Performance Partner...extensive experience in pulp and paper electrification projects helps create...

PerformancePartner2 • 2006 ABB’s voice in the pulp & paper industry

Integrated automation and production solutions improve productivity at

Mondi Packaging Frantschach. p. 6

It’s about power.Electrification solutions for the pulp and paper industry. p. 4

Stora Enso makes a mega investment in Kvarnsveden. p. 10

M-real integrates ABB’s 800xA extended automation system into

its flagship paper mill. p. 11

Stora Enso’s Oulu mill relies on ABB Web Imaging System. p. 12

Reflection Coat Weight Sensor improves online measurements at Iggesund Paperboard. p.13

PerfPartner 6/Final 12/14/06 8:29 AM Page 2

PerformancePartner2

Published by ABB Pulp & Paper • P.O. Box 94, FIN-00381 Helsinki, Finland • Tel: +358 1022 11 • Fax: +358 1022 24503579 Executive Campus Drive, Westerville, Ohio 43082, USA • Tel: +1 614 818 6300 • Fax: +1 614 818 6571 • www.abb.com/pulpandpaper

Editor-in-Chief Marja-Liisa Parkkinen, Marketing Manager • [email protected]

Editorial team William Dannelly • Mike Cracraft • Tua Kauppala • Larry Davis

More than 85 percent of the world’s pulp and paper mills have ABB products installed and running. It could be a complete automa-tion system, motor, power transformer or instrument, but a part of the process depends on ABB. All this equipment is powered byelectricity. Modern power systems are based on highly sophisticated and complex technologies. Innovative engineers and experi-enced installation and service professionals ensure ABB power systems operate reliably and efficiently, and at the same timereduce costs. ABB has built its reputation on these capabilities.


Dear Customer,

It’s about POWERABB’s superior knowledge andextensive experience in pulp andpaper electrification projects helpscreate an economically and techni-cally best solution for the customer.

>> 4

One of the world’s best sack paperhas its roots in an Austrian valleyAmidst the breathtaking southern Austrian Alps,Mondi Packaging Frantschach improves the pro-ductivity of their entire mill with ABB automationand process control.

>> 6

Stora Enso makes megainvestment inKvarnsveden

>> 10

M-real chooses ABB’s800xA ExtendedAutomation System toenhance efficiency

>> 11

Stora Enso’s Oulu millrelies on the ABB WebImaging HDI800 System

>> 12

ABB’s Reflection Coat Weight Sensor improves online measurements at Iggesund Paperboard

>> 13

Latest ABB newsNew orders from around the world. >> 14

PerformancePartner

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s this year comes to a close, we can look back and see that one of the key fac-tors driving profitability for you, our customer, has increasingly been the costof energy.

ABB is often described as a “power and automation” company. These twoareas, which are our primary focus, probably have the greatest impact on the usage andefficiency of energy in the paper process. While we are clearly recognized as the industryleader in automation, our electrification and power distribution business has been quiet-ly winning every major project for the last year – and for good reason. By becoming involved early inthe project cycle, our engineers have designed, delivered and commissioned completepower and electrification projects for the world’s biggest pulp and paper mills.

As you read through this issue of Performance Partner, you’ll see that one of our cus-tomer focus articles describes our recent project at Stora Enso’s Kvarnsveden mill. Whenmill executives decided to build a new paper machine they turned to ABB for the entirescope of supply, from a 132 kV substation to the motors and switches to installation. It isthis completeness that has made ABB a unique supplier to the paper industry. No one elsecan match these capabilities.

To better explain how we deliver electrification projects on this scale, we have alsoincluded a short article in this magazine that describes how our team of dedicated profes-sionals designs a network structure to deliver efficient systems and long-term reliability.

As always, our focus is on your continuing success. Helping you become more prof-itable makes both of us a winner.

Our best wishes for a prosperous new year,

Roger BaileySenior Vice PresidentBusiness Unit [email protected]

A Focusing on our customers▼


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hether it’s a green-field project or anolder pulp andpaper mill in needof modernization,

for over 30 years ABB has been supplyingmills with electrification. As a result, ABBhas developed the in-depth levels of knowl-edge and experience needed to create solu-tions that deliver the best possible resultsfor a mill’s operations and bottom line.

For example, ABB is able to implementan electricity distribution plan for a wholemill based on relatively limited initial data.ABB specialists can draw on experiencegained from working in many differenttypes of mills to correlate the initial datawith experimental data from other projectsof similar types.

Network calculations ensurereliable dimensioningFor a network’s electrotechnical dimen-sioning, ABB uses the Neplan network cal-culation program that models all the cen-tral electrotechnical parameters. The pro-gram ensures reliable dimensioning

throughout the network in both normaland abnormal situations. Importantly, inaddition to loading and short-circuit cur-rents the program factors in the harmonicsfrom loads and voltage drops resultingfrom starting large motors.

With solid skills, an advanced networkcalculation program and a network config-uration that manages the margins, ABBhelps customers obtain highly-efficientsolutions for their electrical systems. Toavoid over-dimensioning, which can bedetrimental to a mill’s cost management,ABB uses diverse operational models tomonitor network dimensioning. Even inchallenging situations where the network isat its weakest, such as isolated operation,ABB specialists can help mills find solu-tions that are technically the simplest – andmost effective.

Maximizing energy efficiencyIn recent years the impact of energy costsand losses has increased steadily, and manyexperts believe the percentage of these costsand losses to total costs will be even moresignificant in the future. With this in

Wmind, ABB has focused heavily on researchand development to improve equipmentefficiency and decrease losses.

Mills can reduce losses by making theirelectricity distribution systems more effi-cient. Choosing the right voltage levels canmake a big difference.

As pulp and paper mills increasingly addlarger units of process equipment, theeffect of these larger units is noticeablethroughout the operation. One result isthat optimal voltage levels are movinghigher. To a large extent 690 V has replaced400 V, which was once a very popular lowvoltage choice. Due to its greater stiffness690 V has also at least partly replaced 3 kVand 6 kV as a motor voltage. And in elec-tricity distribution voltage, 33 kV fre-quently replaces lower voltage levels.

Achieving compatibilityAs a rule, a new electrical system mustrelate to an existing system – and an exist-ing system imposes its own requirementsand limitations on a new system. At thesame time, the new system creates precon-ditions that must be taken into considera-

It’s about

Electrification for the best technical results and the greatest cost-effectiveness

Electrification solutions for the pulp and paper industry

POWER



tion for future mill expansions. So it makessense that when they design a new net-work, mills need to consider the scenariosthat an extension could present. In otherwords, the future extendibility of a milldepends to a large extent on the decisionsmade when the initial system wasdesigned.

To successfully implement a large sys-tem, the quality of electricity and the com-patibility of the equipment and systems arecritical. Although compatibility is anequipment-related factor, it can also beaffected by the different systems used.

The most important factors affectingcompatibility in pulp and paper mill net-works are the harmonics and voltage dropsthat result from starting motors. By model-ing a network accurately, a mill can ensuresufficient margins for different designparameters, even in the most difficult situ-ations, and sufficient compatibility for dif-ferent parts of the network. However, partof the difficulty in making good decisionsis that different solutions can present sig-nificantly different costs. In particular, overdimensioning can cause extra investmentcosts. By optimal proportioning of equip-ment immunity levels and balancing theamount of interference generated in the

network, mills can see significant savings. With today’s effective starting methods,

voltage drops during a motor’s startingprocess are not a limiting factor for choos-ing motor size. Any under-voltagesencountered during motor start-up canalways be adjusted to acceptable levels. Ofcourse, requirements should be checked inall switching situations where start-up isnecessary.

If the motor is large compared to thegenerator, start-up can be an especiallydemanding operation in an isolated net-work. In those situations, the dynamicbehavior of the generator and the excita-tion system should also be considered.

In all starting scenarios, the optimalchoice and dimensioning of the motorarrangements have an important effect oncosts and availability.

In pulp and paper mills, loads causelarge harmonic currents in the networks.This effect needs to be taken into accountwhen designing reactive power compensa-tion and harmonic filtering. Althoughthere are techniques available for eliminat-ing harmonic currents almost completely,their elimination is not always optimal.

The correct adjustment of reactivepower and filtering of harmonics is impor-

tant to a mill’s bottom line because it has asignificant effect on costs. Working withexperts, like ABB, can help mills factor inall the variables and achieve the right har-monics.

Implementation design foroptimal resultsNetwork modeling is used in the applica-tion design process to set the basic valuesfor dimensioning parameters and deter-mine different solutions for relay protec-tion. In addition to basic protection func-tions such as short-circuit and earth-faultprotection, the program models differentkinds of advanced protection solutions,including “load shedding” and “islanding,”and accurately determines operational val-ues.

ABB works with customers to createoptimized criteria that are included in proj-ect-related standards and guidelines, suchas design and dimensioning instructions.By using our extensive experience in thepulp and paper industry, the advantages ofmodern solutions, the results of networkmodeling and our customer’s knowledge oflocal conditions, ABB can develop thestandards and guidelines that will bring amill the best possible results. ■

Energy efficiency begins with a well-designed power distributionand electrification system. ABB ismore than a leading supplier ofpower distribution and electrificationsystems for the pulp and paperindustry. We are a team of dedicat-ed professionals that can design the network structure, recommendoptimal voltage levels, short circuitcapacities and proper electricalsupply to guarantee efficiency andthe best long-term reliability.


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One of the world’s bhas its roots in an A



paper produced covers 60-125 grams perm2. With a speed of 920 meters perminute, the PM 6 is one of the world’sfastest sack paper machines. The PM 8 alsoproduces sack paper and has a wire width of510 mm and a speed of 830 meters perminute, while PM 7 produces kraft paperof 30-150 grams per m2 with a speed of350 meters per minute.

The Frantschach mill also producesapproximately 50,000 tons per year ofunbleached market pulp.

The overall export rate is more than 80%of production. The raw material concernedis spruce and pine wood.

In recognition of its highstandingapproach to in sack paper production, theFrantschach paper mill has R&D responsi-bility within the Mondi Packaging PaperDivision. Many other Mondi sack papermills follow the guiding principles elaborat-ed in Frantschach.

e work alongsidecustomers world-wide to achieveworld grade qual-ity,” states Mr.

Franz Maischberger, Head of the ProjectDepartment responsible for Electrical,Process Control and Process IT. “We wantto be our customers’ preferred, long-termpartner.” The same attitude emerges whenMr. Maischberger refers to suppliers. Heprefers major, global suppliers which pro-vide high quality over the long haul.

Quality is the key factor when discussingthe Frantschach mill. It embraces the endproducts, paper production process, pulpmill process, woodyard process and thestaff ’s know-how.

Three paper machines, the PM 6, 7 and8, produce approximately 250,000 tons ofsack and kraft paper per year. The wirewidth of the PM 6 is 490 mm and the sack

Sack paper, special filter papersand luxury shopping bagsFrantschach’s high quality paper and pulpare used for very special needs by end pro-ducers.

Frantschach’s sack paper goes under thebrand name of ‘ADVANTAGE’, a high-quality sack and kraft paper. Sack paper hasvery high quality requirements, whichentails paying special attention to printabil-ity, strength, energy absorption and porosi-ty. Converting customers of Frantschachproduce 10 sacks every second, to be filledwith 50 or 25 kilos of cement at a rate of4,000 sacks per hour. Very few sack paperproducers are able to meet such qualityrequirements.

The world-renowned coffee filter brand,Melitta, acquires Frantschach’s unbleachedpulp – notoriously, the food industry hasvery high quality requirements. Other spe-

Amidst the breathtaking southern Austrian Alps, in theLavant Valley, there is the Mondi Packaging Frantschachmill with a long history but ultra-modern technology. TheR&D Innovation Center for Mondi Packaging’s paper business is also located in the mill’s environs.

s best sack papern Austrian valley

“W


PerformancePartner8

cial pulp grades produced by MondiPackaging Frantschach can be seen as isola-tion material for transformers. Meanwhile,in luxury shops you can get luxury paperbags based on Mondi PackagingFrantschach’s kraft paper.

Basis for high qualityThe company’s strategy is to modernizecontinuously in order to ensure that it hasthe most up-to-date technology. Major pulpand paper industry machine, equipmentand system suppliers have always formed itsreliable partners and the latest investment isthe reconstruction of its wood yard and rawmaterial mixing in 2006/7, amounting toapproximately Euros 20 million.

“The mill’s strengths lie in quality,research and development, skill, two bal-anced high efficient sack paper machines,and just-in-time delivery,” explains Mr.Maischberger. In recent years, the mill haswon several awards in the above-mentionedareas, for example countrywide environ-mental improvement and innovationawards.

Mondi Packaging Frantschach has devel-oped a continuous learning system,

“Knowledge for Production,” referring tolearning from production processes. Eachshift worker logs information on any inci-dents, problems, and the related actionsand solutions, into her/his PC. In this way,the best practices are identified and experi-ence accumulated. “This enables the24h/7day online availability of everythingwe have experienced,” Mr. Maischbergeraffirms.

“Safety, health, environmental friendli-ness and a zero rate of accidents are ourworking environment goals,” states Mr.Maischberger. “This is a question of atti-tudes rather than techniques,” he contin-ues. As the result of this ambitious pro-gram, the safety performance develops sig-nificantly over the last few years.

More than 500 persons are working atFrantschach location. In October 2006, theFrantschach pulp and paper mill will cele-brate its 125th anniversary as a mill with along history but the modern technology.

ABB a long-term partner Walking around the mill, you will seeequipment and PCs bearing ABB logos.The second generation of Manufacturing

Execution Systems MES (the equivalent ofCollaborative Production Management(CPM)) solutions have been deployed inproduction planning and optimization,production tracking and quality manage-ment. Three Quality Control systems deliv-ered by ABB perform online quality controlon PM 6, 7, 8 and the flash dryer, whileABB’s Automation System has just beenupgraded and extended to cover the woodyard, in addition to the paper machines, thepulp mill and the power plant.

CPMAround 10 years ago, ABB delivered anMES system to the Frantschach paper mill.“It was working well, but was nearing theend of its lifecycle,” Mr. Maischbergerrelates. “The new corporate structure -Frantschach mill became a member of theglobal Mondi Packaging Group - has alsocreated new requirements. A new systemwas therefore desirable.”

For this reason, the Mondi PackagingFrantschach decided to acquire newProduction Planning, Production Trackingand Quality Management Systems fromABB in 2002. “Our experience of ABB’s

Franz Maischberger



earlier systems was decisive in our decisionto purchase another CPM solution fromthem, as well as the financial aspect. Theapplications were designed as multi-millsolutions, possibly covering similar millsbelonging to Mondi Packaging in thefuture.”

A template solution, a proto system basedon ABB’s IndustrialIT CPM solution, wascreated as a first step. Mondi PackagingFrantschach’s and ABB’s IT specialistsworked on this together and, since it wasimportant that the system fitted in themill’s processes perfectly, it incorporatedmany customized features while beingbased on a standard CPM solution. A chal-lenging additional aspect was the link of theABB-CPM solution to a centralized SAPsystem being built simultaneously.

The scope of ABB’s delivery includedProduction Planning, Production Trackingand Quality Management systems, cover-ing the production scheduling of the flashdryer, paper machines, winders andrewinders as well as warehousing and logis-tics . The system supports 70 concurrentusers.

A fundamental, new feature of the tem-plate/proto solution is the Capability toPromise (CTP) feature, which gives online100% assurance that Mondi PackagingFrantschach is able to deliver the right qual-ity at the right time to its customers.Another unique feature lies in its integratedplanning functionality which enables paperproducers to forecast the amount of pulpneeded for paper and market pulp produc-tion and to balance this with the plannedproduction of bulk pulp.

The project, entitled SPARK 2, lastedthree years. “We are pleased with ABB’swork,” confirms Mr. Maischberger. “Wereceived application support from Helsinkiwhen needed, while the reasons underlyingour investment decisions – improvedprocesses, quality and better customer serv-ice – have all been borne out.”

A similar system, based on thisFrantschach template, was successfullyinstalled at the Mondi Packaging Dynäsmill in May 2006.

Enterprise integration the key tosuccess“This is a fully integrated mill,” confirmsMr. Maischberger. “Every aspect of the millcan be controlled.” As the newest invest-ment, the wood yard was modernized andis also controlled using the control systemdelivered by ABB.

The control system of the pulp mill wasdelivered in 1996-2000 and was upgradedthis year, including the latest advanced fea-tures of the current system. The systemincludes 12 ADVANT AC 450 controllersand 16,000 input/output points gatheringinformation on processes, with about 20operator workstations. The paper mill sys-tem is based on ADVANT AC 460 tech-nology operating all three paper machineson one Distributed Control Network.

Sitting in a conference room, Mr.Maischberger made a direct connection tothe pulp and paper mill processes simulta-neously, displaying the continuous cookingprocess, paper machine operation and QCSin real time and online. This is one benefitof the distributed control system. Accessrights are set up so that each user gets theinformation he/she needs for timely andinformed decision-making. In the sameway, online history data is made availableimmediately. This fully integrated solutionwill help to improve the productivity of theentire mill.

QCSPrintability, strength, total energy absorp-tion and porosity are the most importantquality features in sack paper. For the qual-ity control of these, Frantschach has aQuality Control System for every papermachine; these ADVANT 1190 systemshave been controlling the basic paper prop-erties for years. “They are reliable andworking well,” said the mill staff.

Franz MaischbergerMr. Maischberger is head of the projectdepartment for Electrical, Process-Controland Process IT at Mondi PackagingFrantschach. He has been working at themill for 29 years; his passion for stable state-of-the-art technology perhaps provides oneof the reasons for Frantschach mill’s posi-tion as a technological forerunner. ■

Taking care of the environmentAt Mondi Packaging Frantschach a greatdeal of attention has been paid to environ-mental issues. Due to its solid improve-ment in technology, waste water figureshas dropped to an 1,500 InhabitantsEqual Value, while SO2 emissions havetumbled from 1,800 to 40 mg/m3. In1998 the mill was certificated according tothe Environmental Management SystemISO 14001.

Mondi PackagingThe Mondi Packaging Frantschach ismember of the Mondi Packaging Group, aleading European paper and packagingcompany. It is active in the bag and flexi-bles business and has more than 100 pro-duction facilities worldwide.

The Mondi Group is owned by theAnglo American Group. Mondi operatesworldwide and is principally involved inproducing paper, packaging solutions,coating and business paper. In 2005, salestotaled USD 4.02 billion and it employed16,278 people.

Mondi Packaging Frantschach GmbHis located in Austria, at the heart ofEurope. Mondi Packaging Frantschachwas founded in 1881 and nestles in theLavant Valley, surrounded by tree-cladmountains. The nearby town ofFrantschach-St. Gertraud has 3,000inhabitants, and the area is renowned forskiing during the winter and its hiking andbiking routes in the summer.

A good neighbor


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Stora Enso makes a mega investment in Kvarnsveden

Focusing on our customers 1▼

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he Kvarnsveden mill is situ-ated in Borlänge in centralSweden in the middle offorests and by the river Dal-älven. Forests and the avail-

ability to create electricity from the riverwere good reasons to build a paper millthere over 100 years ago.

With an annual capacity of 420,000tons, the new PM 12 is one of the world’slargest paper machines for the productionof uncoated SC magazine paper, and todayKvarnsveden with production capacity of1.1 million tons is one of the biggest millsin Europe.

Maximizing a mega millIn 2002, Stora Enso announced a plan toinvest in a new paper machine. Access tolocal fresh fiber, production structure andknowledge of uncoated magazine paperwere factors that allowed Kvarnsveden tosecure new investment that amounted toUSD 540 million.

Project KP-M involved at it’s peakaround 1,200 people and included a newpaper machine, a new roll packaging line, aTMP-SC plant, a new wood chipping lineand an extension of the raw and wastewater plant. The project took nearly twoyears.

Working with full speedPM12 started up successfully in earlyNovember 2005. ABB’s close cooperationwith the paper machine supplier Metsoresulted in a smooth test run and also a

smooth start-up. The inauguration of thenew production line took place at the endof April, 2006.

Liquid cooling new technology“It was quite a shock, when we heard thatthe frequency converters, being a part ofthe drive system delivered to the mill, wereliquid cooled,” the maintenance managersaid. “We noticed however in practice, thatthey are working well, and we do not needany more fans to cool the electricity room.It means a much lower noise level there.”

Liquid cooled frequency converters rep-resent ABB’s newest technology in thisarea, and the Kvarnsveden installation isone of the first for paper mills.

The drive system for PM 12 included121-pulse incomer sections, 37 drive sec-tions with ACS 600 drives, 11 drive sec-tions with ACS 800 drives for lower volt-ages, AC 800M controllers with G200control panels, 36 drive sections to twoTwinLine calenders, 32 drive sections fortwo Win-Roll winders each, 6 drive sec-tions for the WinBelt rewinder as well asengineering, commissioning, customertraining and spare parts.

One of the biggest electrifica-tion projects“This delivery is one of our most extensiveelectrification solutions. We had over 100people simultaneously working for electri-fication,” said ABB’s project managerKenneth Storvist. ABB delivered the powerdistribution, process electrification and

building electrification, plus all servicessuch as project management, engineering,site management, commissioning, installa-tions and customer training.

For power distribution ABB delivered132 kV substations, 63 MVA main trans-formers and 37 11 kV Unigear switchgear;23 Resiblock distribution transformers andMicroSCADA network monitoring andcontrol systems as well all installations andmaterials.

The process electrification deliveryincluded 15 MW refiner motors, protec-tion and excitation systems, bus ducts,intelligent MNS motor control centers -500 motor starters, 150 ACS 800 singledrives, 400 process motors, safety switches,and all installations and materials.

In addition, ABB was responsible forbuilding electrification including main 400V distribution boards, lighting and processcontrol voltage sub-boards, general andemergency lighting, UPS, maintenanceoutlet panels and a fire detection system forthe entire PM 12 building.

Service is number 1“Everything must work 365 days a year,”said mill staff. The shift crews werechanged from five to six and all the facili-ties run continuously. This means that it isonly possible to shut everything down formaintenance during long public holidays.

The mill staff also remarked that main-tenance is number 1. Therefore havingABB local, and spare parts at ABB Västeråsor Helsinki, is a major advantage. ■

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M-real chooses ABB’s 800xAExtended Automation System toenhance efficiency

hen M-real needed toincrease efficiency attheir flagship Kirkniemimill in Finland, compa-ny executives decided to

switch from their existing automation sys-tem to ABB’s Extended AutomationSystem 800xA. The new system is fullyintegrated with M-real’s existing IT infra-structure and its systems, servers and PCs.

M-real Kirkniemi, which began opera-tion in February 1966, is located 70 kmwest of Helsinki.

Today, three paper machines working ata speed of 1,100-1,500 meters per minuteproduce 730,000 tons of publishing papereach year for the world’s leading magazinesand newspapers.

All three paper machines are currentlyequipped with ABB’s Sectional Drives andQuality Control and PM 1 is controlled byan ABB distributed control system. Thenewest ABB solution, the system 800xA,started up in February 2006 to control andmonitor production at the mechanical pulpmill.

Modernizing the millThe Kirkniemi mill is currently updatingtheir open control systems. In 2003, M-real

signed a group-wide IT outsourcing con-tract with IBM which prepared the way forthe 800xA project. Hardware selectionswere streamlined and part of the grinderywas modernized.

With the new outsourcing, the mill’sproduction capacity increased substantially,imposing greater demands on the infra-structure including new requirements forthe automation systems and IT.

Enterprise integration“Our processes are more extensive nowa-days, and the older systems and solutionsdon’t meet today’s ever increasing demands.Also, capacities have increased at the mill.These are the reasons new tools were need-ed,” says Ari Skyttä, Project Leader at theKirkniemi mill.

The decision to acquire ABB’s 800xAsystem came after a very tough competitiveprocess. Mill personnel thoroughly exam-ined different kinds of systems and checkedhow they actually worked out. As the resultof this investigation, the mill found thatABB DCS technology was very advancedand well-suited to the company's plans.

System 800xA is a uniquely scaleable andflexible automation system. It integrates allautomation functions in a single operationand engineering environment that providesunique single-point data access for theentire plant. At Kirkniemi, the 800xAreplaced the old technology in the grindery.

The 800xA delivery included four

Process Portal units and a number ofremote terminals plus 2,000 I/Os. Thisgives the operators and management theability to have different views of theprocess. They can obtain the type and classof information required for timely andinformed decision-making.

ABB’s global alliance with M-real’s IToutsourcing partner, IBM, adds furthervalue. The System 800xA solution is fullycompatible with all IBM servers and soft-ware. This means that System 800xA isseamlessly integrated with M-realKirkniemi’s existing IBM systems, serversand personal computers.

M-real supplied the hardware, includ-ing the servers and personal computers, forthe project, which is updated by IBM aspart of the mill’s IT system structure.

On-time start-up “The start-up went successfully, and asplanned,” observes Skyttä. “The projectschedule was challenging. Processes wererunning continuously.”

A major portion of the change andrebuild work had to be done simultaneous-ly, however the actual downtime was onlythree to four days.

M-real also appreciated that ABB ProjectExecution Services supports all phases of acomplete turnkey delivery, from the specifi-cation stage, through system design andengineering/manufacturing, to installationand start-up. ■

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Ari Skyttä





tora Enso’s history in Oulu datesback to 1935 when the facilitywas still called Oulu Oy PulpMill. Although through theyears the names have changed,

the pulp and paper-making tradition hasbeen maintained. At the moment, Oulumill with its 800 employees is one of thelargest art paper plants in the world.Having its own printing laboratory addsthe finishing touch, enabling continuousresearch and development work.

As a main raw material for the mill’scoated woodfree papers of high quality,oxygen bleached pulp is used. It is charac-teristic of all of the manufactured papergrades that are intended for high-end imageprinting, such as art books, brochures,upmarket catalogues and luxury magazines.

Production Manager Harri Pihlajaniemifrom Stora Enso, states that when qualitycounts as much as in Oulu mill’s case,defect-free paper is a critical factor. TheABB Web Imaging System was a majorinvestment but it will enable the mill toimprove its production quality and efficien-cy significantly.

Extensive deliveriesThere are two production lines at the Oulumill, PM 6 and PM 7. Both lines have abase paper machine, an off-machine coaterand two re-reelers, one before and the otherafter the coater. The production speed ofPM 6 is 1,400 m/min while PM 7 clocks

up 1,600m/min. The wire width of both is9,000 mm.

ABB delivered new technology WebImaging HDI800 Systems for both basepaper machines, as well as AutomaticBraking Systems for the re-reeler prior tothe off-machine coater. The first deliveryfor PM 7 took place in September 2005and the year after the second system wasdelivered for PM 6.

Both deliveries included a complete webinspection system. At the paper machine,the Web Imaging HDI800 System detectsall important defects and classifies them byusing neural network based technology.Serious defects are then patched at the re-reeler. Stopping is very accurate and fastusing the Automatic Braking System withabsolute length marking. At the unwindingstation of the off-machine coater, the oper-ators can verify which defects may stillcause problems at the coating stations.

The delivered Web Imaging HDI800Systems included automatic classifiers andcomplete integration with the mill datainfrastructure. During the projects, ABBalso introduced a revolutionary Ink JetColor Marker for absolute length marking.The new markers have been installed inboth production lines

Clear benefits for the customerThe main concern at the mill is to ensuredefect-free paper for the off-machinecoaters. Some of the defects are of very low

contrast and their detection requires highimage quality and state-of-the-art detectionalgorithms. If the defects are not discoveredat an early stage of the process they maycause web breaks and damage as well as sig-nificantly increasing expenses at the plant.

The basis of the new Web ImagingHDI800 System is its advanced defectdetection with fast cameras and an accurateclassification system using neural networktechnology. The Web Imaging HDI800also enables additional software engines forproduct specific analysis, such as vergé,watermark and uniformity measurements.

The Ink Jet Marker is used to encodeabsolute length marks which are then readat the re-reelers. The Automatic BrakingSystem drives and stops the re-reeler accu-rately at the defect position so that thedefect can be patched. At the coater, theunwinding station uses the same absolutelength codes to synchronize the defect mapwith the coating stations. In this way, theoperator can identify which defects causeweb breaks and which do not.

The benefits of a single, common systemfor the Web Imaging HDI800, seamlessintegration with the mill systems and sharpimage quality were highly appreciated atthe Stora Enso Oulu mill. HarriPihlajaniemi states that the supplier’s relia-bility and previous references were impor-tant factors when choosing ABB.

Compared to the former systems, moredefects are now caught. Critical defects areeasier to distinguish from harmless ones,and the operator has more time to concen-trate on challenging flaws. In addition, ifthe number of defects rapidly increases, thisis usually a sign of a bigger problem such asa dirty paper machine. As a result, not onlyare defects patched but their cause is speci-fied more effectively.

In general, as troubleshooting becomeseasier with the new system, the runnabilityof the whole production process increases.This means savings in time and productioncosts and, above all, the high quality ofpaper is maintained. Thus, customer satis-faction is guaranteed in the future, some-thing on which the Stora Enso Oulu millsets a high premium. ■

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Stora Enso’s Oulu mill relies on theABB Web Imaging HDI800 System

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ABB’s Reflection Coat Weight Sensorimproves online measurements at Iggesund Paperboard

ounded in 1963, IggesundPaperboard’s Swedish mill isknown for its high-quality, solidbleached board – and also forhaving one of the longest board

machines in the world (270 m). Iggesund has developed a reputation for

perfection and regularly wins Europeanawards for paperboard excellence.

“As we always aim to improve the consis-tency of our papermaking, we decided toinstall the Reflection Coat Weight Sensoron KM 1,” explains Hållén.

One reason that Iggesund turned toABB: they understand that mill require-ments and process conditions require a con-sultative approach to coat weight technolo-gy selection. ABB offers the expertise andtechnology to precisely meet any coatweight measurement requirement.

Cost-effective Immediately after installation, Hållén wasimpressed by the Coat Weight Sensor’s

impact on the mill’s bottom line. “I discov-ered very quickly that the Reflection CoatWeight Sensor is definitely easier to main-tain,” he says. “Less effort is required and Ican even get better results with fewer sen-sors.”

Reflection Coat Weight Measurementuses direct infrared absorption to measurethe influence of clay, latex, calcium carbon-ate, cellulose and moisture to accurately cal-culate coat weight and percent moisture.

Improved accuracyIncreasing online measurement accuracy isimportant to any papermaking process.According to Hållén this was definitelyachieved with the Reflection Coat WeightSensor.

Says Hållén: “We carefully watch for anyvariance between the online and lab results.With our old sensors we had reduced thevariance to about 1.0 2-sigma. With thenew sensors we have almost halved thisvariance to about 0.6.”

Easier to calibrate, faster responseThe amount of calibration required has alsobeen reduced at the Iggesund mill. Hållénsays that because the ABB sensor can be cal-ibrated in isolation, mill personnel don'thave to worry about the effect it will haveon their other sensors.

Improved speed of measurement hasensured that Iggesund can respond swiftlyto sheet changes. “We can now see thechanges more quickly when we adjust thecoat weight,” notes Hållén. “The fasterresponse gives us the possibility of reducingour waste and making more high qualitypaperboard.”

Iggesund has been so impressed by theperformance of their new sensor that millpersonnel are already considering addingmore ABB sensors. “At the moment I’mlooking to deploy the Reflection CoatWeight Sensor on more of our scanningplatforms,” says Hållén. ■

F

“The Reflection Coat Weight Sensor is easier to maintain, easier to cali-brate, is almost twice as accurate and allows us to see changes morequickly,” says Gunnar Hållén, Iggesund’s Senior Process Engineer.

Gunnar Hållén




>> Worldwide market review

Major IndustrialIT ordersBrazilABB has signed contracts worth USD 55 million with KlabinSA, one of Brazil’s largest paper manufacturers and exporters, tosupply electrical and automation systems for a new paperboardline. ABB’s technology will help boost output by 50 percent.

The new manufacturing line will produce Liquid PackagingBoard (LPB), a base material used in liquid packaging. Capacitywill increase from 700,000 to 1,100,000 tons per year atKlabin's Monte Alegre mill in the state of Parana. Production isscheduled to start in September 2007.

“This project underlines our continued leadership inadvanced solutions for pulp and papermakers,” said Veli-MattiReinikkala, head of ABB’s Process Automation division. “Byintegrating key systems for power, productivity, protection andenergy savings, we are helping customers become more com-petitive in today’s challenging global marketplace.”

ABB’s scope of supply includes new automation systemsbased on the IndustrialIT System 800xA platform and upgradesto existing systems for a uniform operating environment. ABBwill also supply electrical systems including a 69 kV substation,transformers, refiner motors and protection equipment, processelectrification, and paper machinery drives. ABB monitoringand quality systems will be provided to ensure top performanceof paper and pulping machinery supplied separately by Voithand Andritz.

ChinaABB received an order from Guangzhou Paper Co. Ltd todeliver a Sectional Drive System for their new production linethat’s being built with a projected start up at the end of 2007.The drive system will cover the paper machine and two winders.In addition, ABB will deliver ventilation drives and MVmotors. The production capacity of the new production linewill be 400,000 tons.

FinlandABB has received a contract from Myllykoski Paper Oy toassume responsibility for maintenance operations at the mill inAnjalankoski, Finland. The ABB Full Service agreement isworth more than USD 150 million and is scheduled to beginon January 1, 2007. ABB has been a frequent supplier to themill, providing services, electrification products, motors, drivesand web imaging.

The new performance-based agreement will help MyllykoskiPaper to focus on papermaking as ABB assumes responsibilityfor mill maintenance and productivity. The arrangement coversautomation, electrical and mechanical maintenance and plan-ning as well as material management. About 170 MyllykoskiPaper employees will transfer to ABB.

The new contract compliments more than 150 ABB FullService relationships with customers in pulp and paper, metals,mining, chemicals, oil and gas, telecommunications and otherindustries. ABB employs some 1,800 service personnel inFinland and more than 20,000 worldwide.

Myllykoski Paper Oy markets, develops and manufacturerssome 500,000 tons of coated and uncoated papers annually formagazines and advertising materials. The company currentlyemploys about 800 people at its publication mill and reportednet sales of USD 350 million in 2005.

USA Dunn Paper awarded ABB a contract to supply an IndustrialIT

Quality Control System (QCS) to Dunn Paper’s mill in PortHuron, Michigan, USA. The QCS will be installed on the mill’slargest paper machine, PM 3.

Dunn Paper’s reputation for quality will be further enhanced,as ABB’s system reduces variations in moisture and weight. TheQCS will also increase the mill’s capacity and efficiency byreducing the time it takes to make grade changes.

“Our customers will receive a roll of paper that has a muchlower variation in moisture as well as fiber content”, says DunnPaper’s President & CEO, Brent Earnshaw. “They will seeimproved consistency in the product, roll after roll, which willhelp improve our customers’ efficiencies and lower their costs.”

A Dunn Paper team of managers, operators and engineers,chose ABB’s QCS after making numerous visits to other papermills to analyze ABB’s technology and to get first-hand feed-back from mill personnel about their ABB technology.

“We were most impressed with the technology offered byABB”, Earnshaw says. “ABB stepped up to the plate as the bestpartner and that was a significant factor.” The new QCS, whichis scheduled for installation in autumn of 2006, includes inter-face to the existing CD actuators as well as the new Slice Profilerfor the headbox. It is an investment of USD 1.3 million.According to Earnshaw: “This investment evidences our long-term commitment to providing the highest quality to our cus-tomers.”

Dunn Paper, Inc. produces a wide array of specialty coatedand uncoated MG papers used in various food packaging andspecialty label applications. Founded in 1924, the company wasacquired by Meriturn Partners, LLC in 2003. The company islocated at the southern tip of Lake Huron in Port Huron,Michigan, approximately 60 miles north of Detroit. Dunnpaper is affiliated to Valentine Paper, Inc. in Lockport,Louisiana.

An especially large number of Quality Control Systems,Actuators, Open Control Systems and Drives have been orderedby US mills during the past year.

Some of the many examples: Cellu-Tissue’s mill inGouverneur, NY, purchased an Actuator; Boise InternationalFalls upgraded its 1180 Scanning Platform to ABB’s latestQuality Control QCS800xA quality control solution; andAppleton Papers ordered Open Control for a recovery boiler.In addition, Drive systems have been ordered for three sites.

Worldwide Web Imaging HDI800 orders

FranceSweitzer Mauduit PDM Industries mill in Quimperle placesorder with ABB for the new Web Imaging HDI800 System.

GermanyABB won a Web Imaging HDI800 System order from JohnsManville’s Wertheim mill.

SwedenBillerud Gruvön purchased a Web Imaging HDI800 System.

USAABB has received orders for Web Imaging HDI800 Systemsfrom Johns Manville for their Etowah, Tennessee, plant andfrom the New Page mill in Luke.



>> Worldwide market review

Mill profitability solutions thefocus at CPM Users’ GroupSeptember meeting ABB's Annual CPM Users’ Group meeting took place in Prague,Czech Republic, on September 13-15. The meeting days fully cov-ered topics that included product releases, integration possibilities,technology workshops and case studies from US and Europeanmills.

ABB’s CPM solutions include Production Planning andOptimization, Production Management and Tracking, EnergyManagement, Quality Management and a new reporting solutionDecision Support System DSS800. In each of these solutions,modularity is the main feature. As a result, the new features releasedin September are especially easy to update. A common user inter-face, Vtrin, offers mill-level views with real-time data, role-basednavigation and many other benefits.

At the meeting ABB featured its Business Service Interface, asoftware infrastructure enabling data interchange between ABBIndustrialIT systems and any third party system. The ABB BusinessService Interface includes a plug-in to ABB Industrial Connectivity(ECS) and its modeling tool. An example of its use is the ABB-SAPjoint solution. Several of this model’s solutions are being used inAsia. The runtime environment is ABB’s 800xA AutomationSystem.

ABB also covered an especially interesting example of how inte-gration can benefit a mill. The integration of ABB’s Full Service®

with CPM solutions clearly improves production efficiency. Formany reasons, including production bottlenecks, the total produc-tion capacity of a mill’s paper machine is seldom full used. Totalefficiency can be measured and reported by using a well-knownparameter, Overall Equipment Effectiveness (OEE). OEE showswhat kind of improvements and correcting efforts should be madeto increase efficiency. This is important because even one per centmore production capacity can equal significantly greater profit

Decision Support System DSS800 is another new IndustrialIT

solution that was discussed at the meeting. DSS800 is a flexible andversatile Web-based reporting solution that offers greater reportingoptions than traditional systems ever have. The customized reportsthat the DSS800 produces offer benefits to management as well asoperators.

The workshops covering these new ABB solutions were wellreceived, and ABB was able to demonstrate how each option cangive papermakers important advantages.

ABB Road Show travels to Bavarian mills in southern Germany

On October 18, a team of ABB experts headed toBavaria in southern Germany, to introduce the latestABB solutions and answer questions on-site. UPMSchongau mill was the first mill they visited, the next

was Stora Enso Baiernfurt, and the last, on the 20th, was UPMAugsburg.

This autumn road show was a continuation of the popularspring tour, when the team visited several mills in Germany andAustria. At each stop, ABB described their newest solutions for thepulp and paper industry.

The ABB team consisted of local and international product spe-cialists, lead by Paul Goss, Account Manager for the UPM andStora Enso mills in Europe. ABB’s mill tour gave each mill’s pro-duction, automation and service personnel a chance to meet one-on-one with ABB staff. ABB specialists were on-hand to answerspecific questions and demonstrate ways to work more efficiently.

On October 20th at UPM Augsburg, the ABB team had itslongest visit to date. The road show took extra time to visitAugsburg’s world record-holding paper machine PM 3, which runswith ABB’s drives.

Mill feedback has been so positive that plans for next year’s roadshow are already in the works.


Process variations make your stomach jump?

© Copyright 2006 ABB.

ABB delivers a suite of solutions that save costs over the

entire product lifecycle. Using a common architecture

and state of the art technology, we reduce the time and

complexity to design and commission systems. High

performance and reliability are the backbone of IndustrialIT’s proven value.

Cost savings begin as soon as these solutions, designed specifically for the paper

industry, are in operation. Papermakers can maximize their return by using

ABB’s process optimization services and remote monitoring tools.

To find out more, visit www.abb.com/pulpandpaper

Improve your ride with IndustrialIT for Papermaking.


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