
Secure VPN connections
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Digital trust
Valmet Industrial InternetWay forward through co-creation with the customers
Valmet Performance Center
Advanced Human / Machine interfaces and
mobility (Dashboards / KPI)
New contributing technologies
– AR / MR / VR (e.g. Microsoft HoloLenses)
– Location detection technologies
New data driven applications and services
through advanced analytics and AI
– Reliability improvement
– Performance improvements
– Improved quality and reduced process variability
– “Digital Twins”
Vertical and horizontal integration through
strong ecosystem of partners
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Innovation
Innovation
Customer satisfaction
Benefits and results
Summary
Customer satisfaction
Innovation
Digital Twin