Klabin Bacell S.A.

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implementation of rlink-pppi at a pulp mill
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Klabin Group

• Klabin group is the largest paper manufacturer
  and the second largest pulp manufacturer in
  Brazil, as well as leading 10 out of the 11
  markets for packaging and tissue paper items in
  which it is active.

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location of klabins sites
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klabin bacell

• Klabin Bacell, located in Camaçari, State of
  Bahia, produces dissolving pulp used primarily in
  the textile filaments, acetate grade and food
  industry.

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the plant

• the plant is one of the world's most modern
  bleach dissolving pulp plants which works with
  modern technology alternatives and high
  automation degree in its process control, managed
  by an ISO 9002 certified Quality System. It is
  the first industrial unit in its category to
  produce pre-hydrolysis Kraft Dissolving Pulp
  through TCF system (Total Chlorine Free), which
  is by itself one of the most significant
  evidences of its environmental performance.

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SAP/R3 at Klabin context

• Almost all sites of Klabin in Brazil run SAP/R3

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The RLINK project at Klabin Bacell

• Bacell was the first Klabin mill where PI System
  was installed ( PI 2 System in 1995)
• The implementation of SAP/R3 4.6c at Bacell
  started in March, 2001 and the go-live happened
  on December 1st
• RLINK PPPI implementation at Bacell started three
  months later ( June )
• Project Team
• Maria Helena Del Grande (Project manager - Klabin
  Bacell)
• Adroaldo Munhoz (Team Leader - Cybertecnica)
• Flavio Maeda (Analyst - Cybertecnica)

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RLINK Cybertecnicas expertise

• Both Adroaldo and Flavio attended the RLINK class
  at OSI office in Germany
• The whole implementation of RLINK at Klabin
  Bacell
• Complementation of the RLINK solution at CSN
  with standard PI monitoring tools (PI-PB and VBA).

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project overview

• RLINK PPPI project was divided in two major
  parts
• migration from PI 2 system to PI 3.3 system
  running in a W2K machine
• implementation of RLINK PPPI (WNT machine).

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original pi system configuration
OVMS 7.1
V2.2
PI-HOME
SICP
PI
PI
RDB
Ethernet TCP/IP
Client applications

Dec-Alpha-OVMS
NT 4.0

• PI-ProcessBook
• PI-DataLink

V2.2
PI
-
API
-
OVMS
P I - API - OVMS
V 1.3
PI
OVMS
PI - API - NTI
PI
-
IN
-
FI
-
CHIP
-
AXP
PI-IN-YO-CPLUS
PI
-
IN
-
FI
-
CHIP
-
AXP
PI-IN-OS-RELDB-NT
CENTAP
YOKOGAWA (DCS)
SCALES
SCALES
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actual pi configuration
Windows 2000
PI-HOME
RLINK - PPPI
V3.3
PI
PI
MSQL
Ethernet TCP/IP
Client applications

Dec-Alpha-OVMS

• PI-ProcessBook
• PI-DataLink
• PI ManualLogger

V2.3
PI
-
API
-
OVMS
PI
-
API
-
OVMS
PI
-
IN
-
FI
-
CHIP
-
AXP
PI-IN-YO-CPLUS
CENTAP
YOKOGAWA (DCS)
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project environment
SAP R/3
PRD DB
DEV DB
Test environment
Production environment
TCP / IP
RLINK 1.4
PI Server 3.3
RLINK 1.4
PI API

• PI e RLINK
• Win-NT 4 sp6
• SQL Server v7
• SAP GUI

• RLINK
• Win-NT 4 sp6
• SQL Server 7.0
• SAP GUI

YOKOGAWA (DCS)
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Registry configuration
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integration plant floor - erp
ERP - SAP R/3
PP-PI
QM
PM
MM
Client applications
Plant Suite -ServerR/3 Link
Packaging area discrete process
PI System
PROCESSO
MS-SQL
Scales
DCS
Manual Entry
Pulp production area - continuous process
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data flow diagram
Instructions
Messages

• Process order info.

• Process order status

• status
• production reporting
• activities
• batch characteristics

• Process Order Info.

(manual entry)

• production
• consumptions
• activities

• status

• Manual production reporting
• activity info

Campaign Manager
PI System
MS-SQL

• Process info.

• Dry rate
• consumptions
• activities

• discrete production information

• Qty of wood consumed in a process order

• process information

DCS
SRM
Scales
Packaging line - bales - reels
Wood receiving and preparation
Pulp production plant
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pulp production stages
Continuous process
Discrete process
PMADE
wood raw materials
liquid effluents
Bits of wood
PMARR
raw materials water
steam
cooking
SBOBI
unbleached pulp
PBRAN
Delignification / bleaching
water raw materials
Bleachedpulp
SFARD
Black liquor
RECUP
raw materials
White liquor
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Resource networks

• Continuous process
• PMADE - wood preparation
• PMARR - unbleached pulp production
• PBRAN - bleached pulp production
• RECUP - recuperation phase
• Discrete process
• SFARD - packaging of the final product
  into bales
• SBOB - packaging of the final product into
  reels

However all sub-plants are of type BPI (PI-Batch
Plant)
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Activities and materials - PMADE
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production reporting -data flow
SAP/R3
PI_PROD PI_CONS PI_PHACT PI_PHST PI_CRST
RLINK
PI System
Quantity of energy and water consumed in the PO
quantity of each type of wood consumed in the P.O.
...
PINet Node
Campaign Manager
PI-ProcessBook
DCS
ODBC
SRM
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bill of materials / recipe relationship
RAW MATERIALS
WOOD MATERIAL1 MATERIAL2 MATERIAL3
MATERIAL4 MATERIAL5 MATERIAL6
Stock of produced material - HALB Five different
materials - one per recipe
CAV_RECEITA_1 CAV_RECEITA_2 CAV_RECEITA_3 CAV_RECE
ITA_4 CAV_RECEITA_5
from DCS tags
INDUSTRIAL WATER ELECTRICAL POWER
.. TO THE NEXT PROCESS PHASE UNBLEACHED PULP
PRODUCTION
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material tag and common name tables - PMADE
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activities for wood preparation

• Organic liquid effluent
• Inorganic liquid effluent
• Machine working hours - direct costing
• Machine working hours - indirect costing
• Man working hours - direct costing
• Depreciation

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campaign manager
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campaign manager is used...

• to view general information of all recipes
  available in rlink for the specific resource
  network
• process order id
• control recipe id
• control recipe status in rlink
• material produced / planned quantity
• total produced and remaining quantity

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campaign manager is used...

• to view further information about the bill of
  material of each Control Recipe
• material id
• description
• quantity programmed to be consumed / produced
• total quantity already reported to SAP
• last quantity reported of each material (PI_CONS
  and PI_PROD)
• timestamp of the last production report (partial
  finish)

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campaign manager is used...

• to change the control recipe status

To finish the process order
To partially finish the process order reporting
production to SAP
To interrupt the process order in progress
To start the control recipe when there is no
other process order in progress
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manual input screen
the manual input box is automatically opened only
when there are materials that need manual
reports of production (all information associated
with .MI tags in material_tag and common_name
tables)
SEND TO PI
Current Time
Timestamo of either the last production report or
the start time of the control recipe
Bacth id sent to SAP with the PI_CONS
Wood consumption in this process order for this
period of time
Produced material
Storage location
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control recipe status changings
process order current status
first production reported to SAP (partial finish)
timestamp when the process order was started in
RLINK
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discrete process - packaging area

• after the production of the Bleached Pulp this
  material (HALB) is available for the next phase
  of the process the drying phase
• after the bleached pulp has been dried it needs
  to be prepared to be shipped to the customer. The
  final product (FERT) can be shipped into reels or
  bales. Each unit shipped to the customer is
  called Bacell lot

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the interaction between RLINK and the packaging
line

• The process control is performed by a software
  that controls the packaging line. It communicates
  with equipments situated in the plant floor such
  as the scale and the printer
• This application sends and receives data from
  RLINK and PI
• The process information is continuously sent to
  RLINK in background.

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the process flow
PI_PROD PI_CONS PI_PHACT PI_BT_CR PI_BT_CL
1. The process control software (SRP) start the
production of a Lot. 2. Each SAP Lot produced is
weighted by the scale 3. When a Lot is closed,
the PCS sends the information of each SAP Lot
directly to RLINK (using customized stored
procedures)
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questions ??