Business Execution - Solution & Technologies (Best) offers its clients single-source solutions for fully integrated and advanced computer-based systems. Although Best supplies solutions to many industries, one of its focal markets is the pulp and paper industry.
In providing solutions and services to this industry continuously over the past decade, Best has accumulated considerable knowledge of the pulp and paper business, as well as experience in the technologies on products required to control and optimise the various plants. The company believes that adding real value to an enterprise can be achieved best by integrating all business support systems. As a single-solution entity, the company has no particular bias to any specific products but rather aims at offering proper intellectual solutions.
Best offers a comprehensive ambit of services (normally turnkey) to its clients in terms of process control, manufacturing execution systems and related services. These services include all those typically associated with such processes, as well as some of the more 'exotic', including modelling and simulation of realtime processes, neural networks logistics (supply chain) and business.
Best's mission is to help organisations derive real economic value from well-integrated automation solutions. Best uses intelligent and advanced technologies to automate, integrate and optimise all manufacturing, management and information processes so as to facilitate the accessibility of information for organisational decision-makers. This kind of approach offers particular support and benefits to those who are implementing Enterprise Resource Planning systems.
Besides providing general process control and MES solutions, Best has become a pioneer in the industrial no-man's-land of bridging the gaps between realtime systems and transactional-based systems. This domain has been under-developed as many of the systems in use are essentially modular in nature with immature communication abilities. By monitoring the status quo and projecting future trends, Best is continuously involved in the development and deployment of total package technologies to achieve full integration of organisational systems.
Best's approach pivots on four critical success factors:
* Good, lasting supplier and client relationships.
* Correct selection of appropriate technologies.
* Sound system infrastructure in terms of engineering designs and principles.
* Sound integration process for the human factor (management of change).
With South African offices located in Gauteng, Richards Bay and Durban, and international offices in Southampton as well as international alliances in Australia and Spain, Best is well positioned to provide knowledge-based solutions.
Best has extended the concept of system integration from the traditional role of SIs to cover the integration of various control environments, manufacturing execution systems and advanced manufacturing systems.
Best's involvement with the pulp and paper industry
Brown Fields Projects:
Based on the extensive experience Best has had in this field, a protocol called the 'BestMap Methodology' has been developed to minimise the relatively high risks that these types of projects can present. The methodology ensures the incorporation and alignment of all of the affected and involved parties and incorporates clear identification of objectives, team members, risk factors and risk amelioration measures.
1. Strategic upgrade of existing Honeywell TDC2000 systems throughout Sappi's Ngodwana mill.
Sappi's Ngodwana Mill at Nelspruit consists of two fibrelines. The existing control system was a Honeywell TDC2000, which will not be supported by Honeywell from 2003.
Best was involved from the start of this project and has assisted Sappi with the development of the strategy for the project as a whole. Subsequently, Best also executed the design and implementation of the replacement systems.
The project is ongoing and to date two very successful replacements have been achieved. These have taken place during scheduled mechanical shutdowns to ensure no impact on production. Benefits already identified include increased production, improved quality and incorporation of level 2 control solutions, which have improved system effectiveness and utilisation.
2. Automation of the entire fibre line at Sappi's Usutu mill using a Siemens PCS7 system.
The control of the fibre fine exit from the brown stock washing plant at Sappi's Usutu Mill in Swaziland consisted of panel-mount instruments. In an effort to improve plant operation and consistency, Sappi decided to automate these plants using a Siemens PCS7 system. Best designed and implemented the entire control system. Benefits include improved plant stability and increased production rates.
Green Fields Projects:
1. A new fine paper mill for Thai Paper in Thailand based on an ABB distributed control system.
Best was contracted to manage the DCS, instrumentation, electrical design and commissioning for the project, in addition to the implementation and commissioning of the DCS software for the paper machine.
2. New ozone bleach plant for Sappi's Ngodwana mill based on a Honeywell TDC3000.
As part of Sappi's ongoing initiative to make their processes more environmentally friendly, the chlorine-based bleaching process at the Ngodwana mill was replaced with an ozone process. The new process, designed by Andritz, required sophisticated controls and Best was contracted to design the base layer control strategies and to implement the control system. The new control system was implemented on a Honeywell TDC3000 system and required the integration of this system with ABB variable speed drive systems, Allen Bradley PLCs and Modicon PLCs.
Advanced control
1. Advanced control of Sappi Ngodwana's continuous kraft digester on Number 1 fibre line.
Along with the upgrade of the Number 1 fibre line at Sappi's Ngodwana Mill, Best was awarded the contract to do the advanced control for the continuous kraft digester. The new advanced control was implemented on a Honeywell TDC3000 system and replaced the ABB Accuray system.
As the proprietary ABB technology was not made available, the advanced control schemes were engineered from first principles. Benefits included better kappa number control and improved consistency in final product quality control.
2. Ongoing study, co-sponsored by Sappi's Saiccor Mill at the University of Pretoria, aimed at developing an advanced control system for multiple batch digesters.
Historically, control of the chemical reactions involved in an acid sulphite batch digester has never been accurate due to the complexity of the reactions and the variability of the raw materials. With the increased availability of data and the emergence of powerful new technologies, a study aimed at developing a control methodology for this operation was commissioned with the University of Pretoria and jointly funded by Best and Sappi Saiccor.
Best has been intimately involved with the project and has provided technology and process control input and expertise. A mechanistic process control model has been developed and is currently being tested on the plant.
Process information management systems
1. Design and deployment of a PI system for Mondi's Richards Bay Mill.
This system consists of a plant-wide process information management system used in the day-to-day reporting of mill operations and long-term 'historisation' of mill data. Apart from the on-line availability of data, the system has already been instrumental in identifying problematic control strategies.
2. Development of a 'plug tracking information system' based on a knowledge-based expert system.
One of the most onerous quality control requirements for pulp and paper manufacturers is the identification of raw material inputs and process history for final product batches. An exacerbating factor is the numerous transitions from continuous to batch modes of operation, typical of pulp and paper processes.
Best developed a 'plug tracking' system, based on an expert system, which is capable of automatically and accurately tracking 'plugs' of production through a process and identifying the inputs and process histories of specific batches.
3. Web-based process information management system.
An integrated database incorporating all laboratory and production data is collated and stored. This data is now accessed via the intranet in the mill and the Internet for remote locations. The process optimisation team have access to a clear and concise representation of live and historical data at all times. This system integrates information from a number of different sources including ABB Distributed Control System, Siemens PCS7 Control System, Honeywell Plantscape and TDC3000, Forté bale data system and Laboratory database.
Systems integration and strategic projects
1. Pulp and paper manufacturing execution system.
This involved a design study and business case development for the integration of all existing systems and databases into a manufacturing execution system for the regional operation of a major international pulp and paper company.
2. Strategic model aimed at optimisation of diverse operations.
This project involves the development of a strategic model to be used for complex scenario planning with the objective of optimising the regional operation of a major international pulp and paper company.
Automation of the pulp and paper industry has now come to encompass all aspects of the business from operations right through to logistics, sales and commercial activities. As a result of this trend the traditional understanding of what a system integrator is must be challenged. It is no longer sufficient to have various aspects of the business automated as an island and it is also no longer sufficient to automate for the sake of automation or to keep up with technology. Best believe that with a structured strategic approach to all aspects of automation and optimisation, business cases can be developed with a high degree of confidence and used to define a cost efficient road map into the future.
With Best's combination of skills, expertise and technologies, the company is positioned to offer practical solutions covering the traditional domain of automation and systems integration as well as extending this to the strategic integration of an enterprises systems based on sound business cases.
BeST SA
(011) 884 0510
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