implementation of rlink-pppi at a pulp
mill
Klabin Group

Klabin group is the
largest paper
manufacturer and the
second largest pulp
manufacturer in Brazil, as
well as leading 10 out of
the 11 markets for
packaging and tissue
paper items in which it is
active.
© Cybertécnica 2002 / Flávio Maeda
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location of klabin’s sites
© Cybertécnica 2002 / Flávio Maeda
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klabin bacell

Klabin Bacell, located in Camaçari, State of
Bahia, produces dissolving pulp used
primarily in the textile filaments, acetate
grade and food industry.
© Cybertécnica 2002 / Flávio Maeda
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the plant

the plant is one of the world's
most modern bleach dissolving
pulp plants which works with
modern technology alternatives
and high automation degree in its
process control, managed by an
ISO 9002 certified Quality System.
It is the first industrial unit in its
category to produce prehydrolysis Kraft Dissolving Pulp
through TCF system (Total
Chlorine Free), which is by itself
one of the most significant
evidences of its environmental
performance.
© Cybertécnica 2002 / Flávio Maeda
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SAP/R3 at Klabin context

Almost all sites of Klabin in Brazil run
SAP/R3;
© Cybertécnica 2002 / Flávio Maeda
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The RLINK project at Klabin Bacell




Bacell was the first Klabin mill where PI System
was installed ( PI 2 System in 1995);
The implementation of SAP/R3 4.6c at Bacell
started in March, 2001 and the go-live happened
on December 1st;
RLINK PPPI implementation at Bacell started
three months later ( June );
Project Team:
• Maria Helena Del Grande (Project manager - Klabin
Bacell)
• Adroaldo Munhoz (Team Leader - Cybertecnica)
• Flavio Maeda (Analyst - Cybertecnica)
© Cybertécnica 2002 / Flávio Maeda
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RLINK Cybertecnica’s expertise



Both Adroaldo and Flavio attended the
RLINK class at OSI office in Germany;
The whole implementation of RLINK at
Klabin Bacell;
Complementation of the RLINK solution at
CSN with standard PI monitoring tools (PIPB and VBA).
© Cybertécnica 2002 / Flávio Maeda
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project overview

RLINK PPPI project was divided in two major
parts:
• migration from PI 2 system to PI 3.3 system
running in a W2K machine;
• implementation of RLINK PPPI (WNT machine).
© Cybertécnica 2002 / Flávio Maeda
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original pi system configuration
PI-HOME
V2.2 OVMS 7.1
SICP
PI
RDB
Ethernet TCP/IP
Dec-Alpha-OVMS
P IPI-API-OVMS
- API - OVMS V2.2
NT 4.0
PI
PI- APIOVMS
- NTI V 1.3
PI-IN-FI-CHIP-AXP
PI-IN-YO-CPLUS
:
Client applications
•PI-ProcessBook
•PI-DataLink
PI-IN-OS-RELDB-NT
PI-IN-FI-CHIP-AXP
CENTAP
YOKOGAWA
(DCS)
SCALES
SCALES
© Cybertécnica 2002 / Flávio Maeda
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actual pi configuration
PI-HOME
V3.3
Windows 2000
RLINK - PPPI
PI
MSQL
Ethernet TCP/IP
Dec-Alpha-OVMS
PI-API-OVMS V2.3
:
Client applications
•PI-ProcessBook
•PI-DataLink
•PI ManualLogger
PI-IN-FI-CHIP-AXP
PI-IN-YO-CPLUS
CENTAP
YOKOGAWA
(DCS)
© Cybertécnica 2002 / Flávio Maeda
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project environment
SAP R/3
Production
environment
PRD
DEV
DB
DB
Test environment
TCP / IP
RLINK 1.4
PI Server 3.3
RLINK 1.4
PI API
PI e RLINK
• Win-NT 4 sp6
• SQL Server v7
• SAP GUI
RLINK
• Win-NT 4 sp6
• SQL Server 7.0
• SAP GUI
YOKOGAWA
(DCS)
© Cybertécnica 2002 / Flávio Maeda
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Registry configuration
Registry Key
PI_INFO
Parameter
PI_INIFILEWITHPATH
PI_PASSWORD
PI_USERNAME
PLANT_SUITE_INFO DBNAME
PASSWORD
SERVERNAME
USERNAME
SAP_INFO
CLIENT
DESTINATION
LANGUAGE
PASSWORD
SERVER_DEST
TCRDPATH
TCRPPATH
USERNAME
SAP Service
SAP Host
PROGRAM ID
© Cybertécnica 2002 / Flávio Maeda
Value
C:\PIPC\DAT\PILOGIN.INI
piadmin
plant_suite
KBSRV05
rlink
900
OSISOFT
PT
OSI_2
C:\RLINK\PPPI\CLIENT\FE
C:\RLINK\PPPI\CLIENT\FE
KBRLINK
sapgw00
10.0.0.174
KBSRV05.tcrd.exe
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integration: plant floor - erp
ERP - SAP R/3
PP-PI
PM
Client
applications
MM
QM
Plant Suite -Server
R/3 Link
PROCESSO
DCS
PI System
Manual Entry
Packaging area
discrete process
MS-SQL
Scales
Pulp production area - continuous process
© Cybertécnica 2002 / Flávio Maeda
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data flow diagram
ERP - SAP R/3
PP-PI
Instructions
Messages
•Process order status
•Process order info.
Plant Suite -Server
RLink
•Process Order Info.
(manual entry)
Campaign
Manager
•Qty of wood
consumed in a
process order
SRM
Wood receiving
and preparation
•Manual production
reporting
•activity info
•production
•consumptions
•activities
•status
•status
•production
reporting
•activities
•batch
characteristics
MS-SQL
PI System
•Process info.
•process
information
DCS
Pulp production plant
© Cybertécnica 2002 / Flávio Maeda
•Dry rate
•consumptions
•activities
•discrete
production
information
Scales
Packaging line
- bales
- reels
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pulp production stages
Continuous process
Discrete process
PMADE
wood
raw materials
Wood
Preparation
liquid effluents
Bits of wood
PMARR
raw materials
water
unbleached pulp
water
raw materials
SBOBI
Reels
PBRAN
Delignification /
bleaching
Black liquor
raw materials
steam
cooking
Bleached
pulp
RECUP
Drying
SFARD
Bales
Recuperation
White liquor
© Cybertécnica 2002 / Flávio Maeda
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Resource networks

Continuous process
•
•
•
•

PMADE
PMARR
PBRAN
RECUP
- wood preparation
- unbleached pulp production
- bleached pulp production
- recuperation phase
Discrete process
• SFARD
• SBOB
- packaging of the final product
into bales
- packaging of the final product
into reels
However all sub-plants are of type BPI (PI-Batch Plant)
© Cybertécnica 2002 / Flávio Maeda
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Activities and materials - PMADE
ELAPSED TIME
0,856
ORG_COZ
INO_COZ
RESOURCE
RESOURCE ID
MATERIAL
WOOD
MATERIAL1
MATERIAL2
MATERIAL3
MATERIAL4
ENERGY
INDUSTRIAL WATER
© Cybertécnica 2002 / Flávio Maeda
EFLORG
EFLINO
ACTIVITY1
ACTIVITY2
ACTIVITY3
ACTIVITY4
ACTIVITY5
ACTIVITY6
0,5
0,1
0,2
0,15
0,23
0,31
0,07
0,23
0,8
0,019
0,477
0,252
0,252
14,133
0,505
MIN
M3
M3
MIN
MIN
MIN
MIN
MIN
MIN
TAS
XY
XX
ZZ
XY
KWH
M3
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production reporting -data flow
SAP/R3
PI_PROD ; PI_CONS ; PI_PHACT ; PI_PHST ; PI_CRST
RLINK
PI System
Quantity of energy and water
consumed
in the PO
PINet Node
...
Campaign
Manager
DCS
quantity of each type
of wood consumed in
the P.O.
PI-ProcessBook
ODBC
SRM
© Cybertécnica 2002 / Flávio Maeda
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material tag and common name
tables - PMADE
material_id
INDUSTRIAL WATER
CAV_RECEITA_1
CAV_RECEITA_2
CAV_RECEITA_3
CAV_RECEITA_4
CAV_RECEITA_5
ENERGY
WOOD
MATERIAL1
MATERIAL2
MATERIAL3
MATERIAL4
MATERIAL5
MATERIAL6
resource_id
PICADOR
PICADOR
PICADOR
PICADOR
PICADOR
PICADOR
PICADOR
PICADOR
PICADOR
PICADOR
PICADOR
PICADOR
PICADOR
PICADOR
resource_id Common_name
INO_CAV
ORG_CAV
PICADOR
PICADOR
PICADOR
PICADOR
PICADOR
PICADOR
SAP_EI
SAP_EO
SAP_02
SAP_03
SAP_61
SAP_62
SAP_64
SAP_DP
quantity_tag_id
100AGUACONS.CALC
102CAVACO.MI
102CAVACO.MI
102CAVACO.MI
102CAVACO.MI
102CAVACO.MI
100ENERCAV.CALC
101WOOD_TAG.MI
101MATERIAL_TAG1.MI
101MATERIAL_TAG2.MI
101MATERIAL_TAG3.MI
101MATERIAL_TAG4.MI
101MATERIAL_TAG5.MI
101MATERIAL_TAG6.MI
batch_tag_id
C
P
P
P
P
P
C
C
C
C
C
C
C
C
misc_tag1
102STORAGE_LOCATION.MI
102STORAGE_LOCATION.MI
102STORAGE_LOCATION.MI
102STORAGE_LOCATION.MI
102STORAGE_LOCATION.MI
101BATCHID_TAG.MI
101BATCHID_TAG1.MI
101BATCHID_TAG2.MI
101BATCHID_TAG3.MI
101BATCHID_TAG4.MI
101BATCHID_TAG5.MI
101BATCHID_TAG6.MI
tag_id
100EFLINORG.CALC
100EFLORG.CALC
100MAQHCAV.TOT
100HHCAV.TOT
100DIFCAV.TOT
100OUTVARCAV.TOT
100MAPCAV.TOT
100DEPRECAV.TOT
© Cybertécnica 2002 / Flávio Maeda
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activities for wood preparation






Organic liquid effluent
Inorganic liquid effluent
Machine working hours - direct costing
Machine working hours - indirect costing
Man working hours - direct costing
Depreciation
© Cybertécnica 2002 / Flávio Maeda
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campaign manager
© Cybertécnica 2002 / Flávio Maeda
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campaign manager is used...

to view general information of all recipes
available in rlink for the specific resource
network:
•
•
•
•
•
process order id;
control recipe id;
control recipe status in rlink;
material produced / planned quantity;
total produced and remaining quantity;
© Cybertécnica 2002 / Flávio Maeda
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campaign manager is used...

to view further information about the bill of
material of each Control Recipe:
• material id;
• description;
• quantity programmed to be consumed /
produced;
• total quantity already reported to SAP;
• last quantity reported of each material
(PI_CONS and PI_PROD);
• timestamp of the last production report
(partial finish);
© Cybertécnica 2002 / Flávio Maeda
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campaign manager is used...

to change the control recipe status:
To finish the process order
To partially finish the process order reporting production to SAP
To interrupt the process order in progress
To start the control recipe when there is no other process order in progress
© Cybertécnica 2002 / Flávio Maeda
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manual input screen
the manual input box is automatically opened only when there are materials that
need manual reports of production (all information associated with .MI
tags in material_tag and common_name tables)
All the values are validated using the zero and span
of each .MI tag before sending to PI
SEND TO PI
Current Time
Timestamo of either the last production report or the start time
of the control recipe
Bacth id sent to SAP with the PI_CONS
Wood consumption in this process order for this period of time
Produced material
Storage location
© Cybertécnica 2002 / Flávio Maeda
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control recipe status changings
process order current status
first production reported to SAP (partial finish)
timestamp when the process order was started in RLINK
© Cybertécnica 2002 / Flávio Maeda
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discrete process - packaging area


after the production of the Bleached Pulp
this material (HALB) is available for the
next phase of the process: the drying
phase;
after the bleached pulp has been dried it
needs to be prepared to be shipped to the
customer. The final product (FERT) can be
shipped into reels or bales. Each unit
shipped to the customer is called Bacell
lot;
© Cybertécnica 2002 / Flávio Maeda
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the interaction between RLINK
and the packaging line



The process control is performed by a
software that controls the packaging line. It
communicates with equipments situated in
the plant floor such as the scale and the
printer;
This application sends and receives data
from RLINK and PI;
The process information is continuously
sent to RLINK in background.
© Cybertécnica 2002 / Flávio Maeda
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the process flow
PI_PROD ; PI_CONS ; PI_PHACT ;
PI_BT_CR ; PI_BT_CL
PMU
SAP/R3
RLINK Plant_Suite Database
Download of
process orders
information
SRP
Upload of production information of each SAP Lot produced for the P.O by the end
of the bacell lot.
Each SAP Lot generate:
- 01 PI_PROD (corresponding to the lot’s dry
1. The process control software (SRP) start the production of a Lot.
weight);
2. Each SAP Lot produced is weighted by the scale;
- n PI_CONS (for each material - obtained from PI
3. When a Lot is closed, the PCS sends the information of each SAP Lot
tags);
directly to RLINK (using customized stored procedures)
- n PI_PHACT (for each activity - obtained from PI
tags);
- n PI_BT_CL (for each batch characteristic).
scale
This information is sent together to RLINK
From the available process orders
the operator chooses just
one to start
PI
© Cybertécnica 2002 / Flávio Maeda
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questions ??
© Cybertécnica 2002 / Flávio Maeda
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