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TRANSCRIPT
AIA
Automation Tech 2004
An AIA symposium on Integrated Automation for Global Competitiveness
ITC Grand Maratha , Mumbai, 8th November 2004
AIAPAPER MACHINE 4 : STATE-OF THE-ART MACHINE
AIA Global Paper & Paperboard consumption
46.5 million
5.9 million
286.7 million
REST OF THE WORLD INDIA CHINA
Rest of world
ChinaIndia
Tonnes
One of the top 5 employers industry in the world
AIA
Forest Sector
Agricultural sector
Paper equipment
Chemical industry
Engineering & material handling
Unorganized waste distribution network
PAPER INDUSTRY
Printing industry
Publishing industry
Advertising Industry
Media
Education sector
Packaging Industry
Printers, copiers etc.,
Industrial usage
Household
Backward & forward linkages … importance in country’s industry
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Importance to national economy
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
16.00
Bev andTobacco
Apparels Manmadefibre, wool
and silk
Leather Metals Paper% c
on
trib
ute
to m
anu
fact
uri
ng
sec
tor
Output GVA Capital employed Labour
Source : ASI
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Labour Productivity ... better than most peer industries but lags country average
0.00
0.50
1.00
1.50
2.00
2.50
Bev andTobacco
Apparels Manmadefibre, wooland silk
Leather Metals Paper India average
Rs.
Lak
hs
per
em
plo
yee
Source : ASI
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Capital productivity ... lags that of most peer industries
0.00
0.50
1.00
1.50
2.00
2.50
Bev andTobacco
Apparels Manmadefibre, wooland silk
Leather Metals Paper Indiaaverage
Rs.
Lak
hs
per
em
plo
yee
Capital productivity defines as Output/EmploymentSource : ASI
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ITC Ltd.Paperboards & Specialty Papers Division
Unit : Bhadrachalam
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PSPD on mapPSPD on map
Kolkata
Divisional HQ Secunderabad.
Manufacturing Locations:•Bhadrachalam
•Papers & Paperboards• 210000 TPA
•Tribeni•Cig.Tissue & Specialty Papers•30000 TPA
•Bollarum•Cast coating,Poly Extrusion & Super calendered•18000 TPA
• New acquisition•Kovai
•Recycled Paperboards•65000 TPA
•New Delhi
•Mumbai
•Bhadrachalam•Bollarum•Secunderabad
•Tribeni
• Bangalore
•Kovai
• Chennai
•Kolkata
AIA Products from ITCPaperboards & Specialty Papers Division
Cigarette Bd
Gypsum Bd
Aseptic
Cup Stock
Market FBBD & SBS
Coated & Uncoated Boards300000 TPA
Writing & Printing
Kraft
Paper30000 TPA
Cigarette Paper
Decor
Fine Printing & Specialty packaging
Specialties30000 TPA
PaperboardPaper
Specialities
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4141
CHOICE OF LEADING BRANDS
Our Specialities
PAPERBOARDS & SPECIALTY PAPERS DIVISION
AIA ITC - PSPD
Vision statement….
To be a valued player in the global Paperboards & Specialty Papers Industry by
Ø Leadership in quality - products, processes, service and people;ØContinuous enhancement of value for all
stakeholders, andØUpholding societal values and expectations.
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CONTEXT
“ The future of Indian Industry depends on actualization of best possible strategies to maximize resource utilization through automation to ensure delivery of quality products with optimum cost at the doorsteps of customers across the globe”
AIA Context settingAutomation in the Pulp & Paper Industry
Automation objectives in the pulp & paper industry:
Reduce costs
Reduce raw material usage.
Optimise manpower
Reduce environmental impact.
Deliver Consistent quality
Quality is a moving target. Quality requirements evolve as the product mix changes/matures and/or customer requirements change.
Delivery - OTIF
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Information explosion
Many different storage formatsPaperFilesDatabasesWeb based
Many different systemsLegacy systemsNew systems Different architectures
Access problemsTedious and time consumingInconsistent or outdated information
WWWWWW
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New challengeseAuctionCan we deliver 100 tons for $300/ton
next Friday? An answer is needed
within 10 minutes!
Supplier Xis critical!
What happens if we don’t get any
delivery?
Process sector X fails
Find the problem and repair now !
Board meeting today
Turnover and profit per product and
region?
a
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Automation functions in the Pulp & Paper Industry
Sales and Marketing
Engineering and Maintenance
Logistics & Distribution
Supervision and Operation
Business Systems
Optimizations and maintenance
Production Equipment
Plant Engineering
Optimization of production
Not just limited to simple loop control
AIABhadracahalam – an automation case study
Automation at Bhadracahalam has evolved with the mill.
Automation implementation evolved as:
New and bigger machines were added.
Product mix evolved to Value added products.
Customers demanded better products & shorter delivery periods
Export markets were targeted.
Ambition levels were raised.
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•Digital controls enhanced the potential for better control performance.
•Technological changes in field sensors coupled with digital electronics enhanced reliability of measurement and speed of response.
•Process control applications improved with sophisticated algorithms, simulation models and software packages.
EVOLUTION OF AUTOMATION -CURRENT SCENARIO
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Field instruments and fibre optic connectivity enhanced reliability of the system.
Process computers emerged as a source of better information and operational advice.
Integration of drives with digital controls and online qualtiy control system became a reality enabling engineers to enhance process performance for productivity and quality.
EVOLUTION OF AUTOMATION -CURRENT SCENARIO
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AUTOMATION &PROCESS CONTROLSJOURNEY OF PSPD - UNIT BCM
1985 - Conventional single loop controllers centralisedinto a no of large panels in control room in all the sections.1992-2001 - Installation of quality control systems and distributed control systems of ABB coupled with VIB steam profiler enhanced productivity and quality in Paper Machine-1.1992 - Installation of digital controllers of Foxboro alongwith online QCS system of Measurex in Paper Machine-2.1996- Digital distributed controls of ABB incorporated during project planning in coal fired boilers resulted in enhanced efficiency of operations.
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AUTOMATION &PROCESS CONTROLSJOURNEY OF PSPD - UNIT BCM
1996 - Conceived state of the art technology alongwithautomation in Paper Machine-4 during project implementation.1997 - Successful commissioning of Paper Machine-4 with ABB digital controls integrated with drives and online QCS to produce high quality paperboards catering to different customers throughout the globe.Precise measurement ensuring high quality,improved C.D profile control with accurate
measurement, faster stabilisation, reduced losses, fiber saving, high productivity of manpower.
AIA AUTOMATION &PROCESS CONTROLSJOURNEY OF PSPD - UNIT BCM
1997 - Commissioned the state of the art finishing and packaging line till despatch with automated controls in rewinder (Jagenberg, Germany), reel packing (Lamb, Germany), Computerised crane (Demag, Germany), sheeters (Wilpemco, USA), automatic storage and retrieval system (ASRS) for pallets (Efacec, Portugal).
2002 - Commissioned ECF fiberline with state of the art DCS controls of ABB to produce high quality pulp with highest productivity meeting stringent environment guidelines.2002 - Commissioned state of the art recovery boiler alongwith energy efficient evaporators and lime kiln with ABB distributed control systems ensuring highest manpower productivity and meeting environmental guidelines.2003 – 2004 : OPTIVISION – Manufacturing execution system from Tata Honeywell
AIAULMA defect detection system commissioned in 2004. to identify minor defects in paperboards - elimination of defects at source.
ULMA - TREND OF RESULTS
17
14
10
10
8
4
0 5 10 15 20
Oct-03
Nov-03
Dec-03
Jan-04
Feb-04
Mar-04
No of Defects
Dur
atio
n
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QCS
RSP
Pre-Coat Scanner
Pope ReelScanner
Steam Profiler
20011993
Automation base at ITC
PM1 Rack Room
PM1 Control Room
Operator Station
Dry End
Wet EndDrives
MP280 AC450 Controller
PM Sectional Drives
S800 I/O
Control Net
Recovery Area
Operate IT
Remote Mill PC’s (x4)- Operate IT Client (Pulp
Mill) - X-Windows (PM1& 4)
Mill Office
Plant Network - TCP/IP
Pulp MillOperate IT
AC800 Controller
O2 Delign., BWS &
Screening
CLO2, Chiller & O2
SRB Evaporator
Bleaching
S800 I/O: (AI, AO, DI,DO)
Pulp Mill
Engineering / Operate IT
Shift in charge
Redundant Control Network
Field AI: Hart
HART Maintenance
System
Profibus
2002
SFT Wet End 1
QCS
Steam Profiler
CCK & PM1
Wet End 2 Dry End
RSP
Before MG Scanner
RSP
Before Size PressScanner
RSP
Pre-Coat Scanner
Pope ReelScanner
MP280 AC450 ControllerPM4 Rack Room
QN
X
Term
inal
s
CCK
IMSWet EndDry End
PM4 Control Room
Wet End
Dry End
SFT
Operator Station
Engineering Station
Base Sheet Scanner
3rd Party FSS
PM Sectional Drives
S800 I/O
ULMA WIS
1996
2003
1994
Pope ReelScanner
QCS
PM#2 QCS
HMx
Optivision from HMxIncludes• Production planning• Product tracking• Trim Optimisation• Invoicing and despatch
2003
PM 5
PM 5
Wet end
AC800 Controller
Engineering /
Operate IT
Shift in charge
O2, CIO2 & chiller,
SOES800 I/O
S800 I/O
Dry end QCS
Pope ReelScanner
Pope ReelScanner
RSP
Pre-Coat Scanner
2004
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AUTOMATION
QUALITY
ENERGY
EFFICIENCY
ENVIRONMENTAL
COMPLIANCE
PRODUCTIVITYCUSTOMER
SATISFACTION
COST
COMPETETIVENESS
BENEFITS OF AUTOMATION
AIA BENEFITS OF AUTOMATION
Overall plant efficiency enhanced to 105 %
Reduction of power consumption from 1456 KWh to 999 KWh per ton of production, during the last 6 years period.
Reduction of water consumption from 183 KL to 75 KL per ton of production during the last 6 years period.
Ongoing energy conservation efforts resulted in ‘Best Energy Efficient Unit’ in Paper Industry by CII and Energy Management Award from Govt of India for several times.
AIA BENEFITS OF AUTOMATION
• Huge gains in labor productivity
Tonnes Employees1997 85000 14002004 222000 1400
Most environmental friendly paper mill in India recognized by CSE
AIA Bhadracahalam – an automation case study
Learnings for ITC
Invest gradually
Automation investment gradually over time, provides benefits and evolves as the business model evolves.
Invest in the latest technology
Enables ITC to utilise the maximum effective life of the equipment and beat the obsolescence curve.
Helps us compete with our global competition.
Automation investments have probably the largest ROI
AIA Bhadracahalam – an automation case study
Challenges
Attracting and retaining talent
Industry should provide proactive solutions:
Maintenance proposals?
Involving users during the design phase.
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THANK YOU