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| UPM Kymmene Kaukaa (Finland) | | Everything Under Control | Operating equipment based on WinCC flexible in a cellulose factory
The cellulose factory UPM Kymmene Kaukaa converted all the graphic operating devices to Simatic WinCC flexible last year. With the conversion function from Simatic ProTool the applications were easily translated into the WinCC flexible format. The commissioning also went off without any problems. In the bale press the remote control of operating devices was converted locally with the innovative option WinCC flexible Sm@rtService.
The industrial estate in Kaukaa in Finland is the location for several UPM-Kymmene factories. These include the Kaukaa cellulose factory specializing in newspaper, a paper factory and a chemical factory. Production of the cellulose began in Kaukaa in 1897 with the sulfite method, the sulfate method was introduced in 1964. There are two fiber lines in the cellulose factor: Only line makes long fiber cellulose from pine, the second line short fiber cellulose from birch and wood chips. For the manufacture of wood-based printing papers the factory produces fully bleached solid long fiber cellulose, so-called reinforcing cellulose and fully bleached short fiber cellulose for fine papers, adhesive papers etc. A staff of 350 people produces 720,000 tons of bleached sulfite cellulose annually.The cellulose is pressed into bales in the bale presses. The Kaukaa factory houses a 4-machine and a 1-machine press. The old Simatic OP25 operator panels of the 4-machine bale press were replaced by new Simatic Multi Panel MP370 12-inch touch displays four years ago of which a total of five are in operation (four for the individual machines and one for the total plant). This improved the user friendliness above all because the old keyboards were difficult to operate. In the course of the conversion the keys were made bigger and easier for operators wearing gloves to operate. A special color scheme also provides additional information in the different situations.The 4-machine bale press also includes a total of nine cellulose binding machines (incl. the reserve machines). The binding machines are equipped with Simatic MP270B 10-inch touch displays and are controlled by Simatic S7-300. The 1-machine bale press is equipped with six control panels which all have a Simatic OP7 text display. Two additional MP370 12-inch touch displays are available in the control rooms for operation and monitoring (HMI) of the presses.Simple conversionIn the Fall of 2004 they began updating all operating devices originally configured with Simatic ProTool to WinCC flexible. "Continuing to run the operating devices with ProTool was uneconomical for Kaukaa", Juha Timonen designer at Kaukaa explains the reason for the conversion, "because this product will be taken off the market in the near future" On the hardware side changes were necessary neither to the operating devices nor to the connecting cables. Modifications of the existing applications were made by the Finnish engineering consultants Karelplan GmbH who specialize in building and process automation. The applications could be transferred easily from ProTool to WinCC flexible with the conversion function. According to Project Manager Harri Hyppiä from Karelplan commissioning went off without any problems.Remote control simplifies monitoringThe room conditions for the 1-machine bale presses in the cellulose factory made troubleshooting in the event of a fault difficult before the modernization. Two of the binding machines belonging to the bale presses are on the upper floor and two on the ground floor. Since the operators work mainly in their own control room from where they are unable to view the bale line as a whole, they wanted their own display at their second workstation. Originally they wanted to install a Simatic Multi Panel there too but Harri Hyppiä found a lower cost and easier alternative: a remote control of the existing control unit MP370. This was implemented with the WinCCflexible/Sm@rtService option.The Multi Panel was connected to the Kaukaa network via the integrated Ethernet interface and a remote connection established with the PC in the control room. In this configuration only two checkmarks had to be set in the appropriate dialog box in the existing application and the Ethernet address of the Multi Panel entered. Markku Jussila, operator in the Kaukaa cellulose factory, confirms: "The possibility of remote control made our job much easier. The status and alarm indicators can now be monitored by the PCs on the network.Article as PDF (German)
Motion World 3 / 2005 | |
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