valmet industrial internet dialogue with data. zonal -2- 2018.3 valmet ppt.pdf · 2019-04-17 ·...
TRANSCRIPT
Dialogue with data
Valmet Industrial Internet
© Valmet | Industrial Internet1
Dialogue with data
• Combining process and business data
from different mill or plant systems
• Utilizing advanced analytics, artificial
intelligence (AI) and our know-how to
discover hidden improvement potential
• Using the findings in daily process and
operations optimization
Valmet Industrial InternetLeveraging new data-driven opportunities
© Valmet | Industrial Internet2
Process data• From process automation system and measurements
• Process and quality controls into targeted setpoints
Company level data• Business planning and fleet management
Mill and plant level data• From ERP, MES and CMMS systems
• Production management and operations optimization
Results
Reduced raw material & energy cost
Improved end quality
Reduced downtime
Optimized maintenance
Unique Combination for PPP customers
© Valmet | Industrial Internet3
Valmet develops its
Industrial Internet
solutions building on the
unique combination of
process technology,
services and automation.
Industrial Internet solutions
Customer’s process
Valmetexperts
Valmet’s competence
network
Valmet DNA
Valmet Industrial Internet platform componentsare based on certified and secure world-leadingtechnologies
25 November 2018 © Valmet | Industrial Internet4
Valmet’s cloud environment
Database
Valmet Customer Portal
Valmet Performance Center
Online
connections with
customers
Performance
agreements with
remote
connections
Co-creation of
advanced
analytics with
customers
Valmet-supplied
lines with Valmet
DCS and QCS
systems
540420
81,000 90Advanced
process control
installations
350800~1600
Ongoing
Today, customers are extensively utilizing our Industrial Internet capabilities
© Valmet | Industrial Internet5
Valmetexperts
Valmet’s competence
network
Customer’s expert
420 Condition
Monitoring (CM)
references with
over 81 000 I/O
tags
Valmet Industrial Internet (VII)Building blocks
© Valmet | Industrial Internet6
Applications and services
• Data visualization, reporting and guidance
• Asset reliability optimization
• Operations performance optimization
• Valmet Performance Center
Solution ecosystem
brings leading industry players
together to co-create value-
adding applications and services.
Automation and IT platform
Process technology
Applications and services for board & paper producers
Industrial Internet portfolio
25 November, 2018
© Valmet | Industrial Internet
Asset reliability optimization Operations performance
optimization
Advanced reporting and
guidance
Valmet Performance Center
Analytics
as a service
Remote
monitoring &
optimization
On-demand
expert
support
Process
performance
monitoring
Process
simulators
On-site
analysis &
reporting
Dynamic
centerline
manager
HoloMill Pulp to paper
optimization
Real time
quality
prediction
Mill-wide
optimization
Cost
Monitoring &
Optimization
Paper
Machine
Diagnostics
MillTracer
Control loop
performance
monitoring
Condition
monitoring
remote analysis
Web break
prediction
Connectivity
Valmet Performance CenterEasy access to the expertise you need
© Valmet | Industrial Internet8
Valmet
Performance Center
Local
Valmet
experts
Customer
experts
Global
equipment fleet
Valmet expert
network
TissuePaperEnergy Automation
Remote monitoring
and optimization
Pulp
Performance Centers for:
Automation
On-demand expert supportData discovery and analysis
process
Valmet Performance Center
© Valmet | Industrial Internet9
Easy access to the expertise you need
– Remote tools bring our expert network close to you
– You have a place to contact when help is needed
Services
– Continuous remote monitoring, controls fine tuning
and optimization.
– On-demand expert remote support
– Data discovery and big data analysis services
based on the customer’s business problem (e.g.
defining root causes for process variations)
Secured data connection with your mill
Your channel for data-driven performance improvement
Energy optimizationwith remote supportfor paper and board machine
Energy optimization with remote supportfor Recycled Fluting Machine
© Valmet | Industrial Internet11
Service description
– Process optimization both remotely and on-
site to save energy
– An operator application integrated to the
machine control system
– Energy usage shown in real time and
compared to best achieved performance
– Grade-specific energy consumption and
history reports
– Continuous monitoring and reporting by
Valmet Performance Center experts
Benefits
– Increased awareness and understanding of
energy used in the process
– Improvement opportunities can be identified
– Energy savings in electricity and steam
– Significant cost savings
OCM kuva
Anssi: vaihdatko metso-logot
valmetiksi☺
Energy optimization with remote supportResults for a containerboard customer (name confidential)
© Valmet | Industrial Internet12
Corrugating Medium 105 g/m2Corrugating Medium 105 g/m2
Oct 2014 Dec 2014 Oct 2014 Dec 2014
Ste
am
Consum
ption [
t/t
]
Ele
ctr
icity C
onsum
ption [
kW
h/t
]
300
280
260
240
220
200
180
160
2.2
2
1.8
1.6
1.4
1.2
1
Key facts of the containerboard machine
• Grade: recycled fluting
• Basis weight 90–150 g/m2
• Design speed 1,200 m/min
• Trim width 6,660 mm
• Start-up 2014Electricity consumption reduction
from 245 kWh/t to 205 kWh/t
Steam consumption reduction
from 1.55 t/t to 1.4 t/t
Results
16%energy
savings in
electricity
10%energy
savings in
steam
2M€/avalue
Predictive Condition MonitoringImproved reliability through real-time monitoring solutions
Performance monitoring for TwinRoll wash pressService description and benefits
© Valmet | Industrial Internet14
• Service description– Real-time monitoring of TwinRoll operational
performance and end product quality
– Fleet management: Data collection and
modelling for predictive maintenance
– Customer interface with KPI dashboards for
analyzed and visualized performance data
– Automated recommendations for operators
– Continuous monitoring and reporting by Valmet
Performance Center experts
Benefits
– Relevant information for maintenance and
production decision making
– Improved maintenance predictability and fleet
performance
– Fewer unplanned stops and improved
performance
Performance monitoring for TwinRoll wash pressPotential results for a pulp mill
Improved washing efficiency and
reduced chemical consumption through
better wash liquor distribution and even
pulp formation
Fewer unplanned stops in production
Extended machine component lifetime
through predictive maintenance
© Valmet | Industrial Internet15
Results
Potential savings in wash
losses
15%
Potential increased
lifetime of wear parts
10%
Pu
lp f
low
Pulp consistency
By adjusting pulp flow and pulp consistency
based on automatic recommendations it is
possible to achieve the optimal operating
window faster
Reaching optimal operating
window after start-up
Pulp to Paper Optimizationvia Advanced Process Control (APC)
© Valmet | Industrial Internet17
Service description• Collecting large data set of process and/or
analyzer data
• Modelling and predicting final pulp, paper and
board properties. Modelled variables include:
– Pulp hand sheet properties: tensile, tear, bulk, SCT,
CMT
– Paper and board properties: tensile, tear, porosity,
internal bond, STFI
• Quality models and predictions are implemented
online and visualized for operators
Benefits• Online strength information
• More stable final product quality
• Online quality predictions help optimize raw
material and chemical consumption, energy and
quality
Pulp to paper optimization
Linerboard burst model vs process
MeasurementModel
R-squared 84.7%
Bu
rst [k
Pa m
²/g
]
Time
2016-07-18 2016-08-15 2016-09-12 2016-10-10 2016-11-07 2016-12-05 2017-01-02
185
190
195
200
205
210
29.4.
8:00
29.4.
12:00
29.4.
16:00
30.4.
0:0030.4.
4:00
30.4.
8:00
30.4.
12:00
30.4.
16:00
30.4.
20:00
Magazine paper CD tear prediction
CD
Tear
[mN
]
Target
Plab Measured
Predicted - based onPlab mesurements
Model prediction NOW
Paper and board properties modelling
Control the process to final pulp and paper properties
© Valmet | Industrial Internet18
Service description ( sack paper m/c)• Control the process to final pulp, paper and
board properties by Model Predictive Control
(MPC) to reduce variability.
• Controlled variables based on process and
customer needs, strength and other properties
models
• Optimize process by MPC and move process
toward economic optimum
• Manipulated variables:
– Low consistency refining specific energy
– Stock blending, flows and consistencies
– Chemicals and starch
– Water removal, wet pressing, draws
Benefits• Raw material and energy savings
• Decreased breaks, increased PM speed
• Online strength information, more stable final
product quality
Pulp to paper optimization ( Sack Paper M/C)
Strength
Reduced
variability
Before
Target
shift
HW Refining
SW Refining
Specific Energycontroller loops
Paper
Machine
Chest levelsStock flowStock consistency
Specific Energycontroller loops
Stock ratios
•Basis weight 60–135 g/m2
•Design speed 1,200 m/min
•Trim width 4,440 mm
•Upgrade 2000
Pulp to paper optimization
Results for a sack paper customer (name confidential)
© Valmet | Industrial Internet19
Results
Pulp quality window
performance improved by
26%
Tensile strength
window performance
improved by
32%
Significant reduction in paper properties
variation
Improved paper machine stability and
higher machine speed
Tensile strength quality window Tear strength quality window Freeness and fiber length quality window
On-control data of 3 months (green color)
Valmet Control PerformanceAutomation system control loop performance improvement
Service description and benefits
© Valmet | Industrial Internet21
Service description– Automation system control loop and actuator
performance is continuously monitored and
analyzed by automated tools
– Priority list of non-performing loops is reported
on a regular basis
– Valmet Performance Center experts evaluate
the results and make recommendations on
actions. Remote tuning is also available.
– Customer can view control loop performance at
corporate, mill, department, and loop level
Benefits– Prioritized recommendations for maintenance,
resulting in better allocation of resources
– Reduced unplanned downtime and
maintenance cost
– Raw material and energy savings
– Improved product quality, less quality variability
Plant life cycle
Con
trol perf
orm
an
ce
Production disruption
Target
Predictive
maintenancePreventive
maintenance
Corrective
maintenance
Performance of the loops
under control
Typical
performance
Acceptable level
Valmet Control Performance
Control loop performance improvementResults for confidential customer, fiber line and recovery line
• Control loop performance
improvements are achieved by
implementing recommendations,
e.g. control loop variability
reduction, operating point changes
or fixing actuator and
instrumentation issues
• Better maintenance resources
allocation
• Peak performance sustained long
term by stabilizing processes
© Valmet | Industrial Internet22
Confidential customerFiber line and recovery line processes
• Cooking, washing, oxygen delignification, bleaching
• Evaporation, recovery boiler, causticizing and lime
kiln
Temperature control loop tuning
Reduced
temperature
variation
Consistency control loop tuning
Before tuning
After tuning
Measurement
Control output
Continuous dialogue with data – way forward
Valmet Industrial Internet roadmapWay forward through co-creation with customers
Integrated customer portal and mobility
Growing fleet of intelligent machines and more
diagnostics embedded into processes
Valmet Performance Center as a platform for
digital services and big data analytics
New contributing technologies
– Mixed reality through Microsoft HoloLens
– Location detection technologies
Data driven applications and services through
advanced analytics, machine learning and AI.
– For reliability and performance improvement
Advanced process controls for all process areas
and mill wide optimization
Vertical and horizontal integration through strong
ecosystem of partners
© Valmet | Industrial Internet24