AIA

Automation Tech 2004

An AIA symposium on Integrated Automation for Global Competitiveness

ITC Grand Maratha , Mumbai, 8th November 2004

AIAPAPER MACHINE 4 : STATE-OF THE-ART MACHINE

AIA Global Paper & Paperboard consumption

46.5 million

5.9 million

286.7 million

REST OF THE WORLD INDIA CHINA

Rest of world

ChinaIndia

Tonnes

One of the top 5 employers industry in the world

AIA

Forest Sector

Agricultural sector

Paper equipment

Chemical industry

Engineering & material handling

Unorganized waste distribution network

PAPER INDUSTRY

Printing industry

Publishing industry

Advertising Industry

Media

Education sector

Packaging Industry

Printers, copiers etc.,

Industrial usage

Household

Backward & forward linkages … importance in country’s industry

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Importance to national economy

0.00

2.00

4.00

6.00

8.00

10.00

12.00

14.00

16.00

Bev andTobacco

Apparels Manmadefibre, wool

and silk

Leather Metals Paper% c

on

trib

ute

to m

anu

fact

uri

ng

sec

tor

Output GVA Capital employed Labour

Source : ASI

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Labour Productivity ... better than most peer industries but lags country average

0.00

0.50

1.00

1.50

2.00

2.50

Bev andTobacco

Apparels Manmadefibre, wooland silk

Leather Metals Paper India average

Rs.

Lak

hs

per

em

plo

yee

Source : ASI

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Capital productivity ... lags that of most peer industries

0.00

0.50

1.00

1.50

2.00

2.50

Bev andTobacco

Apparels Manmadefibre, wooland silk

Leather Metals Paper Indiaaverage

Rs.

Lak

hs

per

em

plo

yee

Capital productivity defines as Output/EmploymentSource : ASI

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ITC Ltd.Paperboards & Specialty Papers Division

Unit : Bhadrachalam

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PSPD on mapPSPD on map

Kolkata

Divisional HQ Secunderabad.

Manufacturing Locations:•Bhadrachalam

•Papers & Paperboards• 210000 TPA

•Tribeni•Cig.Tissue & Specialty Papers•30000 TPA

•Bollarum•Cast coating,Poly Extrusion & Super calendered•18000 TPA

• New acquisition•Kovai

•Recycled Paperboards•65000 TPA

•New Delhi

•Mumbai

•Bhadrachalam•Bollarum•Secunderabad

•Tribeni

• Bangalore

•Kovai

• Chennai

•Kolkata

AIA Products from ITCPaperboards & Specialty Papers Division

Cigarette Bd

Gypsum Bd

Aseptic

Cup Stock

Market FBBD & SBS

Coated & Uncoated Boards300000 TPA

Writing & Printing

Kraft

Paper30000 TPA

Cigarette Paper

Decor

Fine Printing & Specialty packaging

Specialties30000 TPA

PaperboardPaper

Specialities

AIA

4141

CHOICE OF LEADING BRANDS

Our Specialities

PAPERBOARDS & SPECIALTY PAPERS DIVISION

AIA ITC - PSPD

Vision statement….

To be a valued player in the global Paperboards & Specialty Papers Industry by

Ø Leadership in quality - products, processes, service and people;ØContinuous enhancement of value for all

stakeholders, andØUpholding societal values and expectations.

AIA

CONTEXT

“ The future of Indian Industry depends on actualization of best possible strategies to maximize resource utilization through automation to ensure delivery of quality products with optimum cost at the doorsteps of customers across the globe”

AIA Context settingAutomation in the Pulp & Paper Industry

Automation objectives in the pulp & paper industry:

Reduce costs

Reduce raw material usage.

Optimise manpower

Reduce environmental impact.

Deliver Consistent quality

Quality is a moving target. Quality requirements evolve as the product mix changes/matures and/or customer requirements change.

Delivery - OTIF

AIA

Information explosion

Many different storage formatsPaperFilesDatabasesWeb based

Many different systemsLegacy systemsNew systems Different architectures

Access problemsTedious and time consumingInconsistent or outdated information

WWWWWW

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New challengeseAuctionCan we deliver 100 tons for $300/ton

next Friday? An answer is needed

within 10 minutes!

Supplier Xis critical!

What happens if we don’t get any

delivery?

Process sector X fails

Find the problem and repair now !

Board meeting today

Turnover and profit per product and

region?

a

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Automation functions in the Pulp & Paper Industry

Sales and Marketing

Engineering and Maintenance

Logistics & Distribution

Supervision and Operation

Business Systems

Optimizations and maintenance

Production Equipment

Plant Engineering

Optimization of production

Not just limited to simple loop control

AIABhadracahalam – an automation case study

Automation at Bhadracahalam has evolved with the mill.

Automation implementation evolved as:

New and bigger machines were added.

Product mix evolved to Value added products.

Customers demanded better products & shorter delivery periods

Export markets were targeted.

Ambition levels were raised.

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•Digital controls enhanced the potential for better control performance.

•Technological changes in field sensors coupled with digital electronics enhanced reliability of measurement and speed of response.

•Process control applications improved with sophisticated algorithms, simulation models and software packages.

EVOLUTION OF AUTOMATION -CURRENT SCENARIO

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Field instruments and fibre optic connectivity enhanced reliability of the system.

Process computers emerged as a source of better information and operational advice.

Integration of drives with digital controls and online qualtiy control system became a reality enabling engineers to enhance process performance for productivity and quality.

EVOLUTION OF AUTOMATION -CURRENT SCENARIO

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AUTOMATION &PROCESS CONTROLSJOURNEY OF PSPD - UNIT BCM

1985 - Conventional single loop controllers centralisedinto a no of large panels in control room in all the sections.1992-2001 - Installation of quality control systems and distributed control systems of ABB coupled with VIB steam profiler enhanced productivity and quality in Paper Machine-1.1992 - Installation of digital controllers of Foxboro alongwith online QCS system of Measurex in Paper Machine-2.1996- Digital distributed controls of ABB incorporated during project planning in coal fired boilers resulted in enhanced efficiency of operations.

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AUTOMATION &PROCESS CONTROLSJOURNEY OF PSPD - UNIT BCM

1996 - Conceived state of the art technology alongwithautomation in Paper Machine-4 during project implementation.1997 - Successful commissioning of Paper Machine-4 with ABB digital controls integrated with drives and online QCS to produce high quality paperboards catering to different customers throughout the globe.Precise measurement ensuring high quality,improved C.D profile control with accurate

measurement, faster stabilisation, reduced losses, fiber saving, high productivity of manpower.

AIA AUTOMATION &PROCESS CONTROLSJOURNEY OF PSPD - UNIT BCM

1997 - Commissioned the state of the art finishing and packaging line till despatch with automated controls in rewinder (Jagenberg, Germany), reel packing (Lamb, Germany), Computerised crane (Demag, Germany), sheeters (Wilpemco, USA), automatic storage and retrieval system (ASRS) for pallets (Efacec, Portugal).

2002 - Commissioned ECF fiberline with state of the art DCS controls of ABB to produce high quality pulp with highest productivity meeting stringent environment guidelines.2002 - Commissioned state of the art recovery boiler alongwith energy efficient evaporators and lime kiln with ABB distributed control systems ensuring highest manpower productivity and meeting environmental guidelines.2003 – 2004 : OPTIVISION – Manufacturing execution system from Tata Honeywell

AIAULMA defect detection system commissioned in 2004. to identify minor defects in paperboards - elimination of defects at source.

ULMA - TREND OF RESULTS

17

14

10

10

8

4

0 5 10 15 20

Oct-03

Nov-03

Dec-03

Jan-04

Feb-04

Mar-04

No of Defects

Dur

atio

n

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QCS

RSP

Pre-Coat Scanner

Pope ReelScanner

Steam Profiler

20011993

Automation base at ITC

PM1 Rack Room

PM1 Control Room

Operator Station

Dry End

Wet EndDrives

MP280 AC450 Controller

PM Sectional Drives

S800 I/O

Control Net

Recovery Area

Operate IT

Remote Mill PC’s (x4)- Operate IT Client (Pulp

Mill) - X-Windows (PM1& 4)

Mill Office

Plant Network - TCP/IP

Pulp MillOperate IT

AC800 Controller

O2 Delign., BWS &

Screening

CLO2, Chiller & O2

SRB Evaporator

Bleaching

S800 I/O: (AI, AO, DI,DO)

Pulp Mill

Engineering / Operate IT

Shift in charge

Redundant Control Network

Field AI: Hart

HART Maintenance

System

Profibus

2002

SFT Wet End 1

QCS

Steam Profiler

CCK & PM1

Wet End 2 Dry End

RSP

Before MG Scanner

RSP

Before Size PressScanner

RSP

Pre-Coat Scanner

Pope ReelScanner

MP280 AC450 ControllerPM4 Rack Room

QN

X

Term

inal

s

CCK

IMSWet EndDry End

PM4 Control Room

Wet End

Dry End

SFT

Operator Station

Engineering Station

Base Sheet Scanner

3rd Party FSS

PM Sectional Drives

S800 I/O

ULMA WIS

1996

2003

1994

Pope ReelScanner

QCS

PM#2 QCS

HMx

Optivision from HMxIncludes• Production planning• Product tracking• Trim Optimisation• Invoicing and despatch

2003

PM 5

PM 5

Wet end

AC800 Controller

Engineering /

Operate IT

Shift in charge

O2, CIO2 & chiller,

SOES800 I/O

S800 I/O

Dry end QCS

Pope ReelScanner

Pope ReelScanner

RSP

Pre-Coat Scanner

2004

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AUTOMATION

QUALITY

ENERGY

EFFICIENCY

ENVIRONMENTAL

COMPLIANCE

PRODUCTIVITYCUSTOMER

SATISFACTION

COST

COMPETETIVENESS

BENEFITS OF AUTOMATION

AIA BENEFITS OF AUTOMATION

Overall plant efficiency enhanced to 105 %

Reduction of power consumption from 1456 KWh to 999 KWh per ton of production, during the last 6 years period.

Reduction of water consumption from 183 KL to 75 KL per ton of production during the last 6 years period.

Ongoing energy conservation efforts resulted in ‘Best Energy Efficient Unit’ in Paper Industry by CII and Energy Management Award from Govt of India for several times.

AIA BENEFITS OF AUTOMATION

• Huge gains in labor productivity

Tonnes Employees1997 85000 14002004 222000 1400

Most environmental friendly paper mill in India recognized by CSE

AIA Bhadracahalam – an automation case study

Learnings for ITC

Invest gradually

Automation investment gradually over time, provides benefits and evolves as the business model evolves.

Invest in the latest technology

Enables ITC to utilise the maximum effective life of the equipment and beat the obsolescence curve.

Helps us compete with our global competition.

Automation investments have probably the largest ROI

AIA Bhadracahalam – an automation case study

Challenges

Attracting and retaining talent

Industry should provide proactive solutions:

Maintenance proposals?

Involving users during the design phase.

AIA

THANK YOU