Metso customer magazine for the flow control business ... · Metso customer magazine for the flow...

From tools to cobots and intelligent instrumentation10

Metso customer magazine for the flow control business » ISSUE 1/2016

Intelligence for improved performance

Neles NDX valve controller: Born to perform8 Life at the global

valve service center in Finland16

Lean approach in R&D and production » 4

Expect customer- centric results.

Faster.

This magazine makes a number of claims regarding operational performance that either we have seen in customer cases, were achieved in Metso testing or have been calculated. The magazine does not imply that these performance levels or improvements are achievable for all sites.

“Often our engineers work very closely with the customer to find the optimum solution. This is where Metso’s expertise can provide much value for the customer.”

MARKUS HAUHIA, DIRECTOR, GLOBE VALVES, METSO

PUBLISHED BY Metso Flow Control Inc. P.O. Box 304, FIN-01301 Vantaa, Finland tel. +358 20 483 150 [email protected] metso.com/valves

EDITOR-IN-CHIEF Kati Tattari, [email protected]

DESIGN AND LAYOUT Brandkind, brandkind.fi

PRINTING Hämeen Kirjapaino Oy, June 2016

ISSN 2343-0540

ADDRESSES Metso customer data

© Copyright 2016 Metso Flow Control Inc.

All rights reserved.

Reproduction permitted quoting “Results flow control” as source.

All product names used are trademarks of their respective owners.

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results flow controlResults flow control customer magazine is published two times a year in English.

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EDITORIAL

Metso is the world’s leading industrial company in the flow control business. Our knowledge, people and solutions help drive sustainable improvements in performance and profitability in our customers’ business.

OUR STRENGTH as a flow control solutions provider comes from our capability and vast knowledge of serving various customer industries around the world. We are committed to helping you reach a higher level of performance in your selected area of business. This issue of our customer magazine highlights, from various perspectives, how we can support your success every day.

TO EARN AND KEEP our reputation as a trusted partner, we constantly seek out opportunities to exceed our customers’ expectations.

WE HAVE BEEN ABLE to achieve this trust by, for example, adopting an Agile and Lean approach. Customer feedback in product development has been key in this approach when creating our new Neles NDX valve controller. This is the Metso Way when bringing you solutions and services that increase your productivity.

LET’S TAKE the Lean journey together and maximize your value.

JUHA YLI-PETÄYSVice President, Valve Technology

MORE EXCLUSIVE CONTENT ONLINE: metso.com/showroom IN THE WORDS OF OUR EXPERTS: metso.com/GoWithTheFlow

» Making the big difference

04 EXPECT CUSTOMER-CENTRIC RESULTS. FASTER. The Lean model in R&D at Metso

08 BORN TO PERFORM The new Neles NDX valve controller

10 FROM TOOLS TO COBOTS Intelligent instrumentation and expert personnel

» Metso experts at your service

14 BETTER SERVICE THROUGH UNDERSTANDING Expert services improve business performance in industrial gas

16 NO TWO DAYS ARE ALIKE Life at Metso’s Global Service Center

» Technological development

18 RELIABILITY MEANS HIGH UPTIME Neles globe valves prove their capabilities in challenging conditions

22 DRIVING SUSTAINABLE DEVELOPMENT New digital technologies for the pulp and paper industry

26 CURRENT Latest product and solution news

» The world is our Showroom

28 FULFILLING STRINGENT PTA PLANT REQUIREMENTS Reliable valves for the Siemens PTA project in Rotterdam

30 AHEAD OF THE PACK Improved efficiency for South African carton board manufacturer

35 INCREASING PUMP WEAR LIFE AND SAVING WATER Tripling pump wear life in one of Brazil’s largest iron ore mines

» Intelligent innovations

37 THE PERFORMANCE WITHIN Intelligent products tell you when maintenance is needed

» News

42 NEWS Latest Metso news from around the world

3results flow control 1/2016

Faster.COVER STORY THE LEAN MODEL IN R&D AT METSO

TEXT: Metso PHOTOS: Francois Perthuis and Metso

Expect customer- centric results.



ETSO HAS LONG BEEN A BENCHMARK in the use of Lean processes in production. The company wanted to take what they had learned on the factory floor and implement a similar efficient way of working into the office environment as well.

KNOW WHAT YOUR CUSTOMER NEEDS | “To successfully apply the Lean approach to an R&D project requires discipline and an open mind towards cooperative working. You need to set clear goals and a steady marching pace,” explains Kalle Suurpää, Director, Neles smart products, Flow Control, Metso. “The idea is not just to have some product out to market faster, but rather to reduce the customers’ waiting time for a solution that they have found a need for. Asking the customer about their needs should always be the first step in product development.”

The development of the NDX valve controller was the first project to truly adopt the Lean approach in R&D at Metso. “Based on input gathered through interviews and feedback brought to the table by our sales force, there was a clear picture of the type of product we wanted to see at the end of the project. In addition to savings, which is something that everyone is looking for, the customer input steered us towards developing solutions that made installation,

commissioning and use easier and more intuitive than ever before – Regardless of the type or manufacturer of the valve being used.”

PICKING UP THE PACE IS A TEAM EFFORT | The Lean approach brought along numerous changes in the way the R&D team worked. The active involvement, cooperation and open dialogue between all departments, from mechanics and software to external partners, sales staff and customers, gave a new sense of purpose to everyone. It helped emphasize the big picture and ultimate goal throughout the process. The newly introduced 3-week sprint cycles helped maintain momentum across the board and showcase the progress made in the regular project team meetings. New visual tools for project management also provide a constant and up-to-date overview of the project status.

With the design process of the Neles NDX intelligent valve controller, Metso took the Lean approach and successfully applied it to R&D, bringing out the new product to market a staggering year and a half faster than projected in a traditional development project.

M

Kalle Pokki and Kalle Suurpää inspect the final product.



Neles NDX represents the new era of R&D at MetsoThe first product to come to market through the Lean pipeline is the new and exciting Neles NDX valve controller. The Lean approach ensured a much shorter time to market than what has previously been the norm and the close cooperation between numerous teams of dedicated professionals ensured that the outcome was a high-quality product that delivers the added features and the improved user experience our customers desire.

Changing your approach to the product development process is no easy task. Not only do processes need to be changed. Also attitudes must be adjusted. For people who take pride in their attention to detail and are used to delivering perfection, it was not easy to bring an unfinished work in progress to the table for everyone to see on a regular basis. But the weekly team meetings and stakeholder meetings held after each three-week sprint cycle provided the opportunity to make corrective moves and take fine-tuning actions on the go. Setting a limited number of achievable goals over a shorter time rather than trying to push along tens of different tasks simultaneously also proved to be a motivating way of working for most.

FINDING THE RIGHT TOOLS FOR THE TRADE | Kalle Suurpää reminds us that making changes in an important function, such as R&D, should not be taken lightly. “Positive change can only be achieved by first knowing what needs to be changed. It’s pointless to force a change in the way of working to suit a particular new tool. It should be the exact opposite way around. Only when you

What is Lean?LEAN IS A LEADERSHIP METHODOLOGY that focuses on maximizing customer value while streamlining processes to eliminate wasted time, resources and materials. For management this means going from optimizing separate elements of a project to focusing on the optimized flow of an entire project towards a set goal. The end result should be a reduced time-to-market and a product that has everything essential and nothing extra and unnecessary.

IN FOCUS

READ MORE ABOUT THE NELES NDX ON PAGE 8.



room still has the opportunity to see the whole project status at a glance.

Kalle Pokki, Metso’s Chief Engineer, Firmware, told us that extensive testing was another function that was taking up a lot of time and pushing back completion dates in the past. “We wanted to develop our automatic testing capabilities to allow us to concentrate on more creative problem solving tasks and speed up the product development process,” Mr. Pokki explains. “We can now run numerous parallel tests and simulations overnight and start analysing the findings first thing in the morning.” These developments in the degree of automation utilized in product testing ended up being one of the major contributors to the reduced time-to-market.

THE LEAN NDX PROJECT – PERFORMANCE PERFECTED | The all-new Neles NDX valve controller promises to deliver performance perfected. “It is a bold statement, but one we can proudly stand behind.” Kalle Suurpää sums things up by saying, “It is a product that has been designed based on exactly what our customers have asked for combined with over 50 years of in-house experience. We took the customer input, and re-imagined the valve controller to make it easier, safer and more reliable than ever before. We achieved the goals we set in terms of an improved overall user experience that ranges from new easy-to-understand visual installation instructions to advanced functions that not only sound alarms, but also suggest appropriate corrective actions.” In the process, the R&D team at Metso has also perfected their design process and made the Lean approach the new standard in R&D.

MORE INFORMATION:Kalle SuurpääTel.: +358 50 483 7680E-mail: [email protected]

IMAGE: The entire team behind the Neles NDX embraced the Lean approach.

know what you need to achieve can you identify or develop the tools to bring about that desired change.”

One example of these new tools has been the new highly visual digital project management platforms taken into use. The design team went from post-it notes on the wall, which was working well for them, to something similar with the added benefit of security and remote access. In addition

to existing in the digital realm, their project board is still physically present in the project room, on a large touchscreen giving them that same tactile and rewarding feeling of moving tasks from “in-progress” to “finished”. Also, everyone in the

“We took the customer input, and re-imagined the valve controller to make it easier, safer and more reliable than ever before.”

We wanted to develop our automatic testing capabilities to allow us to concentrate on more creative problem solving tasks and speed up the product development process.KALLE POKKI, METSO’S CHIEF ENGINEER, FIRMWARE



The Neles NDX valve controller has been the first product developed and designed at Metso utilizing the Lean approach. An improved user experience was at the core of the design. The robust and reliable product provides a solution for all valve brands in a wide range of applications, regardless of the customer or industry.

Born to perform


IMAGE: The new Neles NDX was born to perform in demanding process environments, regardless of industry.


VISIT THE NELES NDX PRODUCT PAGE AND WATCH THE VIDEOS: Go to http://goo.gl/rtqdBP or scan the code

HE ALL-NEW NELES NDX is a welcome addition to Metso’s already comprehensive portfolio of high-quality valve

controllers. In our new development process customer input plays an increasingly important role. Many of the new features have, in fact, been implemented to address the day-to-day challenges our customers have told us about. Because of this, it has come as no surprise that our customers have shown a great deal of interest in this new product since its launch.

The Neles NDX was developed by our dedicated team of professionals to offer unparalleled control accuracy and reduce process variability. This translates into direct improvements in the profitability of any customer process. Accurate control helps ensure production quality and minimizes production losses. It also helps optimize the consumption of raw materials, chemicals and energy. Another important performance factor considered during product development was ensuring availability and reliability with a simple and durable construction.

The controller has been designed for easy 3-step installation onto a wide range of valves, regardless of type or size. Extremely fast and easy

T

50 years of valve controllers:

1961

1959

1996

1975

2016

2003

Neles control valve

NP series pneumatic positioner

NE series electropneumatic

positioner

Digital valve controller

ND800

Digital valve controller ND9000

Neles NDX

installation creates huge time savings, especially when commissioning a globe valve. And what’s more: thanks to the hot-swap support capability, it is possible to install the controller on a valve currently in the process.

Among its many features, the new valve controller also has superior self-diagnostics and data storage capabilities. By combining the real-time availability of comprehensive performance data with an all new simple and easy-to-use user interface both process adjustment and preventive maintenance needs are easy to detect and act upon virtually instantaneously.

50 YEARS OF VALVE CONTROLLER EXPERIENCE | Many things,

including the needs of our customers, have evolved over the years. Our products, just like the Neles NDX, have always been focused on delivering performance and reliability. The experience of 50 years and more than 1 million delivered devices gives us the confidence to say that we truly have the expertise needed to deliver the big difference to our customers. That’s what we call performance perfected.

MORE INFORMATION: Sami NousiainenTel.: +358 20 483 5383E-mail: [email protected] Marko RissanenTel.: +358 20 483 5644E-mail: [email protected]

TEXT AND PHOTOS: Metso



“The new Neles NDX delivers reliability, performance and accuracy in a complete package designed for superior usability and ease.”


The Industrial Internet of Things, or IIoT, is thoroughly changing the way we work. While production is becoming more and more automated, the human element remains as important as ever. The focus of human work is shifting towards knowledge-based tasks: expert personnel interface with intelligent machines, employing new digital skills and seizing the opportunities offered by digitalization.

FROM THE GUEST WRITER’S DESK

New jobs are being created in R&D, programming, sales and smart services.

TEXT: Juha Turunen, Industrial Internet Lead, Accenture Digital PHOTOS: Tomi Parkkonen and Metso

From tools to cobots and intelligent instrumentation

HIS IS THE 3RD ARTICLE in a series addressing the opportunities created by the Industrial Internet of Things (IIoT). In the two previous articles we established the basics of

IIoT and addressed the potential of 3D printing and additive manufacturing. The topic of this article is industrial work and how it is changing due to digitalization. This is a very sensitive topic, because people anticipate the change either with fear or with optimism. Some even

might require convincing that industrial robots can co-exist (cobots) with industrial workers in the same space without risk of injuring people. A big hand to Metso for bringing up topics like the change of work practices so that we can discuss them, benefit from them and learn from them.

T



Let’s take a look at some recent news about the IIoT and robotics impacting the work. As the sheer number and variety of these news topics demonstrate, the pace of technological development is accelerating:

• Mercedes announced that they will increase the number of people working on the assembly of the new Mercedes S-class, because there are so many

• Mining company Rio Tinto is digitalizing its whole delivery chain from pit to port. This involves use of more automated mining and transportation equipment.

• Woodside, an Australian LNG producer, runs 2500 predictive algorithms on a production train to predict equipment behavior.

COBOTS HANDLE ROUTINE TASKS, HUMANS PROGRAM AND DEVELOP | Accenture has done some studies in which we have tried to understand exactly how industrial work is about to change and what the impacts are. These studies conducted for the World Economic Forum 2016 and for industrial customers indicate that

• The Industrial Internet benefits firstly society, and secondly companies, through more environmentally sound, more sustainable and life-saving solutions.

• The level of automation will increase and in manufacturing, investments will mainly be made on solutions involving collaborative, human-augmented and autonomous machines.

• The new core capabilities of an industrial worker will be the capability to co-work with, program and teach cobots.

• Cobots can deal with situations in which the level of customization is low and pre-definable.

• IoT technology will be pervasive and new intelligent instrumentation products are entering the markets, allowing more information to be collected from the use of the equipment and from the actual manufacturing process.

The Industrial Internet benefits firstly society, and secondly companies, through more environmentally sound, more sustainable and life-saving solutions.JUHA TURUNEN, INDUSTRIAL INTERNET LEAD, ACCENTURE DIGITAL

customization possibilities that a human is needed to address them.

• AlphaGo, an artificial unit developed by Google to play Go, beat the world’s best Go player in a best of 5 games series. Go is considered the most challenging board game.

• In 5 years, manufacturing companies expect the focus of technology in the production environment to evolve from human- to machine-centric.



E VIEW TECHNOLOGIES like the IoT and 3D printing as enabling technologies for Metso. New service concepts, in particular, would benefit from new data and knowledge. Ten years from now when we look back at today, I suspect we will see this period as the beginning steps of the true

digital journey. The opportunities are huge. ‘Customer first’ is a good principle to do business by. Many customers

are keen to develop new solutions with technology and service providers like Metso. Many new innovations have already been developed in close cooperation with our customers.

The Internet of Things (IoT) is a megatrend that everybody is talking about. It is a cycle that starts with the data. We are continuously provided with new information. Through learning and interpretation, that information is transformed into knowledge and expertise. At Metso we integrate knowledge, people and solutions to develop new innovations and services.

As an equipment manufacturer, Metso is in a key position to enhance process performance by means of new technologies. The IoT is great news for equipment, but an even better opportunity for services.

For Metso, the IoT offers a new building block. By combining the IoT with our core technologies, we can offer even more added value to our customers. All this progress does not come overnight. It takes time, but it will still happen much faster than many would think. We just need to have a clear vision and recognize the opportunities before us.

MORE INFORMATION:Jari Riihilahti, Vice President, Technology, MetsoTel.: + 358 40 5620 415E-mail: [email protected]

So, routine jobs are increasingly being replaced by automated systems. Also, job descriptions are becoming more knowledge-based, with technology in an assisting role. Industrial workers are becoming industrial knowledge workers, interfacing with intelligent equipment. Not all jobs in manufacturing are disappearing: new jobs are being created in R&D, programming, sales and smart services.

Technology changes how we work and how we work influences technology. The benefits of the IIoT are not realized unless operational models and work practices change. This requires collaboration between industrial equipment manufacturers and their customers. Companies like Metso will find new solutions and sales, while the customer benefits from more efficient operations and asset management that result in cost savings.

COLLABORATION IS THE KEY | Industrial companies should evaluate and seek opportunities to introduce new IoT-based ways of working to increase the digital capabilities of their personnel. Parallel to this, companies should seek collaboration and share information about equipment in order to bring about new, mutual process improvements. Sharing and combining data often makes it more valuable for both supplier and customer.

I am an optimist and in my opinion the IIoT is a good thing. The IIoT will help solve some of the global environmental issues, and new ways of working will be part of the progress brought about by the IIoT. Instead of waiting, companies should start to experiment with and implement wearable solutions in mobile work and adopt cobots in manufacturing to transform their workforce and to reap the benefits of the IIoT.

“The focus of human work is shifting towards knowledge-based tasks.”

WIoT presents opportunities for both our customers and us

IN FOCUS



INDUSTRIAL GAS

Better service through industry understanding

NDUSTRIAL GAS production is an extremely demanding process. While safety and ensured availability

remain critical, customers also demand products and services that are geared towards maximizing process efficiency and profitability. It takes a dedicated and experienced service partner like Metso to help you optimize your process and minimize maintenance costs at the same time. The services we offer have been developed by our experts to address the specific needs of both the process and the business.

WE ENSURE the presence of skilled service experts near you, and help formulate cost-effective and highly individualized maintenance strategies. A service plan based on installed base and criticality analysis and an inventory audit enables the optimized use of your resources, and down the line a modernized and harmonized installed base helps reduce maintenance costs. Device management services and genuine spare parts ensure maximized availability and an extended runtime between shutdowns. Unplanned shutdowns can be virtually eliminated with intelligent maintenance based on device condition analysis and planning of preventive maintenance.

MORE INFORMATION:Damien FerroneTel.: +31 6 5548 7935 E-mail: [email protected]

Expert services are helping improve business performance

I“Early detection

with smart devicesallows us to plan

maintenance without interruptingproduction.”

LE HAVREFRANCE

“What we are seeing is a much

more efficient unit witha higher percentage

recovery.”

DETAILED INFORMATION ONLINE: http://goo.gl/GPojkU or scan the code

40+Metso service

centers sharingexperts and

resources

GERMANY MUNICH



No unplanned shutdowns CHALLENGE

Unplanned shutdowns in the PSA plant have resulted in significant losses in the refinery.

THE METSO SOLUTION Valves upgraded with Neles SwitchGuards and intelligent maintenance services from the local Metso service center.

RESULTS No unplanned shutdowns since 2009.

LE HAVRE, FRANCE

“No unplannedshutdowns since

the implementationof the plannedmaintenance

routines.”

70%of industrial gases

flow throughMetso’s valves

Optimized maintenance CHALLENGE

Improve diagnostics and maintenance efficiency and planning.

THE METSO SOLUTION Upgraded Jamesbury valves and actuators. Intelligent controllers added to all control valves. Long-term maintenance program developed.

RESULTS Efficient detection of performance changes through diagnostics. Optimized shutdown activities with better schedules and service container offering.

PRIOLO, ITALY

Reacting rapidly to customer needs

CHALLENGE Lack of existing solution with extremely high tightness in demanding cryogenic and oxygen services.

THE METSO SOLUTION Neles BWX metal-to-metal seated butterfly valve designed for industrial gas applications. The device was designed and delivered in record time to address customer urgency.

RESULTS Improved technical and commercial competitiveness through increased safety, improved process performance and assurance of the plant’s compliance with the latest (and future) safety and quality standards.

MUNICH, GERMANY

3,000+Metso site visits

per year

“Diagnostics allowedus to get as close aspossible to the endof a component’s

lifespan without risk to production.”

ITALY PRIOLO



YEARS ON THE JOB brings about a kind of confidence that can only come from experience. Olli Sjö is not intimidated by anything that rolls in through the service

center doors. In fact, he seems to prefer the more challenging cases. “I love a good challenge. I especially enjoy working on the larger heavy-duty valves. They are something I have specialized in over the years.”

SERVICE IS A TEAM EFFORT | “Valves and valve controllers get sent here for repairs from all over the world. All these ones here are from Finland, but that one over there, for example, has been shipped in from Taiwan,” Olli explains. Devices being brought in are treated in order of urgency. Some devices are

brought in for scheduled maintenance, while in other critical cases a valve may be in and out of the shop within a matter of days or even hours.

It makes perfect sense that one of two Global Service Centers is located right here on the outskirts of the Finnish capital of Helsinki, adjacent to the factory, R&D department and sales office. Not only are parts readily available for the service team, but close cooperation and continuous open dialogue between all departments creates added value for the customers. “Just as we are in close and direct contact with our customers, we also actively talk to other departments here on site. In many instances it is through services that the customer’s feedback and wishes are communicated to Metso.”

DELIVERING SERVICE TO WHERE IT’S NEEDED | Talking to Olli Sjö, you cannot miss his passion for the job and dedication to the customers. He emphasizes the importance of

36mutual trust and respect between Metso and the customers. “We do this for our customers. We have to prove to be worth their trust every time.” The service team’s dedication is regularly put to the test when they must head out to the customer’s site at a moment’s notice. “It is not unheard of at all that a call is placed in the early morning hours on a public holiday, and we are on our way to the other side of the world within an hour,” Olli tells us.

He can recall years when he has clocked up more than 80 days away from home. While Olli is happy that today he gets to spend the day at his work bench here in Helsinki, Finland, he values the fact that the job he loves has taken him to almost 20 different countries over the years. He has travelled as far east as Japan and as far south as South Africa, all while lending his know-how and experience to Metso’s valued customers.

SAFETY IS A PRIORITY | Olli Sjö compares the staff at the Global Service Center to family doctors: they know the customer, understand the circumstances, are aware of the full history and share the responsibility. “Regardless of any type of time pressure, work has to always be done right. We have a responsibility for both a smooth process performance and the safety of the people on site.” Safety matters are kept actively in mind at all times, and know-how and skills are maintained regularly.

The team at the service center is tight-knit and committed to providing excellent service. Together they have more than one hundred years of experience between them. Olli sums up their thoughts on safety: “Throughout the team’s history there has never been a life-threatening incident resulting from their work. We have never been caught up in a situation where we would not have been able to perform.”

SUMMING UP WHAT SERVICE IS | Olli Sjö does not make a big number about what he does. He is, however, sure to emphasize the importance of the entire team that he is a part of. He speaks warmly of the know-how and experience of the other technicians and gives the young guns their due respect for their enthusiasm regarding all of the smart devices they are keen to work on whenever possible. He is a true team player, and to him service is a team sport.

Our interview with veteran Service Technician Olli Sjö reveals that there is no such thing as a typical day at the Global Service Center. Each day brings new, interesting challenges from all over the world.

METSO GLOBAL SERVICE CENTER, FINLAND

“It is not unheard of at all that a call is placed in the early morning hours on a public holiday, and we are on our way to the other side of the world within an hour.”



TEXT: MetsoPHOTOS: Robert Lindström

No two days are

ever alikeat the Global Service Center



Measured by uptime, Metso’s reliable Neles globe valves have proven their capabilities even in the most challenging process conditions.

Reliability means high uptime TEXT: Marjaana Lehtinen

PHOTOS: Metso and Shutterstock



USUALLY ABOUT 80% OF ALL APPLICATIONS can be covered with Metso’s standard GU and GB, unbalanced and balanced, Neles series globe valves. They are the workhorses of our portfolio representing the quiet majority of valves. They have a robust design, and they have been engineered for long-term performance in oil and gas industry applications. Metso’s Neles globe valves have also proven their capabilities in the severe steam service applications of power plants. The steam conditioning AS series valve package is engineered to provide both steam pressure reduction and temperature control or to work as a stand-alone de-superheater.

For its linear globe valves, Metso offers a wide variety of trim options for different applications, including general and severe processes. The Omega trim features a carefully calculated number of flow passages and turns to provide sufficient capacity and remain within critical flow velocity limits. It offers prolonged trim and valve lifetime, tackling even the toughest applications for anti-cavitation and noise reduction purposes.

Among the latest updates and new releases that deliver added value to our customers are the robust and reliable Neles NDX valve controller and the recently updated Neles VD actuator package. The unique field reversibility of the Neles VD spring diaphragm actuators allows for the actuator spring to be changed easily in the field without the need for any additional parts, making it a compact and efficient overall package.

The Neles NDX valve controller

is one of the new releases.

MORE ON PAGE 8.

ADVANCED TECHNOLOGIES IN FOCUS

“Often our engineers work very closely with the customer to find the optimum solution. This is where Metso’s expertise can provide much value for the customer.”

MARKUS HAUHIA, DIRECTOR, GLOBE VALVES, METSO.

Metso globe valves and accessories serving the oil & gas industry



MANUFACTURING, RTD AND SERVICE FEW YEARS AGO, Metso added globe valves to its control valve portfolio, making it by far the widest on the market. For our customers, this means that they can now get all their valves from one source. What’s more, single-source supply means single-source

responsibility – no more shopping around is needed. Over the past 60 years, we have supplied hundreds of

thousands of valves, providing us with extensive experience and an deep knowledge of various control applications. We definitely know which control valve, material and coating best suits any given application or flow media.

Whatever the customer need or challenge, we are able to deliver a suitable standard or customization to best meet it. To ensure this, we support the customer in valve sizing and selection with our NelProf valve sizing software. This way, our customers get the right valve solution that features the lowest cost and optimal performance throughout its life cycle.

IDEAL FOR OIL & GAS AND POWER APPLICATIONS | Globe valves are widely used in oil refineries as well as in gas processing, petrochemical and chemical plants. “With the globe valve product line included in our offering, we can now provide almost all automated valves for oil and gas processes,” points out Mika Nissinen, Vice President of Oil and Gas Business Line, Metso. “We have been positively surprised by the interest shown especially by customers in the power industry, and we have received many orders from them for steam conditioning applications in power generation, among others.”

Regardless of the industry sector, all customers have one thing in common: they are looking for high process uptime with no unscheduled production breaks to reach high profitability. Uptime is really the synonym for reliability and financial success. Metso’s Neles globe valves are known for their reliability and proven performance, even in the most critical processes. They operate at extreme pressures and temperatures. They are available with a variety of seat, seal, trim and actuator options to make them ideal for a wide range of process conditions.

We have been positively surprised by the interest shown especially by customers in the power industry, and we have received many orders from them for steam conditioning applications in power generation, among others.

MIKA NISSINEN, VICE PRESIDENT OF OIL AND GAS BUSINESS LINE, METSO

“Whatever the customer need or challenge, we are able to deliver a suitable standard or custom solution to meet it.”

ARefined processes OVER THE PAST YEARS, Metso has expanded and developed its manufacturing and technology operations globally. Today, it has world-class valve technology centers and valve production facilities in Finland, the United States (two facilities), Germany, China, South Korea, India and Brazil. They provide research and technology development (RTD), customized engineering, as well as sales and services that support Metso’s ability to engage in comprehensive and efficient cooperation with its customers. The production facilities feature modern and standardized processes following Lean principles, ensuring high-capacity and high-quality production, as well as enabling strong on-time delivery performance and shorter lead times.

Metso’s valve RTD team is now also using innovative ANSYS software in flow and strength simulation when entering new areas that are too expensive or time-consuming to test with traditional methods. Simulations save time and help achieve the optimum valve design faster. Our testing laboratories also house the industry’s most state-of-the-art cryogenic testing facilities, dedicated to testing valves intended for LNG and other low-temperature processes.

READ MORE ABOUT LEAN AT METSO ON PAGE 4.



GLOBAL KNOW-HOW

UAE: Abu Dhabi Oil Refinery Company’s (TAKREER) chemical refining complex

CHINA: Longyu Coal chemical plant project, Phase II

SAUDI ARABIA: Saudi Aramco’s petroleum refining and petrochemical production complex

TURKMENISTAN: Turkmengas’s petrochemical plant project

INDONESIA: PT OKI Pulp & Paper Mills, under construction. Read more on page 23.

TURKEY: A geothermal power plant for Zorlu Energy Companies Group

SIMPLICITY EQUALS RELIABILITY | “The fact that we offer both standard globe valves and special solutions for severe conditions makes us stand out from other suppliers. Our target in product development is always to go for the highest standards,” adds Markus Hauhia, Director, Globe Valves, Metso.

Take, for example, the innovative and fundamentally simple construction of the Metso globe valves with their simple, yet very tight sealing. Our R&D team approached the solution from a different angle compared to other suppliers. First, the team came up with an idea, then simplified it and engineered the best possible solution with regard to operation. The secret lies in an ingeniously simple construction – and simplicity means reliability.

Metso’s globe valves feature uncompromised safety and meet the highest environmental standards. Thanks to the innovative stem sealing solution, emissions from the valves are very low. For applications where zero emissions are a requirement, a special bellows seal solution is available.

INTELLIGENCE BRINGS ADDITIONAL BENEFITS | Metso’s intelligent Neles valve controllers, such as the Neles NDX featured in this issue, are used in various industrial applications, and they are a perfect match with the globe valves, too. Their unique diagnostics provides a solid foundation for valve performance optimization as well as for proactive and predictive maintenance.

The diagnostics features prove their value, for example, before a scheduled shutdown when you have to determine which valves need to be serviced or replaced, keeping shutdown times to a minimum. In addition to reliable globe valves, customers can count on Metso’s strong support that starts with professional project execution and lasts throughout the entire product life cycle.

MORE INFORMATION:Markus HauhiaTel.: +82 10 5437 9696E-mail: [email protected]

EPC companies rely on Metso METSO HAS COOPERATED closely with engineering, procurement and construction (EPC) contractors globally for several decades as their value-adding partner. Metso’s valve technology and engineering know-how has been delivered to more than 100 projects led by Korean EPC companies around the world.

One of these companies is GS Engineering & Construction, the main contractor for the expansion project of the petroleum refining and petrochemical production complex of Saudi Aramco, Saudi Arabian Oil Company, in Saudi Arabia. According to GS Engineering & Construction’s Instrument Lead Engineer Jang In-Cheol, this is one of the company’s biggest projects. “We need trusted partners to work with us. We have completed several successful projects globally with Metso. They understood what we needed in this project and could provide us with the engineering support and services we needed. We know from experience that Metso provides reliable and high-quality products that contribute to our goals in efficiency and environmental aspects.”

Another South Korean EPC contractor, Samsung Engineering, chose Metso’s industry-leading Neles globe valve technology for Abu Dhabi Oil Refinery Company’s (TAKREER) chemical refining complex in the United Arab Emirates. “We have had good support from Metso in our past projects. To ensure smooth startups, Metso offers its wide product knowledge and application expertise, global manufacturing facilities and sourcing, full expediting and inspection support as well as a global service network and comprehensive startup support,” says YunKi Sung, Vice President, Procurement Department, Samsung Engineering.

RECENT GLOBE VALVE REFERENCES



“New winds are blowing. The demand for packaging grades is increasing as more and more items are bought

online and need delivery packages. Many paper

machines are being converted into board

machines.”



OST OF THE TRUE pulp and paper industry-specific valve innovations come from Metso. These innovations include, for example, the capping valve for batch cooking, high

consistency valve for bleaching, NelesAce valve for basis weight control, ceramic ball valve for erosive applications and intelligent valve controllers. To date, Metso has delivered about 3,200 basis weight valves and more than 1,600 capping valves. Neldisc was, in fact, the first metal-seated butterfly valve in the world. Metso’s products feature innovative, yet fundamentally simple construction, operation and maintenance features to optimize process performance at the lowest cost.

“We are the global market leader in valve solutions and services for the pulp and paper industry. Our installed base is huge; we have supplied valves to almost all pulp and paper mills around the world over the past 60 years, and 75% of the world’s pulp flows through our valves,” says Mika Sjöholm, Vice President, Pulp and Paper business line, Metso. “Actually, we intend to strengthen our leading position further and develop new innovative valve solutions and services that bring benefits to the global pulp and paper industry.”

SECURING CUSTOMER SUCCESS THROUGHOUT THE MILL LIFE CYCLE | “New winds are blowing. The demand for printing grades is decreasing due to the growth of electronic media. On the other hand, the demand for packaging grades is increasing

Driving sustainable

development

TEXT: Marjaana Lehtinen PHOTOS: Metso and Shutterstock

In a world of constant change, some things remain the same. One of them is Metso’s commitment to serving its customers in the pulp and paper industry around the world. New digital technologies allow us to do so faster and more efficiently than ever before. We provide our customers with world-leading flow control products and services built on technological excellence, experience and the highest safety standards.

COMMITTED TO THE PULP AND PAPER INDUSTRY

METSO IS BUSY SUPPLYING thousands of valves with accessories and spare parts for PT OKI Pulp & Paper Mills, located in southern Sumatra, Indonesia. The order was Metso’s largest ever flow control products delivery for the pulp and paper industry. Metso’s extensive delivery consists of high-quality valves for control and on-off use. In addition to segment, ball and butterfly valves, the delivery also includes standard and severe service globe valves complemented by intelligent valve controllers.

“Metso’s reliable valves and intelligent valve controllers are designed to eliminate emissions and increase process efficiency. When using our valves, the customer can increase sustainability and safety in the pulp making process,” says See Hoe Lau, Senior Vice President, Asia Pacific market area, Sales and Services.

PT OKI PULP & PAPER MILLS, INDONESIA

Globe valves for the world’s largest pulp mill



METSO’S DIGITAL SOLUTION efficiently manages device and spare parts inventory, delivering measurable benefits through optimization.

40-60% reduction in inventory

15-20% reduction in spare parts expenditure in initial years

100% spare parts coverage and on-time delivery

THE METSO DEVICE MANAGEMENT SOLUTION is just one of numerous instances where modern tools have been able to deliver substantial results for our customers. This a digitalized solution helps our customers optimize spare parts coverage, related costs, storage space and delivery times.

The solution begins with establishing an accurate picture of the customer’s installed base. Devices are then categorized according to criticality classes based on their impact on production, safety and the environment. With this information, Metso works with plant management to reduce stock value and optimize inventory by identifying critical devices to hold in stock, defining target inventory levels and long-term lifecycle plans for each field device.

A solution that gives you an up-to-date view of your entire installed based can not only help reduce your spare parts inventory by up to 60%, more importantly it also gives you the information needed for planning maintenance, repair, upgrade and replacement needs. Metso has enabled 100% on-time spare parts deliveries for many of its customers, and in most cases spare parts expenditure has been reduced by 15-20% during the initial years after implementation.

Digitalized spare parts efficiency

Reduce spare parts inventory by up to 60%

with Metso’s device management solution.

METSO DEVICE MANAGEMENT SOLUTIONIN FOCUS

FIND OUT HOW METSO’S DEVICE MANAGEMENT SOLUTION HELPS PULP AND PAPER MILLS IMPROVE SPARE PARTS EFFICIENCY: http://www.metso.com/solutions/device-management or scan the code



“We are continuously investing in the development of new digital tools and services to improve the customer experience.”MIKA SJÖHOLM, VICE PRESIDENT, PULP AND PAPER BUSINESS LINE, METSO

as more and more items are bought online and need delivery packages. Many paper machines are being converted into board machines, especially in the Nordic countries,” Sjöholm points out. “In the pulp business, new production capacity is being built by expanding existing mills and building new ones.”

We at Metso want to help mills meet these new challenges, improve process efficiency, boost business profitability and promote sustainability throughout the mill life cycle. Our valve solutions offering covers all pulp and paper processes and is by far the widest on the market. “For years, we have also been supporting our customers with value-adding services. Thanks to these things, our customers can avoid unexpected valve failure and unscheduled shutdowns,” Sjöholm says.

Metso is now taking service one step further. In the future, services will include, for example, energy efficiency analyses that reveal whether valves and control loops are operating in the most optimal way.

MORE THROUGH DIGITALIZATION | Digitalization, one of today’s megatrends, is an interesting area into which Metso is expanding its services. We are continuously investing in the development of new digital tools and services to improve the customer experience. The first step includes providing the customers with correct sizing and product information about valves in an electronic format directly into their information systems upon valve delivery. Having immediate access to the correct information helps start-up, maintenance and upkeep during operation. Thanks to modern cloud services, the mill does not need to build a new system for the digital valve information.

“There are thousands of valves in a pulp or a paper mill. When you are in a great hurry, finding the correct information about the products in the traditional way is like detective work,” Sjöholm says. “This is why we have further developed our Device Management Solution in which we are responsible for valve inventories and maintenance. We are now capable of delivering our product data in a digital format into the customer’s maintenance system, too.”

EXPANDING GLOBAL PRESENCE | Metso’s modern service centers and more than 400 dedicated service professionals around the world provide services for both Metso and third-party field devices, including valves, actuators, smart devices and pumps. In

addition, they are the source for spare parts, field support and diagnostic services as well as training programs. Building on these technical services, Metso offers business solutions, such as Shutdowns and Turnarounds, Intelligent Maintenance, Device Management and Control Performance, to optimize maintenance, reliability and production efficiency.

“We are continuously expanding our presence close to our customers and developing our service network. We want to ensure that our customers have access to our support not only during the delivery and startup periods, but also during the entire mill life cycle,” Sjöholm remarks. “For the customers, our service know-how and capabilities mean efficient and on-time maintenance. This, in turn, results in maximized process availability, better efficiency, lower total cost of ownership, increased sustainability and higher safety.”

MORE INFORMATION:Mika SjöholmTel.: +358 20 483 5308E-mail: [email protected]

BELARUS: JSC Svetlogorsk Pulp, China CAMC Engineering

BRAZIL: Maranhao Pulp Mill, Suzano Pulp & Paper

CHINA: Xinhui PM12, April Group

CHINA: Tiger BM, Stora Enso

FINLAND: Äänekoski bioproduct mill, Metsä Group

FINLAND: Woops container board conversion, Stora Enso

FINLAND: Board machine conversion, Kotka Mills Read more on page 43.

INDONESIA: Oki Pulp, Asian Pulp & Paper

INDONESIA: Kerinci PM3, April Group

SWEDEN: Värö Pulp line, Södra Cell

VIETNAM: Nine Dragon PM42, Nine Dragon

RECENT PULP AND PAPER REFERENCES



PST SYSTEM NELES VALVGUARD VG9PST

Taking PST to new heightsMetso has launched a groundbreaking intelligent partial stroke test (PST) system called Neles ValvGuard VG9PST.

THE SOLUTION HELPS CUSTOMERS DIAGNOSE the performance of emergency shutdown (ESD) valves, improve the cost efficiency of installations that use an external solenoid valve and ultimately eliminate costly spurious trip risks associated with such installations. The new solution has unique features, like increased pneumatic capacity, and it is targeted especially for oil and gas industry customers, bringing advanced features for their ESD valve diagnostic needs.

Already in 2000, Metso became the first SIL3 (safety integrity level) certified intelligent partial stroke device supplier. The Neles ValvGuard is technically the most advanced solution on the market with a widespread installed base. Truly knowing the condition of the valves at any given time enables the operators and management to have a full picture of how to best mitigate risks.

The intelligent safety solenoid and PST device, Neles ValvGuard VG9000H, will remain as Metso’s main product for ESD valve control. It includes an integrated solenoid valve and thus is the most economical and safest solution on the market.

MORE INFORMATION: Janne Laaksonen Tel.: +358 40 500 9105E-mail: [email protected]

THE ALL NEW NELES NDX INTELLIGENT VALVE CONTROLLER complements Metso’s comprehensive valve controller portfolio perfectly. It is simple, easy and reliable, yet packed full of functionality. The new user interface is easy to read, understand and interpret, and the simple and robust design makes it easy to install and maintain. We at Metso call it performance perfected.

Performance perfectedNELES NDXVALVE CONTROLLER

READ MORE ABOUT THE NEW NELES NDX ON PAGE 8.



Technological developments and new product innovations are the current that carry performance to new levels. A steady stream of upgrades, updates and new product launches keep us at the forefront of the flow control industry.

METSO HAS INTRODUCED THE “WIRELESS LINK” capability with the Axiom quarter-turn and Prism linear discrete valve controllers. This helps save valuable time, increases safety and lowers maintenance costs by remotely setting switches, operating valves and viewing valve diagnostics.

The system utilizes reliable, secure Bluetooth® Smart wireless communication with a free App used on a conventional iPhone® or iPad®. The Wireless Link App also enables users to conveniently store maintenance information, tag numbers, cycle counts and electronics temperatures. The app also includes a direct link to installation and maintenance manuals when connected to the internet.

The wireless link and app are available with Metso Axiom and Prism models using AS-Interface and DeviceNet™ protocols making setup fast, convenient and inexpensive.

MORE INFORMATION:Bob JensonTel.: +1 (218) 737-0732E-mail: [email protected]

VALVE CONTROLLER AXIOM AMI

Wireless and mobile control

Metso announces the Hawkeye HX with Ex d explosion proof and IP68 submersible ratings in an all 316 stainless steel enclosure for the most challenging environments.

THE HX IS IDEALLY SUITED for oil and gas and offshore applications for point sensing of linear and manual valves. It is also an excellent solution for pulp and paper corrosive or extreme service knife gate applications, including ultra-cold.

The devices have been designed and built to provide rugged and durable performance in demanding conditions assuring high tolerance to vibration. The new HX recently received hazardous location FM approvals for IEC (International), ATEX (Europe), NEC (USA), and CEC (Canada) for being explosion proof, dust-ignition proof, intrinsically safe and in accordance with ingress protection standards.

MORE INFORMATION: Kevin Hufnagle Tel.: +1 (218) 737-0713E-mail: [email protected]

Explosion proof and certified

LINER POINT SENSOR HAWKEYE HX



Fulfilling the stringent requirements atPTA plants

TEXT: Martin DreßenPHOTOS: Metso and Shutterstock

THE SIEMENS PTA PROJECT IN ROTTERDAM, THE NEATHERLANDS



LASTIC BOTTLES MADE FROM PET AND POLYESTER CLOTHES are part of everyday life – and both are made from basic chemicals of terephthalic acid. Purified Terephthalic Acid (PTA) is produced in an oxidation process where ever-fresh air is required.

A PTA machine train consists of a steam turbine, a gear transmission compressor for ambient air, an off-gas expander and a motor generator. Caused by an exothermic reaction in the process, a large amount of steam is created, which among other things, is used to drive the turbine. Once the process is started at the rated speed of the train, steam production increases.

QUICK-CLOSING VALVES FOR DEMANDING OXIDATION PROCESS | Quick-closing valves need to safely shut off the steam flow in less than one second to limit the speed upward in the case of a turbine trip. Since this is such a critical valve application, high demands are placed on all the materials and instrumentation. In addition, all installed butterfly valves are required to produce as little energy loss as possible.

AN UNRIVALED VALVE OPTION | The Neles BW series of valves comes in a nominal size from 28” to 48”. The valves can be installed in pipelines with flanges according to all required industry standards. Due to their higher than industry average Cv values, Neles valves offer significant benefits in this application. Also, our nominal sizes can often be up to 4” - 12” smaller than those of many other valves. This helps customers achieve substantial cost savings.

SEALING SYSTEM FOR AN UNBEATABLE SOLUTION | The valves are used in the main steam line to start the turbine. This is where yet another advantage of the Neles BW series of valves comes into play. The unique sealing system allows the valve to be used even with a supercritical pressure ratio as well as in a small opening angle of approximately 10 degrees. Thanks to the sealing system, all stringent requirements as well as the operating hours of Neles valves are among the best in the industry.

Metso delivered its first valves to the Siemens PTA project in Rotterdam some time ago to help the plant successfully and cost efficiently meet even the strictest requirements for a modern PTA plant.

MORE INFORMATION:Martin Dreßen Tel.: +49 8294 8695 5406 E-mail: [email protected]

P

The Siemens PTA project in Rotterdam has been able to successfully fulfill even the most stringent requirements of the industry with Metso’s Neles valves that offer unrivaled performance and cost efficiency.

Metso delivered valves to the Siemens PTA project in

Rotterdam



for South African carton board manufacturer The face of packaging is changing with the traditional carton board market seeing an increase in the demand for plastic packaging, especially in sectors of the food industry.

Ahead of the pack

MPACT SPRINGS MILL, SOUTH AFRICA

TEXT: Verity Ross PHOTOS: Kevin Wright



30

Mpact Springs Mill is a 24-hour operation, running 7 days a week, and therefore unnecessary downtime is averted at every opportunity.



31

TO STAY ABREAST of these global trends and remain competitive in the market place, the way forward for South African-based Mpact Springs Mill was to improve operational efficiencies and product quality, reduce costs and increase output.

Metso was selected and privileged to partner with and assist this major packaging manufacturer in reducing its overall operating costs, while improving quality and increasing throughput. The scope of supply for Metso was the selection and installation of Neles Valves.

According to Howard Emmett, Mill Manager, Mpact Springs Mill, the demands of meeting their objectives were highly challenging as the mill has many complexities and works with recycled fibre to produce a world-class product.

Mpact Springs Mill differentiates its products from competitors by producing very high quality board with excellent surface properties. One of the advantages of this is that suppliers are able to use multi-color print on their product, thus creating a high definition for marketing and advertising on the packaging. Further benefits are the rigid properties, which accommodate aesthetic and excellent shelf packing. Food safety accreditation

is achieved by applying protective coating barriers that meet international standards for dry food packaging as well as moist and fatty food packaging.

Another large factor is that 90% of the fibre used in the manufacturing process is from recycled fibre, which is environmentally friendly and crucial in today’s world.

Metso valves have helped with the optimisation of our production processes and lowered the entire manufacturing environmental footprint,” says Emmett. “Water conservation, energy and waste reduction is where Metso’s expertise became a vital component to improve the entire process.”

THE CHALLENGE | In order to meet Mpact Springs Mill’s Key Performance Indicators (KPIs) from an operational perspective, the mill had to consider control variability, equipment reliability, time and material efficiencies to achieve a higher level of total efficiency. Further down the line, the engineering department has KPIs regarding reliability, availability and sustainability of equipment.

About three years ago Mpact Springs Mill introduced an operational improvement program that they named ‘The Way Forward’. “It is systematically structured to improve operational efficiency and thereby establish a sustainable and rewarding business for employees and shareholders. The sustainability of the mill will be determined by the success of this program,” comments Emmett.

“In order to set this up we had to consider all the dynamics of running a successful operation. We had to look at water, energy, safety, people development, cost management, business

“Metso valves have helped with the optimisation of our production processes and lowered the entire manufacturing environmental footprint.”



re-engineering, product development, investments and profitability etc. The program is planned over a 5-year period and all aspects have been considered. The program has been split into different disciplines with action lists developed for each discipline.”

Operational targets have been established for the next 3 years and the disciplines include:

• Housekeeping• Back to Basics• Electrical, Instrumentation and Automation• Mechanical• Board Making• Product Development• Production Bottlenecks• Investments• Safety & Risk Action Plan• Resource The Way Forward• People Development

Over the last three years Mpact Springs Mill has made significant investments into capital projects. Almost 90% of the investment capital was spent on quality improvement, energy reduction, process stability and total cost improvement. “It was not necessarily capacity that Mpact Springs Mill was looking for, but due to the improved efficiencies and optimization of the processes we did get capacity. We exceeded our quality improvement and energy efficiency targets at the same time,

IMAGE: Clayton Prins,,Sales Engineer, Metso, and Rudolf Keller, Technical Manager, Mpact Springs Mill, inspecting one of the more than 370 delivered valves from the Neles portfolio.

Mpact Springs Mill production FEED MATERIAL: Recovered fiber

END PRODUCTS: Carton and core board

END PRODUCTS: Packaging

PROCESS DESCRIPTION: The operation produces food-grade quality carton board and high strength core board from recovered and virgin fiber sources. The process includes pulping, cleaning, screening and refining of raw material that is then made into board on two multiply forming machines.

Mpact Springs Mill site OWNER: Mpact Operations (Pty) Ltd

LOCATION: New Era, Springs, South Africa

NUMBER OF EMPLOYEES: 380

IN OPERATION: Since 1951

MARKET POSITION + TRADE: No.1 producer of carton and core board products for South African market

CUSTOMER RELATIONSHIP WITH METSO: 5 years

FACTS AND FIGURES

Challenges AIMING TO SOLVE STOCK PREPARATION

CHALLENGES

INDUSTRY CHALLENGE IN THE REGION AND AT THE MILL: Due to increasing energy, fresh water and raw material costs, it was necessary for the mill to reduce costs relating to usage and fiber yield. The equipment had exceeded their intended useful life, resulting in increased maintenance costs and unplanned downtime.

IN FOCUS



applications,” says McCrum.The range of valves and intelligent valve controllers is

designed to eliminate emissions and increase process efficiency and reliability in the pulp and paper production process. The company was chosen as the main supplier of valves for Mpact Springs Mill due to the backing of its global expertise. “The dedication of our team getting to grips with what Mpact Springs Mill needed to achieve their goals went a very long way to Metso receiving the order. This went from considering the bottom line to setting up a dependable backup and support process during the project execution,” says McCrum.

The company’s proven track record of delivering engineered performance and reliability to the pulp and paper industry has made it the market leader in control and on-off valves globally. About 75% of the world’s pulp flows through Metso’s valves, which is an enormous portion of the market.

The extensive valve order for Mpact Springs Mill included a total of 370 ball, segment and butterfly valves for on-off and control applications from the Neles product portfolios. The control valves are equipped with Neles ND9000 series intelligent valve controllers, which have the capability for advanced performance and diagnostics.

Further results are a reduced spares holding capacity and an increased lifetime. “The feedback from our customer is very positive: the Metso team is capable, supportive, knowledgeable and dependable with their expertise,” concludes McCrum.

MORE INFORMATION:Douglas McCrumTel.: +2711 961 4245E-mail: [email protected]

seeing a total cost reduction,” says Emmett. “If you get the basics right, it takes you to the next level.”

Mpact Springs Mill is a 24-hour operation, running 7 days a week, and therefore unnecessary downtime is averted at every opportunity. The company is proud of its excellent working relationship between staff and management, a vital element in a country that has become plagued with strikes. They have a large internal employee development program in place, plus they are committed to working with learners. The company also boasts an excellent safety and environmental record with all the relevant procedures in place and ISO certification.

METSO’S COMMITMENT | According to Regional Sales Manager Douglas McCrum at Metso Flow Control, Mpact Springs Mill has, over the last number of projects, standardised on Neles valves in their plant. “In the international arena, Neles is highly reputable in the pulp and paper industries and has become renowned for reliability and control performance. The most up-to-date technology available on the market is being used in our valve controller design.

“Taking these qualities into consideration has enabled us to assist Mpact Springs Mill to improve efficiencies and reduce any downtime or process variability that may occur due to valve failures. Our valve design is developed specifically for these

Water conservation, energy and waste reduction is where Metso’s expertise became a vital component to improve the entire process.

HOWARD EMMETT, MILL MANAGER, MPACT SPRINGS MILL

“The feedback from our customer is very positive: the Metso team is capable, supportive, knowledgeable and dependable with their expertise.”



Increasingpump wear life and saving water Itaminas, one of Brazil’s largest iron ore

mines, achieved three times the wear life over conventional pumps and cut back considerably on the use of water by selecting Metso to install slurry pumps with expeller gland seal technology.

TEXT: Audrei Moron

ITAMINAS IRON ORE MINE, BRAZIL

IMAGE: Tailings dam. Most of the water is recovered and reused in the process.

PHOTOS: Audrei Moron and Shutterstock



RON ORE is one of the world’s most commonly used metals. It is the key ingredient for almost 95% of all metals produced globally per year.

In Brazil, the world’s third largest producer of iron ore, the Itaminas mine in Sarzedo, in the state of Minas Gerais,

produced 7.5 million tons of iron ore in 2014, making it the second largest supplier of pig iron in the country.

IHIGH PARTS WEAR LEADS TO NEW SOLUTION | The Itaminas company operates 24/7 and manufactures sinter feed, pellet feed and hematite iron ore, which requires a continuous and flawless operation.

The process begins with the concentrator and then moves to the magnetic separator, cyclone, product stalls and finally on to the tailings tank. The ore is then pumped to the tailings dam via

a pumping system comprising of five stations. Each station is equipped with three pumps, two in operation and one built as a standby unit.

As the iron ore at the Sarzedo location has a density of 1.85 kg/m3, the previously installed pumps had very high wear

TOP: Tailing pumping station, with backup pump for flawless operation.

LEFT: Audrei Moron with Esley Cardoso.

“Maintenance is much simpler and less frequent now. The tailings pumping system has been working for more than two years now without any failures.”



due to the abrasiveness of the material being pumped. Therefore, those pumps were not suitable for the specific duty.

The pumps only had a parts lifetime of approximately three months. In addition, labor to maintain these pumps was expensive and complex. Therefore, Itaminas chose Metso’s pumps with the goal of decreasing the company’s maintenance downtime and increasing production.

EXPELLER GLAND SEAL DECREASES MAINTENANCE | Experts from Metso installed the Orion HM series pumps fitted with an expeller gland seal, which operates without the use of gland sealing water. This pump is also fitted with high chrome wet-end spare parts, which are highly recommended when pumping very abrasive slurry material.

“Maintenance is much simpler and less frequent now,” says Esley Cardoso, Itaminas’s operational supervisor. “The tailings pumping system has been working for more than two years now without any failures.”

75% LESS MAINTENANCE; WATER SAVINGS UP | After the installation of the Orion HM series pumps, Itaminas has been able to reduce maintenance of the pumps by 75%. Plus, since the implementation of the Metso expeller gland sealing technology, the mine is saving over 6 billion liters of water.

“As water availability is extremely scarce at the mine, by being able to eliminate the use of gland sealing water, the mine has greatly reduced its costs thanks to the new technology,” explains Guilherme Almeida, Metso Technical Support.

To improve customer service and guarantee the shortest possible shutdown times, Metso also provided a consignment of stock parts and components to Itaminas. “They only pay for the parts they use. With the maintenance workload reduced, Itaminas can direct the team members to other tasks,” mentions André Rizzotti, Metso Sales Engineer.

RESULTS

After the installation of the Orion HM series pumps, Itaminas has been able to reduce maintenance costs by 75%. Plus, the expeller gland sealing arrangement is allowing the mine to save significant amounts of water.

FIGURE METSO X CONVENTIONAL PUMP COMPARISON

STOCK PROGRAM REDUCES UNPLANNED DOWNTIME | The stock program involves a monthly stock evaluation and unit count. Monitoring and suggestions for improvements from the Metso experts help Itaminas to secure flawless operations.

Metso uses its knowledge and experience from other similar types of installations to give recommendations that can help make a difference for Itaminas. Not only has this arrangement reduced costs for the mine, it has additionally provided the company with immediate access to parts whenever needed. This reduces unplanned downtime and ultimately leads to maximized production.

In total, Itaminas has installed over 70 Metso pumps at its mine, making it one of Metso’s largest installed bases in Brazil.

MORE INFORMATION:Audrei MoronTel.: +55 15 2102 1379E-mail: [email protected]



ASSEMBLY IN HOURS

WEAR COMPONENT LIFETIME IN MONTHS

Metso Another supplier

109876543210

Metso Another supplier

1

4

9

3

The performance from withinA refinery in South America was approaching its scheduled maintenance shutdown, which is carried out every three years of plant operation. According to the original plan, the refinery aimed to overhaul all the critical emergency valves in the plant. This entails organizing cranes, preparing the logistics to transport the valves to the supplier’s facility, changing all the valves’ wear parts, and finally putting them back into operation. This time, however, the refinery decided to think twice before going forward with the plan.

HE FACILITY’S HIGH RELIABILITY targets required that every emergency shutdown (ESD) valve must be operated with an intelligent solenoid valve, which could implement partial stroke testing (PST) on a regular basis to identify any degradation

in such critical emergency valves. For this shutdown, the refinery decided to take full advantage of the performance information that these intelligent valves could provide.

An analysis of all the performance information in advance of the maintenance shutdown showed that 40% of the valves were developing a performance problem. Yet 60% of the critical valves were still operating at the same performance level as at the beginning of their lifecycle. Based on this information, the refinery decided to carry out full maintenance activities only for those valves that indicated lower performance. The rest of the valves were just double checked to confirm that they did not show signs of any wear that would cause risk to their performance. This approach paid off: the refinery was able to reduce maintenance costs by 58% from its original method. Shutdown time was also secured, which led to

“The information that the valves could provide helped the refinery move forward with a much smarter way of analyzing, learning and improving its processes.”

INTELLIGENT SOLENOID VALVES

TEXT: Juha Yli-PetäysIMAGES: Metso and Shutterstock

Timproved safety since the amount of maintenance work decreased. This example provides an accurate depiction of the capabilities and benefits that an intelligent solenoid valve can provide for its end users.

INFORMATION LEADS TO KNOWLEDGE | Some people argue that knowledge can be a pain. When operational personnel are aware of a critical failure, as described in the example above, they are placed in a difficult position. They may become overly concerned with thinking about how to act when a critical safety valve is not operating properly. How can they arrange for such quick maintenance actions?


» Intelligent innovation

Moreover, it was very valuable for the operators to get a better understanding of which valves were still operating as they had been since the very start of operation.

Thanks to the diagnostics information, it was possible to save considerably more time and money by not fully maintaining all of the valves, as well as to plan more carefully the maintenance needed for the 40% requiring full maintenance at an earlier phase. The information also gave the operators the capability to analyze the reason for the deteriorating performance in those valves. This enabled them to lean more about the specific application requirement, which undoubtedly leads to higher reliability and better process performance when the causes can be determined.

Valve vendors can be of tremendous help to the end user when performing such analysis work. Typically, they can help analyze if there is any room to further improve the selection and sizing of the valve. Additionally, they can call on their broad experience from other similar valve applications. Such in-depth application knowledge can make a big difference when selecting the most appropriate valves for critical tasks.

INTELLIGENT SOLENOID VALVE ANALYZES ESD VALVE PERFORMANCE | An intelligent solenoid valve is a product specially designed to close the ESD valve in case of a safety demand. A third-party certification body certifies the intelligent solenoid valve for operation in particular applications. Typically, the valves have reliability figures that allow them to be operated in Safety Integrity Level (SIL) 3 applications.

In addition to its main function of implementing the safety action, an intelligent solenoid valve is capable of analyzing the performance of an ESD valve. This is thanks to all the necessary electronics and microprocessors that have been built into it in order to be able to perform the PST. Therefore, the intelligent solenoid valve can use this test to identify if the ESD valve’s performance has changed over its lifetime.

Using the PST, a valve is stroked only partially so it can move to a specific opening angle, such as 20%. After reaching this opening angle, the valve returns to its original position. When a

What if this failure jeopardizes the entire plant’s operations?

Others, however, believe that information leads to knowledge, knowledge leads to understanding, and understanding leads to wisdom. Even if information received from an intelligent solenoid valve is not positive, it is the first crucial step needed to enable more reliable and safe operation in any plant.

In this particular case, it would have been very time consuming and costly to remove all of the plant’s critical emergency valves, as had always been the approach in

the past. By carrying out full maintenance on the 40% of the valves experiencing performance degradation, the plant could ensure reliability and safety, plus return to normal operation quicker than if all of the valves had been overhauled. By using the

information prior to shutdown, the entire process could be planned and carried out much more efficiently.

The operating personnel also responded very proactively by choosing to re-evaluate their normal procedures of overhauling all of the valves. The information that the valves could provide helped the refinery move forward with a much smarter way of analyzing, learning and improving its processes. In the end, it makes better business sense to know and react to specific problems rather than remain ignorant of them.

USING INFORMATION PROACTIVELY | With the diagnostics provided by the intelligent solenoid valve, the plant operators were able to identify the valves experiencing problems earlier than without such a performance test.

“The intelligent solenoid valve is an integrated solution that fulfills end user needs, while simultaneously simplifying installation. This leads to higher reliability, safety and cost efficiency.”

An intelligent solenoid valve (above) significantly simplifies installation when it carries out the safety action and performance testing. The simplified installation results in greater benefits when it comes to reliability, safety and lower total installation costs. Positioner (PST) and solenoid valve (below).

FIGURE 1 The simplified installation

HART Safety demand

Safety demand+ HART

Neles ValvGuard

Air supply

CLOSE

Air supply

Solenoid valve

Positioner

CLOSE S



when it comes to ESD valve control.Even though it is generally believed

that diagnostics do not provide many benefits to an EPC, this is not the complete truth. Diagnostics can help identify possible problems throughout the commissioning phase. That in itself is highly appreciated by EPCs when working towards a fast process plant startup.

MORE INFORMATION: Juha Yli-PetäysTel.: +358 40 777 0737E-mail: [email protected] Janne LaaksonenTel.: +358 40 500 9105E-mail: [email protected]

Originally published in Hydrocarbon Engineering magazine, December 2015 issue.

valve is only moved partially, the PST can be carried out without disturbing the process. Still, the stroke is sufficient enough to identify any performance deviations over the lifetime of the valve. Typical problems that can be identified with PST include valve sticking, valve or actuator corrosion, soft material cold flow, pneumatic leakages, solenoid valve problems, and many more.

The intelligent solenoid valve is an integrated solution that fulfills end user needs, while simultaneously simplifying installation. This leads to higher reliability, safety and cost efficiency (Figure 1).

HIGHER RELIABILITY AND SAFETY WITH SIMPLIFIED INSTALLATION | An intelligent solenoid valve can offer greater benefits to an end user as well as an EPC contractor. From an end user’s point of view, the main benefit is simplified installation, which leads to higher reliability and safety since additional components from the ESD valve can be eliminated.

When safety action, PST implementation, high pneumatic capacity and limit switches are added into the same package, the integrated solution provides extensive, but also extremely simple, installation for the critical control of the ESD valve. It is good to keep in mind that these benefits target both reliability and safety. Other advantages can also be gained when using the diagnostic information, so that predictive maintenance activities can be used.

Earlier studies have estimated that a properly functioning predictive maintenance program can provide savings of 30 - 40% compared to a program that uses reactive and preventive maintenance alone. Customer feedback has proved that running scheduled maintenance shutdowns with the help of predictive maintenance information can cut valve-related maintenance costs by up to half in the best cases. In addition, and perhaps even more importantly, the preliminary preparation of maintenance actions can ensure that the

schedule is kept as planned to eliminate any risk of losing valuable production time.

LOWER EPC CAPITAL INVESTMENT COSTS | From an EPC contractor’s point of view, the main benefits come from the capital investment. The installation alone simplifies the whole case considerably. The number of pneumatic components used is reduced to provide a lower cost solution for the EPC.

Furthermore, when considering an integrated solution where the solenoid valve and PST functionality are in the same package, the DCS/safety system I/0 number can be cut by half. I/0 card cost is one thing. But space is money. An intelligent solenoid valve provides a solution where the space can be optimised and the I/0 card amount is reduced to half

FIGURE 2 Information is the first step in gaining knowledge.

An intelligent solenoid valve can identify and visualize the performance of an ESD valve in an easily understandable way, as shown in this example from the Neles ValvGuard intelligent solenoid valve.

Go with the flow! Check out our renewed expert blog at: metso.com/GoWithTheFlow

Blog



Discover the latest Metso Flow Control news stories from around the world

Metso selected as main supplier of valve solutions for next-generation bioproduct mill

ETSO HAS SIGNED a comprehensive framework agreement with Metsä Fibre to supply valve solutions for the world’s

first next-generation bioproduct mill in Äänekoski, Finland. Metso’s valve solutions will be used in all of the mill’s process phases. The delivery includes more than one thousand valves and peripheral devices and is one of Metso’s largest valve orders in Finland. Metso also takes care of the spare part services for the mill. The bioproduct mill will start its operations in the third quarter of 2017.

“We are very pleased that Metsä Fibre trusts our valve expertise. The design of the

bioproduct mill puts special emphasis on minimized emissions, low specific water consumption, and high energy and material efficiency, among other things. The availability and efficiency of the production processes can be maximized by utilizing optimally

selected, reliable valve solutions,” says Mika Sjöholm, Vice President, Pulp and Paper business line, Metso.

Metso will supply the plant with Neles ball valves, segment and butterfly valves for on-off

and control applications and Neldisc butterfly valves for manual on-off duty. The control valves are equipped with Neles ND9000 series intelligent valve controllers, which have the capability for advanced performance follow-up and also enable predictive maintenance

planning activities. Metso also aims to ensure the correct timing of future maintenance needs of the mill’s valve installations by utilizing digital valve controller properties and product information management.

M“We are very pleased that Metsä Fibre trusts our valve expertise. The design of the bioproduct mill puts special emphasis on minimized emissions, low specific water consumption, and high energy and material efficiency, among other things.

PHOTO: MetsäFibre

METSÄ FIBRE, ÄÄNEKOSKI, FINLAND


» News

Strong valve expertise utilized in boxboard machine conversion

Metso opens new valve service centers in Sweden and Poland.

The 1,700 square meter facility comprises a valve service center, Metso sales office and training facilities. The center is ideally located in the Gothenburg area close to the pulp & paper and oil & gas customers on the west coast of Sweden. It will also play a key role in supporting Södra Cell’s Värö pulp mill expansion project.

Metso is responding to the growing demand for local valve expertise close to its customers by opening a service center in the city of Torun. Services are provided for Metso and third-party field devices, including valves, actuators and smart devices. In addition, the new center provides spare parts as well as a wide range of field support and diagnostic services. The center is ideally located close to pulp and paper, refinery and petrochemicals customers in the Central and Eastern European region.

Strengthening valve services network

ETSO IS SUPPLYING hundreds of valves to a mill in Kotka, Finland, where the current printing paper machine is being rebuilt to produce high-quality and environmentally friendly consumer board grades. The order includes Neles ball control valves, segment

valves, and Neldisc disc valves for shut-off and control applications. The control valves are equipped with ND9000 series intelligent valve controllers. The new line will be commissioned in the second quarter of 2016.

“Metso has unique knowledge and expertise in pulp and paper industry valves. Our requirements for the valves used in the machine conversion specifically target the reliability of the valves and the efficiency of the production process. The production line conversion timetable is short, so proven project know-how and good experience were important criteria for us when we selected the valve supplier,” notes Jari Mäkelä, who is in charge of the machine conversion automation and electrification at Kotkamills.

PHOTO: KotkaMills

METSO SERVICE CENTERS, SWEDEN AND POLAND

TORUN, POLAND

M

Timo Hänninen, Vice President, Service business line, and Tom Adolfsson, Head of Sales & Service, Sweden, launching the new Metso service center in Gothenburg, Sweden.

GOTHENBURG, SWEDEN


» News

KOTKAMILLS, KOTKA, FINLAND

Control valves engineered to optimize uptime and lower your costs.

That’s how we make the big difference, the Metso Way.

There is a place where the process always flows. Where efficiency reigns. Where safety is supreme. And where costs are always lower. That place is called uptime. Metso makes it possible with control valve solutions that have been field proven to outperform competitive products. And then we back them with a wide range of expert services.

Discover more at metso.com/valves.

#TheMetsoWay

Neles® NDX valve controllerdelivers performance perfected

That’s how we make the big difference, the Metso Way.

The Neles NDX has been carefully designed and manufactured to make the big difference to our customers, regardless of end use industry or application. Savings are created through accurate, long-lasting and maintenance-free performance and through time saved as a result of extremely easy installation and use. The Neles NDX provides the reliability and robustness you’d expect from a valve controller by Metso, for all valve brands in standard applications.

Find out more about the savings, safety and reliability that each Neles NDX valve controller offers at metso.com/ndx.

#TheMetsoWay

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