Russian Paper Mill Modernizes Networks

The right software in the right context can help manufacturers in process industries increase output, improve quality, and increase plant profitability. The Kotlas pulp and paper plant in Karelia, Russia, has found these possible through the use of IAS (industrial application server) and FactorySuite from Wonderware.

The combination of these two platforms has provided a set of automation and reporting tools and helped plant operators with many critical functions:

• Integration of automation tools from many suppliers and producers into a unified system to support centralized production management;

• Preparation of production and management reports;

• Overall equipment effectiveness (OEE) calculations for manufacturing optimization; and,

• IAS support for centralized development of engineering systems.

Manufacturing software provider Klinkmann has supplied Wonderware products to pulp and paper, oil and gas, chemicals, food processing, brewing, pharmaceuticals and other industry sectors. Wonderware and Klinkmann designed ready-made control and reporting concept models that shortened the time to develop and implement specific functions tailored to the needs of each company and operating unit. This shortens implementation time and the cost recovery period for the project.

Integrated operations management

Product quality and production efficiency largely depend on automated processes, operational management, and the right software tools. One such tool is the computerized operational management system (COMS) developed by system integrator Rakurs (Russia) and based on Wonderware IAS.

In 2004, Rakurs implemented COMS for sulphate bleached wood-pulp production at Kotlas’ plant in Karelia, Russia. That Wonderware based platform was introduced to collect operational data and report on production to enterprise level management.

The system was designed to perform specific tasks:

• Automated collection of production data and compilation in a self-managing database;

• Presentation of processes and operating reports with charts describing real time status of production equipment, with calculations of downtime and production optimization;

• Alarm management for upsets and system breakdowns;

• Productivity control and output of semi-finished products by the main production areas;

• Control of chemical feedstock reserves and semi-finished product storage;

• Operational control of raw material consumption; and,

• Data preparation for enterprise level IT systems.

Technical implementation

The Kotlas system consists of three levels. On the lowest level (sensors and actuators) information collection and initial processing takes place using Siemens S7-300 controllers and ET200M remote stations of distributed I/O connections linked by Profibus.

The IAS based production server is on the middle level where it is responsible for data storage, calculation execution, and interaction with clients. The Wonderware IAS serves as the basis for the COMS system, providing:

• Concentration of business-wide logistics in the frame of one production model, which minimizes time spent on system development and support;

• Scalable without restrictions on the size of applications;

• Implement changes in separate units and elements without stopping the whole system;

• Powerful script language that supports Microsoft.Net libraries;

• Built-in security system;

• Integrates easily with other Wonderware products including InTouch HMI and InSQL data warehousing; and,

• Integrates easily with various fieldbuses, PLCs, and distributed control systems (DCS).

Data archives are kept in Wonderware Industrial SQL real time databases. The open architecture supports Internet and Intranet applications and integrates readily with existing plant control systems. For “smart” clients, InTouch Terminal services, a special version of InTouch HMI software, is installed on the server to perform terminal sessions.

InTouch Terminal does not require the same version of Microsoft Windows to be installed with all client locations. The plant operates Windows 98, Windows 2000, and Windows XP at various points. In-Touch terminal has the same functionality as standard InTouch with the capability to revise mnemoschemes, production process charts, reporting, and operating documents without installing InTouch on each client device.

The main advantage of terminal client is the ability to centralize operation and management applications. System administrators can input changes without leaving work stations or discontinuing client work. Any changes they make appear immediately on the users’ screens. This allows fast and efficient introduction of new client applications and simplifies back-up procedures and information recovery while reducing overall costs. Network traffic used by one terminal client consumes around 5 Kbps, and information on the screen is updated once per second, which allows slow modem connections while still maintaining acceptable work conditions.

Rakurs has wide experience in automation system development including pulp and paper producers, such as Svetogorsk and Arhangelsk. Applying the Wonderware IAS based COMS system at Kotlas made for a short implementation period in spite of the breadth of the project. The open architecture of the system supported the variety of controllers and instrumentation while communicating easily with ERP applications.

Once the system was running, Kotlas found certain system elements particularly helpful:

• The software model and common information environment encompassed the entire production process scope;

• Existing production equipment and systems were retained and integrated into the application server;

• IAS is scalable from 250 to 1 million production variables;

• Capabilities to service simple and smart clients as needed;

• Capabilities to create redundant systems when necessary;

• IAS provides centralized support, expansion, and servicing all created production applications; and,

• Communication with ERP and higher level IT systems of the company.

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