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Ahead Customer Magazine 01 19 Data
INSIDE:
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Management message 3
14
FORESEE DIGITALLY WITH METRIS
The ANDRITZ umbrella brand for digital solutions
Automation on a global scale 4
ANDRITZ Automation 6
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2 3
INTERVIEW
early adopters that we find in each industry sector. These are the people
we want to know and have dialogue with.
Yet, we also know that the process industries are not adventurous. There
is too much capital at stake, so risks have to be mitigated. Our challenge
is to make sure that our solutions are balanced: HIGH in technology and
performance and LOW in risk.
What are the key facts about ANDRITZ Automation that you would like
customers to know?
That we provide automation services and solutions for a wide range of
industries. That we offer a range of skills and services from pre-feasibility
consulting, to estimates, to project management, to hardware and soft-
ware engineering, up to plant simulation, optimization and commission-
ing on site. That we have more than 2,000 automation experts around
the world in 110 locations. That we have a close connection with our col-
leagues in the Business Areas so that we integrate process + machinery +
automation in a single interface to reduce commissioning, start-up, and
4 5
AUTOMATION FOR INDUSTRIES
6 7
Hydro Pulp & Paper
Automation Automation
The pulp, paper and power plant automation de-
partment focuses on automation, electrification and
instrumentation systems, helping mills to realize their
full potential. The department serves the capital and
service divisions on chemical pulp mill, power boiler,
paper and tissue machine projects globally.
CONTACT
It supplies dynamic simulation, patented advanced control solutions
ANDRITZ AG and operator training tools, focusing on simulation, electrical and
ahead-hydro@andritz.com
controls, operator training, and process optimization. Engineering
andritz.com/hydro
specialists are mainly based in the product homes and are assisted
by local support staff.
8 9
Metals Separation
Automation Automation
ANDRITZ Separation is the world´s leading separa-
tion specialist with the broadest technology port-
folio and more than 2,000 specialists in 40 coun-
tries. Industries ranging from environment to food,
chemicals, and mining and minerals are benefitting
from basic automation solutions and on to sophis-
ticated technologies that recognize changes and
CONTACT
imbalances within the production process.
ANDRITZ AG
ahead-metals@andritz.com
The ANDRITZ Separation specialists use their in-depth expertise to
andritz.com/metals/automation
provide scalable solutions that are individually tailored to region-
al and application-specific requirements, be this automation for
new equipment or upgrades to prolong the equipment’s life cycle.
Customized upgrades, process optimizations, safety audits, and
training complete the range of full services. With the aid of Metris
addIQ control systems, plant performance can be enhanced mea-
surably while keeping downtime to a minimum. As a supplier for cut-
ting-edge automation technologies and digitalization, best-in-
class performance is ensured. •
10 11
EVENT
CONTACT
SCHULER AG
ahead-schuler@andritz.com
schulergroup.com
12 13
METRIS
Foresee
Smart Customer
Sensors Care
INDUSTRIAL IOT
digitally
and process performance
SMART SERVICE
with
VENTURES
Metris
term experience in supplying
industrial measurement, con- Portfolio options created
trol, and optimization solutions for industry and in general
for various industries, ANDRITZ is as well as the specific require-
combining its process and equipment ments of key industries served by
expertise with the latest advancements in ANDRITZ all rely on the three strategic fo-
the digital era. The result of this power- cus areas of the Metris brand: Industrial IoT
ful combination is Metris: a portfolio of technologies, Smart Service concepts, and
Industrial IoT, Industry 4.0, digita- ANDRITZ digital solutions. Venture activities. The main technological
lization – current buzzwords that advancements integrated into individu-
industries use when seeking to One of the flagship capabilities of al Metris products are derived from Big
Metris is its ability to optimize industrial Data analytics, Smart Sensor tech-
improve their performance and
processes, known as Metris OPP. Metris nologies, and Augmented Reality
equip themselves for the OPP has been developed over the solutions. Smart
future of industry. past decade and is installed today in
over 50 locations around the world. Metris helps customers to fore-
Sensors
It combines powerful analytical see digitally. With this forward slant,
and data mining software with the ANDRITZ is continuously improving the
knowledge of the world’s top process portfolio and its performance
experts to deliver a smart service – providing tailored and
initiative for customers. fully integrated digital
solutions from a
The depth and effectiveness of the single source. •
Metris portfolio continues to improve Big
thanks to ongoing R&D, collaboration
with key customers and institutions,
Data
and venture activities.
Augmented
Reality
14 15
SOLUTION
Imagine the ability to produce Life is busy. We are all busy. The self-help gurus for industrial optimization formed on a longer-term contractual basis,
exist as well. In most cases, they are much that improves the performance of a produc-
the best product at the lowest We often cram too many activities into our more effective at helping optimize a plant’s tion system. Metris OPP has helped clients
days – both at work and at home, to the performance than the ones at the bookstore worldwide save millions, with pulp mills,
cost every hour of the day – point where it can seem chaotic. At work, we claiming they can help us get our lives back steel mills and chemical plants among the
are stressed due to deadlines or meetings. in order. industries that have reaped benefits in
based on the current realities, In our spare time – especially with the rise of weeks rather than years.
social media – we spend our “free” time However, optimization is a tricky word. The
constraints, and opportunities. staring at screens, texting and tweeting. key to optimization is to “get to the root” of Metris OPP is part of the Metris family of
what it means to be “optimal” for a given ANDRITZ Digital Solutions. It is based on
That is optimization in a All this “busy-ness” and activity may give the process. Is it consistent quality? Lowest cost? continuous developments in the three main
Highest throughput? Highest availability? Metris technologies – Smart Sensors, Big Data
nutshell. Automation plays illusion that we are living life to its fullest. Yet,
inside, we feel that things are not in balance. Lowest equipment wear? Nevertheless, once and Augmented Reality – and improves
Optimi zation
Metris OPP (Optimization of Process Perfor- about each control loop, control valve, mo-
mance) is an ANDRITZ service, usually per- tor, and all the variables in the process. So-
phisticated signal processing and statistical
tools in the software identify control loops
and assets that are not performing to the »
Local analyst
• Full-time on site
Regional specialist
• Remote support
Existing
Collaborative network DCS & ERP
• Control, automation, and
Metris platform
maintenance experience • Platform & methodology
• Best practices • Continuous R&D
database
16 17
optimum and predict the economic impact
this will have on the process. Then human
50 50
OVER OVER
expertise takes over. ANDRITZ experts
work with the customers’ operations and
maintenance staff to prioritize opportunities
and make corrections. In some cases, it can
be a simple fix such as repairing a valve.
Others require analysis of the overall control
objective and changing the process control CONTRACTS IN 14 COUNTRIES MILLION EUROS SAVINGS PER YEAR
strategy to eliminate off-spec production,
overconsumption of chemicals and energy
or sources of process variability. The result is
32 200
increased operational stability and reduced OVER
waste.
0
new goals. When using Metris OPP, a client
can be sure of being heard. A customer-
oriented workflow focused on individual
targets and KPIs is crucial, like cost savings Benefits of Metris OPP
in production, reduced energy consumption
• Identifies opportunities for savings and
or smoother long-term operation. As soon as efficiency enhancement
the KPIs are specified, actions are taken to • Powerful signal processing and statistical CAPITAL INVESTMENT
achieve the goal of improving the processes analysis of control effectiveness
within the 3-month test phase. Under the ple with the Logbook. This stored user data • Reduces off-spec production or wasted
basic pricing model, charges are only can be utilized to enhance daily operations, raw materials
incurred once concrete savings have been find solutions to recurring problems, or train • Increases production by enhancing
realized. Both within the test phase and the new operators. Smart controls and opera- process stability
following quarterly periods, the higher-level tor assistance facilitate an array of start- • Better quality in end product –
goals defined are analyzed, evaluated, and up sequences, diagnostics and root cause less variation
• Predicts failure in specific equipment
adapted if necessary. This approach always analyses as well as adaptive set-points, mul-
and increases equipment availability
guarantees that the ANDRITZ experts and tivariable predictive controls and neural net-
• No capital investment required; flexible
the customer all pull together. works. Regulatory control functions include
payment can be based on savings achieved
control loop tuning and assessment as well • Field-proven model in many contracts
GAINING INSIGHTS THROUGH DATA as dead-time compensators and feed-for- in different countries
Metris OPP can be compared with a tool ward options. • Knowledge database continuously
kit and offers a variety of functionalities incremented
and apps. Tools such as the dashboard REAL-TIME DATA AND AUGMENTED • Continual R&D
allow managers to gain a clear overview REALITY
and access KPIs, balanced scorecards and Field operators and maintenance technicians
project management tools. Engineers, on the can perform more effectively with on-hand,
other hand, can draw on OPP’s powerful data augmented reality support. Real-time data
analytics tools such as data mining, statistics and diagnostics coupled with remote sup-
and power spectral density to quickly port allow improvements to be implemented
implement any efficiency modifications. as and when they are needed. OPP also has
functions that allow a malfunctioning valve
ENHANCED DAILY OPERATION or motor to be adjusted or replaced before it
OPP is an especially powerful aid for op- has had any significant negative impact on
erators and shift supervisors, for exam- production. •
18 19
SUCCESS STORY
A self-operating mill?
Big thinking and big results at FACTS
Company:
Eldorado Celulose
Location:
Três Lagoas, Brazil
Product:
Bleached market pulp
(1.7 million adt/a)
Automation tool:
Metris OPP
20 21
Experiments began with automat-
ed operation back in the 1920s or
“I can tell you this,” he says. “The results in
the first year have been impressive.”
“Metris OPP is a tool
even earlier. The first truly autono-
mous cars appeared in the 1980s. An increase in operational efficiency from
that helps us stay
The development of autonomous
mills is moving at a much faster
89.2 to 93%; variable cost reduction of 7%;
38,000 admt production over the bud-
ahead.”
pace thanks to smart sensors and geted amount; AND controls in automatic Leonardo Pimenta,
tremendous computing power in mode 95% of the time. Technical Control Manager, Eldorado Celulose
small packages that are part of
ANDRITZ’s Metris OPP (Optimization The control room at Eldorado is the action center for production control. OPP soft- METRIS OPP
of Process Performance). ware resides in the DCS for advanced control of fiberline processes and also links Increasing operating efficiency by 3.8% may the smooth, gradual integration of the pro-
process, maintenance, and asset management information into one network.
not sound like a tremendous improvement. cess improvements without impacting daily
Metris OPP is a combination But in a mill currently producing 1.7 mill t/a – mill routines.
of sophisticated software and that amount is equivalent to millions of Bra-
knowledgeable human experts. “I can tell you this. The zilian real in the end. The fact that Eldorado “The main challenge was never the engineer-
This system is aimed at improv- operates sustainably at 13% above design ing itself, but rather the adjustments required
ing production through data results in the first year capacity without any additional capital in- in the way that operators and managers
mining and control strategies, vestments is proof of its efficiency. worked,” Figueiredo says.
with the goal of reducing costs have been impressive!“
and increasing profits. It has Carlos Monteiro, But why would a mill already operating in “The key to us achieving results is the belief
been around in various forms for Industrial Director, Eldorado Celulose the top tier choose a service like Metris OPP? that processes are better controlled by au-
over a decade and is constantly “We are well-managed and have tight cost tomatic, advanced process control than by
evolving and improving. Metris controls,” says Leonardo Pimenta, Technical manual operator intervention,” says Pimenta.
OPP has been implemented in Control Manager at Eldorado and in charge “Stability is essential. Every loop in automatic
over 50 plants in 14 countries. Arguably the do. “Most of our work at Eldorado to date still of the OPP project. “But we can always im- mode makes us money.”
most impressive Metris OPP project is the au- has an operator in the driver’s seat, so per- prove our position. We focus on every detail
tonomous mill at Eldorado Celulose near Três haps ‘automated mill’ more accurately de- to stay ahead of our competitors. Metris OPP KPIS ARE MEASURED CONSTANTLY
Lagoas (MS), Brazil. scribes what we are doing today – with an is a tool that helps us stay ahead.” “There were pretty high targets, especially for
eye towards autonomy in the future.” a well-run mill,” Figueiredo admits. “But we
AUTOMATED OR AUTONOMOUS? STEP-BY-STEP TRANSFORMATION were committed – both Eldorado and us –
“Autonomous implies acting independently,” Carlos Monteiro, Eldorado’s Industrial Direc- The high level of automation at Eldorado to achieving them. We signed an agreement
explains Leonardo Soares Figueiredo, tor, does not care whether it is autonomous didn’t come over night. All changes within in August 2016 with the idea that we would
ANDRITZ’s OPP Project Manager at Eldora- or automated. Monteiro is focused on results. the processes of the mill were and are done have all the front-end work done by the end
step-by-step and executed on a daily basis. of the year so we could start measuring re-
The advantage of this approach is seen in sults in January 2017.”»
Arthur Santos, ANDRITZ OPP Analyst (left), gives a progress update to Carlos Monteiro, Eldorado’s Industrial Director,
while touring the fiberline. According to Monteiro, OPP has made a “big difference” in Eldorado’s performance.
22 23
Early in the project, Eldorado and
ANDRITZ set clear goals against
which to measure success. These
goals, known as Key Performance
Indicators (KPIs), form the basis for
30% of ANDRITZ’s payment, so they
are important. What gets mea-
sured gets done.
24 25
“Metris OPP has made a big solving problems together.”
difference in Eldorado’s “We have put all our efforts into the success of
this project,” Monteiro says. “I don’t think there
performance. In a short are other mills working this way with a team of
committed resources on a full-time basis.”
time, we have achieved
According to Pimenta, when Eldorado de-
excellent results.” cided to go with OPP, it did so in a big way.
“We chose to apply all the concepts and all
Carlos Monteiro,
the technologies that OPP offers at the same
Eldorado’s Industrial Director
time,” he says. “We didn’t want to do it in
pieces, but all at the same time and as quick-
ly as possible. That’s the Eldorado way.” •
98 % +3 %
results show that there is a lot to be gained by strategies being developed. Creation of ma-
extracting the hidden capacity from our as- chine learning tools, automated data an-
sets before having to make additional capital alytics to predict process disruptions, and
investments.” two-way-communication between Metris
OPP and the SAP software of the mill are also
ONGOING PROJECTS in progress.
Another project is currently underway to de- AUTOMATIC MODE OPERATIONAL STABILITY
termine the best production mill balance at “PUT ALL OUR EFFORTS INTO THIS”
any given time. “Think of it as level control There are various “flavors” of Metris OPP in
for the entire mill,” says Santos. “We are writ- various plants. The one thing they have in
ing software to monitor all the tank levels in common is that the work is performed in col-
the mill and combine this info with key pro- laboration with mill personnel – operators,
7%
cess variables. This software will be crucial in technical resources, and management.
AUTOMATED
achieving a higher level of autonomy of the Eldorado is unique in that a joint team was
mill because then we will have a powerful formed – ANDRITZ and Eldorado personnel -
tool that will manage production throughout from the very beginning and works together
the mill using real-time data.” every day.
START-UP
SEQUENCES
The mill is also working on an Augmented Re- “You can find Eldorado process and mainte- REDUCTION OF CHEMICAL
ality project to help maintenance staff ob- nance reliability engineers and ANDRITZ OPP AND ENERGY COSTS
tain instant information in the field simply by analysts In the same room,” Santos says. “We
looking at a piece of equipment with Aug- interact constantly, collaborating and
26 27
28 29
PRODUCT INNOVATION
E X P A N D I N G H O R I Z O N S
30 31
* Trademark of the ANDRITZ GROUP.
The
The Digital Twin in the IDEAS simulator is con- upgrades to the development platform of
nected to the customer’s control system so IDEAS’ dynamically linked libraries with code
that operators can be fully trained in all the optimizations.
start-up, shutdown, and operating scenari-
Smart
os in a virtual, safe mode. So when the plant ELECTRICAL POWER NETWORKS AND
is actually started up, the operators are al- DATA ANALYTICS
ready in a position to achieve the capacity, IDEAS includes objects for modeling electri-
performance, and reliability goals expect- cal load networks such as generator, grid,
ed and the project becomes an outstanding transformer, buses, breaker, and plant load
Press
success. There are dozens of documented units. The electrical solver simulates the pow-
examples of world record-breaking start-ups er balance and load flow distribution in the
and ramp-ups achieved with the assistance network with a real-time response to the
of the IDEAS simulator. dynamics of the plant, such as start-up and
Shop
load variations in the process.
In operation, IDEAS models are connected to
real-time data in order to be executed paral- The process units and the electrical networks
lel to the process. Real-time execution of the can be integrated into a single monolithic
Digital Twin allows the creation of new appli- model and solved simultaneously. Additionally,
cations and capabilities in the customer’s sys- the functionalities of R-language and Python
tem, such as building virtual instrumentation, are invoked through the External Code Inter- Schuler’s answer to Industry 4.0
deploying condition monitoring systems, and face object. In the current era of Industry 4.0,
performing real-time optimization. computationally intensive data analytics and
machine-learning algorithms are rendered
MEETING INDUSTRY NEEDS WITH viable for practical applications – thanks to
CUTTING-EDGE UPGRADES the ascendancy of computing power. A com-
Continuously revitalized with feedback and putationally superior platform is already being
developed and is set for release in 2019. • OE E TR ACK & PROCESS CONDITION POWE R SMART
cutting-edge ideas from a global team of Overall Equipment
TR ACE MON ITORING MON ITORING MON ITORING DIAGNOSTICS
scientists and engineers, IDEAS is constantly Effectiveness
32 33
AUTOMATION NEWS
well underway.” them create and maintain the competitive MSP 400 servo press the mill’s DCS for anal-
with the Smart Assist
edge they need.” • operator software.
ysis and optimization,
Domenico Iacovelli, ANDRITZ process and
CEO Schuler equipment experts in
Graz, Austria, can be vir- The Metris Performance Center is located at the ANDRITZ headquarter in Graz, Austria.
tually at the side of any
customer needing help up, as customer person- jor role in all our business platform makes this pos-
A new Schuler press, the MSP 400 servo press, with start-up, trouble- nel and ANDRITZ start- areas, and we want our sible and allows us to pro-
features process monitoring integrated into shooting, loop tuning, or up engineers on site digital assets to be agile in vide smart services along
the control unit that ensures overload pro- optimization of process have real-time access to the face of rapidly chang- the digital value chain of a
tection across the entire path of the pressing machinery. the top experts for ma- ing market demands,” paper mill. It offers features
force profile. Under development is the ca- chinery, process, and says Gerhard Schiefer, tailored to each custom-
pacity to integrate additional sensors (e.g. for “We know that strong automation as need- Vice President for Glob- er’s preferences.” •
acceleration, oscillation, or pressure) in order customer support is of ed. For example, if there al Automation. “The Metris
to enable comprehensive system condition utmost importance in is a problem with aux-
monitoring and prevent unplanned down- any mill,” says Klaus iliary equipment (e.g., a
time. In addition to productivity improvement, Blechinger, Vice Pres- pump or some stock prep The center offers:
the process and condition data for each part ident for Tissue at equipment), the ANDRITZ • Optimization of Process Performance (OPP) with
produced will provide a basis for full quality ANDRITZ. “With the Metris expert can quickly join Metris by combining the latest technology insights
control. Performance Center, we colleagues in the Metris in digitalization with in-house process experience
can offer support to our Performance Center to • Process knowledge and specialists in production
COMPLETE DOCUMENTATION customers from our com- help provide a solution. start-up support as well as implementation of
Schuler has also already demonstrated its pany’s best experts ex- new control philosophies
• Direct customer contact and faster response by
ability to fully network different production actly when the custom- Another advanced ser-
online, real-time sharing using the latest commu-
facilities with its systems used by customers er needs it. No delays or vice is the ability to col-
nication and augmented reality (AR) tools
who manufacture train wheels. Among other high costs for travel, we lect digital information
• Remote support for stable and economic process
things, this process requires data that is suit- are able to react quickly remotely from the DCS in conditions in case of any process and equipment
able for determining and increasing the over- and efficiently.” order to apply Big Data issues for customers worldwide
all equipment effectiveness (OEE Monitoring). analytics to optimize • A training center for workshops and trainee
This data is gathered by the system so that The services at the production processes or programs for internal and external employees,
a quick glance is all it takes for the produc- Metris Performance provide decision support i.e. special troubleshooting courses for operators
tion manager to determine the total number Center are especially to mill personnel. and process engineers
valuable during a start- “Digitalization plays a ma-
34 35
Modernizing the equipment
and automation at FRIPA
The Bavarian tissue pro- are also included in the signed to be consistent
ducer Papierfabrik Albert scope of supply. with the displays imple-
Friedrich (FRIPA) recently mented in the ANDRITZ
selected ANDRITZ to ex- The special challenge is PrimeLineCOMPACT ma-
pand its stock prepara- to plan a new operating chine (PM6) installed in
tion plant and integrate logic and control rou- 2008. This uniformity will
control of the new equip- tine for the modernized make it easier for an op-
ment into an existing stock preparation plant erator to start and stop
control system. The scope even though some of the the machines in just a
requires modernization documentation has been few steps. After comple-
of the existing operating lost over the years. Ex- tion of the programming
stations and servers. isting equipment from a work in April 2019, start-
stock prep line that was up is to follow in May. •
ANDRITZ Automation will and compile logic dia- shut down will be moved
compile flow sheets of grams after finalizing the to the PM5 line and a
the existing plant sec- functions with the mill. screening plant will be
tions, update the instru- Services such as software modified to now handle
ment lists for previous testing, start-up assis- the processing of broke.
rebuilds, produce supple- tance and delivery of The logic and screen dis-
mental screen displays, the field instrumentation plays on PM5 will be de-
ANDRITZ Hydro will provide the instrumentation and control equipment at five hydropower stations on the Inn River.
36 37
SAFETY AND SECURITY
Moderation
Functional safety
of HAZOP or Risk
assessment and
PL/SIL Assign-
ment
Advisory
Creating safety for high-end technology solutions activity of Functional
safety
safety relevant SUPPORT
standards and evaluation
When designing machinery, planning a new plant, or
regulations
TASKS FOR
optimizing existing facilities, all reasonably foresee-
T ION MACHINERY
I DA
able hazards have to be identified and evaluated in
L
a HAZOP (Hazard and Operability) and/or risk assess- VA AND PROCESS
ment. By doing this, potential threats are minimized
with the help of a safe mechanical design and addi-
T ION SAFETY
tional technical measures. LUA
E VA
ION Validation
One of these additional technical measures is function-
N TAT Safety
al safety.
LE ME of safety
inspection
IMP relevant
Functional safety is defined as the absence of unac- on-site loops
ceptable risks due to hazards caused by the malfunc-
N
tioning of electrical, pneumatic, hydraulic or electronic
SIG Discussions
systems. Hazards caused by malfunctions in electrical, DE
pneumatic, hydraulic or electronic systems may include: with notified
body
SIS
• Errors in specification
LY
• Implementation or realization errors
A NA There are ISO and IEC standards
• Failure during operations that share a risk-based approach FUNCTIONAL SAFETY LIFECYCLE
• Reasonably foreseeable operational errors to establishing functional safety In order to prevent an accident,
systems and assessing safety risks
• Reasonably foreseeable misuse the design, engineering, manufac-
over the lifecycle of the product.
turing, assembly, and start-up have
to be documented and verified in
line with international and local
regulations and with recognized
technical rules.
There are several consequences
when safety is neglected. Be-
Meeting requirements and reducing sides financial and legal dam-
potential risks to a minimum is the age, a company can tarnish its
overall goal that must be achieved. reputation. ANDRITZ Automation
Moreover, functional safety does not attaches extremely high impor-
At ANDRITZ, this applies to pa- deal with hardware alone. It focus- tance to the functional safety of
per, board, tissue or pulp mak- es on software solutions and en- its products, offering high-end
ing and finishing machines, for sures that safety-critical process- technologies that are also safe
example, boiler and exhaust es are controlled better, faster, and to own and operate.
gas cleanings systems, machin- more easily. Functional safety covers
ery and plants for steel forming the entire lifecycle of a machine or
and treatment systems, ma- product to ensure that it has a long-
chinery for the feed and food term und sustainable impact on the
processing industries, hydro- plant’s performance.
power plants, and safety func-
tions in control systems.
38 39
andritz.com/ahead
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