Using Fieldbus Technology on a Pulp Mill Process

Author(s):
Jason Mangano - Daishowa America

Industry:
Pulp/Paper

Products:
Lookout

The Challenge:
Implementing a closed-loop control system using open fieldbus technology that incorporates device-based control products from several vendors.

The Solution:
Using National Instruments FOUNDATION Fieldbus hardware and software products along with several other vendors’ products to complete the installation.

Daishowa America operates a pulp mill in Port Angeles, Washington. We were interested in implementing new fieldbus technology to start the transition from old, high-cost DCS technology to new, low-cost fieldbus technology. In other words, we wanted to move away from vendor dependence and towards vendor independence. Last June, we installed the first non-beta production of FOUNDATION Fieldbus, demonstrating interoperability among several vendors with closed-loop control distributed in the field devices. This installation, which includes two fieldbus hosts and six fieldbus transmitters with two closed loops, six analog inputs, and five analog outputs, uses the National Instruments NI-FBUS Configurator, Lookout HMI software, and fieldbus interface hardware in the host system.

We use the fieldbus technology to control a hydrogen peroxide bleaching process in a mechanical pulping facility. The peroxide bleaching helps us make our quality, bright paper. Using this technology, we optimized brightness, reduced chemical usage, and enhanced chemical tracking.

FOUNDATIONFieldbus Creates Interoperability
Our fieldbus project takes advantage of many features highlighted in the Fieldbus Foundation final specification. The process uses analog output (A/O), analog input (A/I), and PID control function blocks in the field devices for controlling and monitoring the process. Two different manufacturers’ devices operating on one fieldbus H1 segment demonstrate interoperability. We purchased equipment from SMAR International, National Instruments, and Relcom for this project.

System Configuration
We configured the system on the host and downloaded it to the field devices. The National Instruments host also serves as the link active scheduler (LAS) and communicates with field devices to obtain process information and trends for operations. This information helps operators run the field devices and the plant more efficiently. We purchased and evaluated all software and hardware (starter kits) available for fieldbus applications prior to engineering the project to ensure that we chose the best products.

Fieldbus Technology Reduces Costs
Fieldbus technology was not only important for the peroxide project, but plays a major role in our future. By using Fieldbus technology, we experienced significant savings associated with fieldbus control hardware, wiring reduction, maintenance, and system checkout when compared to DCS technology. Equipment costs are reduced because the control hardware, I/O, and communications hardware are all contained within the field transmitters. There is no need for air-conditioned rack rooms with raised floors for cabling. There are also no separate control, I/O, or large power supply cabinets, nor any control, I/O, or communications modules, control and I/O racks, or separate termination units and associated cabling. The equivalent to these are contained in the field.

In the near future, we are planning a significant amount of preventative maintenance on-line in field devices. The conduit and wiring cost savings will be 40 to 60 percent less than DCS installations because only one twisted pair is used to interconnect many field devices. Also, we can significantly reduce cost because of the reduction of cabinets and hardware devices used in a fieldbus installation. With the fieldbus control hardware, software, engineering, and installation, we saved about 55 percent capital over using DCS control - a major factor in going ahead with the project. The success of this technology gives the mill alternatives for future control installations and upgrades. We are planning a second, larger fieldbus project in the mechanical pulping facility.

For more information, contact:

Jason Mangano

Daishowa America

Port Angeles Mill

P.O. Box 271

Port Angeles, WA 98362

Tel: (360) 452-0692

Fax: (360) 452-9004.

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