ABB's paper machine fingerprinting, Identifies opportunities for machine performance improvement. Paper Machine benchmarking establishes current machine performance and provides a basis for evaluating and identifying improvement opportunities.
The resulting diagnostic report provides improvement recommendations and associated estimated ROI. Typical savings potential: $150,000 – $350,000
Benefits
-Facilitates management decision process by focusing on high impact opportunities for improvement
-Provides clear path to quickly close the performance gaps by using the proposed improvement plan
-Provides a solid foundation for continuous improvement based on data
Features
-Access to ABB optimization experts
-Process performance benchmarking
-Detailed ROI-based improvement plan
-Clear communications during data collection and diagnosis activities
Paper Machine Fingerprint
The ABB Paper Machine Fingerprint is ABB’s process performance diagnostic service for paper machine optimization. The fingerprint generates both a performance benchmark and an improvement plan, consisting of a set of improvement opportunities, which are prioritized based on estimated economic benefits. It is a platform-independent, non-invasive service that can be applied to any paper machine.
Process Performance Indicators
The fingerprint involves comprehensive testing and analysis designed to measure four key performance indicators. These performance Indicators are used to assess machine performance and improvement area potential (see Figure 1).
-Product Variability
-Machine Response
-Stock Approach Stability
-Profile Capability
Historical data is used to validate test results.
Machine Testing
Each performance indicator includes a series of indexes derived from specific machine tests. Each test is performed inside product specifications, utilizing ABB’s diagnostic tools and methodologies. The resulting index is used to evaluate the performance level of different areas of the paper process including:
-Mechanical vibration and rotational frequencies
-Machine and cross direction controls
-Lab testing procedures
-Sheet break recovery
-Process control system performance
-Coordinated speed control
-Grade change control
Identifying machine area under-performance is the first step in the improvement process. Understanding the problem and having the expertise to provide solutions is assured through ABB’s extensive experience in paper machine control.
Implementation Modules
In order to provide practical solutions for problems often identified in the paper making process, ABB has developed defined, logical optimization steps for each machine area.
The numerical result or index of each test points to the machine area problem and also points to the bottleneck location in the optimization sequence.
Once the entry point has been established for each machine area, the solution to the performance bottleneck and the remaining steps to optimize the process become clear. The Machine Response indicator is used to determine a performance index for the machine direction controls (see Figure 2). The test entry point is defined by the specific machine tests and data analysis associated with this performance indicator.
The Machine Response indicator includes multi-level testing and analysis applied to Dry Stock, Weight, Moisture, Rush/Drag, and Ash Controls. Similar testing methodologies are involved with each performance indicator. Complete Machine Area testing sequences require three to five working days to collect the data required for the diagnosis and to compare improvement recommendations.
Reporting
An Executive Report and a Technical Report are provided to disclose the findings and recommendations of the process performance diagnosis.
-Technical Report provides supporting data collected during the machine diagnosis.
-Executive Report provides benchmark results, summary of findings, financial impact of recommendations, and an actionable improvement plan, based on the machine diagnosis.
Improvement Plan
The improvement plan defines how to resolve the performance bottleneck and improve performance. In addition, the associated financial impact for each recommendation is provided. Based upon the findings, recommendations may include valve replacement, isolating high frequency machine problems related to: rolls, pumps, screens, machine clothing, cleaning up signal conditioning problems, optimizing or adding control logic, updating standard operating procedures, or re-tuning controls for optimal performance.
The Paper Machine Fingerprint is the first step in achieving and sustaining higher performance levels. Annual Fingerprint, Implementation, and Sustaining services are recommended as part of your service contract agreement to achieve and continue the improvement process. These can be scheduled within a single- or multi-year service contract agreement. ABB is the world leader in pulp and paper applications. In depth knowledge and experience in this area allows comprehensive evaluation, diagnosis, remedial recommendations and implementation, and the ability to manage and sustain process performance improvement.