Paper360 - July/August 2015 - (Page 12)

trendspotting | AUGMENTED REALITY Augmented Reality Re-defines Predictive Maintenance Visualizing mill repairs through wireless measurements, smart phones, smart glasses and cloud computing will revolutionize maintenance prediction and lower costs. MIKA KARAILA Augmented reality may become a new reality for pulp and paper mill maintenance departments. That means on-the-spot visualization and solution of just-beginning maintenance problems, anywhere from the chip conveyors to the wrap line. Using this futuristic-sounding technology, a maintenance technician could be directed by a smart phone handset or "smart glasses" to the exact location of a mechanical component, valve or process measurement in need of a maintenance check. A maintenance history of that specific component would appear on the screen or glass lens and an in-situ diagnostics test, thermal image or vibration analysis from wireless sensors can be initiated. If trouble is noticed by a cloud-computing analysis, more detailed device-specific information, a repair manual or a supplier help center could be accessed. This is all done hands-free without having to go back to a control room or maintenance shop. The real benefit is that important communications are easy, real-time information is easily accessed in a normally noisy mill environment where hearing protection is mandatory and there is no need for information terminals. As a result, a repair can be made quickly and accurately. Ultimately, repairs could be predicted and planned well before failures happen, and that would have a big impact on plant reliability and production uptime. These intelligent maintenance applications are now being developed by Valmet and tested at a mine site and a power plant in Finland. The aim is to implement these maintenance tools for all industrial plants, including pulp and paper mills. They support Valmet's strategy to make maintenance activities more effective and lower 12 Paper360º JULY/AUGUST 2015 cost by utilizing intelligent products, tools and services. WINNING RACES AND WINNING MAINTENANCE The diagnostic intelligence derived from wireless sensor signals comes from a cloud computing network where measurements of machinery, control valves or electronic transmitters are transformed into insightful information so that a repair technician can make an immediate repair for good reasons. As an example of this cloud computing power, the Lotus Formula 1 racing team is using Microsoft cloud-based software to monitor and analyze signals from more than 200 wireless sensors in its race cars. The objective is to make fast and sure adjustments and win races. In a pulp and paper mill, the maintenance department wants to increase process uptime while reducing maintenance costs. Winning races and winning maintenance - both important objectives. EXTENDED REACH There is sound and justifiable reasoning behind these developments. The maintenance of a complex and widespread mill is a daunting, time-consuming and costly task. Nevertheless, it is critical for profitability to ensure that the operation is running at top efficiency with minimal disruptions and no costly failures. Most importantly, worker safety must be ensured. To achieve high equipment availability, it is vital to detect faults early in their development, schedule maintenance and carry out repairs before production is affected. This information access needs to be easily and intuitively operated so maintenance tasks and decisions are fast, decisive and cost effective. The problem is that there are thousands of active maintenance points spread out over hundreds of meters in a mill site. These include valves and field devices that are required for operating the process efficiently and safely and mechanical maintenance points that need periodic checking to ensure they are not showing imminent failure patterns. The new portable user interface extends the reach of hard-wired systems (that usually consist of a few hundred monitored points) to thousands of accessible points. The sensors can be placed during a scheduled maintenance round and can be relocated at a later time. FUSION OF TECHNOLOGIES The applications make the best use of a number of enabling technologies and standards, including magnetic navigation technology, low-power wireless machinery condition sensors, low-power wireless Bluetooth communications or other wireless protocols and cloud computing access via a Wi-Fi connection to the Internet. To be practical as a data collection and concentration application in an existing mill network with a DCS, fieldbus interface and diverse field devices, a common, universal interface is required. The current mobile maintenance application is being developed with a standard protocol using OPC UA. It can be built up from subsystems with their own OPC UA servers and information can be aggregated to a higher level. The OPC UA itself can be installed on top of different operating systems like Windows and Linux and even on Android. This design provides a secure way to interact with information provided by sensors and devices from different network topologies.

Table of Contents for the Digital Edition of Paper360 - July/August 2015

Over the Wire
Augmented Reality
Root Cause Problem Elimination…or Only Analysis?
Steam Profiler Gets New Lease on Life
Maintenance Showcase
From Reactive to Proactive
TAPPI Journal Summaries
Kemira Expands its Global Business and Humanitarian Reach
Consolidation Watch
Association News
PEERS Offers Opportunities for Optimization
Online Exclusives
Index of Advertisers

Paper360 - July/August 2015