Pulp Paper & Logistics
INDUSTRY NEWS 23 ANDRITZ
3 The ANDRITZ Automation operator panel adjacent to the Board Machine 3 at Mayr- Melnhof Karton
that all the ANDRITZ engineers had detailed knowledge of our system.” As Zechner adds, this is one of ANDRITZ Automation’s key advantages: “We don’t deliver our own products; what we do is take existing soft- and hardware and tailor it precisely according to a customer’s requirements.” ANDRITZ was tasked with supplying a variety of equipment that had to be combined into the automation process, including two air turns, tension control, infrared dryers, curtain coater and a new energy recovery system to aid more environmentally friendly operation. Old equipment also had to be updated and integrated into the PCS 7 system, including a calender and a blade and varibar from an existing coating unit. “A key part of setting this up was
agreeing on software standards for the automation processes,” says Zechner. “This means that the programmers can use standardised rules for operating different parts such as motors and ventilation, rather than having to design new ones each time.”
close cooperation with Mayr- Melnhof Karton: “Our automation team now comprises around 2,000 experts around the world and automation for pulp and paper plant machinery has been part of our core services for decades; we now have more than 150 employees working exclusively in this sector.” Zechner’s involvement in the
project began in March 2014. It marked the beginning of what he and Fuchs call “truly excellent teamwork”. Zechner and his team
of three made the short journey from the ANDRITZ headquarters in Graz to Frohnleiten on a regular basis during an intensive planning phase throughout the summer. A key advantage for Fuchs was ANDRITZ’s knowledge of the Siemens PCS 7 SIPAPER APL, which Mayr-Melnhof Karton chose to automate its processes. “It can be a problem for plant manufacturers to adjust to different customer systems, but we always felt comfortable and secure in the knowledge
Mastering unexpected challenges As with any modification and conversion project, there were several challenges that cropped up at various stages in the process. The safety aspect was particularly complex, says Fuchs. “In order to obtain CE safety certification, there are a lot of requirements to fulfil. For example, ANDRITZ developed and installed a concept that restricts access to fast-moving parts in the machinery. These are electronically operated and can only be opened when the
software system verifies that there is no danger to the operator.” The conversion work in
Frohnleiten totalled three months, but it was four weeks ending on 28 November that was the most crucial, when board machine 3 was switched off to undergo modification and subsequent testing. “We were already able to
start commissioning on 20 November, which was a very quick turnaround,” Zechner explains. One key to this success is the extensive testing to which ANDRITZ subjects its products to prior to delivery – a standard service, adds Zechner. “But ultimately, such quick and effective work is only possible if both parties work closely together during both planning and operation. I’ve been at ANDRITZ a long time, but I’ve rarely seen such successful teamwork as on this project.” After several days of operation, the machine was running error- and disruption-free. “If we can produce without any tears for several consecutive days, that’s a great success for a product like this,” Fuchs emphasises. Industrial production of
Mayr-Melnhof Karton’s new FOODBOARDTM
product is
scheduled to begin in March 2015, but Fuchs says that the advantages of the ANDRITZ Automation work are already recognisable. “The new technology is extremely robust. Availability and reliability has improved and we will soon be operating faster than before.”
Rapidly changing industry This project is just one recent example of changes in the automation sector. Environmental developments within many industries mean that production plants and machinery are not
January/February 2015
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