Tales from process control's front line.

The Honeywell 2005 Users Group Symposium, held in Phoenix June 12-16, featured a wide array of presenters from several industry groups. The following excerpts summarize some of the key messages from the pulp and paper portion of the Honeywell Users Group.

Process control IT security, by Kerry Sartain and A.J. Price, Georgia-Pacific Corp.

Process control networks are being exposed to previously unheard of problems, such as malicious users, outside espionage, untrained technicians, "Trojan horses," viruses, inadvertent disruptions, companywide policies, simple computer "glitches," and continuous code changes. To confront these challenges head-on, Georgia-Pacific began devising a blueprint to incorporate secure process control segments that are attached to the business networks, but offer a safe and secure environment in which to operate process control networks.

Kerry Sartain of Georgia Pacific noted that G-P is moving to centrally manage its business IT networks, using dedicated servers and applications such as virus control. While its manufacturing IT networks have traditionally been operated independently by each manufacturing site, the company recognized that common security policies, procedures and infrastructure were needed as all of its sites become more open to electronic communication with the outside world.

G-P recognized that business networks are totally different than manufacturing networks, and that the two needed to be isolated. In cases where manufacturing IT networks were overlaid on business networks, they were much more prone to security problems. The company has developed new standalone manufacturing IT networks with separate routers, hubs, etc, and these networks are secure behind separate firewalls.

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How does the company determine what is a manufacturing device and what is a business device? "If the mill can run for four hours without it, it is a business device," said A.J. Price. The manufacturing network does not include Internet access, email, or anything else that communicates with the outside world.

As a result, the solution implemented by G-P included:

* Physical process control segmentation (independent networks for process control and business, including separate interface from routers and multi-tiered security zones)

* Logical process control segmentation

* Secure traffic chokepoints (including firewalls with virus wall protection and intrusion detection as well as custom traffic analysis)

* Process Control Services Center (a dedicated group to handle manufacturing IT needs)

* Secure remote access for vendors and home based users (including network address translation, secure VPN access, and terminal services)

* Business side terminal servers (with secure remote access and internal access)

* Rules for network use and access policies

The benefits of the system for process control include:

* Increased control and visibility of communications

* Standardized platform for data acquisition

* Nearly unlimited room for expansion

* Flexibility for vendor requirements

* Systems are not subject to forced reboots and network penetration

Continuous process improvement: From Devronizer to DaVinci, by Terry Miller, SCA Tissue North America 

A Devronizer steam shower was installed on the #11 tissue machine at SCA Tissue, South Glens Falls, New York in 2000 to improve product quality and increase production. The Devronizer's impact was immediately evident, with production increases of almost 10% on most grades. In addition to the increased machine production, the Devronizer was also able to reduce cross direction moisture variability in the sheet. In 2003, a Honeywell DaVinci OCS system was installed on the #11 tissue machine to further enhance the Devronizer's performance and to improve overall machine direction control. The machine set production and quality records after the DaVinci was installed. The DaVinci has also enabled continuous process improvements through its analysis tools and controls.

Digester upgrade depends on collaboration, by Mark Caraway, Smurfit-Stone Container Corp.

By 2003, the continuous digester at Smurfit-Stone Container's Hodge, Louisiana mill needed an upgrade. The control software, almost 20 years old, lacked the sophisticated controls of today's finely-tuned systems. Indeed, it was difficult to control plug movement, chip level and Kappa number. Due to the software's limitations, operators tended to run the controls on manual most of the time.

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Honeywell emerged as the choice to upgrade the digester controls. Its project manager not only understood the mill's requirements of keeping the mill running during the upgrade, but also understood the pulp making process.

Statistical process-based controls were used to improve the mill's throughput, quality, and efficiency. In managing the conversion from Measurex Vision to Honeywell TPS (Total Plant Solutions) Advanced Continuous Digester Solution, Honeywell's project manager included engineering, operations, and maintenance staff in the system's planning, design, and testing stages. The mill selected a single representative for the operators to provide consistent input to the project.

One of the key measures of success, said Caraway, was that the operators use the new system on automatic and are reluctant to shut it down for maintenance. Supervisors trust the system and tell operators to keep it on. In addition, throughput has increased, quality has improved, and basic operating costs have dropped.

The mill and Honeywell ensured the participation of key operators in designing and implementing the system. "We chose an area operator with responsibility over both digesters and brown stock washers to spend two weeks working on the new system, with one week in developing regulatory controls, and one week in reviewing the detailed functional specifications," said Caraway.

The new system was presented to the operating staff with minimal mathematical and technical jargon. It was ratified by process, operations and controls people prior to any detailed engineering. As a result, the system was not only accepted but is used effectively by operators, said Caraway.

Information Technology and process control: How to work together to achieve manufacturing excellence, by Ole Fadum, consultant

Computing technologies used in manufacturing execution systems (MES), RPM, quality control systems (QCS) and distributed control systems (DCS) are converging in a common platform. This is true for computers, communications, and data bases. Design, manufacturing and support of systems require the same skill sets and the same set of tools, which is a major benefit to suppliers and users. The barrier to entry in a given market has been lowered, allowing suppliers to offer a wide set of systems. Users are able to support information technologies (IT) and process control technologies with the same people.

While technologies are converging, the users' needs are diverging. Applications are implemented to meet the diverse needs of users and are becoming increasingly complex. Competitive advantage comes from identifying world class business and manufacturing processes and then executing these processes consistently. As a result, the focus is shifting away from technologies to applications.

Using Honeywell's optimization service Process Knowledge Toolkit (PKT) to improve paper process control, Alain Fortier, Domtar Windsor

This paper reported the results of beta testing Honeywell's Process Knowledge Toolkit (PKT) at Domtar's papermaking facility in Windsor, Quebec, Canada. The Windsor, Quebec plant produces uncoated freesheet papers: photocopy paper, magnetic ink character recognition (MICR) forms, bond and computer paper, envelope paper, offset printing paper, and bleached wet-lap pulp. The facility has two paper machines, one wet-lap machine, and three sheeters with an annual paper production capacity of 570,000 tons.

The tests concentrated on PKT's Quality Servers, specifically for grade change tracking, CD control analysis, spectral/signature analysis. During the beta tests the mill achieved a 15.8% reduction of grade change time and $50k savings based on 120 Grade Changes per year. Benefits for CD control analysis included the ability to track control-reaction performance, spot actuator problems, and rapidly evaluate recovery times. The system improved spectral/signature analysis by allowing the mill to easily track and analyze CDs and MD directly on the PKT Server and produce reports by exporting the data in Excel format.

Domtar found that PKT helped improve the process through enhanced performance reporting, gauges health tracking, and on-the-spot data extraction. After the seeing the benefits it derived with PKT, the mill decided to continue to use it after the beta testing phase.

ALAN ROOKS, EDITORIAL DIRECTOR

IN THIS ARTICLE YOU WILL LEARN:

* How G-P upgraded process control and IT security.

* Why a digester control upgrade project was successful.

* Details on several other process control projects.

ADDITIONAL INFORMATION

* www.honeywell.com.