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ABB launches analytics software and services that combines operational data with engineering and IT data to deliver actionable intelligence

The ABB Ability™ Genix Industrial Analytics and AI Suite is a scalable advanced analytics platform with pre-built, easy-to-use applications and services. It collects, contextualizes and converts operational, engineering and information technology data into actionable insights that help industries improve operations, optimize asset management and streamline business processes safely and sustainably.

Analyst studies suggest that industrial companies typically are able to use only 20 percent¹ of the data generated, which severely limits their ability to apply data analytics meaningfully. ABB’s new solution operates as a digital data convergence point where streams of information from diverse sources across the plant and enterprise are put into context through a unified analytics model. Application of artificial intelligence on this data produces meaningful insights for prediction and optimization that improve business performance.

“We believe that the place to start a data analytics journey in the process, energy and hybrid industries is by building on the existing digital technology – the automation that controls the production processes,” said Peter Terwiesch, President of ABB Industrial Automation. “We see a huge opportunity for our customers to use their data from operations better, by combining it with engineering and information technology data for multi-dimensional decision making. This new approach will help our customers make literally billions of better decisions.”

ABB Ability^TM Genix is composed of a data analytics platform and applications, supplemented by ABB services, that help customers decide which assets, processes and risk profiles can be improved, and assists customers in designing and applying those analytics. Featuring a library of applications, customers can subscribe to a variety of analytics on demand, as business needs dictate, speeding up the traditional process of requesting and scheduling support from suppliers.

Scalable from plant to enterprise, ABB Ability™ Genix supports a variety of deployments including cloud, hybrid and on-premise. ABB Ability™ Genix leverages Microsoft Azure for integrated cloud connectivity and services through ABB’s strategic partnership with Microsoft. 

“The ABB Ability™ Genix Suite brings unique value by unlocking the combined power of diverse data, domain knowledge, technology and AI,” said Rajesh Ramachandran, Chief Digital Officer for ABB Industrial Automation. “ABB Ability™ Genix helps asset-intensive producers with complex processes to make timely and accurate decisions through deep analytics and optimization across the plant and enterprise.

“We have designed this modular and flexible suite so that customers at different stages in their digitalization journey can adopt ABB Ability™ Genix to accelerate business outcomes while protecting existing investments.”

A key component of ABB Ability^TM Genix is the ABB Ability™ Edgenius Operations Data Manager that connects, collects, and analyzes operational technology data at the point of production. ABB Ability™ Edgenius uses data generated by operational technology such as DCS and devices to produce analytics that improve production processes and asset utilization. ABB Ability™ Edgenius can be deployed on its own, or integrated with ABB Ability^TM Genix so that operational data is combined with other data for strategic business analytics.

“There is great value in data generated by automation that controls real-time production,” said Bernhard Eschermann, Chief Technology Officer for ABB Industrial Automation. “With ABB Ability^TM Edgenius, we can pull data from these real-time control systems and make it available to predict issues and prescribe actions that help us use assets better and fine-tune production processes.”

Further details can be found online:

ABB Ability™ Genix

ABB Ability™ Edgenius

¹ARC Advisory Group

ABB Wet End Control offers process stabilization, variability reduction and performance optimization for all paper, board and tissue manufacturers

ABB has just launched the latest generation of its Advanced Process Control (APC) to provide complete digital control over wet end operations, optimizing productivity and profit for paper mills globally.

Wet End Control — an ABB Ability™ APC solution for paper mills — stabilizes the wet end process and reduces variability by controlling, monitoring and optimizing retention performance. It uses a multivariable model predictive control approach to predict future wet end process behavior, making automatic adjustments to stabilize ash levels, reduce white water consistency variability and minimize chemical and filler dosages.

This results in improved machine runnability by helping to reduce sheet breaks, and accelerating grade changes and break recovery. Papermakers can then track performance from the wet end to the final sheet. It is available as a subscription-based service delivered via ABB Ability™ Collaborative Operations, with structured remote monitoring and expert analysis of control performance for sustainable results. 

In addition to its impact on productivity, Wet End Control helps to minimize raw material, chemical costs and broke usage, ultimately reducing the environmental impact and leading to lower steam consumption and increased energy savings.

Operator interface for Wet End Control an ABB Ability Advance Process Control solution

“We know that continuous monitoring of wet end operations is crucial to driving process improvements,” said Ramesh Satini, global product manager for Pulp & Paper Control Systems, ABB. “We developed our Wet End Control solution to address this need by automatically managing targets and implementing cost efficiencies within process constraints. By adopting this ABB service, mills will benefit from ongoing insight and collaboration to optimize stability for long-term gains and minimized operator interventions.”

Wet End Control is part of a fully integrated quality measurement, control and optimization solution that works seamlessly with ABB Ability 800xA control system or a third-party alternative (via OPC interface). ABB’s latest APC platform allows dynamic model adaption to capture varying process dynamics for tighter control, while optimally working within operational parameters to maximize the economic gain. The solution is suitable for all mills seeking a quality measurement, control and optimization solution that enables paper specifications to be met at the lowest possible cost.

Rapid revamp of dormant mill will provide cutting-edge, digital solutions to automate operations and optimize performance

Leading Canadian forest product company, Chantiers Chibougamau, has selected technology leader ABB to help overhaul its Nordic Kraft pulp mill in Lebel-Sur-Quevillion in northern Quebec. The order comprises the delivery and integration of a new drives system and ABB Ability ™ Quality Management System (QMS). This includes ABB’s Web Imaging System (WIS) and Web Monitoring System (WMS) into the ABB Ability™ System 800xA distributed control system (DCS). ABB will provide a comprehensive service contract and remote connection for diagnostic and service activity.

The project will transform the Nordic Kraft mill, which had been dormant for 12 years prior to its acquisition by Chantiers Chibougamau in 2018. It will become a modern, efficient and fully integrated digital site, equipped for the first time with complete quality control. The new solutions will accelerate Nordic Kraft’s issue identification and produce semi-autonomous responses to conditions leading to fewer quality rejects.

“The high value and quality of ABB solutions together with our stepwise approach and ability to complete a tight turnaround were the key to this order win,” said John Roberts, Market Segment Manager for Pulp and Paper, ABB. “We worked closely with the mill to ensure that everything we supply has a clear benefit in terms of quality control and ease of operability. Our suite of leading technology coupled with remote monitoring, diagnostic and issue resolution means Nordic Kraft can head off problems before they arise and optimize production to make more on spec kraft pulp.”

ABB NP1200 scanner

As part of the ABB Ability™ QMS, the order includes a new NP1200 scanner with online sensors for moisture, brightness and ABB’s revolutionary Basis Weight Sensor, which offers industry-leading levels of accuracy and reliability in basis weight measurements. The Basis Weight Sensor provides the detailed information needed for optimal machine direction (MD) and cross direction (CD) weight control. The QMS also includes a WIS installation with Web Imaging Dirt Count and a WMS with eight cameras, all designed to provide operators with full visibility over production with integrated online measurement, process and quality controls and defect detection.

“We wanted a reliable and flexible way to make this mill, inoperative for 15 years, more productive and profitable,” said Dany Bellemare, Senior Electrical Engineer and Reliability/Plant Upgrading Project Manager, Nordic Kraft in Lebel-sur-Quévillon. “We were impressed by ABB’s commitment to demonstrating the value in every part of their proposed solution and look forward to a long and successful collaboration.”

Chantiers Chibougamau Ltée, a family business founded in 1961, employs nearly 600 people in Chibougamau, a quarter of the working population in this northern Quebec municipality. The company values ​​the forest resources of the northern boreal forest in Quebec to produce lumber products, I-beams, beams and columns of Nordic Lam glued laminated wood and Nordic X cross-laminated wood panels. -Lam. The latter products are marketed by its sister company Nordic Structures, which relies on a multidisciplinary team of 35 professionals specializing in wood design and engineering. These products are mainly distributed in North America for residential construction and in Quebec for non-residential construction.

Leading US paper and packaging producer looks to increase reliability and performance with dry end drive system replacement.

WestRock Company—a leading provider of differentiated paper and packaging solutions—has selected ABB to replace its dry end drive system. This includes upgrades to its PM12 paper machine drives, motors and the installation of the ABB Ability™ System 800xA control system at its mill in Longview, Washington, USA. Installation and commissioning of the project is planned for completion by year-end 2020.

“ABB was chosen for this project based on the customer’s positive experience with our drives systems at its Longview mill and other WestRock sites,” said Steve St. Jarre, Head of Business Development, Pulp and Paper, Process Industries, ABB.  “We were able to provide a cost-effective, phased approach to this upgrade project. We set up a new 800xA system to control both existing and new drives. The existing drives can be replaced as needed and use the same control platform as the mill evolves.”

The new ABB drive system will have a smaller footprint and require minimal parts. The modular drives are extremely compact, but with all of the parts easily accessible. This not only reduces interruption to production for planned and unplanned maintenance, but also reduces spare part inventories.

“With our aim of improving reliability and productivity, without the need for extensive downtime during installation, ABB offered a practical approach to achieve our goals,” said Rick Siragusa, Project Manager at WestRock. “We look forward to moving forward with the replacement.”

New sensors offer widest variety of measurement options available, incorporating unique principles for unparalleled levels of accuracy and control, with reduced maintenance.

ABB has just launched its KPM KC9 Optical Consistency Transmitter family, a new range of sensors that provide accurate measurement of total and/or ash consistency for better wet end measurement and control in pulp and paper processes. The sensors are suitable for pulp, paper, board and tissue manufacturers using virgin or recycled raw materials, particularly those using ash fillers, where only optical sensors are effective to measure ash consistency.

Available as either inline or bypass sensors, the entire KPM KC9 Optical Consistency Transmitter family offers the widest range of sensor options currently available and is best suited to measure the lowest consistency ranges. Providing reliable and accurate results, the sensors permit maintenance while processes are running, unlike other consistency sensors which require a shutdown and emptying of the process pipe.

ABB KPM KC9 Inline Optical Consistency Transmitter sensor

The sensors work in tandem with ABB’s KPM KRA/KRT Retention Measurement System, used to monitor and control paper and board machine retention. Available in two options, the KRA unit measures white water total consistency as well as ash consistency. The KRT unit measures total consistency only.

“These new sensors employ unique measuring principles to ensure each application is covered cost effectively without compromising measurement accuracy,” said Per Sandstrom, Head of Lab and Process Testing Measurements, Pulp and Paper, Process Industries, ABB. “The sensors provide better control of deinking processes and machine wet end, enabling the highest proportion of on spec product with limited maintenance and lower installation costs.”

Besides its Optical Consistency Transmitter, ABB’s retention measurement system includes all necessary modules to ensure accurate and trouble-free measurement of headbox or white water stock, where consistency is so low that only optical technologies can be used. The system and sensors are part of ABB’s complete solution set for the wet end, including quality control, automation, advanced process control, instrumentation and much more.

ABB KPM KC9 Bypass Optical Consistency Transmitter sensor

The KPM KC9 Optical Consistency Transmitter range

Inline sensors

The KPM KC9 inline consistency sensors are developed to measure single component fiber consistency in liquids from 0-14 percent.

Bypass sensors

The KPM KC9 bypass consistency sensors are developed to measure consistency in liquids from 0–5 percent.

All the new models with updated electrical and software design are evolved from industry-proven KPM OC Optical Consistency Transmitters. These were originally developed in cooperation with Cerlic, which has a 40-year heritage in pulp and paper applications.

For further information on the KPM KC9 Optical Consistency Transmitter family of sensors, please visit: https://new.abb.com/pulp-paper/abb-in-pulp-and-paper/products/process-measurements

New Induction xP Plus is the paper industry’s most targeted, efficient and flexible induction heating actuator system for cross-direction (CD) caliper and gloss profile control

Technology leader ABB today announces the launch of its Induction xP Plus actuator for paper and packaging manufacturers seeking a powerful, efficient, rapid-acting and safe method for controlling caliper on paper machines calenders.

Induction xP Plus rapidly ensures efficient heating up to 100 kW/meter in a highly-targeted area, providing unmatched flexibility for power density and heating zone width. It is the only caliper profiling system available with hybrid control zone configurations of 60 mm, 75 mm or 120 mm, enabling customers to target higher precision heat distribution at the edges, where it is often critical, as well as increasing heat density to get on spec quicker—even after sheet breaks.

“Induction xP Plus significantly enhances our offering as the only actuator featuring ABB’s unique power module technology, hybrid zones for targeted heat distribution and flexible layout configurations,“ said ABB product manager, Frank Condra. “The specification is developed to maximize paper quality and productivity, but crucially, includes an off-machine power module, enabling Induction xP Plus to meet the most stringent industrial safety requirements.”

An evolution of ABB’s highly-regarded Induction xP actuator, the new Induction xP Plus uses ABB’s uniquely efficient fixed frequency/soft switching technology which, in tandem with a lower voltage design, ensures negligible switching losses and lower stresses on electronic components. Induction xP Plus also features serial communications to the power modules, a three-phase power bus distribution system and advancements in the mower module and workcoil. These features combine to deliver the lowest CD caliper variation and associated improvements in reel build, while also providing the best sheet finishing for gloss, smoothness, and printability.

ABB’s Induction Profiler is an integral part of the ABB Ability™ Quality Management System, which is based on industry-leading ABB Ability™ System 800xA. By utilizing advanced measurement, control strategies and high-performance algorithms, ABB caliper and gloss control minimizes caliper and gloss variations under any operating conditions.

Coupled with ABB Ability^TM Collaborative Operations, the Advanced Process Control project will help drive efficiency gains

Double A, one of Asia’s leading pulp and paper producers, has selected ABB Ability™ Advanced Process Control (APC) for its pulp mill in Prachinburi, Thailand. The new contract includes full supply and implementation of ABB’s OPT800 Caust and OPT800 Lime APC applications for better control of the causticizing and lime production processes.

Both APC applications leverage multivariable Model Predictive Control (MPC) algorithms integrated into ABB Ability^TM System 800xA distributed control system. OPT800 Caust stabilizes the white liquor quality by controlling the lime feed and green liquor, causticizing efficiency and production rate changes. OPT800 Lime optimizes kiln operations to reduce energy consumption and emissions, increase reburned lime availability and decrease residual carbonate variations.

“APC represents the future for the pulp and paper industry, with powerful applications to help reduce material costs while maintaining quality and productivity,” explained Thanom Saenchompoo, Sales Manager, ABB. “One of the main benefits of APC is the ability for operators to make changes to processes, observe their impact and keep fine tuning until they are ready to implement those changes in the actual operation.”

The installation and commissioning for the OPT800 Lime APC has just been completed while OPT800 Caust APC will take place by end of the first quarter in 2020.

Completing the order is an ABB Ability^TM Collaborative Operations service agreement, which will help monitor and sustain the performance of the batch digester, lime kiln and causticizers.

Double A Public Co., Ltd., founded in 1991, is Thailand’s leading paper brand and its main mill is located in Prachinburi, Thailand, producing 600,000 tons of pulp and paper each annually.

ABB (ABBN: SIX Swiss Ex) is a technology leader that is driving the digital transformation of industries. With a history of innovation spanning more than 130 years, ABB has four, customer-focused, globally leading businesses: Electrification, Industrial Automation, Motion, and Robotics & Discrete Automation, supported by the ABB Ability™ digital platform. ABB’s Power Grids business will be divested to Hitachi in 2020. ABB operates in more than 100 countries with about 144,000 employees.

International pulp and paper producer Sun Paper has selected technology leader ABB to fulfil two orders for its facilities in Laos and Shandong, China. The first order comprises new drives for the company’s paper machine 1 (PM1) and paper machine 2 (PM2) at its Laos mill, while the second includes a synchronous motor, motor starting equipment, excitation protection control and process drives for chemical pulp production at its plant in Shandong, eastern China.

The first order forms part of the second phase of Sun Paper’s Laos project that includes two advanced packaging paper production lines (PM1 and PM2) with annual production capacity of 800,000 tons. ABB will provide its highly-efficient, distributed PMC800 multi-drive control system with total installed capacity of 41,000KW and more than 120 drive points for both paper machines, which are 7.3m and designed for speeds of 1200 m/minute. For the chemical pulp project in Shandong, ABB will provide two sets of 14 MW synchronous motors, medium voltage motors and a drive system.

ABB wins drives order for two different Sun Paper projects in China and Laos

For both projects, ABB’s scope of supply includes its most advanced PMC800 drive system and ABB Ability™ System 800xA distributed control system (DCS), featuring stable and easy operation, abundant information access and low maintenance requirements. ABB’s drives incorporate unique Direct Torque Control (DTC) technology, ensuring efficient production of high torque at low speeds.

“Competition for these prestigious projects was understandably fierce, but by optimizing our technical proposal and demonstrating our success with previous projects of a similar scope and scale, our China Pulp and Paper team was able to provide the best solution,” said YueMing Liu, Pulp and Paper Industry lead for China at ABB. “ABB also provided the automation solution for phase 1 of the Laos Project, which won the Modern Manufacturing 2018 Solution Excellence Award. By establishing mutual trust in multiple projects with Sun Paper, we hope to provide a solid foundation for our future relationship.”

About the Sun Paper Laos Project
Sun Paper invested in the Laos Project in response to the Belt and Road initiative promoted by the Chinese government, which encourages development along a former trade route that links China with other economies across Asia, Europe and Africa. Phase 1 of the project had a massive undertaking—a 400K ton chemical pulp project that covers the complete process of pulp production, alkaline recovery, pulp board machines, biomass furnaces, and chemicals. Phase 2 will continue to enrich Sun Paper’s product types, increase product grade, promote the product structure upgrading, greatly improve the comprehensive strength and core competitiveness to further consolidate its leading position in the paper making industry of China.

ABB (ABBN: SIX Swiss Ex) is a pioneering technology leader with a comprehensive offering for digital industries. With a history of innovation spanning more than 130 years, ABB is today a leader in digital industries with four customer-focused, globally leading businesses: Electrification, Industrial Automation, Motion, and Robotics & Discrete Automation, supported by its common ABB Ability™ digital platform. ABB’s market leading Power Grids business will be divested to Hitachi in 2020. ABB operates in more than 100 countries with about 147,000 employees.

The NeoGear™ low-voltage switchgear – a technological breakthrough by ABB – is safer, smarter and more sustainable, maximizing efficiency and reducing costs for tomorrow’s digitalized industries

• ABB has reimagined the switchgear– essential technology for safe energy distribution and motor control.
• Available from late 2019, NeoGear is a future-proof, digital solution that brings new functionality, productivity and efficiencies to industrial infrastructure in an electrified future.
• Breakthrough deploys laminated bus plate technology, which until now could be found in aircraft, automobiles and on space stations.

  

Committed to writing the future of safe, smart and sustainable electrification, ABB today launches NeoGear: a revolution in low-voltage switchgear and the first the electrification industry has seen for more than three decades.

Successfully trialed at sites across Switzerland and China, NeoGear deploys ABB’s laminated bus plate technology, which replaces traditional horizontal and vertical busbar systems.

The innovative bus plate technology combined with the connectivity and digital smartness of the ABB Ability™ platform, make it an unrivalled solution. NeoGear is the safest option for operators with no exposure to live parts. It reduces the physical switchgear footprint by up to 25 percent, increases cooling efficiency to reduce heat losses by up to 20 percent, and reduces overall operational costs by up to 30 percent, due to more efficient condition monitoring.

“Today marks the start of a revolution in power distribution” said Alessandro Palin, Managing Director of ABB's Distribution Solutions business line. “Switchgear systems are key to ensuring the safety of the electrified economy, but for more than 30 years they have seen little innovation.  NeoGear is testament to ABB’s commitment and relentless drive to bring future-focused and sustainable alternatives to the market to help shape the infrastructure of tomorrow.”

This hardware development is complemented by advanced digital capabilities. Digitalization is changing how industries use electricity in their machinery, factories and operations: driving them to extend the lifecycle of their assets; modernize equipment to improve safety and efficiency; and to shift towards more sustainable and responsible business models.

Against this backdrop, the ABB Ability^TM enabled NeoGear provides a complete and scalable solution for new projects, system upgrades or migration from legacy systems, to innovate and prepare for the future of electricity distribution and motor control.

NeoGear’s digital capabilities include real-time condition monitoring and predictive maintenance, remote assistance, fault and solutions diagnostics and data analytics for Industry 4.0. ABB Ability™ Condition Monitoring for on-site electrical systems is included, helping customers gain operational efficiency and bring unprecedented flexibility.

“We see rising demand in the market for more innovative switchgear solutions that help customers navigate increasingly challenging environments,” said Marco Tellarini, Global Product Group Manager in ABB's Distribution Solutions business. “NeoGear will give customers unrivalled safety, higher efficiency, better functionality, more flexibility, and as a result both resilience and value. We are proud to add this revolution to our globally established switchgear portfolio.”

NeoGear will help customers meet the increasing demands to keep working environments safe and reduce maintenance downtime and costs across sectors including oil and gas, chemicals, food and beverage, mineral and mining, and water treatment.

Set to transform performance, safety and sustainability of electrification across industry and infrastructure, NeoGear is available to the market in late 2019.

There is a link below to download the product brochure

ABB (ABBN: SIX Swiss Ex) is a technology leader that is driving the digital transformation of industries. With a history of innovation spanning more than 130 years, ABB has four customer-​focused, globally leading businesses: Electrification, Industrial Automation, Motion, and Robotics & Discrete Automation, supported by the ABB Ability™ digital platform. ABB’s Power Grids business will be divested to Hitachi in 2020. ABB operates in more than 100 countries with about 147,000 employees. www.abb.com

www.abb.com

www.new.abb.com/low-voltage/launches/neogear 

ABB will provide Sappi’s Vulindlela project with automation, electrification and instrumentation to futureproof operations

Sappi, the world’s largest producer of dissolving wood pulp, has chosen digital technology leader ABB to supply engineering, procurement and construction for the electrical, control and instrumentation portion of their project Vulindlela. The project is an ambitious plan to increase mill production by approximately 14 percent while reducing the pulp mill’s environmental impact. Due for completion in the winter of 2020, the project includes the design, supply, installation and commissioning of all electrical and automation equipment at Sappi’s Saiccor Mill located in Umkomaas, South Africa.

“Our ability to deliver a complete, multi-faceted solution, centered around a collaborative automation platform that supports the optimization of the entire production process, was key to securing this flagship order,” said John Manuell, Local Business Line Manager for South Africa, ABB Process Industries. “We look forward to helping Sappi reduce its environmental impact with safe processes and equipment, as well as assisting in realizing significant production gains.”

Based on the ABB Ability™ System 800xA distributed control system (DCS), the automation solution is the first pulp and paper project to use the single channel, Ethernet-based Select IO, which enables the decoupling of project tasks. This can lead to a significant reduction in commissioning time and helps ensure on-time, on-budget project execution.

Additionally, the solution is complemented with software tools including Field Information Manager to help manage smart field devices and mobile workplaces that will give operators and production staff access to plant information from anywhere in the mill.  

“A history of working successfully with ABB gave us full confidence in their ability to provide a complete solution that will help futureproof our operations,” said Wayne Weston, Vulindlela Project Director, Sappi. “As world leaders in dissolving wood pulp, we welcome this pioneering, integrated solution that will help us achieve our Project Vulindlela goals.”

Other ABB Ability™ digital offerings, such as Asset Management, Energy Management, Safety systems and Manufacturing Operations Management will help provide total visibility into, orchestration and control of Sappi Saiccor’s entire operation.  In addition to the automation platform, the scope includes the extension of the 132kV distribution infrastructure, the medium voltage reticulation and the process electrification.

Sappi Limited is a global leader in paper, paper pulp and dissolving wood pulp solutions, Sappi Limited (SAP - listed and in the Top 40 on the JSE), is headquartered in Johannesburg, South Africa; has over 12,000 employees; manufacturing operations on three continents, in seven countries (nine mills in Europe, three mills in America and four mills in South Africa) and customers in over 150 countries worldwide.

ABB (ABBN: SIX Swiss Ex) is a pioneering technology leader with a comprehensive offering for digital industries. With a history of innovation spanning more than 130 years, ABB is today a leader in digital industries with four customer-focused, globally leading businesses: Electrification, Industrial Automation, Motion, and Robotics & Discrete Automation, supported by its common ABB Ability™ digital platform. ABB’s market leading Power Grids business will be divested to Hitachi in 2020. ABB operates in more than 100 countries with about 147,000 employees.