Digital IIoT Solutions at ANDRITZmagazin.know-center.tugraz.at/downloads/2017/01 Smart...

Digital IoT solutions for industrial applications with Metris

www.andritz.com

Digital IIoT Solutions at ANDRITZ

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ANDRITZ Digital Solutions

METRIS

METRIS – ANDRITZ GROUP Products and Services

HYDRO, PULP & PAPER, METALS, SEPARATION

SMART Services

eShop

Optimisation of Process Performance

OPP4

METRIS


Smart Sensors

Big Data

Augmented Reality

Customer service portal

Field service support

Spare part catalog (eShop)

Industrial IoT

Provide IoT solutions to improve

customer’s machine and process

performance

B2B Smart Services

Provides the unified entry point for

customers to SMART service

offerings

Cyber Security

Ventures

Coordinate venture capital and

start-up activities within the

ANDRITZ GROUP

A

B

C

METRIS

Mission Statement

CUSTOMER NEED

IS OUR FOCUS

Value

DIGITALIZATION

IS THE ENABLER

Smartsolutionsare thedriver

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METRIS



SMART Services

eShop

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OPP4

METRIS

ANDRITZ GROUP Products and Services

Key Product offerings:

DiOMera


OPPChipperEKGDD Washer PortalWLF – Monitoring


AFC3D-ViSESmart Assist


addIQ

B2B - Smart Services

eShop

HYDRO PULP & PAPER METALS SEPARATION

HYDRO

METRIS


Run of River Power Plant

8x Francis Turbines, each 266MVA

Total Power Output 2.128 MVA

SCADA system

Unit control

Turbine governor control

Electrical protection

Generator excitation control

Switchyard control

Typical use casePower plant automation solutions for

The customer receives the complete system for the power

plant; the equipment will be installed and commissioned at

customers site.

Standard Automation solution for hydropower

One Automation solution for one customer

HYDRO – typical project solutionFor hydropower plant automation

HPP Hoa Binh - Vietnam

Dispatch Center

Centralized control of decentralized

hydro power plants

Seamless control of HPPs at >7 rivers

Operation of up to 160 HPPs from

a central dispatch center

Remote or local operation

6 Operator Stations, 2 Engineering

Stations

Large Screen Display 6x2 70”

Typical use caseSCADA solutions for

The customer receives the complete system for the power

plant; the equipment will be installed and commissioned at

customers site.

Standard SCADA systems for hydropower

One central SCADA system for one customer

HYDRO – typical project solutionFor a SCADA implementation

E.ON dispatch center Landshut

Volatility and cost pressureHYDRO - new challenges from today’s energy markets

RAPIDLY CHANGING

PRICES AND

REGULATORY

CONDITIONS

COMPLEXITY

SECURE RELIABLE

LONG-TERM OPERATION

ON ENERGY

SOURCES

ON STANDARD

SERVICES

Price volatility New financing models Increasing competition

$

FROM SELF-OPERATED

RESOURCES TO PURE

ASSET MANAGMENT

FROM TECHNICALLY

BASED TO FINANCIALLY

ORIENTED

INCREASING NUMBER

OF VOLATILE ENERGY

SOURCES AND

HYDROLOGICAL

CHANGES

Asset management Owners skill changeGrid volatility and

climate change

for today’s power generationHYDRO - success criteria

Reduce total costs, OPEX (total costs = maintenance + unavailability)+

Maximize annual energy production+

Ensure plant availability and safety+

Protect the assets’ value+

Manage complex and instable boundary conditions+

ANDRITZ can help and support to reduce maintenance costs and

optimize power plant operation

We offer a scalable service concept for maintenanceHYDRO – Operation and maintenance

Preventive / predictive

maintenanceSystem assessment Daily maintenance

Remote assistanceBreak down

maintenance24 / 7 assistance

Analysis and

optimization

Enhanced spare part

management

O&M intelligent

modules

Extended warranty

Customizable maintenance services

BASIC

ADVANCED

PREMIUM

+

+

Supervision of units

We offer you a scalable service concept for operation

HYDRO - Operation and maintenance

Assistance for

malfunctions

Unit inspections

Safety / environmental

management

Provision of

operation staff

Power plant staff

management

Local / Remote HPP

operation

O&M intelligent

modules

Spare part

management

Customizable operation services

BASIC

ADVANCED

PREMIUM

+

+

care of your HPP with our global know-how

HYDRO - Operation and maintenance: locally taking

Customer

Customer contact and support

Maintenance and its optimization

On-site O&M, local HPP operation

Optimization of production

Condition monitoring

Remote HPP operation

24 / 7 assistance

Operational data analytics

Global O&M experts

O&M Support

(ANDRITZ HYDRO - Locations)

Control Center

https://www.google.at/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjWjb3QtLXTAhUD6xQKHWu_CYwQjRwIBw&url=https://thenounproject.com/term/software/28793/&psig=AFQjCNGVN9lMHVfJPMgYxB033KL4UF-xEw&ust=1492859351705635

ANDRITZ HYDRO control center remote operation

Automation and Monitoring systems

installed locally

Data hosting and big data analyses in the cloud

Each power plant, every

size, type, location

Local / remote operation

Optimization of production

Customized acc. customer

needs

Typical use caseOperation and Maintenance

solution for

ANDRITZ HYDRO is offering a service for Operation and

Maintenance. The delivered solution comprises local

installation, cloud implementation and remote control from an

ANDRITZ HYDRO location.

Standard Operation and Maintenance solution

Operation and Maintenance

Metris DiOMera – a new approachFor operation and maintenance of hydropower plants

ANDRITZ HYDRO Control Center Italy

PULP & PAPER

METRISANDRITZ Digital Solutions

OPC

PULP & PAPER: OPP (Optimization of Process)

Performance – autonomous operation

Optimizing equipment and plants

in the pulp & paper and other

process industries

Anomalies and deviations

detected in an early stage,

advising operator or taking

autonomous action to correct

Proven technology deployed at

various key customers in the pulp

and paper industries

Example

On-line knowledge of chipper and chipping.

Smart Sensors + Condition Monitoring

ChipperEKGOn-line diagnostics

Chipper Electrical Knife Graphs indicates the knife hit into log and

shows the condition of knives, which is the heart

of chip quality.


ChipperEKGOn-line diagnostics

Example

Knife wearing estimations and knife

change optimization

Detection for poor knife installation

or damaged knife

Abnormal knife force detection

Condition monitoring for bearings

Standard accelerometers for bearing

houses and gearbox

Field box for sensor connections and

operator pushbuttons

Operator interface with traffic light

indicator for knife damages

Your steps to the solutionCustomer benefits

Example

Customer portal with traffic light indicator shows how the end seal,

critical consumable part in Drum Displacer washer, is performing


DD-Washer Customer portal

Customer portal with traffic light indicator shows how the end seal,

critical consumable part in DD-Washer, is performing


DD-Washer Customer portal

Example

New measurements installed to the

DD-Washer’s steering logic

Set-up customer portal with traffic

light indicator

Installation of mobile user interface

as a daily tool for the maintenance

workers

Reliability and predictability of

the Drum Displacer washer

Ability to see the status of

operations at any time

Possibility to seize early warnings

and take immediate actions


Example

Prediction white liquor filter operation for improved reliability


White liquor filter Condition Monitoring

Example

Install sensors to filtrate end sealings

and lime mud dilution Online portal

to monitor the sensors and meters.

User interface with condition-related

alerts.

Improved reliability and

predictability

Increased safety

Better preparation for the next

shut-down

Optimization of the service

interval



White liquor filter Condition MonitoringPrediction white liquor filter operation for improved reliability

Example

Making it possible to have the mill in your hands all the time with

optimized availability and efficiency.

Big Data + Augmented reality

Datalytic team and process

data analyses

Example

ANDRITZ Data Analytics Team

Customer Case: Data analyzes about

impregnation vessel level control

Insight on the first practical steps to start

improving the mill operations together

through digitalization

Getting your fleet information updated and

machines connected

Continuous forecasts on how the function of

the equipment and state of the processes is

going to change

Our team to the solutionWe are able to support you this way

Making it possible to have the mill in your hands all the time with

optimized availability and efficiency.


Datalytic team and process

data analyses

Example

From traditional pulp mills to advanced plants and machinery with

self diagnostics, internal and external wireless technology, utilizing

modern communication medias, diagnostics and big data tools


Decision Support for

Operators and Maintenance

Example

Install videowall and control system

CCTV systems connected to video wall

system

On-line conditon monitoring with advanced

diagnostics

Advanced wireless video/audio

communications, augmented reality tools

Maintenance planning based on actual

needs and fact based information

(e.g. wearing, running times)


From traditional pulp mills to advanced plants and machinery with

self diagnostics, internal and external wireless technology, utilizing

modern communication medias, diagnostics and big data tools


Decision Support for

Operators and Maintenance

R&D

Smart Sensors

SENSOR TYPES

Development of smart, wireless, micro-sensors for

industrial applications!”

Pressure

Magnetic field

Temperature

Ultarsonic

Hall effect

…

MetrisSmart Sensors

METALS


Independent verification of software functionality

(SW FAT)

Improve software quality during engineering phase

and before commissioning

Higher quality of documentation (e.g. functional

descriptions, knowledge database)

One workflow from concept to Mechanical Design

and Electrical & Automation

Full 3D visualization of the production line and

calculation of signal feedbacks

3D Simulation with “Digital Twin”

ANDRITZ 3D-ViSE (3D-Virtuell Simulation Environment)

Digital Twin of Metal Production Lines (1)

3D Data from CAD Software (Solid Edge) Definition of kinematic structures in 3D ViSE Operation of complete virtual production line

(SPS, Virtual Control Panel and L1 HMI)

Knowledge transfer between Mechanical Design Department and

Electrical & Automation Department

Offline simulation of sequences before software engineering

Internal software test and debugging with virtual panels during

engineering phase

Verification and optimization of sequences

Internal trainings

Sales presentation for customers

Operator training before / during commissioning on Digital Twin

Verify locations of further equipment (LOBs, safety fences, safety doors)

Typical use case

ANDRITZ 3D-ViSE (3D-Virtuell Simulation Environment)

Digital Twin of Metal Production Lines (2)

Instruction based accelerated setup

Collision free kinetics calculated automatically

Fine tuning of forming parameters possible

Guided “teach in” for key position points

TargetCurrent Situation

Schuler Smart AssistDigitally assisted “teach in” of presses (1)

Setup of presses is highly depending on

dedicated and more and more rare experts

Setup is time consuming due to complex steps

Manual optimization with step by step approach

Setup time is directly influencing production

Typical Schuler Press Typical Schuler Smart Assist improvement curve

Implemented for MSP400 press incl. roller feeder

Available for all presses with latest automation

platform delivered

Retrofit concept in preparation

Road MapImplementation

Schuler Smart AssistDigitally assisted “teach in” of presses (2)

Structured “teach in” process by using video and

text instructions given at press shop

Setup guidance is including press movement,

feeder and transfer as coupled kinematics

Setup displays at press shop level Combining 176 years of metals forming know how with digital

technology and expertise

SchulerSmart Assist

SEPARATION


A family of addIQ packages

For separation business to optimize operation

From breweries to sludge treatment plants

New Installation

Upgrades

Optimization through

Automation

Typical use caseFocus

Scalability

addIQ ontrol systemsfor solid/liquid separation

Metris addIQ control systems

Intelligence for machine and process control

ANDRITZ SEPARATION - Modules

Flexible classroom training worldwide

Multiple participants in one training session

Training to deal with unlikely

machine/process incidents

Certified operators

Authentic operator interface

Machine digitally modelled

Realistic operating scenarios

and parameters

Typical use caseFocus

Metris addIQ simulation the ultimate tool to qualify and certify

staff

Enhanced Training

addIQ Simulation for solid/liquid separation

Metris addIQ simulation

Operator Training

ANDRITZ SEPARATION – Training Session

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METRIS



SMART Services

eShop


OPP4

SMART SERVICE


Either using an idenfication code at the ANDRITZ equipment

or directly guided through the user-friendly application you will

find the right parts easily.

eShop for spare parts

eShop

ANDRITZ SMART Services

eShop

Implement eShop solution

Equipment should have

identification codes

Streamlining of the part inquiry

and order process

Improved efficiency of a routine

work flow

Up-to-date documentation of

what the machine is made of as

prerequisite for the solution


Either using an idenfication code at the ANDRITZ equipment

or directly guided through the user-friendly application you will

find the right parts easily.

E-Shop

eShop for spare parts

ANDRITZ SMART Services

eShop

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METRIS



SMART Services

eShop


OPP

OPP Goals

Increase the process stability

Reduce the energy or chemical cost

Debottleneck production, increasing total production

Increase the mill availability

Fast response to move from area to area, or production to cost.

Keep existing savings in the long term

Support to Operation: in diagnostics, start-up, mill-balance

OPP – Optimization of Process Performance

OPP is a Metris Service Solution

Control Experience

Automation Experience

Maintenance Experience

Best practices Database

Continuous R&D

Andritz Platform &Methodology

Remote Support Local Support

Collaborative

Network

OPP

Server

EXISTING

DCSMILL

PROCESS AREA

OPC

OPP – Optimization of Process Performance

References – Range of applications

How OPP reaches process performance

Production target due to instability

Pro

duction

Time

Production Capacity

New production level

Variability reduction

Specification

Variable

Time

SP due to variability

New set point

$$$

Chemical or Energy savings

Production Increase

How OPP reaches process performance

0 50 100 150 200 250 300

Pro

du

cti

on

/ D

ay

350

Maximum Production Level / Day

Average Production Level / Day

Reduce process variability

Debottlenecking

Fast start-up

Mill balance

Avoid shutdown using automatic slow down system

Mill balance

Production stability

Equipment failure prediction

<90% (opportunity to improved) 90-91% (acceptable) 91-92% (target) >92% (excellent)

OPP ultimate uniquebusiness model

OPP ultimate uniqueoptimization execution

BUSINESS INTELLIGENCE

Management and technical KPIs, dashboards, balanced scorecard, project management tool, etc LEVEL 4: MANAGERS

LEVEL 3: ENGINEERS (OPERATIONS

AND MAINTENANCE)

LEVEL 2: OPERATORS AND SHIFT SUPERVISOR /

CORDINATOR

LEVEL 1: FIELD OPERATORS AND MAINTENANCE TECHNICIAN

Data mining, statistics, power spectral density, KPIs

OPP, SMS, e-mail, follow-up

Data historian, process displays

Tools for Log book, meetings, risk assessment, work permit

Start-up sequences, diagnostic systems, root cause analysis, process specification check

Advanced Process Controls, Decision support, adaptative setpoints, mill balance

Measurement validation, process diagnostics

Control loop tuning and assessment, dead time compensators, feedforward, etc.

Real time data, diagnostic, procedures, remote support

Risk Based Maintenance, predictive maintenance, conditionMonitoring, Valves, motors, analyzers, interlock bypass, etc.

DATA ANALYTICS

NOTIFIER

PIMS

DAILY MANAGEMENT

OPERATOR ASSISTANCE

SMART CONTROLS

SOFT SENSORS

REGULATORY CONTROL

AUGMENTED REALITY

ASSET MANAGEMENT

METRIS Platform used by OPP

Strategy & Organization

BUSINESS INTELLIGENCE

Management and technical KPIs, dashboards, balanced scorecard, project management tool, etc

Data mining, statistics, power spectral density, KPIs

OPP, SMS, e-mail, follow-up

Data historian, process displays

Tools for Log book, meetings, risk assessment, work permit

Start-up sequences, diagnostic systems, root cause analysis, process specification check

Advanced Process Controls, Decision support, adaptative setpoints, mill balance

Measurement validation, process diagnostics

Control loop tuning and assessment, dead time compensators, feedforward, etc.

Real time data, diagnostic, procedures, remote support

Risk Based Maintenance, predictive maintenance, conditionMonitoring, Valves, motors, analyzers, interlock bypass, etc.

DATA ANALYTICS

NOTIFIER

PIMS

DAILY MANAGEMENT

OPERATOR ASSISTANCE

SMART CONTROLS

SOFT SENSORS

REGULATORY CONTROL

AUGMENTED REALITY

ASSET MANAGEMENT

METRIS Platform

Strategy & OrganizationCUSTOMERS STRATEGIC DRIVERS

PR

OD

UC

TIO

N

RA

W M

ATE

RIA

L C

OST

ENER

GY

CO

ST

MA

INT

CO

ST

QU

ALI

TY

SAFE

TY

ENV

IRO

NM

EN.

PR

OD

UC

TIV

ITY

Autonomous Operations

Decision levels

Maximize company results

Market x Budget analysis and definition of production strategy

Budget control

Speed, Economy, Balanced (It defines how mill balance should work)

Mill Balance control

Start-up/Stop, Speed-up/Slow-down, Recipes (35 controls)

Control of complex variables

Kappa, Brightness, Moisture, Dry-solids, etc. (75-100 controls)

Control of simple variables and avoid interlocks

Flow, Temperature, etc. (1000 controls + 2000+ interlocks)

Equipment (some assets have their own controls)

Big assets, instruments, valves, motors, etc. (15000+ devices)

MARKET STRATEGY

PRODUCTION STRATEGY

PRODUCTION & COST

MANAGEMENT

SMART CONTROLS

REGULATORY CONTROLS

& SAFETY

RELIABILITY MILISECONDS

0.1 -1 SECONDS

3 -300 SECONDS

MINUTES

TO HOURS

DAILY

MONTHLY


How to achieve it

Customer need How to improve it?

Equipment must be reliable

Prediction of failure and

automatic notification based

on on-line data

Risk-based

Maintenance (RBM)

algorithm

Prediction of failure and automatic

notification based on inpections.

AR (Augmented Reality) can help.

Instruments

Motors

Control Valves

On-off Valves

Variable Frequency Drives

Smart Sensors

Pumps

Soft Sensors


How to achieve it


Basic loops must work at least

95% in auto mode, with minimum

IAE (Integral of Absolute Error)

Automatic diagnostics of

instruments and valves

Automatic diagnostics of

control loop performance

Control loop monitoring

and tuning


How to achieve it


Interlocks must be avoided

Automatic

slow-down

system

Eliminate not

needed

interlocks

Delay interlocks

when possible

Review

interlock

limits

“Hacking” operator

actions and make it

automatically


How to achieve it


Key process variables must be

controled inside specifications

Sophisticated control

algorithms must be developed

and updated continuously

Specifications limits must

be reviewed based on best

operations days

Prediction of process

problems and automatic

notification

Prediction of variablesKPIs

Advanced Process Control

Notifications

OEE


How to achieve it


Production rate and

chemical/energy consumption

must work must be always

optimized

Sophisticated control

algorithms must be

developed and updated

continuously

Benchmark with best productions

days and suggest possible

changes in the model automatically

Create a footprint of

key equipment


How to achieve it


How to deal with changes in raw

material

Process model and recipes must be created for every scenario to make the process at its

optimal level


How to achieve it


How to deal when something goes

wrong, like an instrument failure

Switch off part of the algorithm and give

instructions in how to proceed

Start-up sequence to start the process

quickly and in a standardized way

Prediction of variables


How to achieve it


How to reduce the time to repair Show contextual information Have a knowledge databaseTeam of experts to

support the mill


Results

KPI Baseline Goal Jan/17 Feb/17 Mar/17 Apr/17 May/17 Jun/17

Operational Stability

(average/ MSR)hour base

91% 94% 90.3% 94.1% 93.7% 90.5% 93.3% 95.5

Variable Costs (Consumption +Energy)

0% -10% -6,2% -10,9% -10.5% -6.5% -9.7% -11%

OPP controls ON

(% of Time of)

0% 90% 65,1% 90% 95% 85% 96% 97%

Production Records

Before Q1/2017 Q2/2017 Q3/2017

Daily5420 -

5508(+1.6 %)

Monthly average4988 -

5045(+1.1 %)

5105(+2.3 %)

Quarter average4694

4814 (+2.5%)

4872(+3.8 %)

Installation and tuning: Sep-Dec/16

www.andritz.com

Digital IoT solutions for industrial applications with Metris

Digital IIoT Solutions at ANDRITZ

Digital IIoT Solutions at ANDRITZmagazin.know-center.tugraz.at/downloads/2017/01 Smart...

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