Improved Performance with Industrial Internet - … · 24/7 ProCenter for DCS/QCS PaperIQ Select 2010’s Metso PQV web ... Critical part lifetime ... Optimal forming section water

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

24 May, 2017 © Valmet | Wolfgang Shuessler4

Valmet has a long history in the digitalization of process industries

24 May, 2017 © Valmet | Wolfgang Shuessler

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

7 24 May, 2017 © Valmet | Wolfgang Shuessler

Case: Roll cover life time

Increased production efficiency

Case: Magazine paper machineHow to extend intervals between shut downs?

Issue: Calender rolls!

24 May, 20178

Wear and vibration determines shut down interval

© Valmet | Wolfgang Shuessler

How to address these kind of problems?Analytics as service from Valmet


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


𝑅2 = 89, 2 %

Case: Office paper machineHow to run longer intervals?


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


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


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)


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)


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


Valmet Maintenance Pad


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)


Valmet Maintenance PadPanasonic 7” or 10” tablet

23

Current developments


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


KPI Monitoring and BenchmarkingValmet Industrial Internet


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


../valmet_fleet_management_master_v1.mp4

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


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



Innovation

Innovation

Customer satisfaction

Benefits and results

Summary

Customer satisfaction

Innovation

Digital Twin

Future of industrial internet32 24 May, 2017 © Valmet | Wolfgang Shuessler

Documents

Improved Performance with Industrial Internet - … · 24/7 ProCenter for DCS/QCS PaperIQ Select 2010’s Metso PQV web ... Critical part lifetime ... Optimal forming section water