Metso Automation Services

This booklet is designed to give you an overview of Metso’s modular automation service portfolio.

Ranging from managed to individual technical services, our portfolio is designed to deliver the solutions that make the biggest difference to your production and business profitability as a whole.

We ensure your business objectives are met by:

• Offering our personal commitment to resolving customer issues

• Using intelligent tools that focus activity on the areas where the optimal business return can be obtained

• Providing highly skilled service teams that follow Metso standards worldwide to guarantee high-quality results

Thank you for your custom.The Metso Automation Services team

At your service

ContentsIntroduction Managed servicesBusiness solutionsAutomation servicesCase studiesOur presence

Our service teamCommitted to safety: Our goal is zero accidents.

Closer to you: Our service technicians and engineers are located wherever they are needed to best support your business needs.

Excellence: Global competence management ensures our service experts have world-class skills and follow a common methodology wherever they are in the world.

A global network: Your personal Metso team is supported by a global network of service centers and experts.

Personal commitment: Our world-class service is provided by individuals who are passionately dedicated to their customers and their needs.

Metso service agreementsAgreed service levels: Clearly defined performance targets and responsibilities.

Transparent pricing: Clear visibility and control of service costs over the service agreement period.

Close working relationships: The closer we work together, the more effectively we can fulfill your objectives.

Increased service scope: Service agreements allow a broader range of services to be offered to you locally.

Business solutionsImprove business performance

Metso Automation Services portfolio

Managed servicesTake responsibility for business areas

Automation servicesSolve technical and process issues

Metso Automation Services

Managedservices

Improving operations and cutting costsFull responsibility: Metso takes full responsibility for a defined business area for example, device management or for maintenance of all QCS on site.

Shared objectives: Your business objectives in terms of key performance indicators are our goals. Our charges are linked to how we perform against these objectives.

Tailored: We build managed services to meet your exact business needs using business solutions and services as building blocks.

Managed services

Business solutions and services

Metso Automation Services

Business solutions

Customer requirements

Helping you meet your goals Customized: Tailored to meet your individual needs.

Intelligent: Focused effort when and where needed delivers superior results and value for money.

Lifecycle: Maximizes your return throughout the lifecycle.

Broad scope: From field devices to process controls and plant management systems.

Proven: Built around tried and tested Metso products and services.

Plant availability

Process performance

Risk control

Business solutions

Services and products

Business solutionsRisk controlPlant availability

Customer care

Intelligent maintenance

Device management

Lifecycle management

Process performance

Intelligent shutdown

Performance monitoring

Process optimization

Control performance

Lifecycle management

Safety and security

Environment

Competence

Maximize production and minimize costs

Improve performance using less resources

Achieve results by reducing risks

Customer carePlant availability

Value proposition: When you need to restore production, Metso is on call to help minimize disruption to your business.

Solution: • We tailor a support package that will help you meet your system availability targets• The response times can be chosen to meet your operational requirements and budget• We offer a remote support option which allows remote diagnosis of issues and, where possible, remote resolution• We provide a network of highly experienced product and process experts• We provide highly skilled local engineers and technicians to implement solutions

Customer care• Installed base audit• On-call service• Remote connection• Response time for emergency service visit• Service visit• Repairs• Spare parts

Intelligent maintenancePlant availability

Value proposition: Higher system availability and significantly reduced maintenance costs can be delivered by concentrating maintenance resources to where they are needed most.

Solution: • We analyze your system and identify the criticality of each element• We develop a maintenance plan based on criticality• We carry out condition analysis wherever possible to determine wear and the need for maintenance actions• Where condition analysis is not possible, we carry out preventive maintenance• We carry out high-quality repairs and refurbishments to return equipment to peak condition• Where it is more efficient for service delivery, we put resident engineers on site

Intelligent maintenance• Intelligent planning and execution• Installed base audit• Criticality analysis• Maintenance plan• Condition analysis• Preventive maintenance• Repairs• Modernization and upgrades

Intelligent shutdownPlant availability

Value proposition: We offer a single shutdown package designed to minimize shutdown time and costs by targeting maintenance only to devices which require it.

Solution: • We analyze your devices in advance and identify any maintenance that can be done outside the shutdown• We carry out condition analysis to identify devices showing signs of wear or failure• We develop a maintenance plan identifying the devices not requiring maintenance, those that require maintenance without removal and those that need to be removed• We order any spare parts that are definitely required• We provide a service container storing spare parts and tools that may be required• We ensure in advance you have the right information, the correct number of people and the right skill sets to implement the identified repairs

Intelligent shutdown• Intelligent planning and shutdown• Installed base audit• Pre-screen shutdown list• Condition analysis• Repairs• Service container• Startup supervision

Device managementPlant availability

Value proposition: Optimizes your spare parts inventory to reduce costs while ensuring critical spare parts are available to quickly get your process fully operational following a failure.

Solution: • We work together with you to identify your spare parts requirements• We analyze your plant and build a stocking strategy based on products, budget and availability targets• We remove obsolete or unnecessary stock from the inventory• We transfer stock to Metso premises (if required) and disassemble spare parts into their components• We train your staff on the new spare parts process• We provide day-to-day inventory management according to the stocking strategy – providing spare parts and restocking as needed

Device management• Criticality analysis• Installed base audit• Inventory audit• Lifecycle plan• Stocking strategy• Inventory setup• Inventory management

Lifecycle managementPlant availability

Value proposition: We minimize the total cost of ownership for your plant while maximizing production efficiency. By managing the upgrade of hardware and software, we maximize the life of equipment, minimize maintenance costs, and improve the accuracy of process controls.

Solution: • We work with you to understand your production and investment objectives• We develop with you a lifecycle plan• We upgrade hardware and/or software to prevent reliability from falling and/or maintenance costs from rising• We integrate maintenance and upgrades to minimize total cost of ownership• We propose hardware and software upgrades when performance improvements would enhance production and result in a short investment payback time

Lifecycle management• Installed base audit• Lifecycle plan• Modernization and upgrades

Performance monitoringProcess performance

Value proposition: The solution allows plant personnel to optimize production by identifying areas where process performance can be improved. The solution compares process performance against historical data, expected performance and, where available, the performance of similar processes.

Solution: • We carry out a performance audit of your processes and provide the results and proposed corrective actions• We monitor process performance to provide early warnings of process issues and to identify production bottlenecks• We provide a monitoring and reporting solution to manage plant production and emissions

Performance monitoring• Management and results reporting• Operations monitoring• Process monitoring• Controls monitoring • Machine and device monitoring

Process optimizationProcess performance

Value proposition: Minimizes the resources required to deliver a target production yield and quality by optimizing complete production processes. Production gains are sustained in the long term by continually monitoring and optimizing processes.

Solution: • We continuously monitor your processes to detect production variability• We provide recommendations on how to increase production efficiency by reducing production variability and running the process closer to its optimum operating point• We sustain and improve performance over time so that you continue to maintain production efficiency as your production and processes change

Process optimization• Pulp optimization• Paper optimization• Power optimization

Pulp process optimizationProcess performance

• Debottlenecking• Continuous/batch cooking optimization• Brown stock washing optimization• Bleaching optimization• Evaporator optimization• Recovery boiler optimization• Sootblowing optimization• Causticizing optimization• Lime kiln optimization

Services for pulp producersA set of optimization services to reduce costs, improve yield, enhance quality and reduce environmental impact.

Paper process optimizationProcess performance

Services for paper producersA set of optimization services to reduce costs, improve yield, enhance quality and reduce environmental impact.

• Debottlenecking• Mill-wide brightness optimization• Recycled fiber optimization• Mechanical fiber optimization• Stock preparation optimization• Paper and tissue machine optimization

Power process optimizationProcess performance

• Combustion optimization • Steam network optimization • District heating network optimization • Energy management solutions

Services for power producersA set of optimization services to reduce costs, improve power production and reduce environmental impact.

Control performanceProcess performance

Value proposition: Minimizes the required production resources and increases production stability by identifying incorrectly functioning controls, finding the root causes and recommending corrective action.

Solution: • We monitor your controls for sub-optimal performance and emerging device issues (for example, sticking valves)• We tune control loop parameters to optimize control performance• We provide maintenance recommendations to improve performance, and implement these actions together with the customer where applicable• We sustain performance improvements over time

Control performance• Management and results reporting• Root cause analysis• Instrument and valve analysis• Manage corrective actions• Performance improvement• Control strategy consulting

Lifecycle managementProcess performance

Value proposition: We minimize the total cost of ownership for your plant while maximizing production efficiency. By managing the upgrade of hardware and software, we maximize the life of equipment, minimize maintenance costs and improve the accuracy of process controls.

Solution: • We work with you to understand your production and investment objectives• We develop with you a lifecycle plan• We propose hardware and software upgrades when performance improvements would enhance production and result in a short investment payback time• We upgrade hardware and/or software to prevent reliability from falling and/or maintenance costs from rising• We integrate maintenance and upgrades to minimize total cost of ownership

Lifecycle management• Installed base audit• Lifecycle plan• Modernization and upgrades

Safety and securityRisk control

Value proposition: Helps create a safer and more secure working and production environment, ensures that the plant complies with health and safety regulations, and protects key systems and data from malicious attack.

Solution: • We support you during the periodic inspection of the safety-related system by helping with test arrangements and preparing necessary documentation• We work with you to understand your security requirements and what they mean for your automation systems• Our security audit identifies any automation system information security issues• We manage your network security to secure against external threats to the production control systems• We manage your Metso DNA system security to protect production control systems against attack

Safety and security• Safety instrumented system (HIMA) audit• Security audit• Safety followup service

EnvironmentRisk control

Value proposition: Ensures environmental regulatory compliance to reduce the risk of enforcement action. Ensures that systems are in place to minimize the environmental impact of the production process.

Solution: • We ensure you have the necessary environmental monitoring systems in place• We monitor the environmental impact of production processes (for example, leaks, emissions, water pollution)• We identify sources of environmental pollution and identify corrective actions• We provide other business solutions that optimize devices, controls and processes in order to deliver the agreed environmental target

Environment• Environmental monitoring system audit• Environmental upgrade• Environmental monitoring

CompetenceRisk control

Value proposition: Ensures that your team always has the correct skills and know-how to operate and maintain Metso equipment and processes so that production efficiency is maximized and business risks are minimized.

Solution: • We regularly audit how you use your installed systems to pinpoint areas where you could get more value• We work with you to identify skills and competence gaps in your organization which would help you extract more value• We build with you a skills development plan specifying the required training• We deliver the identified training either using predefined courses or by building a customized course to meet your exact needs

Competence• Management and results reporting• Competence review• Development planning• Standard training• Customized training

Metso Automation Services

Automationservices

Automation servicesService Description

Bleaching optimization Reduces final pulp brightness variability and ensures the efficient use of bleaching chemicals.

Brown stock washing optimization Maintains the desired weak black liquor solids and minimizes chemical losses in the process.

Causticizing optimization Increases quality and strength of white liquor, enhances lime mud solids to the lime kiln and reducesprocess plugging by ‘overliming’.

Combustion optimization Stabilizes and optimizes the combustion process to minimize flue gas emissions (for example, SO2, NOx) and to improve combustion efficiency in fluidized bed boilers.

Competence review We evaluate in conjunction with you and each individual team member their competences.

Condition analysisWe monitor the process and/or process devices to extract performance data. A number of monitoring options are available from visual inspection to automated data collection tools depending upon the capabilities of the equipment being monitored.

Continuous/batch cooking optimization Reduces kappa variability and optimizes the sub-process.

Control strategy consulting We propose new or upgraded controls to improve process performance.

Controls monitoring We provide a control loop monitoring system along with its support and maintenance.

Criticality analysis We classify devices and equipment into different criticality categories depending on their process importance.

Customized training We work with you to define a customized training package and then deliver the training.

Automation servicesService Description

Debottlenecking Identifies process bottlenecks which have a cascading impact on the next process, and sometimes on the whole unit. Identifying and solving these bottlenecks defines the operational economics of the whole mill.

Development planning We identify competence gaps and build development plans identifying training to take your team members to the required competence level.

District heating network optimization Enables accurate control of district heating water temperature, network pressures and pressure differentials to minimize heat losses and pumping losses while ensuring heat availability to all customers.

Energy management solutions Optimize production plans, fuel contracts and outage schedules and enable informed trading in electricity exchange.

Environmental monitoring We monitor the environment for pollution from a plant/process and report the results.

Environmental monitoring system audit An audit of the environmental control systems makes sure that the necessary elements of environmental monitoring (for example, water, air emissions and soil monitoring) are in place.

Environmental upgrade We implement upgrades to ensure that the necessary elements of environmental monitoring are in place.

Evaporator optimization Maintains desired dry solids content profile over the evaporation train by coordinating the feed-, medium- and strong-liquor dry solids controls.

Fuel power compensator Compensates for fuel quality variations and fuel feeding upsets to enable better combustion and utilization of lower quality fuels.

Automation servicesService Description

Installed base audit We identify and record in the agreed system(s) the accurate installed base information.

Instrument and valve analysis We identify field devices (for example, valve) issues and recommend corrective actions.

Intelligent planning and execution We provide project management covering planning and execution for the intelligent maintenance solution.

Intelligent planning and shutdown We provide project management covering planning and execution for the intelligent shutdown solution.

Inventory audit We identify and record in the agreed system(s) the accurate spare parts information.

Inventory managementWe carry out day-to-day spare parts storage and management. This covers delivering spare parts according to pre-defined response times, restocking according to the stocking strategy, and removing obsolete stock.

Inventory setup We remove obsolete stock, transfer stock, disassemble it into components, and carry out process training with customer staff.

Lifecycle plan We produce and keep up to date a plan identifying when a specific device, hardware or software should be upgraded in order to meet customer requirements for availability and/or performance.

Lime kiln optimization Manages the lime kiln process in order to reduce lime quality variability and implement a target shift.

Machine and device monitoring We provide a monitoring system to monitor the performance of field devices and machines, along with the associated support and maintenance.

Maintenance plan The plan continuously defines the maintenance program for devices and equipment according to the device or equipment type and its criticality.

Automation servicesService Description

Manage corrective actions We manage the implementation of correction actions by Metso and/or third parties.

Management and results reporting We provide project management and results reporting for a solution.

Mechanical fiber optimization Optimizes pulp quality and process production.

Mill-wide brightness optimization Coordinates brightness agents and unites the pulp and papermaking process.

Modernization and upgradesWe change field devices, system hardware and/or software to a newer variant. Modernization is whenthe change results in no increase in functionality. An upgrade is when the change results in an increase infunctionality.

On-call service We provide easily accessible technical support that helps customers to resolve any issues regarding automation systems or field devices.

Operations monitoring We provide a monitoring system to monitor the overall performance of operations.

Paper and tissue machine optimization Optimizes the paper/tissue machine process.

Performance improvement Our skilled engineers tune control loop parameters to optimize control performance.

Pre-screen shutdown list Our staff identifies which devices can be maintained outside a shutdown.

Automation servicesService Description

Preventive maintenance Execution of preventive maintenance tasks according to the maintenance plans.

Process monitoring Provides timely and accurate information on the development of process performance KPIs.

Recovery boiler optimization Manages the combustion process for both the firing of black liquor and the combustion air.

Recycled fiber optimization Coordinates the pulping, bleaching and flotation processes, decreases brightness and ash variability, andimproves the deinking process.

Remote connection We remotely diagnose and, where possible, solve system and/or equipment issues.

Repairs We repair and recondition automation and instrumentation devices (for example, valves, DCS units). This includes what was previously called ‘Intelligent Valve Repair’.

Resident engineer We offer an on-site expert to provide continuous local expertise as part of a service agreement.

Response time for emergency service visit We put in place resources to deliver a specified response time.

Root cause analysis Our experts find the root cause of control and process issues and propose a solution.

Safety followup service We ensure that the plant automation systems are secure from external threats and viruses.

Safety instrumented system (HIMA) audit We provide safety logic application support and consulting (for example, for turbines).

Security audit Identifies any automation system information security issues.

Automation servicesService Description

Service container We provide for a shutdown a customized container of spare parts and tools that may be required during a shutdown or turnaround.

Service visit An engineer visits your site to carry out emergency corrective action.

Sootblowing optimization Intelligent sootblowing optimizes the process to clean only the areas where it is needed.

Spare parts We provide replacement spare parts for Metso products.

Standard training We provide a number of standard training courses.

Startup supervision We provide on-site troubleshooting support to ensure a smooth production start-up after a shutdown.

Steam network optimizationOptimizes steam and electricity production and utilization of compensating process resources in varying CHP production to ensure better steam pressure control, optimize electricity generation, minimize steam venting and optimize the fuel mix.

Stock preparation optimization Optimizes the stock preparation process.

Stocking strategy We continuously update the spare part stocking strategy based on targets and device lifecycles.

Technical visit Our service experts carry out a visual inspection of devices and their environment for shutdown or maintenance planning.

Metso Automation Services

Case studies

Intelligent maintenance improves maintenance efficiency without compromising quality

Background: • Braskem is the largest petrochemical company in South America and 5th largest in the world• Braskem’s Triunfo plant produces more than 1,200 Kt per year of ethylene and other hydrocarbons• Target was to maintain equipment availability and improve maintenance efficiency to bring down maintenance costs

Solution:Intelligent maintenance business solution implemented to analyze internal and external condition of valves, schedule maintenance based on condition and carry out high-quality repairs.

Our customer’s view:“Not only have we saved in maintenance and inventory costs, but we have also increased the reliability and the performance of our field equipment.”

Results:• 36% saving in maintenance costs • Only 24% of valves required removal for maintenance • Job safety increased• Improved environmental compliance Nelzo Luiz Neto da Silva,

Maintenance Coordinator, Braskem Triunfo

Plant availability

Device management solution reduces inventory costs and capital expenditure

Plant availability

Background: • The world’s leading producer of nickel and palladium• The Harjavalta plant produces nickel salts for the European market• Target was to reduce inventory costs and space needed and ensure spare parts inventory aligned to installed base

Solution:Device management business solution implemented to audit spare parts stock and the process, identify surplus inventory and reduce the number of models in use over time.

Our customer’s view:“Agreements are made between companies, but genuine cooperation and teamwork is built around people.”

Results:• 71% reduction in customer inventory in 2 years• Spare part equipment coverage up from 40% to 90%• Significant reduction in material costs• 100% on-time delivery

Mikko Marjakoski, Chief of maintenance,Harjavalta plant

Intelligent shutdown reduces shutdown costs and time by focusing effort where needed

Plant availability

Background: • CMPC is the largest Chilean pulp company and the world’s 5th largest pulp supplier• The Santa Fe Mill near Nascimento produces bleached eucalyptus pulp with two fiber lines• Target was to maintain valve availability while reducing maintenance costs and resources

Solution:Intelligent shutdown business solution implemented to analyze valve condition in advance and remove only under-performing valves for high-quality repair.

Our customer’s view: “Maintenance costs optimization of control valves, based on predictive maintenance philosophy, allows us to allocate resources to other important maintenance activities at the mill.”

Results:• Less than 20% of the control valves needed removal for service• 70% drop in maintenance costs compared to sister line where all critical valves were taken out (reduced scaffolding, construction, inspection and repair costs)• Maintained target availability for valves

Javier Gonzalez, Electrical and Instrumentation Superintendent,CMPC Santa Fe Mill

Lifecycle management optimizes system performance and total cost of ownership

Plant availability

Background: • Major SC publication paper producer• Target was to upgrade the DCS system selectively to maximize lifetime of the system, improve the return on investment, maintain availability targets and system security and minimize maintenance and service costs

Solution:Lifecycle management business solution implemented to upgrade automation systems to coincide with a jointly agreed lifecycle plan.

Our customer’s view: “Laakirchen mill has dealt with issues of automation asset obsolescence and lifecycle management. We have invested in new technologies and applications that improve reliability and serviceability while, at the same time, reducing costs and improving papermaking performance.”

Results:• System uptime improved by 10 hours per year• System and application engineering change costs reduced by 20%

Siegfried Schober,Automation Project Manager, SCA Laakirchen

Steve Friend,Plant Manager,American Bituminous Power Partners

Power process optimization saves unnecessary investments

Process performance

Background: • ABPP is a joint venture between a number of US power companies• The Grant Town plant has two circulating fluidized bed boilers generating 80 MW and a 3rd party control system• Target was to benchmark plant performance for measurement purposes, improve performance and lower production costs

Solution:Power process optimization solution implemented.

Our customer’s view: “Our business has to include optimization of our processes to ensure that we are operating as efficiently as possible. Every dollar that I invest in bettering our plant must ensure that I achieve that high return on investment. Metso meets our expectations of efficient, low-cost operation.”

Results:• 7% reduction in limestone usage• By reducing limestone injected with the fuel and average SO2 levels, the plant avoided having to install a post-combustion flue gas treatment system estimated to cost $12 million

Reduced variability leads to massive cost savings

Process performance

Background: • One of the largest pulp producers in Brazil• Target was to stabilize pulp quality and kappa variation, improve pulp yield and lower costs per ton

Solution:Continuous cooking optimization, a pulp optimization service within the process optimization business solution, was implemented.

Our customer’s view: “Working together, we got very good results which were much better than expected and which have been maintained.”

Results:• Kappa variability reduced by as much as 93%• Yield increase resulting in annual savings of up to $900,000

Hamilton Brandão,Fiberline Coordinator,Cenibra

Keith Phillips,Control Engineer, SABIC-IP

Tighter process control combats rising energy and raw material costs

Process performance

Background: • SABIC is one of the world’s largest chemicals, fertilizers, plastics and metals producers with annual sales of $75 billion• SABIC Innovative Plastics (SABIC-IP) produces a variety of plastics for OEMs in the automotive and computer electronic markets• Target was to stabilize plant processes to reduce energy and maintenance costs

Solution:Control performance business solution – Metso ExperTune PlantTriage implemented and consultancy provided.

Our customer’s view: “By tightening this upstream control and optimizing the hydrogen process, we are able to save over $1 million per year in energy consumption.”

Results:• Annual energy savings of $1 million• Oscillating loops reduced from 40% to 16%• Loops unable to hold setpoint reduced from 12% to 2%

Doing better business by being a better business

Risk control

Background: • A principal bioenergy producer and the world’s leading peat company• Target was to address the public perception around the impact of peat extraction on the environment by implementing a monitoring solution that increased information transparency

Solution:Environment business solution implemented.

Our customer’s view: “Metso’s service package provides us with a more comprehensive, transparent and real-time solution for parallel use with the monitoring method used currently. In addition, it supports our previous commitment of including all peatlands in our emissions monitoring.”

Results:• Transparency of water quality information improved • Company is able to better manage its environmental footprint

Pasi Koivisto,Business Area Director,Vapo Peat Products

A selection of our customersOil, gas and biofuels

Power Chemicals Metals Mining and construction

Food

Industrial gas Pulp and paper

Our presence – closer to you

Full solution and service portfolio available

Core solution and service portfolio available

Our presence today

1000+

30+

55+ Automation service hubs

35+ Service centers

Service personnel

Countries

www.metso.com/automationservices

Metso Automation Inc.

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