IndustrialIT for Papermaking Papermaking Suite

IndustrialIT Quality Control Powered by System 800xA Extended Automation

IndustrialIT Quality Control

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With more than 100 years of industry knowledge,ABB understands the papermaking business and thechallenges you face today. We combine our extensiveexpert knowledge of your markets, your businessand your processes with our world-class productsand services.

Index

Scanners

Sensors

Cross Machine Actuators

Paper Machine Controls

System Integration

Optimization

Quality Control Displays

Lifecycle Management

Success Stories

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12-15

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18-19

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IndustrialIT Quality Control

MeasureIT

ScannersABB Scanning Platforms are the industry’s strongest and smartest scanners, providing the process infor-mation necessary to optimize product quality. Scanning Platforms are self-contained; the on-board dis-tributed architecture converts sensor inputs into engineering units that are spatial and temporally iden-tified without external processing. The design facilitates rapid installation and expansion. A PC pluggedinto the end column or connected via OPC, makes troubleshooting easy. Working with ABB OperateIT

and ControlIT solutions, MeasureIT Sensors and Scanners give you outstanding process visibility cou-pled with the most advanced control in the industry.

ABB provides the scanning solution on more paper machines than any other scanning technology orany other scanning company.

Scanning Platform SP1200The Scanning Platform SP1200 provides scanningsensor support on processes up to 13 meters andlonger. Its rock-solid 10 mm steel A-frame designis unparalleled in providing a sound foundationfor measurement success. To ensure reliable per-formance in even the harshest mill environments,the system is pressurized by air and has a weldedand well-sealed exterior with no service covers.

Scanning Platform SP700The Scanning Platform SP700 provides a compactdesign, featuring an unparalleled strength-to-sizeratio. It offers the opportunity for SP1200 qualityand performance where space restrictions requirea small footprint.

Scanning Platform RSP1200The Scanning Platform RSP1200 supports ABBsingle-sided infrared measurements for processlocations such as wet presses, coaters and sizepresses.

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“We nailed every one of our ROIs on our projects withABB. What ABB commits to, they deliver.”Bob McDonald, Vice President Operations, Fox River Paper, USA

IndustrialIT Quality Control

MeasureIT

MeasurementsAs an industry leader, ABB prides itself in its ability to provide unique, leading-edge process measure-ments such as Fiber Orientation.

In response to your needs, we also offer multiple basis weight, moisture, caliper and coat weight meas-urement solutions. This provides the freedom to choose process-optimized solutions.

Fiber OrientationABB continues its history of innovation with thefirst true online two-sided fiber orientation meas-urement, freeing operators from the constraintsof laboratory gauges, and providing the informa-tion necessary to eliminate process problemssuch as curl and twist warp, while optimizingMD/CD sheet strength. Fiber orientation offers aninsight into runnability on both the papermachine and converting equipment, and on yourcustomers’ printing presses or copy machines.

ColorABB Color Measurement provides the capabilityto measure and control colors, from high whitesand pastels to the deepest shades, with or with-out fluorescent whitening or optical brighteningagents. The color solution provides online labora-tory quality with a unique high-intensity, UV-richXenon flash; non-contacting, sealed optics; andpatented opacity compensation. Advanced signalprocessing totally partitions the influence ofwhitening agents from shading dyes for improvedcolor control and better agreement with laborato-ry instruments.

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X-RayABB X-Ray Measurement is optimized to measurethe inorganic component of paper even in theface of a variety of furnishes. Inorganic mixturesthat include titanium dioxide, calcium carbonate,silicon dioxide, talc, aluminum oxide and highlyrefined clay derivatives are measured with ease.ABB offers several application-optimized sensormodels to match to your requirements for inor-ganic additives, coating composition and basisweight range.

Basis WeightABB Basis Weight Measurement provides unparal-leled accuracy and streak resolution. These sen-sors minimize, measure and control the mass ofair between the measurement heads, resulting inthe most accurate weight measurement available.The sensors use Krypton, Strontium orPromethium isotope sources, depending on theapplication requirements.

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“Because of our choice of ABB, we have the technologyand tools to manage a highly efficient newsprint mill.”Gilbert Placiard, Head of Electrical Department, Norske Skog Golbey, France

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IndustrialIT Quality Control

MeasureIT

GlossThe Gloss Measurement simulates the humaneye’s perception of gloss to provide continuousonline gloss measurement in accordance withTAPPI standards.

CaliperABB Caliper Measurement incorporates sensingheads that combine low density, extreme durabili-ty and dirt-repelling qualities. These unique sens-ing planes glide smoothly over the sheet forsuperior measurement without damaging thesheet. Caliper options include a Light Touch solu-tion for the most delicate processes and sensingheads optimized to reduce maintenance ongrades with high recycle content.

Transmission MoistureTransmission Moisture Measurement analyzes multiplewavelengths of infrared energy transmitted through thesheet to directly calculate percent moisture and eliminatethe need for basis weight compensation. TransmissionMoisture Measurement provides high accuracy and preci-sion with insensitivity to furnish variations, moisture layer-ing and carbon black.

Reflection Moisture Reflection Moisture Measurement provides single-sided,non-contacting surface moisture measurement across awide process range – from wet press to bone dry levels.ABB’s Reflection Moisture Measurement requires no basisweight sensor compensation on most grades – providingdirect moisture measurement.

Microwave MoistureMicrowave Moisture Measurement provides dual-sided,non-contacting measurement of processes with high mois-ture, high basis weight or dark pigments. It is insensitive tomoisture layering and carbon black content found in recy-cled paper, multiply board and pulp dryer applications.

Moisture MeasurementMoisture is one of the most importantand fundamental paper measurements.ABB offers the expertise and technolo-gy to precisely meet your moisturemeasurement requirements by utilizingone of three methods.

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OptiPakABB combines measurement of formation, opaci-ty and brightness in one compact package.Simultaneous measurement of these importantoptical sheet properties can provide the informa-tion necessary to reduce wet end breaks, improveuniformity and optimize opacifier use.

Service WorkstationCommission, monitor, maintain and troubleshoot ABB Scanning Platforms, Sensors and Profilers withSupportIT Service Workstation. This user-friendly application provides access to mill-wide networksand to remote users via the Internet or dedicatedmodem for system support. SupportIT ServiceWorkstation includes advanced health reporting forthe scanner, sensors and electronics.

X-Ray DifferenceX-Ray Difference offers high measurement sensitivity tocoating solids, combined with low sensitivity to celluloseand water. ABB’s patented X-ray filtering techniques eliminate calibration shifts due to coating compositionchanges. X-Ray Difference measurement is optimized forgrades up to 350 gsm (215 lbs/3000ft2).

Reflection Coat WeightReflection Coat Weight Measurement uses direct infraredabsorption to measure the influence of clay, latex, calciumcarbonate, cellulose and moisture to accurately calculatecoat weight and percent moisture. Reflection Coat Weightis optimized for coated board grades or lightweightprocesses with simultaneous dual-side coating.

Dry Weight DifferenceABB’s high signal-to-noise ratio Basis WeightMeasurement offers unparalleled coat weight accuracy at a lower capital investment.

Coat Weight MeasurementCustomer requirements and processconditions require a consultativeapproach to coat weight technologyselection. ABB offers the expertise andtechnology to precisely meet your coatweight measurement requirements byusing one of three methods.

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IndustrialIT Quality Control

ProfileIT

ProfilersToday’s profiling solutions require tighter zone spacing, higher precision, accurate mapping and cre-ative control solutions. ABB’s focus on quality using our new xP (eXtended Profiling) actuators, pro-vides accuracy and precision required by today’s challenging control applications.

ABB’s complete family of profilers will ensure the lowest CD variability on all primary sheet parameters.

Stock Approach and Headbox Forming Press Section Dryers Size Press Coater Section Calender

Slice xPDilution xP

SteamPlus xP Air-Water xP Coat Weight xP

Induction xP

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Induction xP ProfilerThis revolutionary actuator from ABB controlscaliper and sheet finish gloss by applying induc-tion heating to hard nips, soft nips and supercal-enders. It uses universal workcoil zones at 60 mmwith 120 mm and hybrid options powered by theworld’s smallest, patent pending, water-cooled6000 watt modules packaged into a single beam.

• 50-90% reduction in profile variability

• Improved sheet finishing properties

• Reduced rejects

• Improved reel build

• Highest power density and efficiency available

• Simplified workcoil gap adjustment

SteamPlus xP ProfilerABB’s new T880 actuator family, the T880S, (forstandard applications) and the T880C (highly cor-rosive environments, e.g. tissue and newsprint)are both backed by a 10 year warranty. Built onthe proven reliability of these T880 actuators, theSteamPlus profiler improves on previous genera-tion steambox designs by controlling 100% of the steam flow across the web. Steam is neverapplied to areas of the sheet that are alreadybelow target, thus creating a flatter profile. Therigid box-beam design of the SteamPlus profilerallows a smaller and lighter beam construction,yet maintains structural integrity for installationin the most challenging locations. The addition of a steam heated outer chamber permits calen-der applications.

• 15% increase in production or 55% reduction inenergy costs

• Up to 80% reduction in moisture profile variability

• 10-year valve guarantee

• Up to 80% improvement in gloss, smoothness and porosity

“Caliper and gloss profiles must be perfect. ABB glossprofilers made the development of new grades possible.”Robert Comstock Jr., Assistant Vice President, Blandin Paper Company,Grand Rapids, Minnesota, USA

IndustrialIT Quality Control

ProfileIT

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Slice xP ProfilerThe Slice xP, with an embedded inductive sensorfor precise measurement, uses ABB’s standardAC800 controller and patent pending MultidropIntelligent Power Management and bus communi-cations to eliminate the risk and bulk of I/O,additional modules and extra cables on the head-box.

• 50-80% reduction in profile variability

• Fastest global moves of 128 um/sec (5 mil/sec)

• Quicker grade changes and upset recoveries

• Built-in proactive diagnostics

• Optimized Profibus/Modbus hybrid communications

Dilution xP ProfilerThe Dilution xP uses the industry’s mostadvanced mechatronic technology for superiorcontrol of cross-direction variations, includingprecision planetary gearing, zero backlash induc-tive measurement and optimized hybrid commu-nications combined with power into simplifieddilution header connections.

• 50-80% reduction in profile variability

• Fastest global moves of 8 degrees/sec

• Built-in proactive diagnostics

• Configurable flush cycles for all applicationsincluding radial distributors

Air-Water xP ProfilerThe Air-Water xP Profiler offers the most robustdesign in the industry. There is very little mainte-nance, and reliability is significantly improved byeliminating the requirement for electronics in thehot drying environment associated with remois-turizing actuators. Performance is ensured even ifthe water supply is less than optimum. The noz-zle and actuator design eliminates small orificerequirements associated with needle valve orsolenoid flow control arrangements and thereforeis much less susceptible to plugging.

• 80% reductions in profile variability andimproved reel building

• Precise, continuous flow control withoutelectronics

• Pressure balanced flow control maintainspredictable flow impervious to wear, build-upor water pressure variations

• Precise, homogeneous, droplet size deliversexcellent sheet absorption

• Minimum zone-to-zone interaction eliminatesair-induced streaks

• Common air and water headers eliminatetubing and piping in the actuator beam forsimplified maintenance

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Coat Weight xP ProfilerThe Coat Weight xP ensures an optimum, smoothblade or rod coating application through precisepositioning of the coater blade by using the sameadvanced interface hardware, cabling and mecha-tronic techniques as ABB’s Slice xP and DilutionxP actuator systems.

• Faster recovery after blade changes and starts

• 50-85% reduction in coat weight variability

• Reduced rejects

• Experienced application engineering and fastinstallations

• Custom, super-flexible profile bars available

Water

Air

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IndustrialIT Quality Control

ControlIT

ControlsABB’s Quality Control Solutions offer papermakers the most precise Machine-Direction/Cross-Direction measurement separation, the most reliable multivariableMachine-Direction Controls, leading-edge Cross-Direction Control features and powerfulcolor control applications.

Time-Based Measurement ABB Time-Based Measurement updates Machine-Direction (MD) measurement for control everyfive seconds, reducing unnecessary scan delay.A time-based model allows for continuous meas-urement updates, using either scan or single-point data. This approach eliminates unnecessaryscan to scan averaging, the end result being opti-mal separation of the MD and CD components.

Time-Based Measurement enables more aggres-sive control (both MD and CD), which significant-ly reduces 2-Sigma variation.

Machine-Direction ControlsABB MD Controls apply accurate control actionsbased on multivariable models to predict longdelay process responses. This results in fastresponse for all operations and achieves targetswith the shortest transition, ensuring optimumprocess variability reduction.

Automatic Grade Change utilizes patentedadvanced multivariable models for predicting and eliminating rapid sheet weight and moisturedynamic variations during grade change transi-tions. The new innovative grade change allowsfaster, smoother grade changes with less brokeand without sheet breaks.

ABB MD Controls include:

• Dry Stock Flow Control

• Model-based multivariable feedback control

• Multi-frame Inferential Control

• Coordinated Dryer Control

• Dryer Ratio Control

• Headbox Control

• Coordinated Speed Change Control

• Speed Optimization Control

• Multi-Stock/Ply Distribution Applications

• On-machine Coat Weight and GlossApplications

True sheet variation contour map comparing scan- andtime-based MD and CD separation methods.

The operator’s MD control window displays not only cur-rent, but also historical data, providing key information fornecessary process decisions. Additional overlap displaysallow simultaneous viewing of multiple process areas.

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Auto Map and ModelingModeling

Identification

Real-timeMapping

CDOptimization

ResponseOptimization

ResponseBoost

GradeDependent

Tuning

Cross Direction Control

Measurement #1

Measurement #2

Wavelet Separation

ConstraintHandling

ActuatorInterface

EdgeHandling

MappingIdentification

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Profile Shaping

Measurement ProcessingMD/CD

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Cross-Direction ControlABB Profile Control offers the most reliable and bestperforming solution to the pulp and paper industry.This advanced control suite provides a full range ofoptions for all applications including weight, mois-ture, caliper, coat weight and gloss. The fully auto-mated tools enable easy identification of the processresponse and the mapping parameters.

ABB’s unique concept allows the operator the flexi-bility to control the weighted combination of multi-ple profiles with multiple target profile shapes.

The advanced sheet edge and edge actuator process-ing with fuzzy logic control are applied to optimizeand maintain long-term CD control performance.ABB’s Cross-Direction Control features include:

• Wavelet filtering

• Target profile shaping

• Multiple profile optimization

• Auto mapping and response identification

• Grade dependent tuning

• Sheet edge and edge actuator handling

• Fast startup and recovery

ABB’s industry-leading CD Control philosophyenables papermakers to maximize CD variabilityreduction.

“ABB ControlIT CD solutions with LV control perform very well.The resulting profile uniformity is consistent and stable.”Dave Moore, Senior Process Engineer, SAPPI Somerset Mill, USA

Enhanced CD displays allow for easy identification of theactuator to the process.

ABB’s industry-leading CD control philosophy enablespapermakers to maximize CD variability reduction.

Multi-profile Optimization

Time-based Measurement

Advanced Signal

Processing

Sensor

IndustrialIT Quality Control

ControlIT

Wavelet Profile FilteringABB’s CD Control utilizes patented modernwavelet algorithms that are widely used in imageprocessing, communication, and many otherapplications. The wavelet filter implemented inABB CD Control effectively separates the control-lable profile from the scanning measurement. Theapplication of the wavelet filter significantlyincreases profile signal to noise ratio, avoidsaliasing effects, and contributes to improving theperformance of CD control results.

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Local Variability ControlABB’s unique LV Control monitors both profilesand actuator actions continuously and promptlyperforms improvement to any region for correct-ing localized profile variations.

It automatically detects and corrects local map-ping variations, without operator intervention ordisruptive bump tests.

This control can also be added to the existingABB Nexus based CD Controls. ABB’s CDSolution with LV Control provides papermakerswith consistently low 2-sigma profile values.

ABB’s LV Control includes:

• Identification of problem areas

• Local mapping optimization

• Stable CD profiles under different machine conditions

State-of-the-art technique for separating controllable pro-file variation from noise, enabling more aggressive CDcontrol and lower 2-sigma.

LV control identifies and resolves mapping misalignmentwithout human intervention or bump tests.

Measured Profile

Uncontrollable Profile Controllable Profile

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Combined numeric and graphic display enables the oper-ator to adjust targets and pump settings while monitoringthe effect on the historical trends.

ABB’s advanced multivariable color control accuratelymodels the different dye characteristics to provide uni-form sheet color and shorter shade change times.

Color Control and AdvancedShade ChangeControlling to different shade targets for coloredsheets is one of a papermaker’s most challengingtasks. ABB’s Color Control and Automatic ShadeChange Control offer a comprehensive solution inproducing top-quality colored paper.

ControlABB’s Color Control pioneered the application ofKubellka-Munk theory to model dye addition. Thecontrol matrices dynamically adapt to dye charac-teristics, shade targets, color deviation weightingsand machine running conditions. The amount ofdye added is automatically normalized tothroughput, and the shade is consistently main-tained throughout any production change. Theflexibility of the control allows use of varioustypes of dye pumps and a wide range of dyeselection including OBAs (Optical BrighteningAgents). ABB’s color control provides the abilityto control Brightness/Whiteness using OBA dyes,which is vital to ensure consistency of shade ontoday’s hi-white paper grades.

Shade ChangeABB’s Advanced Shade Change models the com-plex coloring process from stock preparation toreel and provides the required boosting fordesired fast response. The program coordinatesthe addition (or removal) of dyes and OBA, sothat the combined responses reach the reel simul-taneously. ABB’s Advanced Shade Change alsorecords the historical dye usage as part of theshade recipe allowing this data to be reused toproduce the same shade on a consistent basis.The combined effect of all these features is a significant reduction in shade change time.

ABB’s Color Control has been widely applied toall shades of the spectrum from deep shade spe-cialty papers through light pastel grades to hi-white products. It has become an integral part ofthe QCS system for many mills.

This solution offers a complete set of featuresincluding:

• Multivariable Color Control

• Fluorescent Whiteness (OBA) Control

• Dual-Sided Color Control

• Advanced Shade Change

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IndustrialIT Quality Control

Papermaking Suite

System IntegrationABB Quality Control Solutions are implemented on the System 800xA control platform. Itenables you to view operator displays, control status, process data, machine drawings andother useful information, including paper quality control, drives, pulp mill control andstock preparation controls.

Additional information is easily available via the right clickcontext menu, which enables users to quickly analyzethe situation and make a decision.

Alarm

Mechanical Drawing

Real Object Real Time Information

Completely Integrated SolutionsABB’s Papermaking Suite is the realization ofABB’s IndustrialIT initiative. While others are onlybeginning the effort to tie fundamentally differentsystems together in a common user interface,ABB has been using a common platform for bothcontrol and user interface for all of its new prod-ucts since the introduction of IndustrialIT in 2001.

With its Papermaking Suite, ABB’s pulp andpaper customers can now realize the advantagesof a system based on an architecture that tiestogether all major automation systems commonlyfound in a pulp and paper operation.

ABB’s Papermaking Suite breaks down the infor-mation barriers found in a mill’s systems to

enable cost–effective enterprise–wide use ofinformation. Whether it’s putting automation system data in the front office, bringing legacysystem interfaces into automation systems orbuilding new production management applica-tions, ABB’s Papermaking Suite can do it.

IndustrialIT Quality Control is a core product ofthe Papermaking Suite. Working as a totally inte-grated component with other ABB Solutions suchas Paper Machine Drives, Open Control Systems,Field Instrumentation, CPM Systems and WebInspection Systems, paper companies are reduc-ing maintenance costs and increasing asset uti-lization in addition to making better paper.

Live Video

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“With the changes ABB made throughout our mill, I amvery happy to say we are getting the results we wanted.We are lucky to have all our information technology sup-plied by ABB.”Anthony Tan, MNI Production Manager

Total integration from plant network to control valve.

Papermaking Suite System 800xA

IndustrialIT Quality Control

OptimizeIT

DataLoggingSoftware

ConditioningUnit

SamplingUnit

HeadPosition

ProcessSignals

Any GaugingSystem

SensorSignals

Digital Inputor Switch

Real-timeAnalysis Displays

DataFiles

PC Computer

Data Acquisition ToolsProcess Optimizing Tools - XGP300The XGP300 provides a set of powerful softwaretools for detailed data analysis, tuning, reportingand control loop simulation. These tools can beused for analyzing machine-direction as well ascross-direction controls. This set of tools isdesigned for process engineers who have hadtraining in process optimization. XGP-300 is anindispensable tool for optimizing processes andautomation systems.

Process Data Collection Tool -AGP300/AG300The AGP300/AG300, available in both portableand desktop models, enables you to capturesheet measurements from a gauging system aswell as any analog signal, at high sampling speedfrom your machine. Backed by ABB’s wide rangeof pulp and paper solutions and applicationexpertise, this unit offers full flexibility to obtainvaluable insight into your machine and diagnoseyour process effectively.

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Optimizing ToolsABB has developed a range of data collection and optimization tools compatible with allOPC systems. This enables the process engineer to easily access key information foranalysis and optimization.

DataCollection

Tool

DataStorage

OPCServer

OPCServer

Data Type Conversion Tool - OFC300The OFC300 converts any files logged by theOPC Data Collection Tool to formats that can beused with various analysis tools such as Matlab,Excel and XGP300. The Data Type ConversionTool also provides options to re-sample data andfilter with user-specified conditions.

OPC Data Collection Tool - ODA300 ODA300 provides an easy way to extract datafrom any number of OPC servers. ODA300 canautomatically connect to standard OPC servers,make OPC tags available for selection and savean unlimited number of OPC real-time data tagsin compact files. ODA300 can be used as a stand-alone or integral part of a quality control systemfor continuous or on-demand data logging.

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“We think of ABB as a partner, a companion enabling usto grow together. We see ABB not only as a supplier butas a consultant to help us modify our mill.”Nguyen Dinh Tuan, Deputy General Director, Tan Mai Paper Company

IndustrialIT Quality Control

OperateIT

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Quality Control Objects and AspectsThese displays are an integral part of the 800xAPlatform. Quality Control Objects and Aspectsrepresent information associated with papermachine quality control. A user can control all ofthe papermaking process from one location.

Easy to use displays are provided for machineoperators. You can instantly view high resolutionmeasurements, machine-direction and cross-direc-tion variations, profile contour maps, reel reports,grade reports, documentation and support tools.

All data are easy to export to standard spreadsheets for convenient data capture and analysis.Having access to real-time quality control infor-mation enables better process decisions – reduc-ing waste, saving raw material and ultimatelyincreasing shareholder value.

ABB provides a full suite of displays, giving access to allQuality Control information

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Single Upgrade

Continuous Upgrade

Time Time

IndustrialIT Quality Control

Lifecycle Management

“640k ought to be enough for anybody.”Attributed to Bill Gates, 1981

ABB’s Lifecycle ManagementAdvantageWith the introduction of open standards for oper-ating systems and standard PC hardware and soft-ware, a new challenge was introduced to processautomation system owners. While in the pastthere was a level of protection from frequent soft-ware updates and the need for constantlyincreased connectivity requirements, now theseparameters are in constant state of flux. The needfor a focused and active lifecycle managementprogram is clear.

StepUp StepUp programs simplify the upgrade process,provide enhanced performance capabilities, andmaximize the value of installed systems and com-ponents. ABB StepUp programs also minimizemaintenance costs and reduce downtime. As anadded advantage, all StepUp services aredesigned to allow existing data to be used withupgraded systems. Key StepUp programs include:

• StepUp classic 1180M and 1190 systems to thelatest IndustrialIT for Quality Control solution.

• StepUp classic Measurement Platform to the latest Scanning Platform SP1200.

• StepUp classic Advant Operator Stations to thelatest QC Aspect Workplaces.

SoftCare The SoftCare program enables customers to keepup with changing industry and IT standards (e.g.,Microsoft). Through technology-driven enhance-ments customers effectively deal with softwareintegration, security and compatibility. ABB goesfurther with each new software version by alsoproviding ROI enhancements focused to the QCSsystem and customer process.

The pillars of SoftCare value include:

• SoftCare keeps customers current with technology changes.

• QCS Application Software stays current withSystem 800xA platform software versionupdates, the common architecture ofPapermaking Suite.

• Both platform and QCS Applications softwareare updated with system enhancements to cre-ate ROI for our customers.

• Provides the latest maintenance resolutions andenhancements.

• Customer licenses evolve to the next generationsolution (purchase software once, SoftCareremoves the need for costly license updates).

Customers benefit from increased efficiency, relia-bility, production yields and ROA as well as low-ered production and maintenance costs.

SoftCare protects the value of our customers’ existing soft-ware investments by keeping them current with the latestindustry standards and third party OPC connectivity.

StepUp provides a path by which you can cost-effectivelyupgrade your current QCS system, allowing you to takeadvantage of the most recent technological advances.

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Quality Control 2.0IndustrialIT

Quality Control 4.0powered by System 800xA

IndustrialIT2005

When Pasadena Paper’s Pasadena, Texas, operation wanted advice on howto produce a greater range of products, they turned to ABB.

“We place a high value on technical competence and that is how our rela-tionship with ABB was established,” says Fred Row, Mill Manager atPasadena Paper.

Initially, ABB performed an audit that scrutinized the sources of variationsand stability in Pasadena Paper’s existing control system. As a result of thestudy, the mill made several process piping changes that resulted inimproved stability. The results were immediate, and ABB received anotherassignment: installing a new Quality Control System and a DistributedControl System.

With ABB providing technical consulting, ABB IndustrialIT architecture, theintegrated DCS, QCS, sensors and actuators, the mill was pleased with theresults, which included improved quality and an expanded product line.

“Pasadena has improved the quality of the existing coated products, startedproducing new grades and will introduce a new line of digital papers,” saysRow. “Having the versatility to run a greater range of products has reallyexpanded our customer base as well as increased the profitability of ouroperation.” Row says he now receives compliments from his customers.“What better way to show the value of our investment in ABB.”

IndustrialIT Quality Control

Success Stories

Meeting your specific needs; improving shareholder value

IndustrialIT can be successfully applied to any pulp or paper mill – regardless of location, size, age, technology, raw material or final product.

ABB technical expertise helps Pasadena Paper grow their business

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Founded in 1931, Guangzhou Paper Mill in the Guangdong Province, one ofChina’s oldest newsprint mills, had a very modern problem – how maketheir mill more productive. They looked to ABB to provide information tech-nology solutions that would not only increase production, but that wouldalso lower energy costs and improve pollution control.

Guangzhou Paper had already worked with ABB on two major rebuildingprojects and expansions. To obtain the technology they needed to controltheir PM8, Guangzhou Paper chose ABB’s integrated open control and quali-ty control systems for PM8 and also for PMs 6 and 7. The ABB productsboosted Guangzhou Paper’s newsprint production by 70%.

The mill also selected ABB open control for their bleaching system process.Additionally, Guangzhou slashed their electrical power costs with a new on-site station running two turbines generating 50 megawatts each and three220 megaton-per-hour boilers, all controlled with ABB open control.

“Choosing ABB technology is a big plus because the same technology isalso is used to control electrical, supervisory, quality and drive functions,providing integrated information technology with a common architecture forefficient, cost-effective operations,” says Yang Guangyu, vice director andchief engineer at Guangzhou Paper.

Guangzhou Paper – one of China’s oldest newsprint mills – integrates ABB informationtechnology to boost mill production

Suzano Papel e Celulose faced a challenge. They needed complete engineer-ing, commissioning, start-up and training services automation for their PMBM7 in their Sao Paulo, Brazil, Suzano pulp and paper mill. They had tointegrate their process automation. And they wanted a supplier supportedby a local organization.

ABB had previously upgraded the mill’s DC motors, so Suzano understoodABB's capabilities. They chose ABB as their automation supplier and ABBdelivered a two scanning frame Quality Control solution.

Commissioning the new system was an easy process. Most training wasdone on-site with local ABB engineers and the installation was completedduring a very short shut-down period. Startup and tuning goals werereached quickly, resulting in quick ROI for the mill.

“The centralization of all machine operation and control in the same opera-tor workplace has made the operator’s job much easier and more efficient,”says Edson Kobayashi, Suzano Production Manager.

Walmor Martins, Suzano’s Electrical, Instrumentation and AutomationMaintenance Manager, says ABB’s OCS/QCS robustness and reliabilityallowed Suzano to operate and maintain their systems without a residentengineer, which was close to impossible with the technology they hadbefore installation.

“With the current ABB technology, PM BM7 has become the most modernpaper machine within Suzano’s mills,” says Victor Wuo, Project Manager forElectrical, Instrumentation and Automation Systems at Suzano.

Suzano obtains leading-edge solutions with ABB IndustrialIT technology

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Valued at approximately USD 500 million, Stora Enso’s PM4, at theirLangerbrugge mill in Belgium, is both the world’s widest paper machine aswell as the world’s largest machine that exclusively converts recycled paperinto newsprint. So it’s no surprise that it's also the largest single investmentStora Enso has ever made.

To make this important paper machine run optimally, Stora Enso asked ABBto deliver a range of automation, electrification, drives, ventilation, installa-tion materials and services, including an IndustrialIT Web Imaging Systemand a Quality Measurement System.

Start-up on PM4 proceeded especially smoothly. Within 14 days the papermachine ran for 48 hours without a single break and average productionwas running at 800-900 tpd.

“Our decision to use a comprehensive range of ABB solutions in ourLangerbrugge project was based on our good relationship,” said SamiPitkänen, Stora Enso’s Project Director. “I am very pleased with operation ofthe whole mill and with the role suppliers such as ABB played in complet-ing the project on time.”

Stora Enso relies on ABB at the world’s widest newsprint machine

Visit us at our website: http://www.abb.com/pulpandpaper

ABB Inc.579 Executive Campus DriveWesterville, Ohio 43082, USATel: +1 614 818 6300Fax: +1 614 818 6571

ABB Ltd.Finnabair Industrial ParkDundalk, Co. Louth, IrelandTel: +353 42 9385100Fax: +353 42 9385124

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ABB Automation Systems ABSE-721 83Västerås, SwedenTel: +46 21 32 50 00Fax: +46 21 13 41 12