May 2011System Integration & Control Systems Design
Mondi Syktyvkar is one of the largest producers in the Russian pulp and paper industry with one board machine and three paper machines. The mill also comprises a wood yard, two fibre lines, a power plant and a complex of effluent treatment facilities. The STEP project, started in 2008, involved new wood-handling facilities, a recovery boiler, turbine and white liquor process, as well as upgrades to the two chemical pulp lines and rebuilds of the PM14 uncoated wood-free paper machine and the PM21 container board machine.
Recently completed, the project is the largest mill modernisation in the Russian pulp and paper industry in the last three decades. Metso was the supplier for the major part of the automation systems to the mill and was also selected to be the main supplier of valves, delivering more than 1400 control and automated on/off valves and almost 5500 versions.
The main targets for the mill were to replace obsolete technologies, enhance safety, employ additional environmental measures and increase the plants’ overall quality and competitiveness. Metso’s automation delivery included new control systems for both the hardwood and softwood digesters and the new white liquor production area and lime kiln. Systems for both fibre lines were also upgraded and expanded, as were the control systems for PM14 and PM21.
Part of the delivery included Metso’s device and asset management solution DNAFieldAssessor, which allows continuous monitoring of valve performance with remote access to diagnostics and configuration. The mill had already been a user of Metso FieldCare, a standalone version to monitor the valves.
The installation and start-up of the various systems and upgrades by Metso were completed in various phases during the two-year project. In addition to the metsoDNA control systems, the delivery included project management and engineering services, both factory and site testing, installation supervision and start-up assistance. The metsoDNA systems represent the latest in control technology with Profibus DP motor controls and DNAfieldAssessor field device management for intelligent field device configuration. Integrated HIMA safety related systems were also included for the three digesters as well as the oxygen and bleaching stages in the hardwood line.
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