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MEtso’s custoMEr MagazinE no. 3/2011

Keljonlahti power plant –secure and easy to operate thanks to seamless overall solution 8

raahe Works’ power plantautomation represents the fruitful outcome of close R&D collaboration between Metso and Ruukki 12

Metso Dnaintroduces its new and fresh industry-specific control applications 22

2 3/2011 results automation

Metso’s automation contributes to sustainable energy

When it comes to energy, “sustainability” can mean many things to many people. The energy market globally is changing. Renewable energy, such as wind, solar, hydroelectric and biomass, is becoming a more significant component of our sources of electricity. For example, in the United States, these forms of sustainable energy represent almost 11% of electricity generated, up from 7% in 2001.

In Europe, North and South America, Metso is contributing to the continued growth of renewable forms of electrical generation. Metso is supplying several biomass boilers and entire power plant automation systems using the Metso DNA Distributed Control System (DCS) and Metso Neles and Jamesbury valves.

Metso is currently supplying automation systems for projects that will convert coal-fired power plants to biomass service. One example, the Mount Poso generating unit in Bakersfield, California, will provide 49.5 MW of electricity and will be in service before the end of 2011. The new automation system accommodates the burning of wood waste rather than coal, and also integrates the fuel handling and ash handling systems. The system was designed to minimize the change impact on the operators, allowing them to maintain similar interactions with the process and consistent operation.

Also increasing the efficiency of existing fossil-fuel-fired power plants is an important element of improving sustainability. Such efforts can dramatically lower the amount of fossil fuel consumed while also lowering the cost of the environmental controls needed to meet current emission standards. Even a 1% improvement in fuel usage can be a significant savings for a large power plant that can easily justify an investment in automation with less than a one-year payback.

We have satisfied customers globally by enabling them to benefit from our automation technologies while contributing to cleaner environment. For example, in Poland

we are currently delivering combustion optimization for six coal-fired boilers at the 220 MWe Jaworzno/Tauron Power Plant for efficiency improvement and a reduction of nitrogen oxides (NOx). The project is the largest of its kind ever in Poland that aims at climate change mitigation.

Combustion control applications reduce fuel consumption and corresponding emissions Metso has developed a strong portfolio of combustion control applications that improves the efficiency of power plant opera-tions. Our basic control strategies are specifically designed to insure that the proper amount of fuel is delivered to meet the plant’s energy demand and the proper ratio of fuel-to-air is maintained to meet current load requirements. Our advanced control packages optimize the combustion within the opera-tional constraints of the power plant. As a result, today’s power plants use less fuel compared with power plants in the past.

One reason for our success is a unique approach in Metso’s automation system strategy for advanced process control. Even very complex MPC advance algorithms are included in Metso DNA automation systems process stations, which provide extraordinary reliability and safety.

Again Metso DNA is leading the way by introducing new power plant applications that enhance efficiency and environmental performance. Metso DNA automation systems have now been strengthened with new control applications, such as turbine controls for steam and gas turbines, pulverized coal-fired combustion optimization and machine condition monitoring. (More about new Metso DNA, page 24.)

Sustainability may have many meanings to many people. But in the world of power generation, sustainability means Metso.

Ed CollVice President, Energy Process Systems, Metso

published by metso automation inc.P.O. Box 304, 01301 Vantaa, Finland Tel. +358 2048 3150Telefax +358 20483 5888

address changeswww.metsoautomation.com/update

editor-in-chiefAija [email protected]

editorial boardJarmo Ervast, Kirsi Koukkari-Halme, Helena Lamberg, Jaakko Oksanen,Soili Städter, Kati Tattari

cover picture: Mr Ernesto Pousada from Suzano Group and Matti Kähkönen, President & CEO of Metso, had the honor to cut the ribbon at the official opening ceremony of Metso’s new Valve Technology Center in Finland in September.Photo: Pekka Lähteenmäki

lay-outViestintätoimisto Tulus Oy

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© Copyright Metso Automation Inc.All rights reserved.

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Reproduction permitted quoting“results automation” as source.

All product names used herein are trademarks of their respective owners.

ISSN 1237-3265

www.metso.com

results automation 3/2011 3

in this issue

Metso is a global supplier of technology and services that help our customers to process natural resources and recycle materials into valuable products. Our customers operate in the mining, construction, power, oil and gas, recycling and pulp and paper industries. Metso has about 29,000 employees in more than 50 countries. Metso’s automation professionals specialize in process automation and information management application networks and systems, process measurement systems and analyzers, control, on-off and emergency shutdown valves and intelligent positioners, condition monitoring, and life-cycle performance services. www.metso.com

www.twitter.com/metsoautomation

Products and solutions22 It’s in our DNA – Feeling of control

25 Brand-new tool for low solids content measurement

26 Vibration-based condition monitoring implemented

28 Intelligent rotary control valves

30 Metso upgrades fire-safe tests and approvals for valves

30 UV measurement for all inline brightness sensors to pulp and paper processes

31 Metso around the world

2 Editorial

4 news in brief

reporting results8 Jyväskylän Voima Keljonlahti power plant

12 Power plant automation at Ruukki: Innovative R&D through close collaboration

16 Better pulp quality and chemical savings with Metso Kappa analyzer

18 Metso TS at Shandong APRIL SSYMB Pulp & Paper Wastewater Plant

20 Improving shutdown efficiency in Chile

Joint venture in China strengthens position in power automation

Metso is joining forces with SAC, Guodian Nanjing Automation Co., Ltd (previously State Automation Company), to strengthen its position in the power automation control systems market in China. The new joint venture will concentrate on developing the digital power plant concept, focusing especially on the Chinese market.

Metso will own 33% and SAC will own 67% of the joint venture. The joint venture will support Metso’s target to offer proven, cost-effective power automation control solutions to the Chinese markets. The new company will manufacture and market Metso’s maxDNA automation technology and SAC’s digital power plant products. Furthermore, the joint venture will develop new products and provide comprehensive after-sales services. The joint venture will have over 300 employees in China.

“By joining forces, we gain share in the Chinese power market. We have already over 140 power units controlled by our systems in China,” comments Metso’s Steve Gandy, Vice President Sales and Operations, Energy and Process Systems in Asia.

Metso has provided automation systems to more than 700 power plants worldwide. Metso is one of the eight DCS companies recom-mended by the former State Power Ministry in China. The new company will start its operations following official approval by the required Chinese authorities. SAC is a public company owned 58% by Huadian Power International Corporation Limited, one of the five biggest power producing companies in China.

More info: [email protected]

The benefit of using a single control system was again proved in Järvenpää, Finland, when the restart of Metso’s Järvenpää Pilot Coater immediately reached a new world record speed of 3,160 m/min.

The restart took place on September 1 after an auto-mation upgrade. The new 35 group drive is controlled directly by Metso DNA automation system in which the drive controls are integrated with the machine control system. Tension controls are implemented with a new multivariable control, developed by Metso, to achieve more accurate tension management in dynamically changing coater conditions.

The pilot coater can run basis weights of 25 – 350 g/m2. Available coating technologies are OptiSizer film sizing, OptiCoat Duo double backing roll coating, OptiCoat Jet nozzle coating, OptiBlade short dwell coating, OptiLayer curtain coating and ValSpray spray sizing.

Metso DNA offers pulp and paper makers a single system for all controls, from fiberline to baling information, and from headbox to winder, enabling faster startups. It provides pulp and paper makers with measurements, analyzers and a complete selection of state-of-the-art advanced process controls.


Restart of Metso’s Järvenpää Pilot Coater immediately reached a new world record speed of 3,160 m/min.

The world’s fastest and most demanding coating machine starts up with Metso drive controls reaching record speed

Maximilian Furley (on the right) from South American sales team of Metso’s Automation business received the award on October 4th, 2011 from Sr. Jefferson Lunardi, Executive Director of ABTCP.

Best Automation Award from Brazilian Technical Association of the Pulp and Paper Industry

For the sixth time, Metso has been chosen as the best company in the Automation category by ABTCP, the Brazilian Technical Association of the Pulp and Paper Industry. The award was granted on October 4, 2011, at the 44th Pulp and Paper International Congress and Exhibition in

São Paulo, Brazil.In 2011, Metso further strength-

ened its presence in South America. In April, the company concluded an agreement to supply all main technol-ogy for the 1.5 million-ton greenfield pulp mill of Suzano Papel e Celulose S.A., one of the largest vertically inte-grated producers of pulp and paper in Latin America. The new mill will be built in the state of Maranhão in the northeastern part of Brazil. Startup is scheduled for the first half of 2013.

Metso’s scope of supply covers the main parts of the pulp mill, compris-

ing wood handling, the cooking plant and fiber line, pulp drying and baling, evaporation, power boiler, recovery boiler, causticizing and lime kiln. The integrated automation solution for all process areas includes an automation system, a quality management system, profilers, advanced process controls, valves, analyzers, a baling quality management system and a process & quality management system.

Another important Metso delivery includes a valve package to the Montes Del Plata project in Punta Pereira, Uruguay.



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News in brief

New Valve Technology Center in Finland opens with strong demand in valves globally

The new facility is in line with the company’s long-term strategy to invest in quality and delivery capabilities globally for Metso’s valve customers.

Production is working in two shifts at a record pace. ”Our current deliveries have increased by half compared with the corresponding period in the previous year. Production is more than 2,500 valves monthly, and volumes will be further increased in order to meet the growing global demand, “ tells Markku Simula, President of Flow Control business in Metso’s Automation business line.

Metso develops valve services globallyThe fastest growing markets of the technology center specialized in manufacturing of engineered industrial valves are Middle East and China. “Especially companies in Middle East, Brazil and in China have recently invested at an accelerating pace in new production facilities,” explains Simula. The customers include major global companies, such as Saudi Aramco, ExxonMobile, Petrobras and Stora Enso.

Building a new facility in Finland is in line with Metso’s investment decisions of previous years to develop Metso’s valve services globally. In 2010, Metso opened a state-of-the-art facility in Shanghai, China, and is currently expanding its valve production premises in the US. Metso also has high-class industrial valve facilities in Brazil and Germany.

‘’This is a strong message for our customers globally: We are in the business with a long-term strategy to continuously improve our valve products and services globally,” Markku Simula emphasizes.

New facility enhances research and development“Our customers are facing increasing operating pressures and more advanced applications. We have a long tradition to supply valves for tough conditions, so we are ready to meet this demand,” Markku Simula ascertains. The new Helsinki facility further improves Metso’s possibilities for product development. For example, there is a new flow laboratory for valve testing and a new expanded cryogenic

Technology Center view from outside: The new Valve Technology Center in Finland covers an area of 23,000 m2. The adjoining 12,300 m2 office building houses domestic sales, project management, research and development, global service development, training facilities as well as the management and administration of Metso’s Flow Control business unit. The location is logistically ideal. It is close to the Port of Helsinki, airport and main highways. Energy efficiency meets the standards set by BREEAM, which is the world’s foremost environmental assessment method and rating system for buildings.

Pictured from left: Ernesto Pousada from Suzano Group and Matti Kähkönen, President & CEO of Metso.

Production line: In the new factory, material flow and production cells are planned according to lean manufacturing principles, and the main focus is on producing, assembling and testing critical, engineered parts for ultimate performance in the oil and gas industry. Metso secures valve operation and quality with uncompromised manufacturing processes and testing procedures. The factory has ISO-9001:2008, PED, A TEX as well as ISO-14001:2004 certificates.

testing facility for the LNG industry.Metso is the leading supplier of control, on/off and emergency

shutdown (ESD) valves and intelligent positioners and condi-tion monitoring. “We just launched stainless steel versions of all our Smart products for safety and automated on/off valves use. Stainless steel products are aimed at the oil & gas market, which is very important for us. Clearly within these industries, there was room especially for safety products, because we have received very positive feedback from our customers so far,” Simula says proudly.

Due to Metso’s strong position in advanced valves technology, services are becoming a larger business for Metso. In addition to 31 service centers around the globe, a new service center will be opened in India within the next few months.



N EWS I N BR I EF

Large service contract for valves from Arcelor Mittal in Brazil

Metso and Arcelor Mittal Tubarão, located in Espirito Santo State, Brazil, have signed a service contract covering approximately 2,000 automatic and safety valves. The contract also includes intelligent tools for preventive and predictive maintenance and maintenance planning activities. It expands the existing contract and is one of the largest for Metso’s valve operations in South America.

Arcelor Mittal Tubarão is a world leader in the semi-finished steel market, accounting for 12% of global slab sales. It is also one of the largest companies in Brazil.

With Metso’s intelligent tools, the steel plant staff is able to monitor and analyze valve condition while the process is running. Conventional methods require stopping the process and removing or dismantling the valves for closer inspection.

“Constant awareness of overall valve condition prevents unexpected breakdowns, which can result in stopping the process completely, which is extremely costly. The customer can plan the maintenance schedule in advance, so any disruption to the process is kept to a minimum. In addition, the staff can focus maintenance activities on those valves needing it most,’’ explains Tercelino Leite, Service Manager, Automation business line, Metso.


Strong automation foothold in bioenergy production

Metso will supply advanced automation systems and solutions to two new bioenergy power plants currently under construction in Finland, while receiving another replacement order.

Porvoon Energia Oy has ordered a Metso DNA automation system including safety automation for its new biomass-fired power plant. Representing the latest know-how and technology, the plant has a capacity of 12 MW of electricity and 38 MW of thermal heat that will be used for district heating in the town of Porvoo. The boiler will be supplied by MW Power Oy, a company co-owned by Metso and Wärtsilä. The delivery also includes an electrostatic precipitator controlled with Metso DNA.

Another Metso DNA system including safety automation, field de-sign as well as information and reporting applications will be delivered to a bioenergy plant built by Hämeenkyrön Voima Oy. The BFB boiler plant will run on forest residues and other wood-based fuels, with peat as auxiliary fuel. It will produce electricity and process heat for the nearby M-real Kyro paper and board mill, as well as electricity and district heat for a local electricity company, and will have an electricity capacity of 12 MW and thermal capacity of 55 MW.

Additionally, Metso has received an order from Helsinki Energy, one of the largest energy companies in Finland, for a Metso DNA system to replace an existing automation system in its 118 MW Kellosaari reserve power plant. With the modernized system, the plant ensures that electricity will be available for the Helsinki region in case of sudden nationwide disturbance situations. The delivery also includes safety interlockings, field design, field devices, an information management application and integrated vibration monitoring.


Extensive frame agreement for automation systems and related services with Neste OilMetso has signed an extensive frame agreement with Neste Oil for automation and safety system replacement deliveries as well as related services over the years of 2012 – 2016. Neste Oil also placed its first orders according to this agreement for new automation and safety systems for its Porvoo and Naantali refineries in Finland to replace existing systems. The deliveries will take place next year. Thereafter, Metso’s installed base at Neste Oil’s refineries in Porvoo, Naantali, Singapore and Rotterdam will include altogether 20 Metso automation systems and 30 safety systems.

Neste Oil’s refineries are among most advanced ones, and to meet their requirements, Neste Oil and Metso have together developed special automation applications during earlier deliveries. This cooperation will continue also with the new deliveries.

Photo: Neste Oil /Ismo Henttonen

Three Metso DNA automation systems and three safety systems will replace the existing systems in three of Porvoo refinery’s over forty process units. The refinery produces some 12.5 million tons of petroleum products per year in its four production lines. At the Naantali refinery, three new safety systems will be installed, and existing Metso DNA systems will be modified in the oil distillation process units and in the refinery harbor. The refinery mainly produces traffic fuels and specialty products, such as bitumen, solvents and small engine gasoline.

Neste Oil is a refining and marketing company, with a production focus on premium-quality, lower-emission traffic fuels. The company produces a comprehensive range of major petroleum products and is the world’s leading supplier of renewable diesel.



N EWS I N BR I EF

Major automation contracts for advanced ships

Metso has been awarded Metso DNA automation system contracts for three advanced vessels to be built in Finland. One contract is for two Multifunctional Icebreaking Supply Vessels (MIBSV) by Arctech Helsinki Shipyard Oy for Russian Sovcomflot. The second is a Multipurpose Deck Cargo Carrier by STX Finland Oy for Finnish Gaiamare Ltd, which belongs to the Turku-based Meriaura Group.

The MIBSV’s are designated for the Sakhalin-1 Arkutun-Dagi gas field and will be used as supply vessels for the Exxon Neftegas Ltd gas platform. They are designed for the harsh environmental conditions in the Sakhalin area with drifting ice and temperatures down to -35°C.

The Metso DNA Integrated Automation System (IAS) handles control, alarm and monitoring functions in the vessel’s machinery and liquid / bulk cargo spaces. The vessel’s power plant is fully managed by Metso DNA Power Management System.

The Multipurpose Deck Cargo Carrier is an innovative and versatile vessel designed for transportation of large steel fabrications, such as offshore and wind farm structures. For this vessel, Metso DNA system handles control, alarm and monitoring of the machinery plant, includ-ing controller loops, control and standby functions for pumps, fan controls and the management of the diesel electric power plant.

For all these vessels, Metso DNA automation system includes the DNA Operate user-friendly multifunctional operator stations, a redundant fiber optic communication network, redundant process controllers with main and reserve in different locations all enhancing the system reliability and availability, Metso DNA Historian information management system that provides versatile analyzing and reporting tools to optimize machinery performance and fuel consumption, LCD touch panels to accommodate Unattended Machinery Sailing (UMS) mode alarm announcement, and finally a dead man alarm system for machinery spaces.

Further, Metso has a contract for an automation system delivery to a cruise ship being constructed at a European shipyard for a reputable owner.

Automation system for fisheries’ research vessel

Metso has received a Metso DNA automation system order for a fisheries research vessel, which is contracted at STX Finland Oy, Rauma shipyard, by the Namibian Ministry of Fisheries and Marine Resources.

The vessel is 65 m long with a beam of 14 m. The vessel’s task will in-clude monitoring fish stock, as well as sorting, processing, freezing and storing fish. As a multipurpose vessel, it will also be used for collecting samples for seabed research and analysis. Other tasks are metrological research and control of fishing.

Metso DNA automation systems take care of all machinery alarm and monitoring, controller loops, tank level monitoring, control of pumps and valves and the power management system. The power management system will include a mode change program, with auto-matic configuration of machinery and switchboards, for fast and secure transition between sailing modes. Operator stations are multifunctional and process controllers redundant with main and reserve units in different locations, securing maximum system availability.

Ship automation since the early 80s

Metso established a marine team in Norway in early 2010 that with Metso’s global engineering and service network will further develop and execute Metso’s strategic focus and services in the ship automa-tion market.

Metso has engineering resources with broad automation com-petence for machinery, power plant and air-conditioning systems on board ships. Metso’s marine automation solutions are modular and flexible, and fit all types of ships and complexities, from crude oil carriers to passenger ferries, cruise liners, offshore supply and oil & gas processing vessels.

Ship automation systems based on Metso technology have a long history. Ship automation systems started in the early 80s with Damatic Classic and have developed through to today’s Metso DNA. The majority of installations is for advanced ship types, such as cruise liners. In particular, redundancy features and high product quality that guarantee undisturbed and safe ship operations have contributed to the success story of Metso’s automation systems. The Damatic Classic was actually the first-ever ship automation system that promoted full integration between various onboard systems.

The first delivery of an automation system based on Metso technology to a ship was in 1983. Until today, several hundred ships have been equipped with Metso’s automation system.

More info: [email protected], [email protected]

Fisheries Research vessel.

Automation for biomass-fired steam boiler at cheese plant

Metso will deliver a steam boiler plant to Valio’s Lapinlahti produc-tion plants. The boiler plant will be delivered by the Metso-Wärtsilä joint venture MW Power. In addition to the boiler plant, the delivery includes all of the necessary installations, the commissioning and the Metso DNA automation system. Metso DNA serves power generation customers with a comprehensive choice of advanced process controls for optimizing various power production processes, such as the combustion or boiler-turbine coordination.

In addition to the versatile reporting, analyzing and data storage applications, the Metso information management system offers tools for efficient performance, condition and environmental monitoring.

The boiler plant will be fueled by wood chips and peat. The objective is to increase the share of wood chips gradually up to 100%.



N EWS I N BR I EF

it’s all by Metso!Jyväskylän Voima Keljonlahti power plant

Keljonlahti power plant is a magnificent overall system and equipment delivery from Metso. When the project team is ready with its work, the local Metso office will take over responsibility of the plant’s everyday operations.

Even in the most severe Finnish winter conditions, the Keljonlahti location is a spectacular sight to behold. Standing directly along the bank of Lake Päijänne, it generates both electricity and district heat for the growing economic region around Jyväskylä.

The power plant project has been huge in size and has faced a varied array of challenges. A long-term power plant professional, Pentti Huumo is the one who took on the challenge and moved from his previous position at ÅF-Consulting to act as Project Director for Jyväskylän Voima and later as the Production Director for Jyväskylän Energia.

“While working on another project, I became interested in the Keljonlahti investment plans just out of professional curiosity. When I accepted the offer to take charge of this project, I stepped onto a huge and fast-moving train,” he says.

At the next stop, Jari Ihalainen joined the team. He had been responsible for electric automation purchases in the energy company, and the two biggest automation investments of his life seemed to follow one another. The modernization of the Botnia Äänekoski plant was unfortu-nately not yet completed, but the call from Keljonlahti was irresistible. After the project was completed, his business card carried a new job title: Maintenance Manager, Electric Automation.

Just like Huumo, Tero Saarno worked for a consulting company when the Keljonlahti project started off. Actually, his career plans were targeted towards some-

TExT: Tapani Leppänen PHOTOS: Katri Kukkanen


Jari Ihalainen (left) and Tero Saarno.

R EPORT I NG R ESU LTS

Jari Ihalainen, Maintenance Manager

thing completely different. But for him, as well, Keljonlahti was simply too appealing to resist.

“Joining the project was a professional challenge for me. There won’t be too many plants realized in such a size and with such top technology during any one person’s career,” he explains. During the project, Saarno was carrying out equip-ment investments, as well as supervising installations and the plant commissioning. When offered the position of production manager later on, it was easy to say yes to the familiar plant.

Seamless overall solutionThe peat- and wood-fired plant facilitates an overall fuel capacity of 480 MW, which is extraordinarily sizeable for Finland.

Even for Metso, the project was consid-ered large and consisted of process auto-

mation, safety systems, condition moni-toring and reporting, as well as control valves and field devices. The benefits from seamless solutions are well recognized. Still despite good results, such overall solutions are not too common.

Thanks to his consulting background, Pentti Huumo knows the reason behind this: many projects are divided into pieces in hopes of saving costs. Keljonlahti is no exception, as it is not based on solely one enquiry.

“Automation, condition monitoring and reporting were together in the same request, and Metso won the public compe-tition. After that, we were just lucky that Metso also succeeded in winning the fol-lowing smaller investments,” he confesses. “In the end, we managed to achieve one overall solution that is all from Metso, from measurement devices to the control room.”

Metso turbine controllerThe Metso delivery could have also easily included the boiler, but that deal was given to Foster Wheeler.

“Tuning the boiler controls was carried out smoothly thanks to Metso’s proven experience in boiler automation,” confirms Pentti Huumo. He pays special thanks to Pekka Niemi, who was in charge of the main controls for the entire plant.

Collaboration between the turbine supplier Power Machine and Metso was ex-tremely smooth. Following the customer’s request, Metso supplied the turbine control



The more functions we can integrate, the more easily the plant is to operate.“

”

Tero Saarno, Production Manager

and safety systems, although these typically belong to the turbine supplier’s delivery. At Keljonlahti, the turbine controls have been integrated into to the plant’s main automa-tion system, which marked a significant new business opportunity for Metso.

The initiator for the single-system, plant-wide solution, Jari Ihalainen admits still having to cope with a few separate logics, because he was not present when those were acquired.

“The more functions we can integrate, the more easily the plant is to operate,” he states. “The turbine controller offers a brilliant example of this, and it has been invaluable when carrying out application modifications remotely. I must say we have been more than satisfied with this solution.”

His satisfaction is shared by Production Manager Tero Saarno: “After seeing how well this functions, it is very difficult to understand why the turbine controls or any other plant sub-system should be based on separate logics. All automation systems should be integrated within the plant’s main controls, and that should be a rule for all agreements. In addition to turbine controls, this has been the case with our conveyors – and it works really well.”

He explains the reason for the few separate logics at the plant due to the lack of resources during the order phase: “Such a small energy company in Central Finland like us could not afford a supervis-ing organization during the ordering phase. The organization has grown along with the project execution.”

Maintenance as a serviceIn addition to the equipment and system deliveries, Metso’s responsibility covers a broad range of maintenance services. When the project team completed their job, the local Metso office and its leader Jyri Tiihonen in Jyväskylä joined to share the responsibility.

Jyväskylän Voima and Metso have entered a maintenance agreement, which is both the plant’s selected approach and an opportunity made possible by today’s technology. The plant’s own maintenance organization employs a maintenance super-visor and two service operators.

“Today’s technology allows for a wider

view into the process than ever before. Besides, no one can manage the entire system from A to Z. For instance, we do not possess in-depth knowledge of system networks and info systems. This makes the maintenance agreement a great advantage for us,” says Ihalainen.

Pentti Huumo adds that availability cannot depend on one person. “Every specialist needs both top training and someone as back-up. When there is hardly enough full-time work for one person, it is much more practical to purchase it all from Metso.”

As for maintenance, the first year of operation will mainly consist of warranty

changes, and some system modifications and extensions as well. Metso has taken on 99.95% responsibility for the system availability.

“All our main equipment agreements include a warranty for almost 100% availability,” maintenance manager Tero Saarno concludes.

Connected around the clockIn Jyväskylä, the local Metso office serves the Keljonlahti plant with its own contact people: Ari Moilanen is the system specialist, Timo Jelonen the information expert, and Markku Pitkänen takes responsibility for the applications at Keljonlahti. These local experts are the connection to the worldwide Metso organization, which ensures that all questions are answered by the best expertise available. The connection is usually remote.

“In practice, everything except changing big mechanical units can be carried out remotely. This means that the local office is constantly supported by the entire Metso organization, despite geographical borders. This saves a lot of time and decreases the customer’s costs,” Jyri Tiihonen from Metso comments. He also regards this model as

For us it was essential that Metso reacted immediately, and the problems were solved in a fortnight.“

”



a strategic choice, since there is no other system supplier in Finland offering such a wide service network and comprehensive support after project delivery.”

Jari Ihalainen expresses his satisfaction with Metso’s 24h services. We can always contact one of the local Metso experts to tackle the problems remotely. Both Ihalainen and Saarno have been convinced by Metso’s service ability during the project

of large rotating units at power plants as well. Being used to working with it at pulp mills, it was clear for me to have one here too.”

According to Ihalainen, Sensodec is in daily use, serving as an excellent tool for a plant with a small workforce. “It enables us to target service operations at the right spot,” he remarks.

Interpreting vibration levels is like a science on its own, and revision engineer Toni Hult is the man for that at Jyväskylä Energy. The Metso experts are at hand whenever needed, as the maintenance agreement covers Sensodec, as well.

The overall delivery also comprises of a Metso Field Device Condition Monitoring system. As the amount of PA equipment is rather small, and thus not among the biggest maintenance challenges, the commissioning of its condition monitor-ing is not yet finished. Even the most important valves are based on either pneumatic or motorized actuators.

“Equipment breakdowns seldom take place at this kind of plant that combusts peat and other solid biofuels. Over 90% of disturbances at this plant are caused by fuels or the fuel feed,” Tero Saarno points out.

However, the valves have had some density problems in the beginning, mainly caused by process impurities after installation. “For us it was essential that Metso reacted immediately, and the problems were solved in a fortnight,”

Saarno says forwarding his thanks to Metso’s local service troops.

Automated reportingAutomated reporting is one of the most comprehensive development projects executed with Metso at the Keljonlahti plant. This information system produces information directly for the plant’s environmental reporting.

“My starting point was to achieve reporting that is as automated as possible, and Metso’s main engineer for info systems, Matleena Lammi, did a really good job! We now have templates that will work well for many future projects,” Tero Saarno explains.

Saarno estimates that preparing the plant’s monthly reports will take one working day. Environmental reports can be produced directly from the system. In comparison, collecting and handling similar data at the Rauhanlahti power plant takes approximately one week. “I know from my own experience that these reports con-sume a lot of time and manual work, even at the most modern plants,” he says.

Behind him, the brand-new plant is humming comfortably. The preheater-equipped circulated fluidized bed boiler is fired with local fuels. Peat and wood from the surrounding areas are used to boil water that has been processed at the plant’s own water treatment plant. The combined heat and electricity generation reduces environmental load and takes Jyväskylä as a region to be among the top in utilizing renewable energy.

Looking down from the roof terrace of the plant, we see an uninterrupted flow of peat trucks passing through the entrance gates. The freezing temperature keeps dropping, and the city of Jyväskylä looks forward to warming up with more heat.

Jyri Tiihonen

[email protected]

Original article published in Finnish in

Kenttäväylä magazine 1/2011.

and plant commission-ing. The importance of maintenance services will be seen later after the first year of opera-tion. The everyday reality starts once the warranty year is over.

Condition monitoring for large unitsFor mechanical condi-tion monitoring, Jari Ihalainen decided to apply Metso’s Sensodec Condition Monitoring System, which moni-tors the vibration levels of large rotating equipment.

“Diagnostic condition monitoring seems not to be common at power plants. Perhaps it is considered a paper mill tool, but there are plenty



Jyri Tiihonen, Metso (left) and Jari Ihalainen, Jyväskylän Voima

innovative r&D through close collaboration

TExT: Marjaana Lehtinen

Power plant automation at ruukki:

When there is a need to improve a process, there is a way to do it. This has been especially true of the long collaboration between Ruukki’s Raahe Works and Metso. Numerous solutions that have been developed together are found today at power plants around the world.

Time to pose for a partnership portrait. Pictured from the left Jarmo Harjuoja, Veli-Pekka Meriläinen, Seppo Kenakkala, Tapani Seppälä, Veli Vesikukka, Heikki Mylläri, Jyrki Koskela.



innovative r&D through close collaboration

Ruukki in briefRautaruukki Corporation, which uses the marketing name Ruukki, is a major supplier of metal-based components, systems and integrated systems to the construction and engineering industries. The company has a wide selection of metal products and services. Headquartered in Finland, it employs 11,700 persons in 27 countries, including the Nordic countries, the Baltics, Russia & Ukraine and Central Eastern Europe.

Raahe Works, located on the coast of the Gulf of Bothnia, about 70 kilometers south of Oulu, Finland, is Ruukki’s largest production plant responsible for the group’s production of steel and hot rolled products. It is the largest of its kind in Scandinavia, and also one of Finland’s largest industrial employers with about 2,800 people. In 2010, the plant produced 2.2 million metric tons of steel.

The list of ingre-dients in innovative product development is actually simple. In addition to high technology and process know-how, it includes a thorough understand-ing of customer needs and a daring attitude on the part of the customer in question.

When Ruukki people and Metso people meet, it’s like old friends getting together: the discussion starts off where it ended the last time. The roots of this fruitful collaboration go back to the 1980s. Since then, Raahe Works’ power plant has acted as a guinea pig for a large number of Metso pilot projects –

“We have presented Ruukki’s needs, based on which Metso has developed features that we have wanted. A few times Metso has sold us features that have not yet even existed as finished commercial products at that time,” says Tapani Seppälä, Chief Designer, Automation, Investments, Ruukki Metals.

“The people at Ruukki have a lot of know-how and a clear vision of their needs. We appreciate their tremendous courage and open-mindedness in taking part in our pilot projects. They have also trusted our ability to execute things properly,” com-ments Heikki Mylläri, Sales Director at Metso.

60% electricity consumption covered The power plant provides electricity and steam for the entire massive Raahe Works area with its many steel manufacturing process stages. There are two power boilers. Boiler No. 3 was built in 1975 at 84 bar 525°C. The other one, Boiler No. 4 from 1990, produces 42 kg/s of main steam also at 84 bar 525°C. They are mainly fueled by gas from the plant’s two blast furnaces. Also some coke gas is used as well as heavy

oil as spare fuel. In connection with the power boilers,

there are two turbogenerators: TG02 with a capacity of 65 MW/h built in 1975 and TG01 with a capacity of 21 MW/h built in 1963.

Approximately 60% of Raahe Works’ electricity needs are covered by in-house production; 60% of the district heat produced at the power plant and various manufacturing processes is used internally, and the rest is supplied to the town of Raahe.

According to Seppo Kenakkala, Power Plant Manager, there have been plans to build a new power plant. At least for now, they have been put on hold.

PLU technique gets rid of separate systemsThe cooperation between Ruukki’s Raahe Works and Metso started with small steps in the 1980s and has broadened over the years. One of the first major projects dealt with the automation system of Boiler No. 4 where the single-control unit technology was used as a PLU card application for the first time. And what’s best, the same I/O cards still function flawlessly, although the

completely at its own free will with the sole target of improving its power production processes.



process stations have been upgraded to modern ACN technology.

According to Seppälä, the PLU tech-nique was a clear competitive advantage when Ruukki chose the boiler automation system for Boiler No. 4. Metso was the only supplier who was able to offer complete boiler automation with one concept. The PLU technology was also applied to the boiler safety system and burner automa-tion for the first time in Finland.

“We wanted an automation system to carry out all power plant automation tasks and to get rid of separate systems,” Seppälä

recalls. “Our requirements were high. And we did a lot a work together to integrate the whole boiler automation into the same system.”

Turbine control integrated within the main automation system After the mid-1990s, the joint product de-velopment focused on the introduction of a turbine controller. It was incorporated in the turbogenerator TG01 and featured full integration within the Damatic XD process control system used in those days with the ACU and PLU single-control technology.

However, the beginning was far from promising. The supplier who was in charge of the turbine revision did not trust the new and modern concept of an integrated turbine controller, and some of the Ruukki people did not believe in it either.

“There was a huge amount of prejudice against the idea. In fact, I almost ran out of persons who believed in it any longer,” Seppälä now admits.

A few years later, Kenakkala and Seppälä visited the Energy Fair in Tampere, Finland, and took part in a lecture that introduced a new turbine control solution integrated

All three turbines at the power plant are equipped with a turbine controller implemented within Metso DNA.



Veli Vesikukka, Development Technician

within the main automation system. The subject sounded very familiar to them; after all, they had been using the solution already for four years... Today, all three turbines at the power plant are equipped with a turbine controller implemented within Metso DNA.

Sensodec 6S to measure turbine vibrationRaahe Works was familiar with Metso’s Sensodec 6S monitoring system as it was used in the motor-driven combustion blower in the blast furnace. However, its

“We presented the idea of integrating the process automation system, mechani-cal condition monitoring and field device condition monitoring to Metso already ten years ago. Now it is has become a reality. Everything takes its own time,” Seppälä continues.

Vesikukka, who uses Sensodec 6S in his daily work especially appreciates the features that are not available in other systems, such as the signal analysis tool. It enables the user to examine the signal in detail and allows him to see, for example, the frequency bands where bearing damage occurs. The system includes 270 sensors to monitor turbine vibrations.

“Sensodec 6S is a reliable tool. The clear and simple graphics enable users to un-derstand the big picture. They know how to pinpoint the damaged part and can go to the process to see it,” he continues.

“Our machines are old, so they need to be monitored extensively. Without moni-toring, a turbogenerator can break down completely and cause a lot of damage to its surroundings, too,” adds Kenakkala.

Today, Metso has taken vibration moni-toring yet a step further by introducing Metso DNA Machine Monitoring, which offers condition information on all rotat-ing machines for process operators and maintenance staff through one common user interface.

measurement cycles were not fast enough for a turbogenerator. Additionally, there was a desire to integrate condition monitoring with the main automa-tion system.

“With turbines, vibration measure-ments are needed in one-second cycles, since damage can take place fast. The operators must get the alarm early enough,” explains Veli Vesikukka, Development Technician at Ruukki’s maintenance develop-ment department.

In the years between 2004 and 2005, the Ruukki and Metso people spent a lot of time developing a mechanical condition monitoring application suitable for turbines. The hard work was successful, and today all large machines at Raahe Works, including both power boilers, are connected to the condition monitoring application.

Remote-controlled fresh water supply Ruukki has also been involved in Metso’s re-mote application pilot projects. Fresh water needed at the Raahe plant comes from the Piehinki River some 15 km away. There is a dam whose opening is controlled by Metso DNA via a wireless phone network connection. At another location in Pattijoki, there are two dam systems controlled with Metso DNA.

In fact, the long cooperation includes so many pilot protects that it is hard to keep track of them. In this partnership, many good-natured jokes are allowed, too.

“I guess we could say that part of Metso’s product development has its roots in Raahe!” Seppälä remarks with a wide, friendly smile.

Close support from Oulu and Kemi At the early stages of cooperation, Raahe Works relied on the Metso people in Tampere. But since the 90s, the contacts and support have been available at a closer distance. The Oulu Sales Office is situated some 70 km, and the Kemi Service Center is some 180 km from the plant.

The companies have signed a service agreement that covers all the automation systems, casting machines, the power plant, blast furnaces and on-call service. The latest addition to the collaboration is the valve storage service provided by Metso. Today, the power plant island is completely automated with Metso DNA.

“Our cooperation has widened over the years. There hasn’t been much silent treatment; instead we have been on good speaking terms all the time. Usually, there is always some extension or rebuild project going on,” Kenakkala points out.

“Long-term cooperation and good personal relationships increase trust on both sides,” Seppälä concludes.

”



Sensodec 6S is a reliable tool. The clear and simple graphics enable users to understand the big picture.“

Better pulp quality and chemical savings with Metso Kappa analyzerITC Bhadrachalam uses a Metso Kappa Analyzer, to optimize oxygen delignification.

TExT: Nigel Farrand

Best available technologyBhadrachalam selected the best available technologies for this scale of production with TwinRolls for stock washing and ozone bleaching being the most efficient both technically and environ-mentally. Both fiberlines utilize Metso’s SuperBatch cooking in a common building, which enables simultaneous cooking of two

Kappa sampling points, before and after the oxygen reactors.

Situated 300 km east from Hyderabad, India, ITC Bhadrachalam is the country’s largest integrated pulping and paperboard mill. Its original Fiberline 1 was built in 2002 and was the first in India to use Elemental Chlorine Free (ECF) technology. Fiberline 2 started up in 2008 and again the mill was the first in India with superior ozone bleaching technology. The ECF bleaching line 1 was upgraded to the ozone bleaching process at the same time. Combined, the two fiberlines produce between 750 to 800 tpd from eucalyptus, bamboo and subabul provided by ITC’s own plantations. Metso’s compensated brightness measurement had been in use on line 1 since the start, and in 2008, Metso delivered India’s first Kappa Analyzer to line 2.

different wood species for the two separate fiber lines. The bleach-ing sequences used are as follows: For Fiberline 1 – OO-Ze-Do-Eop-D1, and Fiberline 2 – OO- Ze-DP. Ozone bleaching has been successful in pulp production as it reduces costs and the environ-mental load with pulp quality being one of the best in Asia. The pulp is stronger, and ozone pulp also tends to increase brightness stability and runnability in the paper machine.

Chemical savingsOxygen delignification uses OxyTrac™, Metso’s patented two-stage system. It is an important tool for improving yield, reducing the kappa variability to the bleach plant, and lowering the bleach chemical consumption. OxyTrac is designed to maximize the delignification rate without sacrificing pulp quality. The process is based on the knowledge that two phases of reaction occur in



ing of this feedback strategy was the delay due to the retention time of two reactors and the need to vary the ozone dosage to compen-sate for the effect of oxygen. Oxygen is not an expensive chemical, but using too much can make the pulp difficult to bleach and wash, and can cause the loss of pulp strength. Measuring the Kappa num-ber before the oxygen reactor enables a feed-forward approach, with a second measurement after the stage to monitor the result. “Since the Metso Kappa Analyzer was installed, the oxygen charge, NaOH dosage as well as steam charge are based on the Oxytrac inlet Kappa number,” says Muralidhar. “Thanks to the kajaaniKappa Q Analyzer, we now get better pulp quality and savings in chemical costs. This means less impact on the environment.”

Technology leader in India

ITC Ltd. is a multi-business company that encompasses a wide range of businesses – cigarettes & tobacco, hotels, information technology, packaging, paperboards & specialty papers, agri-business, foods, lifestyle retailing, education & stationery and personal care. As part of ITC’s Paperboards and Specialty Papers Division, Bhadrachalam produces high-end virgin pulp and recycled boards for packaging and graphic applications, as well as writing, printing and copier papers. Bhadrachalam’s six paper machines with a capacity of 380,000 tpy are integrated with a 240,000 tpy two-fiberline pulp mill.

M. Muralidhar, Senior Manager at ITC.

Metso’s Ramesh Chandra giving operator training at ITC, Bhadrachalam. One operator commented, “Now I realize for the first time that I see the process response. I can optimize process conditions so that all final pulp quality targets are achieved.”

Ramesh Chandra

[email protected]

oxygen delignification. To optimize each phase requires the correct balance of time, temperature, pressure and chemical addition.

According to M. Muralidhar, Senior Manager, Automation Projects, Paperboards & Specialty Papers, ITC, Metso Kappa Analyzer has enabled ITC Bhadrachalam to significantly reduce chemical dosages in its bleaching process.

Feed-forward Kappa measurementInitially, the oxygen charge and NaOH dosage was based on the brightness and pH at the PO press. The shortcom-



Metso ts at shandong aPriL ssYMB Pulp & Paper Wastewater Plantfor sludge concentration Measurement

Application descriptionShandong APRIL SSYMB Pulp and Paper Corp. Ltd is located in Rizhao, Shandong province. The annual production of plant phase I is 315,000 tons of fine wood pulp, and 1,000,000 tons of fine wood pulp from plant phase II per year. The plant phase II wood pulp line is the biggest single line right now in the world, with the most advanced process technology and equipment, and the highest environment protection level wood pulp line. The wood

pulp plant phase II wastewater plant treat-ment capability is 130,000 tons per day. The wastewater is mainly from the cooking, washing and screening, bleaching, paper machine and the alkali recycle process seg-ments. The wastewater from the different process segments of the wood pulp line is collected by the plant wastewater pipe lines and treated at the wastewater plant.

After the three levels of deep treatment at the wastewater plant, the wastewater is supplied to other companies for manufac-turing purposes. It saves water resources and enables the middle water reuse. Sludge from the waste water treatment is the major solid waste in the pulp and paper industry. It is difficult to treat the sludge. At Shandong APRIL SSYMB Pulp and Paper Corp., Ltd, one part of the sludge is manufactured into healthy organic fertilizer. The healthy organic fertilizer will be used for forest planting and agricultural production. The another part of the sludge is transferred to the boiler plant as fuel for the power generation. So the total sludge utilization rate is 100%.

The Metso TS transmitter is installed at the outlet of the sludge mixing tank.

Shandong APRIL SSYMB Pulp

and Paper Corp. Ltd.

Dilution water

Valve

Primary clarifier sludge

Second clarifier sludge

Flotation tank sludge

Sludge mixing tank Pump Metso TS

Dewateringstation

The sludge from the primary clarifier, the second clarifier and the flotation tank is mixed at the sludge mixing tank totally. The mixed sludge is transferred to the remote sludge dewatering station. At the sludge dewatering station, polymer is added to the mixed sludge. After the press and filter dewatering of the belt press filter, the sludge is treated for the further drying. The final total solids concentration reaches about 40%. It decreases the sludge bulk and water content. This makes it more convenient for sludge storage and transportation.

The excessively high mixed sludge concentration makes the sludge transporta-tion pipeline block easily, or it will consume more power from the feed pump for sludge transportation. Metso TS sludge concentra-tion transmitter is installed at the outlet of the sludge mixing tank. By using the sludge concentration measurement, it controls the dilution water addition to the mixed sludge transportation pipeline. It controls the sludge concentration in the transporta-tion pipeline at a stable and proper range, and makes the sludge transportation more highly efficient and stable.

Customer comments“The Metso TS sludge concentration trans-mitter has been installed for over one year. After the installation and the start up, the measurement is very accurate and stable.



History measurement data.

high level measurement requirements and harsh process measurement. The optical sensor part of the traditional infrared light principal sludge concentration transmitter is sometimes covered by scale formation. This will affect the measurement accuracy. If the color of the sludge changes frequently, it will also affect the measurement accuracy. Yet Metso TS microwave sludge concentration transmitter has none of these measurement risks. Because of its robust construction, Metso TS transmitter life is much longer than the traditional infrared light measurement principal sludge concentration transmitter, and does not

It does not need any maintenance work. It makes our sludge transportation pipeline work well and consume less power,” says xianBing Cao, instrumentation director of the alkali recycle and wastewater treat-ment process segments at Shandong APRIL SSYMB Pulp and Paper Corp., Ltd.

Metso TS sludge concentration transmitter utilizes the most advanced microwave measurement technology. Compared with traditional infrared light measurement technology, Metso TS microwave transmitter measurement is more accurate, stable and requires almost no maintenance work. It is especially good for

require daily maintenance work.

Process and instrumentation dataThe annual production of Shandong APRIL SSYMB Pulp and Paper Corp., Ltd phase II is 1,000,000 tons of fine wood pulp. The treatment capability of the phase II waste water plant is 130,000 tons per day. The normal sludge concentration of the sludge mixing tank outlet is 2%~4%. Metso TS sludge concentration transmitter is used for the measurement and the control loop.

Marko Heikkinen

[email protected]

The sensor installed on site.



The TCU installed on site.

Metso product: Metso total solids transmitter

Customer: Shandong APRIL SSYMB Pulp and Paper Corp. Ltd wastewater plant

Application: Sludge concentration measurement at the sludge mixing tank outlet

improving shutdown efficiency in chileGood preparation for a major shutdown saves time and money. This is especially true with valve maintenance. Metso is a very valuable partner with specialized shutdown services that identify valves needing attention and eliminate unnecessary maintenance work.

Putting experience into practiceEmpresas CMPC S.A. is a Chilean integrated forest industry company with op-erations in Chile, Argentina, Brazil, Peru and Uruguay. With three pulp mills in Chile, it is today the world’s fifth largest producer of pulp. The Santa Fe Mill is located near Nacimiento, about 500 km south of Santiago, and produces bleached eucalyptus on two fiberlines. When preparing for a general plant shutdown of fiberline 2 in 2009, the mill turned to Metso for help in identify-ing which of the many valves in the mill needed service. Javier Gonzalez, Electrical & Instrumentation Superintendent, explains, “Our mill, for many years

Intelligent devices and FieldCareIn Santa Fe’s number 2 fiberline, 74 control valves were identified as critical use and Metso service personnel downloaded the performance data with Metso FieldCare during the three month period before the shutdown. Metso FieldCare is a standalone condition monitoring software supporting open FDT technology for the configuration and diagnostics of any FDT/DTM capable intelligent device. All the valves selected had been equipped with Neles ND9000 intelligent valve controllers when the line was built four years earlier. The ND9000 is a smart, reliable and future-proof positioner, which supports the HART Communication Protocol. Communication to FieldCare can be established by point-to-point

connection or by a device network. “This predictive work helped to reduce the num-ber of valves to be maintained and, therefore, reduce the time invested by the planning personnel for this task,” says Javier Gonzalez.

Downloading positioner data with Metso FieldCare.

TExT: Nigel Farrand

has been doing maintenance for control valve assets based on importance to the process and historical data. This led us to remove a significant number of control valves from the piping every year for maintenance, which had a direct impact on the costs of hiring a large amount of labor to do the maintenance jobs in the short time period during our general shut-down.” The mill entered into a predictive maintenance contract with Metso’s local service center and with three months to the shutdown, preparations were made for valve servicing. Every shutdown is a major investment of time and resources, which can be optimized using the latest tools and extensive maintenance expertise with a Metso maintenance contract.



improving shutdown efficiency in chile

Only 10% of the valves needed extensive workOf the 74 valves, FieldCare showed that seven needed to be taken out for work-shop maintenance and nine more required only minor servicing. Metso service personnel worked together with the mill to develop the list of spare parts needed for shutdown. This list helped to reduce the spare parts cost, previously purchased based on historical data. As a comparison, on line 1 with older valve positioners, the mill’s maintenance department decided to take out 80 critical valves from the process

Javier Gonzalez of Empresas CMPC S.A., summed up the advantages as follows:• Reductionofcontrolvalvesremovedfrompipingformainte-

nance due to condition monitoring work based on intelligent valve controllers: This had a direct impact on the increased availability of equipment not removed because they were in good condition.

• Reductionincostsrelatedtosparepartsusedinmaintenanceactivities: The spare parts analysis, made by Metso, identified spares that the mill had in stock and the ones to be bought, helping to reduce a lot of administrative work at the same time.

• Reductionoftimeneededforvalvemaintenanceactivities, due to a decreased number of valves removed from the piping.

From left to right: Gonzalo Silva, Metso Smart products engineer, discusses maintenance issues with Javier Gonzalez, Electrical & Instrumentation Superintendent, and Jorge Fuenzalida, Service Manager for Chile and OSA1.

because of the lack of accurate knowledge of their condition. Metso’s predictive maintenance with FieldCare resulted in substantial savings on line 2 by eliminating unnecessary assembly and disassembly work and reducing the man-hours required during the shutdown. Javier Gonzalez also states, “It is necessary to add also the time and administrative work that was reduced related to spare parts purchases, due to the analysis done by Metso personnel and the improved delivery time of these items due the service contract we had with them.”

Repeat contract for 2010The following year, in August and September 2010, Metso analyzed the information from 146 intelligent valve controllers in five different areas. At this shutdown, 27 valves were taken out for

Gonzalo Silva

[email protected],

Ulla Partanen

ulla.partanen @metso.com

maintenance, which Metso performed on site. Positioner maintenance service was also carried out as needed, based on the information gathered through FieldCare.

Good return on investmentThe correct spare parts were ordered well in time for the shutdowns, and the cost of the predictive maintenance contract was paid many times over by reducing the number of valves taken out of the process and disassembled. The MTBR (Mean Time Between Repair) was extended for monitored valves, and Santa Fe additionally reported savings by reducing the spare part stock based on Metso recommenda-tions and a reduction in administrative time of buying spare parts. Javier Gonzalez adds, “The optimization of costs related to maintenance of control valves assets, based on the information delivered by a predictive maintenance philosophy, allows us to allocate resources to other important maintenance activities in the mill. The best was that this service was carried out during normal mill operation time without disturbing the process.”

• Reductionofcostsrelatedtomanualworkformaintenanceactivities: Fewer people were hired for maintenance activities because fewer valves were removed from the piping.

• Qualitymaintenancebasedonmanufacturerstandards:Metso personnel carried out maintenance activities for the valves.

• Reductionofbothpotentialsafetyandenvironmentalrisks:Due to the decreased number of valves removed from the piping for maintenance, the probabilities of incidents related to safety and environmental were reduced.

• Reductionofcostsrelatedtovalvemaintenanceactivities:Cranes, scaffolds, welding, additional personnel for safety supervision, and other related costs.



PRODUCTS A N D SOLU T IONS

It’s in our DNA –Feeling of controlMetso DNA brings a long-awaited, something new to process controls. In addition to its new technology, the system takes a fresh approach to usability by taking feelings into account as a part of process control work.

“Despite its fact-based nature, process control work at mills and plants includes a lot of feelings con-nected to solving various situations,” Jaakko Oksanen, Product Manager for Metso DNA explains on behalf of the new approach to usability.

“When all the aspects of business and production processes are under control, people in various tasks can enjoy a feeling of control with their work,” he explains.

A new definition of usabilityBased on research about the work done in user organizations, Metso DNA offers tools that help users manage the tasks at hand and feel confident, even in exceptional situations.

“For instance, users can easily access all the data collected during their absence, like over the weekend. In traditional systems, the history of this information requires separate applications and data analysis is difficult,” Oksanen describes.

Network of experts worldwideMetso DNA also contains tools that sup-port a mill- or corporation-wide exchange of information and knowledge. These tools collect and store an organization’s experi-ences, allowing all your people to share the same event and history information whenever and wherever needed. “ As a result, your experts will no longer need to spend their time on the road to find the solutions to process challenges,” Jaakko Oksanen points out.

Lifelong inspirations without expirationTo turn a new page in your mill’s or plant’s automation history, you don’t have to re-write the entire book. Metso DNA adapts to your lifelong business visions, thus securing business continuity.

“Since dynamic Metso DNA ensures that the customer’s past or existing choices are never a barrier for growth,” Jaakko Oksanen says, “the compatible system can be easily connected with different product genera-tions. And the cost-effective and flexible migration of third-party systems ensures openness to life-cycle growth.”

A tool for greener businessAutomation plays a key role in coping with today’s ever tightening environmental challenges. Metso DNA offers specially designed tools for optimizing industrial processes to achieve lower emissions and less energy consumption – while still not

compromising on profitability and high quality.

“These tools ensure a feeling of control with regard to the mill’s or plant’s environmental issues. Plus the greener mill or plant image is an added bonus,” Oksanen states.

Hard facts for a good feelingMetso DNA provides you with all controls in one system for the machine, controls, quality and drives, which gives customers several benefits.

“Plants and mills can integrate all their process operations into one mill- or even

TExT: Sari Lehtonen-Lammi


Jaakko Oksanen, Metso: “Metso DNA scales up with your goals – from a single standalone controller into a mill- or plant-wide system.”

Veijo Tolonen, Kuopion Energia: “Life-cycle dynamics by Metso,

from Damatic Classic in 1982 to the latest advances of

Metso DNA in 2011.”

PRODUCTS A N D SOLUT IONS

Swipe the screen, feel the process. By researching the user’s work, Metso can ensure that your people will always work with the latest technological advances.

corporate-wide entity, which allows for easy access to information, as well as easy comparing and combining of pro-cess data,” Oksanen lists. “One system also improves the operators’ feeling of being in control, as they only need to learn one system,” he concludes.

A way to serve“It’s in our DNA” not only covers the state-of-the-art technology of Metso DNA, but rather Metso’s way to serve each customer based on his or her specific needs throughout the life cycle of the plant or mill.


The best possible paybackMetso DNA is leading the way again by introducing its new industry-specific control applications, developed to ensure the best possible payback from automation for its users.

Metso has supplied control systems for complicated industrial processes since the 1970s. Now, customers in the pulp, paper, process, power generation and mining and construction industries can further enhance productivity with new industry-first control applications.

Machine condition and runnability monitoringAs a first, machine condition and runnabil-ity monitoring is now embedded within the process controls of Metso DNA. This enables operators to see condition monitoring alarms in the same interface as process alarms. Conventional machine condition monitor-ing requires a separate system often used by system specialists, not operators.

Bjarn-Olof Johansson, Billerud: “Minimal downtime is the source of quick payback for the Metso DNA upgrade.”

New control applications for power plants For power producers, Metso DNA offers new applications to help gain more efficiency and better environmental performance.

Turbine controls for steam and gas turbines enable integrating turbine control, turbine protection and turbine management applica-tions within the plant’s automation system. This eliminates the need for separate systems and pays back through cost-effective maintenance and reliability through redundant process controllers.

Metso DNA PC Combustion Manager is a new application, which optimizes pulverized coal-fired combustion, thus maximizing combustion efficiency at conventional coal-fired power plants.

Intelligent sootblowing optimization has helped customers enhance their fouling management and reduce sootblowing steam consumption. The more effective use of soot-blowing steam has also enabled considerable energy savings.

to changing process needs.All Metso automation systems deliv-

ered after 1988 can be upgraded with new applications as a whole or in sections. Existing equipment and applications can be used in the upgraded system. The system network may also contain different generation subsystems or even different generations of products within a single system, meaning that new product features can be easily added.

Metso DNA is supported by a global network of local experts.



the entire pulp drying line and includes everything from quality control and accurate dirt count to bale registration and marking – and on through accurate quality classification.

New Metso DNA now also for mining and construction Metso has combined its unique know-how of equipment and processes with automation expertise – now also in mining and construction. Thanks to its scalability, Metso DNA can fulfill the needs from standalone single-machine, PLC-like applications to complete mine-level control and information management DCS systems. Small or medium size construction plants, which fall somewhere in between, are naturally also included.

Just the way you need itThe flexible Metso DNA can be executed just the way you need it. It can be designed as a seamless part of your overall plant or mill project, thus utilizing the comprehensive process and machinery know-how of Metso. Or we can supply you with a separate applica-tion that helps you achieve the best possible payback from your plant or mill automation.

Metso DNA can be developed, maintained, and upgraded throughout its life cycleMetso’s long experience in automation systems dates back to 1979. So far, Metso has delivered thousands of systems to various industries globally.

Metso DNA is a single automation system for all functions – process, machine, drive and quality controls. It also covers information management as well as mechanical and field device condition monitoring. Metso DNA is scalable from a single standalone controller to mill- and plant-wide systems in global organizations.

The unique feature of Metso DNA is its single system architecture, enabling lifelong compatibility and upgradeability. This means significant advantages for Metso’s customers since Metso DNA enables step-by-step system upgrade paths to develop their systems according

Increased transparency for pulp and papermaking Metso DNA now offers pulp and paper makers a single system for all controls, from fiber line to baling information, and from headbox to winder. The new Metso DNA provides pulp and paper makers with measurements, analyzers and a complete selection of state-of-the-art advanced process controls. Having all controls for machine, process, quality and drives within the same system gives customers several benefits. In new machine installations, for example, the Metso control system allows quick start-ups.

At paper mills, new integrated winder controls will increase the transparency between the winding process and papermak-ing process controls.

“The winder controls enable operators to follow paper profiles through the winder, which improves both the run-nability and productivity of the winding process,” says Mika Lehmusvaara, Automation Technology Manager at Metso.

Metso DNA applications for the pulp drying line ensure efficient and accurate automated pulp bale quality and information management. Metso’s wide product and solution offering for the pulp baling process physically extends across

Electronic diaries have revolutionized decision-making in pro-duction organizations by taking organizational work experiences into data collection.

Metso now introduces its solids measurement technology called MetsoLS™, which allows wastewater treatment plant operators to measure low solids in difficult applications like centrifuge centrate and aeration tank mixed liquor suspended solids. Until now, there has not been any online measurement technology available that would enable reliable measurement of a media with very low solids contents. Trial use at a municipal plant in Finland has achieved EUR 15,000 savings per centrifuge in polymer and centrifuge usage.

The Metso LS Measurement System is based on LED and laser technology. It deaerates, filters, and measures the process solids along with possessing self-cleaning capabilities to keep the measurement optics clean for continued accurate measurement.

Typical applications Metso LS is specially developed for municipal or industrial wastewater treatment processes to measure low

for choosing the right polymer and to determine the right polymer dosage.

Operation principle in a nutshellThe Metso LS device can be connected online to the process and is able to meas-ure continuous sample flow through the system by utilizing an integrated centrifugal pump. The device has two light sources that measure absorption, scattering and depolarization of these sources as they pass through the flowing media. Metso LS continuously measures both the entrained air index, which indicates overdosing of polymer, and the suspended solids content within the range of zero to 5,000 mg/l. The Metso LS measurement system deaerates, filters and measures the process solids along with possessing self-cleaning capabilities to keep the measurement optics clean. The measurement cell has an extremely strong sapphire glass with high optical properties. The cell and sample lines are automatically cleaned at given intervals.

Bengt Johansson

[email protected]

Brand-new tool for low solids content measurementin wastewater treatment

solids in difficult applications. Typically, such applications are centrifuge centrate and aeration tank mixed liquor suspended solids. The device gives accurate information about centrate water quality, enabling the process to be controlled in the most cost-efficient way. An excessively high solids rate in centrate water would cause the excess solids to be repeatedly treated and centrifuged. Reliable information about the centrate water quality is very important

Key benefitsKey benefits include direct savings in polymer costs. The Metso LS device improves the throughput and function of the centrifuge. A higher solids content of concentrated sludge results in higher thermal energy in the subsequent incineration process, or alternatively reduces transportation costs when shipping to a landfill. Furthermore, Metso LS reduces conventional sampling and laboratory work due to its reliable and accurate operation. The small investment in an online solids measurement system gives significant operational savings and correspondingly a very short payback time.



Process

The turbine’s most important displacement and vibration measurements are illustrated on the operator displays of the control system. The operators are able to react rapidly to system deviations and thus ensure high plant availability.

Vibration-based condition monitoring implementedas part of an automation system boosts maintenance

At any power plant, the steam or gas turbine is not only critical with regard to production, but it is also the most expensive individual rotating machine. You should not take even the smallest risk with its maintenance. Predictive condition monitoring reduces safety- and environment-related risks caused by unexpected equipment failure or system disturbances.

TExT: Harri Mustonen, Erkki Jaatinen

When you know the turbine condition, you are able to predict its service need and add efficiency to its maintenance. You can schedule repairs to take place during the next planned service shutdown so they cause no extra produc-tion downtime.

Being predictive also brings cost sav-ings. You will be prepared for the neces-sary repairs in good time by being able to reserve the needed spares, tools and resources. In case of sudden equipment failure, getting all these organized at a short notice can be challenging – and the process will be down the whole time.

Adding a turbine controller, vibration monitoring and protection featuresTraditionally, power plant automation has been composed of separate islands, whose systems and applications often come from different suppliers. Turbine availability and safety can be improved significantly when the turbine controller, mechanical protection and vibration monitoring are implemented as part of the automation system that controls the whole power plant process.

Metso has integrated its renewed turbine controller, turbine mechanical pro-tection and turbine vibration diagnostics into the Metso DNA automation system, where they operate seamlessly together. In addition to the more advanced turbine controller, also mechanical and vibration measurements are part of the automation

system. In this way, Metso’s strong condi-tion monitoring know-how is fully utilized.

Integrated condition monitoring im-proves turbine generator diagnostics and removes the need for a separate condition monitoring system. The measurement results can be used for turbine protec-tion and for everyday online condition monitoring as well as for more demanding diagnostics purposes.

Vibration-based condition monitoring helps predictive maintenanceMachine protection monitors the most critical turbine parameters and activates interlockings to prevent machine failure. Vibration-based condition monitoring can be expanded to a more comprehensive diagnostics tool for predictive mainte-nance. It enables the plant to follow up the turbine condition online, gather diagnos-



Erkki Jaatinen

[email protected]

Original article published in Finnish in

Promaint magazine 7/2011.

tics data from it and notice creeping faults before they have time to develop into problems.

Metso’s new solution for mechanical condition monitoring, Metso DNA Machine Monitoring, makes it possible to implement vibration measurements and analyses as part of the automation system. The operators and maintenance staff are able to monitor the machine condition data based on vibration measurements directly on the control system user interface at their own workstations. One common view of the machine condition data enables them to solve issues related to the condition of mechanical equipment – together, fast and efficiently. The operators can follow how mechanical failure develops and, if there is a serious risk of damage, forward the infor-mation quickly to the maintenance staff.

The maintenance staff gets the same information at their own workstations on the same displays and is able to analyze the vibration measurements in more detail to find out the cause for the disturbances and to plan right-timed actions. Using the same data on the same display pages also improves cooperation and commu-nication between the maintenance and operations staff.

No more separate data linksCondition monitoring as part of the control system makes it easier to combine informa-tion from the process measurements and vibration measurements. Interpreting

results and drawing conclusions is more efficient when all the information needed can be collected together easily. Separate data links or manual information combined between different information sources are no longer needed.

The investment costs will be lower as both the control and condition monitoring applications share the same system resources, such as the operator stations and the history database. Also, system maintenance is more efficient since all applications are configured and maintained in the same engineering environment.

Complementing vibration data with efficiency calculations and reportsVibration-based condition monitoring can be complemented with the Metso DNA Steam Turbine Performance Monitoring application. It provides the operators and the maintenance staff with useful information about turbine performance, thermal condition and operational efficiency, both in real time as well as based on operation history. It calculates, monitors and reports parameters related to turbine performance. The calculation results are shown on the displays and as web-based reports, which provide an overall picture of turbine performance at a glance.

Information directly to the maintenance systemThe information produced by the condi-

tion monitoring applications can be better utilized when there are information transfer solutions between the automation system and the maintenance information system. For example, a fault notification entered in the electric shift diary, Metso DNA Report Diary, can be transferred to the mainte-nance information system just by pushing a button. Linking boosts the maintenance process and the flow of information in the organization.

Condition monitoring of auxiliary equipment as part of the total solutionCondition monitoring can be expanded to also cover boiler feedwater pumps, combustion air and flue gas fans and similar devices, as well as fuel feed and handling equipment. This results in a comprehensive solution that ensures plant availability and access to real-time information about equipment condition for maintenance planning.

Condition monitoring services support the customer’s predictive maintenance Metso provides power plants with a wide range of services that support the staff in maintenance operations. There are support services for control loop tuning, field device monitoring and analyzing vibration measurements of mechanical devices. If needed, the services can also include regular condition monitoring reports, which the customer can use directly in maintenance planning.

The vibration-based condition monitoring products and services offer an excellent way to improve process availability and boost maintenance at a power plant. Implementing condition monitoring as part of the automation system creates new opportunities for the cooperation between the operators and the maintenance staff. It is also a cost-efficient way to build and maintain condition monitoring system solutions.



Intelligent rotary control valvesTrue cost savings throughout the life cycleProcess control valves need to reduce process variability, provide reliable, safe and robust operation in all process conditions, withstand impurities in flow media and eliminate fugitive emissions – all at the lowest possible cost. With correct control valve selection, all this is possible as well as reduced production costs.

than rising-stem valves in many applica-tions; for example, eccentric rotary-plug valves have already established a firm foothold in refinery and petrochemical control applications.

Cost savings in heater applicationsConventionally, heater-pass control valves have been rising-stem globe-valve designs. However, during the heater cycle, some coke and sticky oil may start to accumulate in the rising-stem gland packing, especially when processing heavy oils. Leakage and sticking reduces the accuracy of through-put control, affecting heater performance and process efficiency while posing environmental and safety risks. Such poorly performing valves must be overhauled and frequent maintenance may be required for conventional globe valves. Unscheduled maintenance can be costly and risky, and can financially impact plant productivity. The gland design of Metso’s rotary control valves is inherently reliable and does not leak, thanks to the rotary stem which does not move process media into the packing.

Metso rotary control valves offer non-clogging flow ports and hard-faced trims for robust and long service life. Costly maintenance work, involving valve removal and replacement parts, is eliminated. By using the same face-to-face length as globe valves, changes in pipe-work con-figurations are eliminated when upgrading to rotary valve technology.

Metso‘s ND9000 intelligent valve con-troller ensures high positioning accuracy and fast response. Trend data collected by the valve controller and analyzed by FieldCare software enables prediction and response to maintenance needs, avoiding unscheduled downtime.

Many refineries in Europe, Asia and Latin America have tested these concepts using Metso eccentric rotary-plug valves in heater coils. These valves have been in service for several years without maintenance or leakage. Cost savings on maintenance of up to EUR 36,000 per

Neles Finetrol, eccentric rotary-plug control valve.

Traditionally, the primary source of savings has been in purchase costs, even at the expense of device quality and perfor-mance. However, it is estimated that only 10% –30% of the total cost of control valve ownership relates to purchase price, with 70% –90% attributable to mainte-nance, repair and operation (MRO). The total financial impact of possible device failures on plant production should also be considered.

Typical heater configuration.

Neles V-port segment valve with high rangeability.

Reduced valve leakage and emissions with rotary valvesElimination of valve leakages and fugitive emissions is a good investment in safety and environmental protection, but it can also improve overall process efficiency. Due to the reliable stem sealing, emissions from rotary control valves remain low over long periods, which provide clear savings throughout the life cycle of the valve. This has made rotary valves more attractive



FieldCare condition monitoring.

An intelligent valve-condition monitoring system enables a systematic approach. Valves that need maintenance are identified and the provision of spare parts, appropriate tools and even the service work can be preplanned, to reduce problems and risks in the process plant. Failures or malfunctions are detected before problems occur. You can see the valve’s diagnostic history, current status and performance and also its future!

Pay-backThe construction of Metso iCVs (Intelligent Control Valves) helps to increase production efficiency by providing superior perfor-mance, reliability and control accuracy. Well-designed rotary control valves can reduce costs related to maintenance, fugitive emis-sions and gland-packing leakage in process plants. Maintenance needs are identified before they affect process performance.

These valves provide direct savings and further savings through improved control performance. The financial effect of enhanced process stability, improved efficiency and lower fuel and raw material consumption can greatly exceed savings on maintenance.

Vesa Lempinen

[email protected]


Reprinted with the permission of Valve World magazine. This article

has been published in Valve World magazine, April 2011.

Split range vs single valve configuration.

Intelligent valve controller ND9000.

role in reducing operating costs. Proper combustion maximizes heat transfer, which minimizes fuel-gas consumption and related costs. Variations in fuel-gas composition and different operation points mean that such valves must control various loads, which requires wide range-ability from the valve or sometimes a split-range configuration.

Metso rotary valves are widely used in these applications. In some cases, a fuel-control configuration of two globe valves in a split-range configuration has been replaced by a single Neles Finetrol® eccentric-plug valve or a Neles V-port segment valve, because their wide rangeability allows accurate control with both small flows and large valve openings. The rangeability of the Neles V-port segment control valve is 150:1. Because advanced ND9000 digital valve controllers ensure high positioning-accuracy and fast response, fuel-gas control runs closer to the set point, thereby reducing process variability and fuel-gas consumption.

Can intelligent technology increase plant safety?Digital control-valve positioners provide digital communications, but intelligent valve controllers, like Neles ND9000, have embedded valve diagnostics and online monitoring capabilities to predict valve failures and maintenance needs. They also provide additional safety for staff and the process environment.

valve in a six-year process cycle may be achieved, depending on local costs and valve type and size. This gives potential total savings on maintenance alone in fired heaters with four to eight control valves of EUR 150,000 to 300,000 in six years. The financial effect of improved control performance, greater process stability and lower fuel-gas consumption can often greatly exceed the maintenance savings.

High-rangeability valves in heater fuel-gas controlOne important application in industrial furnaces is fuel-gas control where accurate, reliable control valves play a significant

Metso iCVs: eccentric rotary-plug, V-port segment, Neles RotaryGlobe, high-performance eccentric disc and top-entry rotary control valves.



Metso is strengthening its product offering by certifying valve products according to the latest widely accepted fire-safe standard – API 607 6th edition.

The plan is to replace all former fire-safe certificates and to widen the range of Metso fire-safe certified products in order to better serve our customers’ needs and requirements and to expand the applica-tions for our product range.

At present, the testing plan applies mainly to Neles ball valves – such as the new D1F-, D2- and X-series valves – as well as L6-butterfly valves and Finetrol-valves. The burnt valves have been selected to achieve as much coverage as possible in terms of size and pressure class with a single test.

State-of-the-art testing facilities To meet the requirements of API 607 6th

Metso’s fire-safe test equipment in new laboratory facilities.

Metso Cormec5 x

Metso upgrades fire-safe tests and approvals for valves

edition, the new tests will be carried out by Metso using its own highly sophisticated fire-safe equipment to test and certify valve products. This equipment, which can be used for valves up to sizes of 8” and pres-sures up to150 bar, is located in the new

state-of-the-art laboratory facilities at the Metso Valve Technology Center (located in the Greater Helsinki region), which was opened in September 2011.

The new laboratory is part of a major investment by Metso aimed at raising standards in valve production and service throughout the many industries served.

Safety, and fire safety in particular, is a top priority for Metso, and all equipment at the new Valve Technology Center incorpo-rates the latest safety features needed to minimize risks related to high temperatures and pressures. Only fully trained laboratory personnel are permitted to carry out such tests.

Veli-Matti Kaunismäki

[email protected],

Juha Perttilä

[email protected]

UV measurement is now a standard part of Metso’s inline brightness sensors to optimize chemical costs at DIP/RCF plants. The previous two inline brightness sensor models, Cormec5 and Cormec5 X, with different measurement capabilities will merge and become one. The new inline sensor with an enhanced measurement capability will carry the name Metso UV Brightness Measurement, Metso Cormec5 X. In addition to brightness and UV+ brightness, it also measures other important optical pulp properties, such as residual ink and color.

Metso Cormec5 X with its UV measure-ment has been well received by European DIP/RCF plants. Fluorescence and UV+ brightness values are typically used for measuring the quantity of the optical brightening agent (OBA) in the incoming raw material and for OBA dosage control in stock preparation. As OBAs are fairly ex-pensive and can be harmful to health, mills have been able to optimize their chemical costs with continuous inline measurement

information while achieving set quality targets. In addition, the mills have been able to ensure that specific grades, such as tissue and hygienic papers, do not hold any chemical residues.

The UV-based measurement can be used together with the industry standard brightness, effective residual ink content (ERIC) and CIELAB color measurements to achieve full benefit from a single-point inline measurement.

Based on experiences at paper mills, Metso Cormec5 X has also proven its capa-

bilities in paper machine approach systems when controlling OBA and color dosage during web breaks and process startups when measurement results from a scanner are not available. During a normal run, it provides fast feedback for paper machine quality controls together with traditional scanner measurements.

Tuomo Kalkaja

[email protected],

Jarmo Koskinen

[email protected]

UV measurement for all inline brightness sensors to pulp and paper processes



Metso around the world

We are happy to launch a new interactive, navigation-type solution that presents the total offering of Metso’s power generation solutions in a visually attractive multimedia format. Instead of single product presentations, the multimedia focuses on complete power generation solutions.

Sochi Winter Olympics are built on top quality aggregates

Only washed, highest quality aggregates are approved for the demanding build-ing contracts going on around Sochi, the city hosting the 2014 Winter Olympic Games in Russia. With the help of Metso’s mobile crushing and screening fleet and a stationary washing plant, Maykop Nerud company is processing ancient river gravel to the very best quality aggregates for the Olympics projects.

Until now, over one million tons of aggregates have been shipped by from Maykop Nerud’s quarry near Krasnodar to Sochi. Because of the high Caucasus mountains, the train network is the only logistic connection feasible. One daily train normally carries 3,000 –6,000 tons of aggregates to the Olympic city.

New OptiConcept M paper and board making line

Metso has launched a new, modular paper and board making line, called OptiConcept M. A member of the well-proven OptiConcept production line family, the new OptiConcept M optimizes machine investment to match each mill’s capacity needs.

Savings in operating costs are achieved through precise dimensioning of processes, proven technological solutions, optimal running parameters, effective maintenance operations and fully integrated automation solutions.

Optimized processes, innovations, smart controls and accurate dimension-ing decrease the use of steam, gas, elec-tricity, water, chemicals and other raw materials, and reduce emission levels.

OptiConcept M has been designed both visually and physically with the requirements of its users in mind. For example, the design of the machinery allows for easy and safe changing of rolls and wear parts, thus reducing the total duration and cost of maintenance shutdowns.

The new OptiConcept M paper and board making line stands for economy, safety and usability.

www.metso.com

Leading the way towards sustainable energy generationMetso is a frontrunner in technologies for sustainable energy generation from a challenging variety of biomass. In combating climate change, our advanced emissions management solutions are leading the development of greener energy generation. To top it all, we also o� er advanced plant automation and management solutions.

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