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Major Asian paper mill increases control system utilization with ABB Ability™ Collaborative Operations

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A Southeast Asian paper mill has relied on ABB to continually update equipment, keep productivity high, maintain predictable service costs and improve process performance.

Customer: Asian paper mill and ABB customer since 2003

To produce quality pulp stock used to create fine paper and stationery with high temperatures, steam in the vapor space, agitation and the slightly corrosive and abrasive effects of the pulp slurry, mill managers must constantly measure, monitor and amend the performance of each paper machine. They gained more control over these processes when they turned to additional ABB Ability™ services between 2012 and the present.

Challenge

The customer wanted to:

  • Ensure that automatic control did not erode over time (2012-2017)
  • Advance control of its paper machine processes (2017)

Solution

Between 2012 and 2017, when the paper mill gradually added ABB Ability™ Advanced Digital Services that focus on drive system availability, loop performance improvement, quality control system (QCS) sensor performance services and other areas of high impact. In late 2017, the mill started using ABB Ability™ Collaborative Operations to monitor three services: Grade Change, Paper Machine Performance, and Advanced Process Control for wet-end retention and ash optimization.

Results

  • Reduced time to complete bump tests by 70 percent
  • Reduced overall loop tuning effort by 75 percent
  • Increased production
  • Reduced chemical costs
  • Reduced ash MDL variation, leading to more saleable product
  • Increased equipment availability
  • Reduced sheets breaks and unplanned downtime
  • Accelerated grade changes

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