Paper360 - March/April 2018 - 21

Fig. 1: Green denotes the stage is in relatively good shape, yellow means "currently possible but needs some
improvement," red means "needs significant improvement."

As data processing tools and methodologies
have improved, it has become apparent that,
within that information mountain, rich veins
of signals are buried. When properly analyzed
and understood, these signals can lead to substantial improvements in daily operations,
improved product quality, reduced energy
demands, and reduced costs. In short, there
is gold buried within all the data.
Unfortunately, just like the valuable ore hiding within real mountains, the useful data
are often contained within a significant overburden, which must be removed to get to the
desired material.
System Design Shortcomings: Vendors
have been trying to make it easier to analyze
long-term data by incorporating relational
databases into the data historian. Data historians do an excellent job storing and compressing data in a time-series format. Unfortunately,
relational databases do not handle raw,
unfiltered time series data particularly well.
Moreover, good data are often interspersed
with bad data because of drifting, scaled or
failed sensors, production downtime, data
transmission issues, or inaccurate or missing
manual entries.
Sorting the good data from the bad data
can become a Herculean task. One recent mill
study2 investigated root causes of paper indents
using several years of data retrieved from a PI
system. A small team of people needed multiple PCs over several days to pull the data
from the historian, followed by several weeks
of scrubbing the data to obtain clean working
files. After all this effort, the team was finally
able to begin the analysis.
Another example of the difficulty of extracting usable data was found in a batch digester
mill investigating changes in production
resulting from screen modifications over a
3-year period. It was even difficult to determine
something as simple as the number of pine and
hardwood digester blows in a specified period.
This mill has three different systems recording
digester blows, all of them using the same blow
initiation signal from the distributed control
system (DCS) as a time-stamp. One system is

the DCS, which initiates the signal to start the
digester blow; a second system is a mill production/accounting system (used by the financial
groups to determine mill productivity and
costs), which obtains blow information from
the DCS through a programable logic circuit
(PLC); a third system is the mill data historian.
The historian time-stamp was also obtained
from the DCS.
After two days of focusing exclusively on the
number of blows, the team determined that
none of the three systems agreed on something
as simple as the number of digesters blown per
day, month, or even each quarter. All three systems were using the same identifier to record
the event, yet the data did not agree.
RECENT IMPROVEMENTS
Hybrid Systems: As the volume of data contained within data historians has increased
over the years, several groups (such as
PARCview, OSI PI, and others) have attempted
to graft relational databases to the data historian to create hybrid analysis systems. These
hybrid systems are significantly more powerful
than the stand-alone systems.

Hybrid systems of this sort work quite well
for real-time data trending and short-term
process upset analyses. Unfortunately, they
are not yet very good at the retrieval and
analysis of long-term Big Data sets due to the
extensive cleanup requirements of Big Data
sets. These systems have also become quite
good at trending real-time process data over a
limited timeframe and providing finite snapshots of process performance and variability.
Bolt-on Tools: To address the difficulty
of extracting the "valuable ore" data from
the "overburden," several companies have
recently developed bolt-on software packages
designed to work with the data historian,
e.g., Wedge by Savcor Oy. Programs of this
type rapidly collect, cleanse, and analyze
"Big Data" sets. These programs provide
fast, online process diagnostics systems
that enable massive amounts of process
information to be extracted from various
sources (including the data historian) for
analysis. Time delayed process models can
be developed, and correlations and probable
root causes of various process problems can
be determined.

Fig. 2: Refiner plate run-life in total operation hours, plotted over a two-year period.

Paper360º MARCH/APRIL 2018

21



Paper360 - March/April 2018

Table of Contents for the Digital Edition of Paper360 - March/April 2018

Setpoint
Over the Wire
The Importance of Safety Training
Data & Decision Making
RISI European CEO of the Year: DS Smith’s Miles Roberts
Buckman’s Junai Maharaj on ‘The Art of the Possible’
Fapajal Tissue: Old, New & Customer-Centric
Progroup Turns 25
PIMA, Paper360° Co-Host Executive Panel
Creating a Lignin Culture
Benefits of Drive-Through Design
Sustainability as Business Leverage
CIPTE Show Highlights Innovation and Sustainability
TAPPI Journal Summaries
Leadership in Maintenance: Where Do We Start?
As a New Reliability Engineer, Are you Confused About Your Role?
R&M Tips
Paper and Board Have Key Roles in the Future of Packaging
Global Paper and Paperboard Demand Growing Despite Declines in Graphic Paper
PPI Awards Showcase Industry Excellence
TAPPI News
ASPI News
Index of Advertisers
Paper360 - March/April 2018 - intro
Paper360 - March/April 2018 - ebelly1
Paper360 - March/April 2018 - ebelly2
Paper360 - March/April 2018 - cover1
Paper360 - March/April 2018 - cover2
Paper360 - March/April 2018 - 3
Paper360 - March/April 2018 - 4
Paper360 - March/April 2018 - 5
Paper360 - March/April 2018 - Setpoint
Paper360 - March/April 2018 - 7
Paper360 - March/April 2018 - 8
Paper360 - March/April 2018 - Over the Wire
Paper360 - March/April 2018 - 10
Paper360 - March/April 2018 - 11
Paper360 - March/April 2018 - The Importance of Safety Training
Paper360 - March/April 2018 - 13
Paper360 - March/April 2018 - Data & Decision Making
Paper360 - March/April 2018 - 15
Paper360 - March/April 2018 - 16
Paper360 - March/April 2018 - 17
Paper360 - March/April 2018 - 18
Paper360 - March/April 2018 - 19
Paper360 - March/April 2018 - 20
Paper360 - March/April 2018 - 21
Paper360 - March/April 2018 - 22
Paper360 - March/April 2018 - 23
Paper360 - March/April 2018 - 24
Paper360 - March/April 2018 - 25
Paper360 - March/April 2018 - 26
Paper360 - March/April 2018 - 27
Paper360 - March/April 2018 - 28
Paper360 - March/April 2018 - 29
Paper360 - March/April 2018 - 30
Paper360 - March/April 2018 - 31
Paper360 - March/April 2018 - RISI European CEO of the Year: DS Smith’s Miles Roberts
Paper360 - March/April 2018 - 33
Paper360 - March/April 2018 - 34
Paper360 - March/April 2018 - 35
Paper360 - March/April 2018 - Buckman’s Junai Maharaj on ‘The Art of the Possible’
Paper360 - March/April 2018 - 37
Paper360 - March/April 2018 - 38
Paper360 - March/April 2018 - 39
Paper360 - March/April 2018 - Fapajal Tissue: Old, New & Customer-Centric
Paper360 - March/April 2018 - 41
Paper360 - March/April 2018 - 42
Paper360 - March/April 2018 - 43
Paper360 - March/April 2018 - Progroup Turns 25
Paper360 - March/April 2018 - 45
Paper360 - March/April 2018 - 46
Paper360 - March/April 2018 - 47
Paper360 - March/April 2018 - PIMA, Paper360° Co-Host Executive Panel
Paper360 - March/April 2018 - 49
Paper360 - March/April 2018 - Creating a Lignin Culture
Paper360 - March/April 2018 - 51
Paper360 - March/April 2018 - 52
Paper360 - March/April 2018 - 53
Paper360 - March/April 2018 - Benefits of Drive-Through Design
Paper360 - March/April 2018 - 55
Paper360 - March/April 2018 - Sustainability as Business Leverage
Paper360 - March/April 2018 - 57
Paper360 - March/April 2018 - CIPTE Show Highlights Innovation and Sustainability
Paper360 - March/April 2018 - 59
Paper360 - March/April 2018 - TAPPI Journal Summaries
Paper360 - March/April 2018 - 61
Paper360 - March/April 2018 - 62
Paper360 - March/April 2018 - 63
Paper360 - March/April 2018 - 64
Paper360 - March/April 2018 - Leadership in Maintenance: Where Do We Start?
Paper360 - March/April 2018 - As a New Reliability Engineer, Are you Confused About Your Role?
Paper360 - March/April 2018 - R&M Tips
Paper360 - March/April 2018 - Paper and Board Have Key Roles in the Future of Packaging
Paper360 - March/April 2018 - 69
Paper360 - March/April 2018 - Global Paper and Paperboard Demand Growing Despite Declines in Graphic Paper
Paper360 - March/April 2018 - 71
Paper360 - March/April 2018 - PPI Awards Showcase Industry Excellence
Paper360 - March/April 2018 - 73
Paper360 - March/April 2018 - 74
Paper360 - March/April 2018 - 75
Paper360 - March/April 2018 - 76
Paper360 - March/April 2018 - 77
Paper360 - March/April 2018 - 78
Paper360 - March/April 2018 - TAPPI News
Paper360 - March/April 2018 - 80
Paper360 - March/April 2018 - ASPI News
Paper360 - March/April 2018 - Index of Advertisers
Paper360 - March/April 2018 - cover3
Paper360 - March/April 2018 - cover4
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