Hazenberg Isa Presentation 2001 Pulp And Paper Startup

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Automatic start-up of PM9 Paper machine by using HPM & AM. Willem Hazenberg for ISA 2001

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  • What is ISA? ISA is nearly 50,000 measurement and control professionals working together around the world to accomplish things they could not do alone
  • Hazenberg Isa Presentation 2001 Pulp And Paper Startup

    1. 1. <ul><li>ABB BV </li></ul><ul><li>ADEX UITGEVERIJ &quot;AUTOMATIE&quot; </li></ul><ul><li>ARRAY PUBLICATIONS </li></ul><ul><li>BADOTHERM PROCES INSTRUMENTATIE </li></ul><ul><li>BELLT GCA BV </li></ul><ul><li>BERENDSEN PMC BV </li></ul><ul><li>CONTROL APPLICATION ENGINEERING (C.A.E.) BV </li></ul><ul><li>CONTROLEC ENGINEERING </li></ul><ul><li>ENDRESS + HAUSER BV </li></ul><ul><li>FISHER-ROSEMOUNT BV </li></ul><ul><li>FOXBORO NEDERLAND BV </li></ul><ul><li>HINT ENGINEERING BV </li></ul><ul><li>HONEYWELL BV </li></ul><ul><li>IMTECH SYSTEMS BV </li></ul><ul><li>KROHNE-PERSENAIRE/KROHNE-ALTOMETER </li></ul><ul><li>MECHADATA Industriele Automatisering BV </li></ul><ul><li>MOORE PRODUCTS CO BV </li></ul><ul><li>MTL Instruments BV </li></ul><ul><li>PEEKEL INSTRUMENTS BV </li></ul><ul><li>PROCOS ENGINEERS & CONSULTANTS B.V. </li></ul><ul><li>SAMSON REGELTECHNIEK BV </li></ul><ul><li>SIEMENS NEDERLAND BV </li></ul><ul><li>STOKER MULTIMEDIA PRODUCTIES </li></ul><ul><li>TELEREX NEDERLAND BV </li></ul><ul><li>THERMO TURNKIEK PROCESS CONTROL BV </li></ul><ul><li>ELECTRIC INTERNATIONAAL BV </li></ul><ul><li>TURNKIEK PROCESS CONTROL BV </li></ul><ul><li>YOKOGAWA INDUSTRIAL SAFETY SYSTEMS BV </li></ul><ul><li>YOKOGAWA NEDERLAND BV </li></ul>Sponsoren ISA Nederland
    2. 2. Automatic start-up of PM9 Paper machine by using HPM & AM . Willem D. Hazenberg De Eendracht Karton Q-TECH SERVICES 26th April 2001 Utrecht
    3. 3. <ul><li>De Eendracht Karton </li></ul><ul><ul><li>PM 9 90000 Tonnes Coated WLC </li></ul></ul><ul><ul><li>PM 10 65000 Tonnes </li></ul></ul><ul><li>GRUBER + WEBER Karton </li></ul><ul><ul><li>PM 2 125000 Tonnes Coated WLC </li></ul></ul>
    4. 5. Vision <ul><li>To turn Gruber + Weber / De Eendracht Karton into the most efficient papermill from Europe. </li></ul><ul><li>To turn Gruber + Weber / De Eendracht Karton into the 10% of the best companies with regard to energy consumption in a global perceptive. </li></ul><ul><li>We buy technology instead of developing it on our own . </li></ul><ul><li>Work with market leaders. </li></ul>
    5. 6. PM 9 Machine Data Appingedam <ul><li>90000 Tonnes Year </li></ul><ul><li>230 - 500 g/m 2 </li></ul><ul><li>100 - 280 m/min </li></ul><ul><li>6 formers </li></ul><ul><li>MG </li></ul><ul><li>sizepress </li></ul><ul><li>2 coaters </li></ul><ul><li>TPS / Lippke </li></ul><ul><li>Products </li></ul><ul><ul><li>Grunoplex ® </li></ul></ul><ul><ul><li>Novoplex ® </li></ul></ul>
    6. 7. PM 10 Machine data Appingedam <ul><li>65000 TON PBL </li></ul><ul><li>170- 600 g/m 2 </li></ul><ul><li>100 - 320 m/min </li></ul><ul><li>272 cm </li></ul><ul><li>7 formers </li></ul><ul><li>TPS/ Da vinci </li></ul><ul><li>Products </li></ul><ul><ul><li>PBL </li></ul></ul><ul><ul><li>Greyboard </li></ul></ul><ul><ul><li>Fivoboard </li></ul></ul>
    7. 8. Papermachine lay out
    8. 9. PM9 Controls <ul><li>Honeywell TDC 3000x With Lippke Scanners </li></ul><ul><li>2 UxS, 1US, 4 Scanners, 2 SAM, 1 APP, PHD, HM, 2 NIM’s, 2 HPM </li></ul><ul><li>Efflux, additive, HMPC </li></ul><ul><li>Automatic Grade change </li></ul><ul><li>Basic weight / caliper control </li></ul><ul><li>Moisture Control </li></ul><ul><li>Stock prep. control </li></ul>
    9. 10. Scanners <ul><li>3e Press Moisture and grammage </li></ul><ul><li>Yankee Total and Top Moisture </li></ul><ul><li>Sizepress Moisture </li></ul><ul><li>Reeler Color, Caliper, Grammage, Moisture, Smoothness </li></ul>
    10. 11. System overview DEK HPM PDC
    11. 12. SAM / Scanner layout PM 9 GUS / US SAM 11 SAM 13 HM 40 HPM 3 & 5 Field I/O FILTER
    12. 13. PM 9 LIPPKE / TPS DATA SCHEME <ul><li>LIPPKE </li></ul><ul><li>CLM </li></ul><ul><li>TDC (AM) </li></ul><ul><li>PHD Collector </li></ul><ul><li>PHD Shadow </li></ul><ul><li>HISPEC PC </li></ul><ul><li>OPTIVISION </li></ul>IT Process control
    13. 14. Da Vinci 3 D Plot Paper machine
    14. 15. 3D map Da Vinci PM 10
    15. 16. PM 9 control room 1993 - 1997 1993 old room Measurex Vision 2001 1994 New operator room 2 UxS stations 1997 First TV monitors 1998 Need for more space
    16. 17. De Eendracht Karton CCP 2000
    17. 18. Shutdown <ul><li>Planned and unplanned shutdown </li></ul>DCS starts the shutdown DCS acts according to the shutdown
    18. 19. A Good start-up start with a good Shutdown <ul><li>Save PV en SP from main controllers and scanners. </li></ul><ul><li>Store them in numerics on HPM. </li></ul><ul><li>Shutdown in the right sequence. </li></ul>
    19. 20. How did we start this project <ul><li>Get a list for start-up actions from the operators </li></ul><ul><li>Make from this list one total list together with the operators/shifleaders. </li></ul><ul><li>Make a sequence program which Send: “” commands </li></ul><ul><li>Look for every send:”” command what can the control system do. </li></ul><ul><li>Do it . </li></ul>
    20. 21. Start-up start sequence <ul><li>Put all flags in a safe condition </li></ul><ul><li>Read all numerics and validate them. </li></ul><ul><li>If validation is not ok, then recalculate them. </li></ul><ul><li>Start automatic mill checks, for valves and others. </li></ul>
    21. 22. Validation <ul><li>Make a regression model of PV en output values </li></ul><ul><li>Make a border ± 5-10% around </li></ul><ul><li>Check of actual stored value is between this border lines </li></ul><ul><li>If not, take the calculated regression value </li></ul>
    22. 24. Start-up start sequence 2 <ul><li>Prepare all pumps to start condition. </li></ul><ul><li>All fan-pump and cleaning systems running. </li></ul><ul><li>All additives are on cascade mode to thickstock. </li></ul><ul><li>All Thickstock flows are 5% less then the validate shutdown values for easy start-ups. </li></ul>
    23. 25. Start-up start sequence 3 <ul><li>Open main valves. </li></ul><ul><li>Lower steambox by break detect signals. </li></ul><ul><li>Get the right moisture on the MG. </li></ul><ul><li>Put German press roll on. </li></ul><ul><li>Put coaters on. </li></ul><ul><li>Get first quality paper. </li></ul><ul><li>Program goes back to start condition. </li></ul>
    24. 26. Abnormal Situations <ul><li>Closed main valves. </li></ul><ul><li>Stop main pump systems. </li></ul><ul><li>Stop on delay vacuum pumps. </li></ul><ul><li>Program goes back. </li></ul><ul><li>Wait for restart permission from operator . </li></ul>
    25. 27. Measure Time between Sections <ul><li>Wet-end to steambox. </li></ul><ul><li>Steambox to moisture OK on Yankee. </li></ul><ul><li>German roll press on Yankee. </li></ul><ul><li>Time coaters on sheet. </li></ul><ul><li>First Quality on reeler. </li></ul>
    26. 28. Operators <ul><li>We can do it faster. </li></ul><ul><li>They had a problem. The didn’t use the start-up program. </li></ul><ul><li>The best way to start-up is to use the program . </li></ul>
    27. 29. Results <ul><li>Faster start-up. </li></ul><ul><li>Less divergences between shifts. </li></ul>

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