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At a Glance:

  COMPANY

  • Global Pulp and Paper Leader
  • With over 200 facilities in US, Europe and Asia

  CHALLENGES

  • Repeated Production Line Failures over 18 months without known cause
  • Production downtime costs exceeding $800K over 18 months
  • Added costs and limited resources strained to manage unforeseen emergencies
  • No relevant, real-time data collected to understand case, predict or prevent future failures

  SOLUTION

  • Denison’s Comprehensive Power Quality Assessment
  • Denison’s Data Analytics, Interpretation and Reporting
  • Denison’s Securely Managed Remote Monitoring Service

  BENEFITS

  • Clear understanding of several root causes of operations disruptions
  • Ability to identify, recommend and implement remedial actions to prevent future failures
  • Ongoing remote real-time monitoring of critical production lines for identification of issues before disruption occurs
  • Identification of power quality issues as a core driver to production line disruptions
  • Agreement to conduct Comprehensive Assessments and Data Analytics solutions to other locations for greater cost savings

  FINDINGS

  • Both teams agree conservatively that the recommendations made by Denison, once implemented, have potential to decrease failures, increase the useful life of the asset, and show a conservative break-even of 5 months, resulting in hundreds of thousands of savings on the production line.
  • Poor Power Quality Causes over 70% of Operations Disruptions. Without a comprehensive approach to understand the root causes of failure, and the collection and interpretation of real-time data, unforeseen disruptions due to poor power quality will continue.

Case Study

Production Disruptions due to Poor Power Quality

Industry: Pulp and Paper

Reducing Operational Disruptions in Manufacturing
A Focus on Power Quality and Data Analytics

Background:

The customer is one of the world’s leading global manufacturers of tissue, pulp, paper and paper towel dispensers, packaging, building products and related chemicals with over 200 manufacturing sites in the US, Europe, and Asia.

Over the last 18 months, without notice or known cause, a series of production line shutdowns have occurred on one of its highest capacity paper lines. The cost of shutdowns combined with failed assets needing to be replaced sooner than their useful life resulted in hundreds of thousands in costs and added risks to the company. Failure to identify root cause of failure meant ongoing failures would be expected resulting in further unquantified costs.

According to Rockwell Automation, poor power quality is the leading cause of over 70% of production line failures. Without a comprehensive approach to monitor, measure, collect and interpret variables and data causing poor power quality, manufacturing is unable to know the root causes, determine a path forward towards remediation, much less act to prevent or possibly predict future failures.

Operational Downtime Due to Poor Power Quality:

After several initial meetings with both the OEM and the customer, Denison’s technical team determined that one of the possible root causes of drive failures could be due to poor power quality. Denison’s team conducted extensive site surveys of the plant and line impacted and met with operations personnel to understand historical and current data relevant to the analysis. A comprehensive review of plant one-line and controls diagrams was initiated to determine what monitoring / metering equipment would be needed to support the test. Denison designed, fabricated, delivered and coordinated the installation of the test equipment needed to collect in real time relevant data over several months. Denison’s team remotely monitored, interpreted, analyzed relevant data and worked with the customer to format the data into a relevant schema report for actionable insights.

An abnormally large incidence of voltage and current imbalances, resonance and harmonics existed as a result of the study causing poor power quality. Interpreted data resulted in engineered solutions to address the core root cause drivers of poor power quality. Non-linear power loads (created by a myriad of machines such as variable frequency drives VFDs) create harmonics, and power distortions leading to poor power quality. The increased use of sensitive electronics on the plant floor will only increase the need to focus on power quality and its impact to production across all manufacturers.

Specifically, Denison’s Team Provided:

  • Comprehensive Power Quality Assessment and Project Management
  • Design, Fabrication and Delivery of Monitoring Sub-systems required
  • Integration with OEM and other resources required through completion
  • Remote secure monitoring and diagnostics of real-time data
  • Data analysis, interpretation and reporting of relevant actionable insights
  • Final Recommendation Report inclusive of ROI calculations, showing 5-month return
  • Monthly securely hosted, cloud based service offered by Denison’s team for ongoing diagnostics

Outcomes:

By using a combination of Denison’s Comprehensive Power Quality Assessment and Data Analytics Solutions, the company was able to pinpoint several root causes of production failures unknown by the OEM or the customer. Using real-time engineering data collected, the team was able to interpret, make remedial recommendations, to mitigate ongoing disruptions.

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Case Study:
Production Distributions due to Poor Power Quality Pulp and Paper Industry