Tchnicl Articl Nvs tcnlgis pr vli d dsmpnh Nw tchnlgisfr prfrmnc vlutin nd cntrl lps udit t pulp nd ppr plnts Autrs Brnrd Srs Trrs M Sc I Edurd Shigu Hri Dr 2 Plvrs chv timiz9 d prcsss prcss d ppl clul s mlhs d cntrl mnutn9 prditiv prsnt trblh vis prsn tr trvs d xmpls prmics n industri d cluls ppl nvs frrmnts pr vli9 d ds m pnh uditri d mlhs d cn trl cntrl ds divrss vri vis d prcss dispnivis fund mntl pr brn dsmpnh d plnt pr qulidd d prdut finl rsultnd num mir lucrti vidd Cm s plnts d cluls ppl pssum m urn grl numr lvd d mlhs m muits css suprir mil trn s prticmn t impssivl vli9 digns tic d cd um dls simultnmn t sm frrmnts pr tl finlid Abstrct This ppr prsnts thrugh prcticl xmpls frm pulp nd ppr industry nw tls fr prfrmnc vlutin nd uditing f cntrl lps Th cntrl f svrl vilbl prcss vribls is fimdmntl fr gd prfrmnc f th plnt nd frfinl prduct qulity rsul ting in lrgr prfitbility As pulp nd ppr plnts hv frquntly high numbr f lps svrl tims surpssing 1 lps it is lmst impssibl t vlut nd digns ch n f thm simultnusly wi thut tls dsigndfr this tsk S th prfrmnc vlutin sftwr lists th lps ccrding t prfrmnc nd cnmic rturn mking pssibl t priritiz th lps tht prsnt th wrst prfrmnc nd cn giv th bst rsults ifptimizd Th us f ths lp mnitring tchnlgis llws ls cntinuus imprvmnt fprcss prductin bcus it is pssibl t ctut in prctiv wy whn th vlutin indics indict prfrmnc dcrs tndncy viding lrgr ls ss Bsids dignsing th priritis fr ptimiztin th sftwr hs svrl utmtic dignsing indxs f cntrl lps It ls hs svrl tlsfr dtild uditing nd lp tuning This wrk will prsnt sv rl xmpls tht us ths tls in pulp nd ppr industril plnts Kywrds prcss ptimiztin pulp nd ppr prcss lps prdictiv mintnnc cntrl d Pr ss mtiv sftwr d v li9 d dsmpnh pd listr s mlhs d crd cm dsmpnh rtrn cnmic trnnd ps sivl pririzr quls qu prsntm pir dsmpnh qu pdm tr zr mlhrs rsultds s frm ti mizds us dsss tcnlgis d mnitrmnt d mlhs prmit mlhri cntinu d prcss d pr Rfrncis ds utrs 1 Dprtmnt d Atn Otimiz Sistms Bl Hriznt MG Brsil E mil bmrd trrs@tn 2 Nrwgin Univrsity f Scinc nd E Tchnlgy mil hri@chmng ntnu n cm br
du9 pis pd tiv qund pr tur d frm s s indics d vli 9 j stivrm pntnd um tn industri d invstid mnt dnci d s iss tnd t dicr qud d dsmpnh vi prds mirs Alm d in um s priridds pr timiz9 sftwr j clc dispsi9 d zns d indics utmtic s d dig s crc ppl rmnt mnt prcb ncssidd d Est trblh ir timizr plnt prcdimnt ds mlhs rltris fmcids pls insp9 d grfics sftwrs m suprvisris prdrs tur s mlhs d cntrl pns ppl cluls pssum numr lvd d mlhs d urn cn trl dvid cmplxidd d prcs s Nss prdutiv d tip plnt cnsquncis smpnh dsss mlhs prcss Cntud qund s significtivmnt nutn9 significtiv gsts s cnsum u rduzir cm m d insums E ps sivl btr rdu9s vribilidd m numr d mlhs qu prm Est trblh ir ms ris xmpls s ds significtivs n dsgst d tud n md mnul ntr utrs prbl prsntr vri rsultds industris d ns ppl j bti cluls DE DE DE A cmunic9 d sftwr d v li9 d dsmpnh sistms cm s d cntrl SDCDs CLPs instrumn tndnci mnitr9 cntinu ds pr umntr dss fr ficinci ds trblhs d ns prjudicvm nvs pd us ditri d mlhs d md rlvnts d bix d d tn Prcurv d sistm Plnts d s m fznd trdicinlmnt fit r industriis d cluls dnci rs n trvs d ppl in vrific9 pr prsntr vris xmpls d uti liz9 dsss frrmnts m plnts ncssris pr qu tum justs uditri dtlhd sintni ds mlhs clrmn vlind d frm cntinu Ihs d cntrl d d frm timizd s s dtc9 utmtic d d mlhs prblms vist vstimnt j rlizd mnitrnd sintni nu mlhs d cntrl Tnd sui ind divrss frrmnts pr um s m s rliz9 d 15 milh5s m nstic ds mlhs d cntrl Ps cluls trn d US m ts rlizd trvs d prt tc Ihs d cntrl kpp n sid d digstr n prdu9 d cluls d cnsistn dignstics utm prblms frrmnts pr uditri d mlhs pdm grntir cl OPC tics d tril pr cnctividd d sistms ci d cix d limnt9 d n s d OPC DA cntrl d divrss vrivis cm s vlrs d um pr9 d sistm dntr mquin d ppl fundmntl pr qulidd finl d prdut A mdid cntrl d cnsistnci d plp b slutmnt critic qulidd d pr ds ptmrs dut mit mnitrr cntinumnt n industri d cluls Vriv5s td nss flh t rsistnci tr prmtr chv ftm prcss dsd ppl bs mssic frm9 d umidd pcidd qulqur u spct imprtnt d prdut As sim cntrl d cnsistnci urn ds ftrs fundmntis pr qulidd d prdut 21 grntir Buckb Swrtz Alm diss ncssri qu cm m d insums A ni vis ntr utrs vrivis ttl dsjvis utiliz9 dsss frrmnts duis pr cd mlh glbis sim n pr s m qu prsntr prd d dsmpnh nts qu iss sj vs n cus pr9 d prcss dm prblms p prjudicr significtivmnt vlvuls Assim cplmnts dvm sr smpnh m s quis rduzids pr umntr d d prcss Cnsidrnd di mlhs s qu crc cust m um d US mlh 15 mil histrs sj Nst trblh sr OPC Os dds c d pln dsmpnh mlhs d cntrl dsmpnh pdrnizd d crd cm prid d tmp durnt qul plnt trblh m su dsmpnh tim dsjd Urn prid d vli 9 dfinid cm qul ps qul s KPIs Ky Prfrmnc Indictrs s clculds Vl infrmr qu mis d 45 KPIs s clculds cd p m Esss KPIs infr grups d usuris grnts d Opr9 ngnhirs quips Mnutn9 dsmpnh nibilidd ds quipmnts rcinis ds Cm s ds pr ds mlhs d cntrl fnts d scil9 disp prsn9 cndi9s p quipmnts KPIs fmcm mdids d prsntd dsmpnh d sus tivs d pr dul spcificmnt mlhs d cn trl nst fcr d d tds crctristics citds cm u vli9 d mlhs d cntrl dt ntrirmnt u csss frrmnt d mnitrmnt s mdir t prcss frrmnt d mnitrmnt cpz d dtct ls c imprtnt tmbm tmp rl ltds s utilizds pl sftwr pr n grrmnt d qu um instrumnt9 d d cntrl d plmnts cm scil9s pdr indus clt d dds trvs m HDA dds histrics mm PID vris utrs rs rid d vli9 Alm d sintni ds cntrld umntnd s u prblms gr ruids ntr pd gir mlh cml r d prcss Alm diss h prsn9 d frts m tmbm nts d Mnutn9 quip mmnt linridds s pr s rs d prcss As dsmpnh vribilidd d prcs qulid cnsidrd fzr s vlir prximd d mil mlhs d cntrl pr plnt Dsss mlhs crc d 2 tipicmnt prm m md mnul d tmbm rdu9 d cnsu Ihs d cntrl trvs d nts indivi s cntrlm tmprturs prsss num d Pd j vli9 cnti sus impct rtig sfr9s n s usuris ns pnts qulidd d 1 pdm m qu prdu9 fmc mirrtm d invstimn
intnis plnts sftwr clcul cntinu mnt divrss indics d dignsti c cm vribilidd rr mdi bslut Hrris indx mdls d plnt nivl d ruid prcntul d tmp qu mlh prmnc m mdlidd mnul u cm su sid sturd dsgst ds tudrs n tr utrs Fnsc t l 24 Tr rs t l 24 Trrs t l 24b Pr nlis dtlhd sftwr d vli9 prsnt vris frrmn ts d dignstic nlis cm cr rl9 cruzd utcrrl9 grfi c d rbustz vrific9 d histrs grrmnt d vlvul idntific9 d scil9s sus cuss prids dtrminds trvs d dnsidd s Figur 1 Sftwr d vli d dsmpnh list trvs d rltris n Wb s mlhs cm pir dsmpnh qu pdm trzr mlhr r trn cnmic Emnd t l 24 Qunt mir nt prcntul mi r ptncil d gnh cm timiz pctrl d ptnci histgrms n liss sttistics ntr utrs Tds s vli9s histric ds dds cl tds s rmznds m bnc d dds prpri cm cpcidd tul d rmznmnt pr t dis ns DE 3 1 Oscill s sintni A Figur 2 ilustr nlis d sci l9s m um mquin d ppl A sin tni grssiv d um mlh d tm prtur TIC cusv Glycl scilv5s qu ftvm distribui9 d vpr d mquin d ppl lvnd scilv utrs it mlhs Utiliznd s sf twr d vliv d dsmpnh b srvu s qu s indics d scilv ds mlhs dss unidd stvm m 1 u sj nts msm d bsr vr grfic tmprl xibid n Figu r 2 j fi pssivl idntificr s m Ihs qu stvm scilnd s pri ds d scil9 Idntificm s s p rids d scil9 trvs d nlis d dnsidd spctrl d ptnci qu uti Figur 2 Sintni grssiv m um mlh d tmprtur cusvscil 6s m vris utrs mlhs Atrvs d sintni dqud ds ml hs fi pssivl liminr s scil 6s Emnd t l 24 liz trnsfrmd d Furir pr idn tificr d frm cnfivl ficint s pics d scil9 su ptnci spc trl Rul nd Grry 1998 Ordnn t ROI A Figur 1 ilustr urn xm qu pdm trzr mirs bnficis d s pls prids d scil9 frm pl d um plnt cndns d pp1 Emnd t l 24 qu list s dz finncirs s frm timizds Alm d prsntr umnt gl idntificds prids cincidnts pr tds s mlhs cm msm prid mlhs cm pir dsmpnh ms bl pr s mlhs d cntrl rs d mlh d glicl Atrvs d
Figur 3 Grfics d rbustz simul s indicm qu s nvs prmtrs d sintni sr mis cnsrvti vs u sj mis rbusts cm mnr prbbilidd d lvr sistm scil s A curvm zul prsnt sintni tul curvm vrmlh nv sintni dmlh d glicl ds dmis mlhs 3 2 1 Bnficis d uditri d utiliznd s sftwr d mnitrv d dsmpnh nlis frm dt 1997 83 3 mquin d pp Um tp muit imprtnt n ds prmtrs mis cnsrvtivs li 1998 84 3 uditri d mquin d ppl fi d minnd s s scilvs grntind 1999 83 2 clcul ds gnhs btids Pr iss pr9 mis stvl d sistm A vrific9 drbustz ds prmtrs Mdi 83 6 frm cltds dds d tds s m Ihs imprtnts d mquin d ppl d sintni tmbm pd sr fit tr Tbl 1 Tmp d utiliz d snd qu cd vrivl fi nlisd ys dsftwr cnfrm s bsrv n Figur 3 N grfic d rbustz cruz rprsnt mdl idntificd d mlh r m zul clr umr gi d instbilidd u sj s pr css mudr simul9 m mlh fchd d sintni stivr dntrdss r curvs m zul vrmlh n gr fic sistm pd sr lvd inst bilidd Qunt mis lng stivrms d r zul clr mir sr rbus tz ds prmtrs d sintni Nst figur pr xmpl curv vrmlh prsnt cmprtmnt mis rbust stnd mis lng d r zul clr 3 2 Aumnt d ficinci m um mquin d ppl Um fbric prsntv prbl ms d ficinci m um d sus mquins d ppl m cmpr9 s dmis Rul 2 tmp d mquin d ppl ns ns ntri rs timiz Nv 1999 9 1 Dz 1999 83 3 prd d Ntl Jn 2 884 Fv 2 88 6 Mr 2 894 Abr 2 9 2 Mdi 88 3 Tbl 2 Tmp d utiliz d mquin d ppl ns mss ps trirs timiz Aps timiz9 tmp d uti liz9 d mquin umntu m 5 rsultnd num umnt d lucrtivi dd d US 1 8 milh n Alm d frm dtctr s scilvs scn dids usnd crrl9 nlis d dnsidd spctrl d ptnci Os dds nlisds frm s sguints vribilidd dnsidd spctrl d ptnci dsmpnh ds vlvuls histr s grrmnt gnh d prcss Um vz rslvids s principis prblms justds s mlhs cr rtmnt s dds frm nvmnt cltds pr sss mlhs nlisn d s s msms vrivis pr qu fss pssivl clculr gnh cn mic d uditri A Figur 4 prsnt s grfics tmpris nts ps timiz9 d mquin d ppl btids pl sis tm d mnitrmnt d qulidd pr bs mssic umidd mss sc Cm s grfics trn s ms us dss mquin r d 83 Si diss prdut s tmu mis uni ms scls nt s clrmnt r multnmnt su vribilidd frm d mlhr qulidd cm du9 d vribilidd d prcss prsntv s lt d 1 4 pr mnr vribilidd 71 pr bs ps uditri 1 bs mssic d 6 1 pr umi ms sic d 2 91 pr umidd A A Figur 5 prsnt nlis d dd A Tbl 1 prsnt s vl rs d tmp d utiliz9 d mqui Tbl 2 prsnt s tmps d utili z9 d mquin ns sis mss s dnsidd spctrl d ptnci nts dpis d uditri pr bs mssic n nts d su timiz9 guints timiz9 Cm pd sr vist pls grtics d
Figur 4 Cmpr ntr s grfics tmpris nts ps timiz d mquin d ppl Ests grtics frm grds pl sistm d mnitr d qulidd Cm mbs tm msm scl pd s bsrvr qu vribilidd s rduziu bstnt Rul 2 dnsidd spctrl d ptnci s s Cm s custs stimds d u sc qu stv cusnd urnumn cil9s rduzirm s significtivmn ditri frm d crc d US 68 mil t incitvl d vribilidd d pr t snd qu s msms rsultds f cnclui s qu rtrn d invsti dut Rul nd Grry 1998 rmbsrvds pr s dmis mlhs mnt crr m mns d urn ms A mquin d ppl rcb plp Cm s dds btids nts ps Tl rsultd mstr qu timiz9 m trs frms krft trmquimic uditri fi pssivl clculr s d prcss frnc urn ds mirs TMP rcicld Ess Ultim plp sguints bnficis rtrns d invstimnt m plnts btid prtir d prdut rjitd mlhr dsmpnh d mquin d pis trn bjtiv d timizr us nvid um btdir nd crri ppl prtid fit mis fcilmn d quipmnts j dispnivis su mistur cm gu nffi dilui t ps vri9 n grmtur qu 9 Tds s mquins d ppl s br cm mnr frqunci 3 3 Idntificl d scill s limntds cm s msms plps mir ficinci trvs d nlis spctrl krft TMP A plp rcicld dif umnt d prdutividd Urn prblm muit imprtnt n rnt m cd mquin pis driv d gnh cnmic stimd m US industri d ppl cnsist n intr su prpri ppl fr d spcific9 1 8 milh 9 ntr s divrss mlhs d cntr sftwr fi utilizd pr cl Alm diss uditri gru I Rul nd Grry 1998 Iss fz qu culr dnsidd spctrl d ptn utrs gnhs qu psr d n mn prblms cm vribilidd tndm ci cm us ds dds btids m survis s t imprtnts qunt s splhr pl mquin d frm urn pnt lclizd nts d mqui s mnsurvis cm sciltri As scil9s prmncm n d ppl spctr prsntd mlhr cnhcimnt d mquin d cmum ds mirs fnts d vri n Figur 6 pl qul s pd ntr ppl bilidd n prcss d prdu9 d clrmnt qu dnsidd d ptn mlhr prbilidd ppl dsd prpr9 d plp t ci d frqunci d 1 sgunds pssl mis bm trind pr r scgm finl A rdu9 u limi 16 5 minuts s dstc ds dmis slvr prblms n mquin n9 dss mbint dclic pd r qu crrspnd xtmnt ci mlhr qulidd d prdut finl sultr num rdu9 xprssiv d v cl vist n rstnt d prcss cnhcimnt rplicvl pr utrs ribilidd Em grl s scil9s s Pr vrific9 cltrm s mquins d ppl cus d crc d 5 d vribili dds d sid d mquin d ppl pr9 suv dd d mquin btv s dnsidd spctrl d p mnr dsgst ds quipmnts Um mquin d ppl stv tnci prsntd n Figur 7 n qul frrmnts dds dispnivis pr mnutnl prditiv prduzind ppl fr d spcific 9 dvid urn cicl d 16 minuts s bsrv qu frqunci d 1 sgunds s dstc ds dmis rdu9 d ncssidd d mnutn9 n bs mssic umidd mss Esss dis grfics d dnsidd
Figur 5 Anlis d bs mssic pl sftwr d mnitrmnt A vribilidd fi rduzid d 1 41 pr 685 AIl m diss pls grtics d dnsidd spctrl d ptnci vrific s qu s scil fs tmbm s rduzirm d frm significtiv spctrl d ptnci mstrm clr d prcss dsprcu qu signi r fluid cm bix cnsistnci N mnt urn prblm d scilv n fic qu fnt d prblm fi n ntnt cm ss quipmnt cir frqunci d 16 minuts Alm dis cntrd prdut vltu str m culv plp cnsistnci s tr s cncluiu s qu prblm s n cnfrmidd cm vlrs citvis nv mis spss n suc9 v cntrv nts d mquin d ppl Fit is s prblm fi dsc z s rduzi qus zr A ms 1 Sbnd s diss dcidiu s vrificr brir d qu dcrri scil9 n r m tmp n sid d mquin s cus d prblm sri rcicl d plp dslignd tmprri cicl d plp Em puc tmp ds cbriu s qu cus rumbmb plp s dilui A s misturr pl p grss cm fin bmb grdu mnt Aps dus hrs scil9 d circul9 prjtd pr bmb lmnt vltv bmbr Ess ci
rmcltdspl sftwr md 1 fi clculd Figur 9 Cm us dst mdl pssi vl justr s prmtrs d cntrl dr qu rsultm n mlhr dsmp nh d prcss Alm diss tmbm s pd simulr rspst d prcs s disturbis n crg u n st p int cm s v n Figur 1 Nss figur curv zul rprsnt rs pst d prcss qund s usm s vlrs ntigs ds prmtrs d sin tni nqunt curvvrd prsn t rspst cm utiliz9 ds n vs prmtrs Vrific s qu jus Figur 6 Anlis d dnsidd spctrl d ptnci d dds btids num pnt lclizd nts d mquin d ppl t ntig muit grssiv cusnd scilv n vrivl d prcss cnsquntmnt m td mqui n d ppl Os nvs prmtrs pr utr ld rsultm num rspst mis mrtcid sm cusr scil9 n vrivl d prcss Os rsultds cim cmprvm qu simul9 d urn brn mdl pd uxilir n dcis d sclh ds mlhrs justs ds prmtrs d pm A timiz9 d prcss um ds rs cm mir rtrn d invsti mnt m plnts pis trn pr bj tiv grntir qu quipmnt tul Figur 7 Anlis d dnsidd spctrl d ptnci d dds btids num pnt lclizd dpis d mquin d ppl trblh m su mlhr ptmr sj sm ncssidd d nvs ins u tl9s cmtds s custs d ng cl durv crcd 16 minuts prt ds d scil9 s prblms rlci nhri instl9 mnutn9 d tmp bmbnd prt sm nds vibr9 just d mlhs Outr pnt d grnd rtrn bmbr Pr cnfirmr ss rsul intr9 ntr mlhs mcnic s mnutnv prditiv pis pssl td bmb d circul9 fi dsli prntmnt slucinds d Mnutn9 pssui s frrmnts gd intrduziu s nvmnt s hbilidds ncssris pr mn plp rcicld n mquin d ppl 3 4 Mdlgm sintni tr s gnhs Els s cpzs d d Nss situ9 n hvi prsn9 Um frrmnt imprtnt d tctr cnsrtr s prblms nts d scil9 qu prm rprci qund s rligv bmb sftwr d mnitrmnt sintni d mlhs cpcidd d mdlr msm d grrm impct sbr prdu9 As msms tcnics pdm Ess xmpl mstr cm s prcss Grry nd Rul 22 sr usds m utrs mquins d p mlhs d cntrl trn significtiv impct n vribilidd d prdut Pr s mdlr mlh sftwr ncssit ds dds ds vrivis m pl m utrs s9s As mlhs d cntrltrn impc finl cm nlis d dnsidd nipulds d prcss ps umv ts significtivs n vribilidd d spctrl d ptnci pd rpidmn t idntificr fnt ds prblms ri9 fit n mlh N xmpl prsntd pl Figur 8 m urntn prdut finl Nst cs frrmn ts cm dnsidd spctrl d p d scil9 Cnhcnd s s pri qu d mistur d plp s dds f tnci pdm idntificr rpidmnt
d simulr rspst d prcss di nt d tis vri9s Os rsultds prsntds cm prvm ptncil d gnh cn mic n us d sftwr d mnitr mnt vli9 dignstic sint ni d mlhs BUCKBEE G SWARTZ J Cn sistntly cntrlling cnsistncy Ins trumnttin Systms nd Autmti n Scity 21 EMOND M NAUD S LAGA CE J Nw Prfrmnc Mnitring sftwr cutting dg tchnlgis Figur 8 Dds cltds pl sftwr pr btn d mdl dinmi c d prcss A curv suprir rprsnt css infrir ltr f vri f n sid d cntrldr fnt d prblms d d vrivl d pr scil Pl cnhcimnt ds principis prids d scil9 pssivl sbr s cu Pulp Ppr Cnd 15 5 Pgs 19 23 24 FONSECA M Scix Filh C TORRES B S Avlic d dsm pnh uditri d mlhs d cn trl Intch 63 32 37 24 GERRY J RUEL M Simultin s vibr9 just ds mlhs int n th rd t ptimiztin Cntrl Figur 9 Mdl btid prtir ds dd s btids pl sftwr rs ntr mlhs u prblms mcnics histrs grrmnt S prblm idntificd fr d just ns mlhs us d mdls dsts mlhs prmit clculr m pucs minuts s justs d PID qu fmcm s mlhrs rsultds m fc d vri9s tnt n crg qun t n st pint lm d pssibilidd Slutins Nvmbr 22 RUEL M PID Tuning nd Prcss Optimiztin Incrsd Prfrmnc nd Efficincy f Ppr Mchin ISA 2 Nw Orlns USA RUEL M GERRY J Qubc qundry slvd by Furir trnsfrm Intch 45 8 53 55 1998 TORRES B S FONSECA M AQUINO R D FARIA D C Aplicc d sftwr ddicd pr dign6stic d mlhs d cntrl sintni rduc d vribilidd d prcsss 4 Cngrss Intmcinl d Autm9 Sistms Instrumn t9 ISA Shw Suth Amric S Pul SP 24 TORRES B S FONSECA M PASSOS L F FARIA D C Av lic d dsmpnh dign6stic utmtic sintni d mlhs d 1 cntrl uxilids pr sftwr d dicd Rvist Cntrl Instrumn Figur 1 Rspst d sistm vri f n crg n st pint cm us ds prmtrs ntigs m zul nvs m vrd t9 An 1 Numr 98 Nvmbr Pgs 69 75