ANDRITZ Optimization of Process Performance (OPP) is a service contract that has been proven to improve the performance of a variety of production systems. It is part of Metris – Industrial IoT Solutions.
OPP is a risk-free investment with guaranteed results
ANDRITZ OPP is based on continuous developments in the three main Metris technologies – Smart Sensors, Big Data and Augmented Reality – and improves production systems by analyzing a huge amount of data collected throughout the systems. Under the basic pricing model, charges are only incurred once concrete savings have been realised. OPP has helped clients worldwide save millions, with pulp mills, steel mills and chemical plants among the industries that have reaped proven benefits in weeks rather than years.
How does OPP work?
The analytical software collects information from systems about each control loop, control valve, motor, and variables in the process. Sophisticated signal processing and statistical tools in the software identify loops that are not performing optimally and predict the economic impact on the process. Then, the human expertise takes over. ANDRITZ experts work with your operations and maintenance people to prioritize the opportunities and make corrections. For some loops, it can be a simple fix like repairing a valve. Others require analyzing the overall control objective and changing the process control strategy to eliminate off-spec production, overconsumption of chemicals and energy or sources of process variability. The result is an increase operational stability and reduction of waste.
Who benefits from OPP?
Tools such as the dashboard allow managers to gain a clear overview and access KPIs, balanced scorecards and project management tools.
Engineers can draw on OPP’s powerful data analytics tools such as data mining, statistics and power spectral density to quickly implement any efficiency modifications. The Notifier alerts operators about process deviations that require fast action, while the Data Historian tool acquires and stores big data and presents it in a way that you can immediately see what you need.
OPP is an especially powerful aid for operators and shift supervisors, for example with the Logbook. This stores user data that can be used to enhance daily operations, find solutions for recurring problems, or train new operators. Smart controls and operator assistance facilitate an array of start-up sequences, diagnostics and root cause analyses, as well as adaptive set-points, multivariable predictive controls and neural networks. Regulatory control functions include control loop tuning and assessment, as well as dead-time compensators and feed-forward options.
Field operators and maintenance technicians can perform more effectively with on-hand augmented reality support. Real-time data and diagnostics coupled with remote support allow improvements to be implemented as and when they are needed. OPP also has functions that allow a valve or motor to be adjusted or replaced before it has had any significant negative impact on production.
Benefits of ANDRITZ OPP at a glance
- Identifies opportunities for savings and efficiency enhancement
- Powerful signal processing and statistical analysis of control effectiveness
- Reduces off-spec product or wasted raw materials
- Increases production by enhancing process stability
- Better quality end product – less variation
- Predicts failure in specific equipment and increases equipment availability
- No capital investment required; flexible payment can be based on savings achieved
- Field proven model in many contracts in different countries
- Knowledge database continuously incremented
- Continuous R&D