—
ABB Ability™ Quality
Management Solutions
for pulp and paper
Outstanding process visibility and advanced control
—
—
At ABB, we’re dedicated to results.
Our focus is to help our customers
strengthen competitiveness and
profitability through continuous
improvement.
From the pulping process
through converting operations,
our solutions provide superior
Table of contents
04 Customer challenges
05 – 07 ABB Ability™ Quality
Management Solutions
08 – 11 Network Platform scanners
12 – 17 Measurements
18 – 19 CD actuator systems
20 – 23 Quality and production process
control
value in maximizing quality,
increasing performance and
reducing operational costs.
25 – 27 User interface
28 – 29 System integration
30 – 31 ABB Ability™ System 800xA:
Commitment to a common
architecture
32 Performance Services
33 Lifecycle management
34 How we meet customers' quality
management needs
4
ABB ABILITY™ QUALITY MANAGEMENT SOLUTIONS FOR PULP AND PAPER 5
ABB ABILITY™ QUALITY MANAGEMENT SOLUTIONS
—
Customer challenges
Increased customer demands
Mills in mature, high-cost markets face
tighter specifications and customer
requirements, creating the need for
higher levels of accuracy in quality
testing.
High cost of rejects
Off-spec paper can lead to runnability
issues, rejects and customer
complaints, costing mills profit.
Difficult conditions
Harsh, hot environments at midmachine and press locations make
measurements difficult.
High input costs
Fiber, energy and labor costs can
affect profitability and contribute to
missed opportunities.
—
ABB Ability™ Quality Management Solutions
Leading-edge online measurement and control
performance from the category creator
From our origin as the first on-machine paper property measurement system
provider to the latest advanced control and analytics solutions of today, ABB
solutions have earned a reputation for superior design and performance.
ABB is well-known throughout the industry as the
supplier of choice for comprehensive, integrated
quality measurement and control solutions for
tissue, pulp, paper, packaging and specialty
applications. From a singly applied Cross
Direction (CD) actuator, to standalone
measurement through completely integrated,
large scale paper mill solutions, our customers
count on us as a reliable, performance-driven
technology partner.
From inception, our company has valued and
nurtured the contributions of a strong team of
professionals to design, produce, apply and
support our efforts in the pulp and paper
industr y. In fact, ABB has been providing paper
makers with the most advanced measurements
and controls available for over 70 years. With a
growing team of almost 2,000 dedicated paper
making experts, ABB has the resources to meet
your challenges now and in the future.
6
ABB ABILITY™ QUALITY MANAGEMENT SOLUTIONS FOR PULP AND PAPER 7
—
ABB Ability™ Quality
Management Solutions
An integrated system with a robust and reliable
design, advanced analytics and an excellent
user experience
ABB ABILITY™ QUALITY MANAGEMENT SOLUTIONS
ABB Ability™ solutions
Dilution xP profiler
SteamPlus xP profiler
SteamPlus xP profiler
Air-Water xP profiler
Induction xP profiler
Coatweight xP profiler
Induction xP profiler
Network Platform scanner
Evaluate quality throughout the entire
manufacturing process to ensure on-spec paper
at the lowest cost.
• Gain full visibility over process and system
performance with integrated online
measurement, process and quality controls
• Speed up root cause identification of quality
issues and provide faster corrective action
thanks to seamless system integration
• Increase efficiency and product output by
reducing sheet breaks and optimizing
runnability
8
ABB ABILITY™ QUALITY MANAGEMENT SOLUTIONS FOR PULP AND PAPER 9
—
Network Platform scanners
Necessary process information
to optimize product quality
NETWORK PLATFORM SCANNERS
ABB provides scanning solutions on more paper
machines than any other company. We have
earned this trust by providing the most advanced
Quality Control System (QCS) measurements,
data acquisition and communication technology
in the industry. This allows excellent insight into
both the measurement system and paper
machine health.
The industry-leading Network Platform family of
scanners enables papermakers to apply the
highest quality measurement technology on all
applications. With a robust, sturdy design,
advanced signal processing and sensor support
features, mills gain precise measurements and
maximum operational performance – even in the
harshest of environments.
—
01 The in dustry-lead ing
Network Platform family
of scanners enables paperma kers to apply th e
highest quality measurement technolo gy on all
applications.
Superior design and performance
ABB Network Platforms are the industry’s strongest and most advanced scanners, providing the
process information necessary to optimize product quality. All platforms are built to specified CD
width for lowest installation cost and greatest flexibility.
The reinforced carbon steel “A”-beam construction with strong end columns provides superior vertical,
horizontal and torsional rigidity. This stable structure is critical for precise alignment of sensor source
and detector heads in harsh environments without the need for compensations.
Expect the same superior design and performance across all Network Platform scanners:
Design
• Smooth exterior with no external openings or
exposed hardware or cables minimizes
contamination
• Fully integrated system electronics are
completely accessible from the end column
• Structural thermal stability means no liquid
cooling and reduced utility costs
• “Seam-side down” upper and lower beams
prevent materials falling in the structure
• Advanced external coatings resist chemical
agents for long corrosion-free life
• Thermal coefficients between structure and the
carriage rails allow for equal expansion and
contraction
• Optical encoder ensures precise sensor
positioning
Performance
• Accurate edge-to-edge measurement of all
critical sheet characteristics
• Reduced risk of sheet breaks with wide sensor
carriage that delivers a long-lasting, smooth
ride across the moving web
• Most detailed product picture with full-sheet,
1,200-datapoint profiles
• Same-point and tight measurement of sheet
edges with streak-optimized sensors
• Smallest variations revealed with edge-to-edge
total sheet measurement and advanced edge
modeling logic
• No realignment necessary throughout life of
scanner with factory laser-aligned rails and
stress-relieved platform structures
—
01
10
ABB ABILITY™ QUALITY MANAGEMENT SOLUTIONS FOR PULP AND PAPER 11
NETWORK PLATFORM SCANNERS
Network Platform scanner family
All Network Platforms include advanced capabilities such as extensive and remote diagnostics, stepby-step expansion and complete end column access for all maintenance tasks. These capabilities
expedite installation while also minimizing downtime and startup requirements and lifecycle costs.
NP800
The Network Platform 800 (NP800) is a high-performance
platform right-sized for scanning of small-to-mid size
tissue and paper machines. The RedDot award-winning
design provides customers with maximum uptime for
continuous precision measurements that detect the
slightest imperfections in the web. The advanced carbon
steel “A” frame provides excellent strength-to-size ratio
enabling cost-effective installation in the tightest locations
and low operational costs.
• Maximum 6.23 M (245 in) sheet trim
• Up to 4 sensors at 25 degree passangle
• Construction: Monocoque 6 mm thick A-Beam with welded
box end column
NP1200
The NP1200 provides scanning sensor support on processes
of all sizes. Its solid 10 mm steel A-frame design is
unparalleled in its ability to provide a rigid foundation for
measurement success. This inherent stability for online
sensors is true even when carrying multi-sensor packages at
extreme pass lines across the widest sheets. To ensure
reliable performance in even the harshest mill environments,
the system is pressurized by air and has a welded and wellsealed exterior with no service covers along the beams.
• Maximum 10.23 M (403 in) sheet trim
• Up to 7 sensors at 25 degree passangle
• Extended widths and pass angles up to 45 degrees are
available upon request
• Construction: Monocoque 10 mm thick A-Beam with
welded box end columns
—
02 Upgrade to the latest
measurement
technology without
the nee d to replace
an existing scanner.
Diagnostics
Included with all scanners are Network Platform
Engineering Tools that allow users to commission,
monitor, maintain and troubleshoot. These userfriendly applications – accessible via the mill
network or through remote connection – include
advanced health reporting, trending and sequence
of event monitoring for the scanner, sensors and
electronics.
Lifecycle path for scanners
Cost-effective lifecycle support and evolution is
extremely important given the mission criticality
of Quality Control Systems. Network Platforms
can be easily updated with the latest processing
and sensor technologies as they are developed to
protect investments over the long term and
ensure a solid foundation for ongoing operation
and future QCS developments.
For previous generations, ABB follows a step-wise
approach to scanner and sensor upgrades to
minimize downtime, lifecycle cost
and budget impact.
Smart Platform to Network Platform Upgrade
The Network Platform structure, mechanical drive
system and cabling is functionally identical to
Smart Platform designs.
As such, our cost-effective upgrade path
leverages the existing scanning platform and
adds new Network Platform software, signal
processing and sensor support features, saving
mills time and money.
With an upgraded frame, mills can also take
advantage of new sensors specifically designed
for the advanced computational and signal
processing capabilities of upgraded architecture,
such as moving from the old Hemi+ moisture
sensor to the High-Performance Infrared
Transmission (HPIR-T) moisture sensor, or
upgrading from Smart Color to the new High
Performance Color Measurement.
Benefits of an upgrade:
• Supports new online Spectral Analysis Package
for sensor signals
• Enables upgrades to latest sensors most of
which have higher sampling rates – some
sensors up to 5,000 samples/sec
• Improved sensor/scanner diagnostics package
and configuration tools
• Enhanced alarm and event handling for
diagnostics
• Significantly improved software update,
backup and restore functionality
RNP1200
The RNP1200 supports ABB single-sided (reflective)
measurements for process locations such as wet presses,
coaters and size presses. Design is the same as the NP1200,
but with a single beam so it is able to fit in tight machine
locations where good reflective moisture or coat weight
measurements are critical.
• Maximum 10.23 M (403 in) sheet trim
• Up to 2 sensors at 25 degree passangle
• Extended widths and pass angles up to 90 degrees
are available upon request.
• Construction: Monocoque 10 mm thick A-Beam
• Mounting and head package customization is also
available
—
02
12
ABB ABILITY™ QUALITY MANAGEMENT SOLUTIONS FOR PULP AND PAPER 13
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Measurements
Improve paper quality with precise and
MEASUREMENTS
continuous online measurement
With over 70 years of experience specifically in online paper property measurement,
ABB is an industry leader in providing unique, leading-edge measurements to
optimize machine stability and improve process efficiency.
ABB’s robust and reliable sensors provide high
resolution, precise and accurate measurements
that take advantage of a unique compact design
for continuous online measurement even in the
harshest environments. Advanced diagnostics
and reporting facilitate faster troubleshooting
and reduced maintenance cost and downtime.
Remote support is also available.
We offer complete measurement solutions
including multiple options for basis weight,
moisture, caliper and coat weight. This allows
the choice for application specific, processoptimized solutions.
Weight
ABB's heritage includes the development of
nucleonic basis weight measurement for the
paper industry. Since that time, our industryleading approach has expanded to include new
technologies for many applications.
• Nucleonic Basis Weight
ABB Basis Weight Measurement provides
unparalleled accuracy and streak resolution for
optimum MD and CD weight control all in a
compact design. The sensors use Krypton
(STLK11) or Strontium (TLS1) isotopic sources,
depending on the application requirements.
Each application-optimized sensor uses
radiation transmission techniques to achieve
laboratory quality accuracy and precision on a
wide range of paper grades. Factory calibration
ensures single, linear measurement range for
long-term accuracy.
• High-Performance Infrared Fiber Weight
(HPIR-FW)
For tissue and non-woven measurement
applications, ABB provides a proven design that
delivers safe and reliable performance to
directly measure fiber weight, moisture and
temperature in a single sensor without
radiological isotopes and the regulations
associated with them.
With these highly precise measurements,
operators can more confidently use MD and CD
controls for reduced variability, faster start-ups
and grade changes while also shifting targets
closer to acceptable quality limits to save on
energy and raw material costs.
Virtual measurements
In addition to our full lineup of physical sensors, ABB offers Virtual Measurements that use machine and process
inputs to produce online calculations of important process variables or product properties.
These measurements can be used to provide:
Online measurements that are not
available from physical sensors (e.g.
strength)
More frequent measurements based on
infrequent physical measurement and
process variables
Virtual Measurements utilize models generated from machine learning technologies to predict an online
measurement, increasing the frequency of the measured paper, pulp or process property. These inferred
measurements are available in informative, user-friendly displays that also include alarms, alerts and performance
indicators. With confidence in the reliability and accuracy, maintenance and operations can take action to reduce
variability and achieve quality, productivity and profitability targets.
Stand-in virtual measurements for physical
sensors when physical sensors are unavailable
Validation measurements for direct
measurements from physical sensors
14
ABB ABILITY™ QUALITY MANAGEMENT SOLUTIONS FOR PULP AND PAPER 15
MEASUREMENTS
Moisture
Almost every controllable variable on the paper
machine has an impact on moisture. ABB uses
the latest technologies in order to provide
superior online moisture measurements for
CD and MD control.
• High-Performance Infrared Transmission
(HPIR-T)
ABB’s HPIR-T is the premier moisture and sheet
temperature sensor with an accuracy that helps
maximize control performance to save both
energy and fiber costs. HPIR-T sets a new
standard for precision by increasing speed and
number of measurements; its innovative optical
design doubles the signal-to-noise ratio of the
instrument to provide an industry-leading
moisture measurement rate of 5000 per second.
Robust and inherently stable, it is a consistently
high performer even in severe environments.
HPIR-T is air-cooled, field replaceable, and without
continuously moving parts.
• Microwave
Microwave Moisture Sensors have been
specifically designed for the most challenging
paper web applications; where basis weight and
water weights are high or over a broad range of
temperatures. The unique properties of
microwaves ensure that the moisture
measurement is unaffected by ink residues,
pH, inorganic fillers or colored pigments, which
makes it particularly suitable for applications with
significant recycled content. Measurement output
is robust, stable and insensitive to external
influences.
• High-Performance Infrared Reflection (HPIR-R)
Mid-machine and wet press moisture
measurements help optimize energy, press
loading and quality performance while also
detecting streaks prior to the size press. The
Reflection Moisture sensor provides
papermakers with both process insight and
installation flexibility. The single-sided, noncontacting moisture measurement can be
applied across a wide moisture and location
range; it is usually mounted on an RNP1200,
allowing the sensor to be deployed in tight and/
or hot locations or fabric-backed processes.
Color
High-Performance Color Measurement provides
color, brightness, opacity and whiteness
measurements while scanning over the moving
web. The next-generation sensor incorporates
novel LED technology to make color measurement
faster and more reliable by using a high-speed
spectrophotometer. The sensor works in
conjunction with ABB’s advanced Color Control
to minimize off-spec product and reduce shade
change and start-up times, while helping mills
precisely control color to a target shade.
Caliper
ABB Caliper sensors measure product thickness
and deliver unparalleled accuracy, fast response
time and streak resolution for optimum CD
caliper control and process analysis.
• Glide Technology (GT) Caliper
With patented gliding technology and a low
density, aerodynamic design, GT Caliper glides
smoothly over the sheet to deliver superior
measurement without marking or damaging the
sheet. Caliper options include a light touch
solution for the most delicate processes and
sensing heads optimized to reduce dirt pickup
on grades with high recycle content.
• Optical Caliper
Dual-sided contacting caliper sensors pose
challenges for certain applications. ABB has
developed a new Optical Caliper sensor that is
non-laser based, eliminating measurement
errors caused by light penetration into the
sheet. Instead, the revolutionary technology is
based on the confocal displacement method
that delivers unrivaled accuracy and stability.
Fiber Orientation
The greatest insight into runnability can be
gained when comparing the difference in fiber
orientation between two sides of the sheet. ABB’s
laser-based Fiber Orientation sensor delivers
continuous online, two-sided measurement
providing information on both fiber angle and
ratio. This helps eliminate process problems and
optimize sheet strength and mechanical
conditions faster than relying on lab
measurements alone.
Ash
ABB 2-Component and 3-Component X-Ray
Measurements accurately measure ash weight on
a broad range of applications. These sensors are
highly sensitive to inorganic additives used in the
production of quality paper, such as fillers and
coatings. Pre-calibrated at the factory, these
sensors accurately measure the ash weight of up
to three components simultaneously.
16
ABB ABILITY™ QUALITY MANAGEMENT SOLUTIONS FOR PULP AND PAPER 17
MEASUREMENTS
Gloss
Leveraging a measurement principle that
simulates the human eye’s perception of gloss,
Gloss Measurement provides continuous online
measurement in accordance with TAPPI
standards and offers flexibility to meet differing
machine requirements. The compact, totally
enclosed measurement design includes high
intensity LED, which ensures low maintenance
and long-term reliability.
Optical Properties (Optipak)
Coat Weight
Customer requirements and process conditions
require a consultative approach to coat weight
technology selection. ABB offers the expertise and
technology to meet your requirements by offering
multiple options.
• Direct Infrared (IR) Coat Weight
ABB’s IR Coat Weight provides direct
measurement of coating components and
percent moisture at each web surface through
its unique focusing device, detection
capabilities and signal processing of many
infrared wavelengths. This integrated solution
for measurement, process control and
supervision provides great flexibility and
performance; it is designed to overcome
challenges posed by applications such as heavy
grades, simultaneous coating of both sides of
the sheet and limited machine space. Plus, our
AutoCal method processes signals from
multiple online sensors for unprecedented,
optimized measurement.
Choosing the right sensors for your mill
Measurement Best for Benefits
Weight
Nucleonic Basis Weight - STLK-11 High resolution weight measurement for
Nucleonic Basis Weight - TLS-1 Board and pulp grades >1080 gsm up to
HPIR-FW Light tissue and towel grades with virgin
HPIR-T All paper and board grades < 500 gsm High accuracy
Microwave Heavy pulp and board grades, grades
Reflection All grades that require a single sided
Glide Technology (GT) All grades up to 2032 microns (80 mils)
Glide Technology - Light
Touch (LTGT)
Optical High end grades up to 1016 microns
Dry Weight Difference All coated grades Excellent precision and accuracy
X-Ray Difference Lighter coated grades and those with
Direct IR (reflection) Coated board applications with tight
paper and board grades <1080 gsm
4900 gsm - Harsh environments
fiber
Moisture
with very high optical broadband light
absorbers
moisture measurement; particularly good
for heavy grades in hot, mid-machine
locations
Caliper
that can use dual contacting
measurement
Grades up to 2032 microns (80 mils) with
surfaces sensitive to marking
(40 mils)
Coat weight
need for excellent precision and accuracy.
inter-coater space
Excellent process visibility and accuracy
Excellent reliability and broad range
Single sensor for multiple properties.
Lower cost and greater simplicity;
no nuclear source
Ultra-fast measurement
Excellent measurement accuracy in
harsh environments
Excellent precision and accuracy.
Can be installed in tight locations
Excellent precision and accuracy;
reduced maintenance; good performance
with contaminants; lower cost
Excellent precision and accuracy;
reduced maintenance; good
performance with contaminants
Excellent process visibility and
CD performance with minimal
process intrusions
Best resolution and precision
on light coated grades
Excellent precision, good accuracy
with Autocal
The Optical Properties Measurement combines
measurement of three visual paper properties
in one compact package: Formation, Opacity
and Brightness. Continuous and repeatable
measurement of sheet formation online allows
papermakers to capitalize on this dimension of
process visibility while also measuring opacity
and brightness according to TAPPI standards
for substantial economic and quality benefits.
• Dry Weight Difference
ABB’s high signal-to-noise ratio Basis Weight
measurement is combined with our highly
accurate moisture measurements to offer
unparalleled coat weight accuracy.
• X-Ray (Ash) Weight Difference
For lighter grades of paper needing the highest
accuracy and precision, X-ray Difference offers
high measurement sensitivity to coating solids,
combined with low sensitivity to cellulose and
water. ABB’s patented X-ray filtering techniques
eliminate calibration shifts due to coating
composition changes.
18
ABB ABILITY™ QUALITY MANAGEMENT SOLUTIONS FOR PULP AND PAPER 19
—
CD actuator systems
Accuracy, precision and speed
CD ACTUATOR SYSTEMS
—
Fast, precise response to dynamic
Slice xP
production and quality challenges
in the cross direction with
advanced control, analytics
and diagnostics from ABB's
CD actuator systems.
Weight xP
ABB's Weight xP suite is designed for better basis
weight or coat weight control and features
advanced electronics and a rugged design that
is both robust and highly reliable. The common
system architecture enables easy installation
and maintenance.
By combining absolute position measurement
with ABB's patented fusion sensor technology,
these actuators deliver unsurpassed precision,
speed and diagnostics.
Benefits of choosing the Weight xP family of
actuators:
• Improved machine performance and runnability
• Increased efficiency with faster grade changes
• Decreased raw material usage
• Reduced rejects and improved quality
Whatever your needs, ABB’s actuators offer the speed and accuracy needed for superior control
Suitable for Weight xP SteamPlus xP Air-Water xP Induction xP Plus
Slice xP Dilution xP Coatweight xP
CD weight
CD moisture
CD caliper
CD fiber
orientation
CD coat weight
CD gloss
Uncoated papers
Coated grades
Uncoated
packaging
Tissue
• •
• • • •
• • •
•
• • • • •
• • • • • •
• • • • •
• • •
ABB pioneered stepper control of headbox slice
spindles in 1985, with close to a thousand
headboxes with ABB actuators in operation. With
Slice xP, weight profile variability is minimized by
the precise positioning of the slice lip for
optimum stock flow adjustments.
Dilution xP
ABB’s Dilution xP actuators have been installed on
consistency profiling headboxes from all leading
suppliers and can be fitted to any type of dilution
valve. Weight profile variability is minimized by
accurately adjusting the valve opening to control
the flow of dilution water.
•
•
Coatweight xP
ABB’s Coatweight xP delivers fast, accurate and
reliable coating profile bar positioning. The
actuator ensures an optimum, smooth coating
application through precise positioning of the
coater blade.
SteamPlus xP
ABB SteamPlus xP precisely and efficiently applies
steam close to the sheet surface to minimize
profile variability and reduce dryer section steam
usage. Unique to ABB’s diffuser design is its
ability to keep the steam jets more than 100mm
from the sheet to protect against pulp build up
and blockages. That, coupled with its
maintenance-free T880C actuator design,
proprietary screen slides and integrated cleaning
system means mills benefit from steady
steambox performance without the need for
regular maintenance, improving fiber usage and
paper quality.
Benefits
• Reduces moisture profile variability by up to
80%
• Manage steam usage for 5-10%+ increase in
production and/or 5-10% reduction in energy
costs
• Improved reel build, sheet break recovery and
runnability
• Increased press felt life, sheet strength
properties and sheet surface properties
Air-Water xP
The Air-Water xP is a re-moisturizing system that
delivers excellent sheet absorption due to its
patented atomizer design. By producing
predictable, homogeneous droplets, the actuator
maintains precise flow, impervious to wear or
water pressure variations while being resistant to
plugging.
Benefits
• Up to 80% reduction in profile variability
• Improved reel building and runnability
• Fast recovery at start-up and after grade
changes or process upsets
Induction xP Plus
Workcoil beam
Power module cabinet
Mills will reduce caliper variability with
ABB Induction xP Plus. The system heats the
calender roll by electromagnetic induction, and
the resulting increase in temperature enables
rapid corrections to sheet finishing profiles.
Benefits
• Ensures maximum heating in concentrated
area in the shortest time
• Reduces CD caliper variability by up to 90%
• Delivers up to 80% improvement in recovery
after sheet breaks and start-up
• Enables best sheet finishing for gloss,
smoothness and printability
20
Without automatic shade change
Without automatic shade change
Start Finish
Finish
New target
Old target
With automatic shade change
With automatic shade change
Start
0,5
New target
Old target
Percentage
ABB ABILITY™ QUALITY MANAGEMENT SOLUTIONS FOR PULP AND PAPER 21
—
Quality and production process control
Maximizing and replicating quality
QUALITY AND PRODUCTION PROCESS CONTROL
As the linchpin of the QCS, quality and process
controls are highly reliant on all the components
working together.
ABB’s measurement and control packages
operate seamlessly together to improve quality
for pulp, paper, packaging and tissue makers by
reducing variability, improving grade
repeatability and on-grade utilization.
• Weight
• Moisture
• Ash
• Opacity
• Coat weight
• Caliper
Machine Direction Controls
ABB’s Machine Direction (MD) Controls ensure
minimum variability in paper properties while
minimizing fiber and energy consumption using a
model-based control approach. MD Controls not
only allow for the best steady-state disturbance
rejection during cruise operation, but they also
significantly reduce off-spec time during start-up
and sheet break recovery through fast tracking
response.
Ash con trol
Wet-en d level 1
FC
level I
Weight control
SC
level I
Mills also benefit from optimized production with
minimized energy consumption, increased
throughput and improved availability of both
resources and the machine.
With proven availability, built-in performance KPIs
and local support connected to a global network
of extensive papermaking expertise – all of which
can only be found with ABB – mills can achieve
sustained performance.
Features
- Proven robust model-based approach with
intuitive tuning
- Model error filtering maintains true
measurement signal while optimizing
disturbance rejection and actuator energy
consumption
- Integrated operator interfaces
Level I I
Moisture control
PC
level I
PC
level I
• Yankee-Hood
• Crepe r atio
• Single Color
• Dual Color
• UV Brightness
• Advanced Shad e
Change
—
03 & 04
The second grap h
shows on average
how much faster
shade changes take
using A dvance d Shade
Change (ASC) control.
• Machine Direction – Tissue Controls
ABB’s MD Tissue Controls reduce energy
consumption and improve the utilization of
equipment in the most efficient way. Yankee
hood control enables the tissue maker to make
use of the faster dynamic response in hood
temperature, while maintaining steady state
with the less expensive Yankee steam pressure.
This maximizes energy efficiency while
reducing moisture variability and start-up/
grade change response.
• Machine Direction Multivariable Color Control
Papermakers can exceed emerging
requirements on sheet color and shade
uniformity with ABB’s proven Machine Direction
Multivariable Color Control. Designed to
provide optimal control utilization under
changing conditions, Multivariable Color
Control helps mills minimize rejects and
optimize dye usage.
Advanced Shade Control brings the shade to a
new target in conjunction with or independent
of grade changes. This considers both the
spectral aspects of color and dye, as well as
time-domain responses, minimizing off-spec
time.
ABB’s highly-intuitive, color system matrix
automatically calculates the online control for
multiple actuators for desired dye additions.
1
Color deviation
10
0
—
03
20 30 40 50 60
Time (min.)
The crepe-ratio control helps maintain the
required speed difference between Yankee and
reel, optimizing creping performance.
Features
- Hood temperature ratios
- Flexible moisture actuator and mode handling
- Selectable crepe-ratio entry format
Not only does this minimize the difference
between the actual and target shade, but it
also gives confidence to operators to maintain
a control-on state.
Features
- Full spectrum top, bottom or dual-side color
and brightness control
- Brightness control of actuators using
fluorescence or optical brightening agents
- Flexible color kitchen configurations and
control
- Master-slave dye configuration available
- Support for mixed dye pump types
- Shade setup, handling and changes can
be independent of or combined with
grade changes
Statistical distribution of shade change time
20
18
16
—
04
With ASC
14
12
10
8
6
4
2
0
57%
10
20
30 40 50 60 70
Shade change time (minutes)
Without ASC
22
ABB ABILITY™ QUALITY MANAGEMENT SOLUTIONS FOR PULP AND PAPER 23
QUALITY AND PRODUCTION PROCESS CONTROL
• Weight
• Moisture
• Caliper
• Fiber orientation
• Coat weight
• Finishing
• Local Va riabilit y
Contro l (automatic
mapping)
—
05 Paper machin e
example, highlighting
the nee d for a
multivariable approach
due to coordination
of multiple act uators
influencing weight,
moistu re, cali per and
fiber orientation
Multivariable Cross Direction Control
For even the most challenging cross-directional
processes, ABB’s Multivariable Cross Direction
(MCD) Control optimizes and balances multiple
paper quality CD profiles, while coordinating the
contributions of multiple sets of CD actuators
within their optimal operational limits.
ABB’s MCD Control not only allows for the best
steady-state or cruise performance, but it also
significantly reduces start-up and sheet break
recovery time while minimizing fiber and energy
consumption. MCD Control can also be
implemented as a standalone or hybrid
companion. It can be configured for third-party
profiles or actuators when required and includes a
vast number of third-party actuator interfaces to
minimize implementation time.
Response modelsSetpoint targets
MCD Control
Actuator
outputs
ABB’s MCD Control is intuitive and simplifies both
the operation and maintenance experience,
resulting in less erroneous operator interactions
and troubleshooting time to maintain control
performance.
Features
- True multivariable high-resolution CD-control
and process modeling
- Integrated operator interfaces
- Advanced spatial modeling and filtering
techniques combined with temporal dynamic
response modeling
- Integrated bump test and modeling
application
- Local variability control (LVC) dynamic
mapping automates and prevents
performance deterioration
Response mappings Profile targets
• Automatic Grad e
Change
• Coordinated Speed
Control
—
06 Gra phs showing
automat ic grade
change performance.
—
07 Performanc e for Wet
End Cont rol is made
visi ble and sustained
with b uilt in, d efault,
and configurable key
performance indices and
dashboard interfaces.
Transition Controls
Whether you would like to gently change grades
within current specifications, or are required
to go off grade in order to reach the new
specifications, ABB's Automatic Grade Change
enables consistency, repeatability and the
minimization of off-spec production while
changing grades. Equally important is the
production rate control. ABB's Coordinated
Speed Change is vital in enabling the system to
make required machine speed changes, while
maintaining sheet properties to specification.
—
06
• Headbox
• Speed optimization
• Stock an d ply load ing
• Consistency
compensation
• Crepe ratio control
• Bulk compensation
• Yankee/h ood control
Dilution
profiler
—
05
Slice
proflier
Steambox
Press
scanner
Optimizing Controls
Finding the operational sweet spot is challenging
when attempted manually. Optimizing controls
identify performance gaps and and consistently
push machine performance to an ideal state
taking quality, production and process constraint
parameters into consideration.
Examples include:
• Speed Optimization Control identifies slack in
steam, stock flow and/or machine speed to help
maximize production rates within established
quality and process constraints
Induction
Size press
scanner
Water
profiler
profiler
Reel
scanner
Measurement
profiles
• Ply Loading takes the individual ply dynamics
into account, allowing the operator to configure
each ply as the grade specification or current
operational conditions require, and ultimately
shaping a unified weight control for optimized
ply distribution
• Consistency Compensation provides flexibility
in determining the actual consistency
measurement to be used (instrument reading,
calculated bias, or lab value) by the Ply Loading
and Dry Stock Flow Control features, minimizing
process upsets before consistency changes
reach the machine
• Ash Control
• White water
consistency
• Broke flow fill er
disturbances
—
07
Wet End Controls
The traditional approach of using retention aids to
control white water consistency is far from optimal
with the ever-changing retention properties of the
base sheet and disturbances to the fiber flow’s
base filler content. This can lead to runnability
issues in dewatering, excessive variability in ash
content and myriad inefficiencies, particularly for
filler and ash-heavy applications.
ABB Wet End Control takes full control of the
short circulation loop to reduce variability and
runnability issues, while decreasing fiber, energy
and chemical usage.
By combining robust and predictive model-based
control techniques to dynamically adjust to
process changes – while simultaneously finding
ways to optimize operational costs within process
constraints – Wet End Control helps mills
maximize productivity and profit.
24
ABB ABILITY™ QUALITY MANAGEMENT SOLUTIONS FOR PULP AND PAPER 25
USER INTERFACE
—
User interface
Flexible displays for
local-to-mill-wide visibility
—
08 Contour map
showing conditioned
weight measurement
—
09 MCD ov ervi ew,
selected zone m apping
response highlighted
The QCS user interface provides a comprehensive
set of role-based displays and analytical tools
tailored for both local and remote users as well as
different levels of the organization.
Based on and integrated with the ABB Ability™
System 800xA platform, mills benefit from a
standard but modification-ready QCS display in a
secure, feature-rich environment that meets a
wide range of user requirements.
Operator Interface
The operator interface is purpose-built to give
the operations team an overview of the process
in an easy-to-access and digest layout for swift,
intuitive decision making. Local languages are
fully supported.
It is preconfigured in a best practice layout that
is based on ABB’s extensive system and process
expertise from decades of serving mills
worldwide. An important advantage of this
configuration is the reduction of complexity
for each display to enable faster operation and
decision making while facilitating easier
onboarding and training of new team members.
Information is segmented into process sections
to avoid overwhelming the operator. Navigation
between sections can be customized by user
preference. Users can instantly view and operate
high-resolution measurements, MD and CD
variations, profile contour maps, reel reports,
grade reports, documentation and support tools.
Specifically, the Multivariable Cross Direction
(MCD) overview display includes the controlled
error profile as well as the participating actuator
sets in a profile, zone -based style (figure 09). The
back-end mapping feature associates each zone
response onto the error profile, eliminating time
spent on understanding the actuator profile
response relationship.
All trend data is easy to export to standard
spreadsheets for analysis. Access to real-time
quality control information enables better
process decisions, reducing waste, saving raw
materials and ultimately increasing profitability
and shareholder value.
—
08
More complex information can be made available
to the user to better understand how specific
variables interact, such as how CD actuators or
a PID-controller response will behave. Some
sections include a prediction horizon, enabling
the operator to have awareness of the full
projected response.
—
09
26
ABB ABILITY™ QUALITY MANAGEMENT SOLUTIONS FOR PULP AND PAPER 27
USER INTERFACE
—
10 MCD bump test
—
11 Colo r overview display
with p lot
—
12 Mul tivar iable CD
Contro l overv iew display
Engineering Interface
The engineering user-interface is focused on
enabling the maintenance and engineering
teams to provide an efficient environment
to continuously sustain performance. This includes
asset optimization, controls performance, and
modeling and mapping for swift on-site or remote
troubleshooting.
• Controls performance
Efficiently sustaining the performance of
controls is the most important task for all
engineering operations – especially the
modeling and tuning of process controls. For
example, performance indices provide the
engineering user with awareness of control
performance.
• Modeling and mapping
The MCD controls include a suite of
maintenance related displays to easily maintain
modeling and mapping without the need for
any offline tools. The integral bump-test
scheduler and execution module as well as an
easily accessed bump test analysis module
increases speed of analysis (figure 10) . This
simplifies the representation of the active
spatial response model and identified process
mapping.
• Graphics building
Graphics building is accomplished in a very
straightforward way with a complete set of tools
and a palette of pre-configured elements. This
simplifies display building, supports the needs
of power users and allows operator display
maintenance closer to final users. The back-end
xml-based graphics source code is available,
making for simplified upgrades.
—
10
—
13 Onl ine Spectral
Analysis display
—
14 Color measure ment
overview dis play
—
15 Auto matic grade
change display
Diagnostics displays and OSA
Diagnostic displays allow operators, maintenance
and engineering personnel to have access to
diagnostics information both for the QCS system
and the paper machine process. The system status
and a full featured, filterable, sectionable and
shelveable process alarming package is included
with the system.
Scanners and sensors all have associated health
pages and performance reports, assisting shiftbased maintenance to be the first line of response
for urgent troubleshooting as well as preventive
and corrective maintenance. All diagnostics
displays and information can be remotely accessed
with security considerations tailored to the
individual user or company protocol.
Online Spectral Analysis (OSA) is a software tool
for process engineers and skilled operators to view
and detect the spectral contents of sheet quality
variations while a paper machine is running.
It empowers machine operators and process
engineers to detect their product and process
problems in real-time and associate sheet quality
issues with machine problems instantaneously
during production. It also helps to avoid unplanned
machine downtime with the early detection of
process issues.
—
13
—
14
• Grade and shade code handling
Online or offline grade code handling easily
manages both grade codes and grade grouping.
It allows engineering personnel collaboration
with paper making subject matter experts using
a simple import/export functionality. Grade
and shade file maintenance is independently
managed so that similar shade targets can be
maintained across the grade structure.
• Simulation
An included process simulation package allows
for activities such as system validation and
operator training to be accomplished without
the need for a complete system installation and
startup. Training and analysis can be done early
and in a safe environment.
Enterprise-wide visibility
—
11
ABB systems are designed to provide the rich and
meaningful information necessary for best-in-class
decision making as well as for additional use in
Industry 4.0 applications. In addition to making
available all individual data items and summary
reports, all operator and maintenance displays
can be made accessible to remote users with
appropriate security measures and read/write
protection in place.
—
15
ABB also has companion applications available
for external users to analyze and make use of
—
12
this information, including advanced analytic
applications, data aggregation, dashboards, etc.
28
ABB ABILITY™ QUALITY MANAGEMENT SOLUTIONS FOR PULP AND PAPER 29
—
System integration
Break down barriers for targeted, cost-effective use of information
—
—
Verti cal and horizontal
system integration
provides the data and
visi bility n eeded to
improve productivity,
quality, asset utilization
and mor e, from a mil l to
enterprise-wide level.
ABB breaks down the information barriers found
in mill and enterprise-wide systems for end-to-end
visualization and the use of analytical techniques
to optimize productivity. Whether it’s bringing
quality and production information to the front
office and business systems, bringing legacy
system interfaces into a modern context, providing
advanced analytics for optimization or building
new production management applications, ABB
has the right solutions.
QCS800xA
ABB Quality Control Solutions are implemented as
a functional extension to the System 800xA control
platform. The Quality Control System (QCS800xA)
can be standalone or work as a totally integrated
component with other ABB solutions.
Business layer
Manufacturing Execution
Operations layer
Automation
layer
Device layer
DCS
These include paper machine drives and field
instrumentation as well as systems for web
inspection, lab management, manufacturing
execution and distributed control.
The systems fully support Edge computing and
localized analytical applications as well as cloud
computing and advanced analytical, enterprisewide solutions.
From relatively simple to extremely complex,
ABB has the experience, capabilities and system
architecture to scale the system to meet individual
needs across the spectrum for automation and
integration with new and existing systems.
ERP
System
QDMS
QCS
Diagnostics Serv ice tools
LMS
Best practices for swift decision making
In papermaking operations, it is important to be
able to trust and act decisively with the wealth of
information available. Because QCS solutions are
implemented within the 800xA platform, the data
is structured in the necessary format with the
rate, method and timing required. ABB's system
is therefore able to fully support analysis and
model-based decision making, regardless if the
data is generated from a physical online sensor, a
virtual measurement, process variables or derived
from an external source. This also includes model
outputs or one in which other algorithms have
been applied to the raw data source.
This logical system architecture coupled with good
data management practices enable us to develop
value-add applications that further benefit the
ultimate users of the information. Some examples
include:
Integration as the foundation of digital
transformation
Even before "Industry 4.0" was formally defined,
ABB had been using a common platform for data
organization, control and user interface for all
of its new products for decades. This means
our solutions have an inherent interconnection
that makes both application implementation
and digital transformation easier. Others are
only beginning to tie fundamentally different
systems together and many lack the experience
to use data in a way that brings real value. With
ABB, you get a wealth of automation, digital, and
industry expertise within everything we do, driving
improved productivity and smarter decision
making.
• Virtual measurements (weight, strength, etc.)
• Sheet break analytics
• Advanced controls (for square point, ash and
retention optimization, etc.)
• Data-based root cause analysis for processes
and systems
• Integrated Manufacturing Execution Systems
• Integrated analytics and artificial intelligence
applications
30
ABB ABILITY™ QUALITY MANAGEMENT SOLUTIONS FOR PULP AND PAPER 31
—
ABB Ability™ System 800xA:
Commitment to a common architecture
ABB AB ILITY™ SYSTEM 800XA:COMMITMENT TO A COMMON A RCHITEC TURE
System
servers
Distributed control systems
Motors Standard drives
Motors
Instrumentation
Chemical delivery systems
Standard drives
Collaborative
production
management
enterprise servers
Drive systems
Enterprise clients
Maintenance workplace(s)Engineer workplace(s)Operator workplace(s)
Mill network, Intranet, Internet
Router/firewall
Router/firewall
Connectivity servers
System supported:
Advant, Freelance, Harmony,
Infi90, MOD, Master, SATT
cpmPlus
mil server
Quality control
systems connectivity server
Actuator systems
Quality control systems
Local I/O and remote I/O
Instrumentation
Intelligent Motor
Control Center
and third-party distributed control systems
32
ABB ABILITY™ QUALITY MANAGEMENT SOLUTIONS FOR PULP AND PAPER 33
LIFECYCLE MANAGEMENT
—
Performance Services
Enhancing process and equipment
performance
ABB brings mills a new breed of digital services that not only tap into the vast amount of
information available but also leverage the deep industry expertise that enable the
delivery of long-lasting value.
Lab measurements
Energy Management
Chemical Systems
Condition monitoring
Driv es system
QCS Sys tem
—
Performance Services
are ena bled by th e ABB
Abili ty™ plat form to
colle ct data input s
from acr oss the mill and
provide a highl y scalable
and inte grated
solut ions, some of
which are shown he re.
ABB Ability™ Performance Services for pulp and
paper mills provide a way of operating that allows
both ABB and customer personnel to use the
same information and communication technology
backbone for troubleshooting, technical support,
condition and performance monitoring,
optimization, and predictive maintenance.
Critical equipment and processes can be remotely
monitored and optimized by both ABB and
customer experts to improve mill performance.
Advanced data processing and analytical
applications uncover trends, data patterns
and relationships to improve operations.
Data inputs
Production planning and management
Alarm monitoring and predictive analytics
provide both ABB and mill experts with the
necessary information to reduce unplanned
downtime. By enabling collaboration in a
seamless and fast manner, mills can improve
availability, throughput, quality and profitability.
Performance Services are enabled by the ABB
Ability™ platform to provide a highly scalable
and integrated solution. ABB Ability™ connects
ABB and customer experts to actionable data
and predictive analytics in a collaborative
environment.
ABB Ability
Infrastructure
QMS-specific Performance Services
• Scanner and Sensor Performance
QMS
Asset management
Order management
DCS Sys tem
CMMS
Data Historian
MES
ERP
• MD Contr ol Performance
• CD Control Perfo rmance
• Grade Change Control Performance
• Wet End Control Per formance
• Refiner Control Performance
• Blending Control Performance
• Virtual Measurements
• Sheet Break Performance
• Online Sensor Correlation
Additional Performance Services
• Pulp Mill Optimization
• Winder Performance
• Paper Machine Drives Performance
• Pulp Tracking
• Process Target Optimization
• Plant Asset Management
—
Lifecycle management
Protecting your investment
We are committed to maximizing the usable life of our customers’ investment. Our
approach to lifecycle management provides our customers with the confidence that
there is a well-defined support and a path forward for existing ABB solutions.
With the four phases, ABB enables customers
to plan ahead and protect their investment,
minimizing maintenance costs and reducing
downtime.
Before they move to different stages, ABB shares
the lifecycle plan with dates well ahead of the
phase ending. The classic and limited phases are
active for a minimum of 10 years combined.
Active
12 months 12-18 months
Removal from
Released for Sale
Active sales
Pre-announcement
Service agreements
ABB helps customers cut complexity, control
costs and maximize capital with our global
framework agreements for service. By first
assessing your assets and identifying your needs,
we can find the right Pulp and Paper Care package
for your mill.
Evolution and upgrades
ABB has developed several upgrade paths for our
scanners, sensors, actuators and controls. These
upgrades can be done in stages to provide a
smooth transition from old technology to new
systems. This approach not only ensures your
investment is protected but also provides
enhanced performance capabilities that
maximize the value of installed systems and
components.
Remov al from Classi c sales
Pre-announcement and
Last Time Buy no tice
Active
• Product marketed and available for sale
Classic
• Functional replacement available
• Product maintenance phase
Limited
• Product no longer manufactured
• Supported with best practical effort
Obsolete
• Support not available
• No longer available for sale or delivery
Most products are active for seven-to-ten years.
10 years minimum
Classic
Limited
6 months
Obsolete Notice
Manufacturing End
Obsolete
QCS ASM
ABB’s QCS Automation Software Maintenance
(ASM) program fosters proactive system management, providing easier software delivery. It
enables access to the latest QMS software for
continuous enhancements between system
upgrades. This program features a tiered
subscription service: 1) QCS ASM Maintain Plus
for access to updates within the current version
and, 2) QCS ASM Maintain & Evolve to go between
major QCS versions.
Spares
ABB's lifecycle support policy is to make every
effort to supply original, high-quality spare parts
for at least 10 years after the active lifecycle
phase. To further support that commitment, ABB
offers several services, including selfassessments, that are designed to optimize your
on-site spares and minimize risk of downtime.
34
ABB ABILITY™ QUALITY MANAGEMENT SOLUTIONS FOR PULP AND PAPER 35
—
Why choose ABB for your quality
management needs?
Leading-edge online measurement and control
performance from the category creator.
WHY CHOOSE ABB FOR YOUR QUALITY MANAGEMENT NEEDS?
More efficient working methods;
information flow improves
productivity
Operational flexibility
throughout the grade
structure
Increased (measurable)
production through
minimal variation
High equipment availability and
improved machine runability
brings clear productivity gains
Better process insight improves
product repeatability
Proven minimum
lifecycle cost
Take control of your quality
For any quality challenge your mill is
facing, ABB's solutions provide insight
into your sheet properties to better
control and optimize processes.
For more information, please
visit our website:
abb.com/pulpandpaper
or email:
Se-pulpandpaper@abb.com
—
ABB Ltd. Finnabair Industrial Park
Dundalk, Co. Louth, Ireland
Tel: +353 42 9385100
—
ABB Engineering Ltd. S.P. Building, No. 5, Lane 369
Chuangye Road Kangqiao Town, Pudong District
Shanghai, 201319, P. R. of China
Tel: +86 21 6105 6777
—
ABB Inc. 579 Executive Campus Drive
Westerville, Ohio 43082, USA
Tel: +1 614 818 6300
abb.com/pulpandpaper
© Copyr ight 2023 ABB. All r ights reser ved.
Specifications subject to change without notice.
3BUS00513 2
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