Setting Up Paper Mill Assets

In this section, you'll learn how to create the asset hierarchy and asset types for Blueprint Paper Mill. By the end, you'll have a structured representation of the mill's equipment ready for operator rounds.

Understanding Asset Hierarchy

Assets in Cyzag Blueprint are organized hierarchically, mirroring the physical structure of your facility. For Blueprint Paper Mill, the hierarchy looks like this:

Blueprint Paper Mill (Site)
├── Unit A – Pulping
│   ├── Digester D-101
│   ├── Feed Pump P-404
│   └── Black Liquor Tank BL-02
├── Unit B – Screening & Cleaning
│   ├── Screen S-05
│   └── Cleaner Pump CP-12
├── Unit C – Paper Machine Line
│   ├── Headbox HB-01
│   ├── Dryer Can DC-12
│   ├── Felt Roll FR-07
│   └── Press Section Drive Motor PM-03
└── Unit D – Utilities
    ├── Steam Boiler B-01
    ├── Air Compressor AC-12
    └── Cooling Tower CT-03

Step 1: Define Asset Types

Asset types categorize equipment with similar characteristics. For Blueprint Paper Mill, create these asset types:

Continuous Digester

• Description: Large pressure vessel for cooking wood chips with white liquor
• Typical attributes: Cooking temperature, pressure, H-Factor, liquor flow, chip level
• Example: Digester D-101

Centrifugal Pump

• Description: Rotating pump for moving liquids through the process
• Typical attributes: Discharge pressure, motor amperage, vibration, seal temperature
• Examples: Feed Pump P-404, Cleaner Pump CP-12

Storage Tank

• Description: Atmospheric or pressurized vessel for holding process liquids
• Typical attributes: Level, temperature, pressure (if applicable)
• Example: Black Liquor Tank BL-02

Paper Machine Dryer

• Description: Steam-heated rotating cylinder for drying paper sheet
• Typical attributes: Surface temperature, steam pressure, condensate temperature
• Example: Dryer Can DC-12

Recovery Boiler

• Description: Boiler that burns black liquor to generate steam and recover chemicals
• Typical attributes: Steam pressure, flue gas temperature, reduction efficiency, smelt flow
• Example: Steam Boiler B-01 (simplified in this tutorial)

Rotary Equipment

• Description: Generic rotating machinery including motors, fans, and rollers
• Typical attributes: Vibration, temperature, amperage, speed
• Examples: Felt Roll FR-07, Press Section Drive Motor PM-03, Cooling Tower CT-03 fan

Air Compressor

• Description: Machine that compresses air for instrument and process use
• Typical attributes: Discharge pressure, discharge temperature, vibration, oil level
• Example: Air Compressor AC-12

Screen

• Description: Pressure screen for separating fibers by size and removing contaminants
• Typical attributes: Inlet pressure, outlet pressure, flow rate, reject rate
• Example: Screen S-05

Headbox

• Description: Equipment that distributes stock evenly across the paper machine wire
• Typical attributes: Stock consistency, flow rate, air content, slice opening
• Example: Headbox HB-01

Step 2: Create Functional Locations

Functional locations represent areas or systems within your facility. For Blueprint Paper Mill:

• Unit A – Pulping: Pulp preparation and cooking area
• Unit B – Screening & Cleaning: Fiber cleaning and screening systems
• Unit C – Paper Machine Line: Paper forming, pressing, and drying
• Unit D – Utilities: Steam, air, water, and electrical systems

Step 3: Create Assets

Now create individual assets and assign them to functional locations and asset types:

Unit A – Pulping

Digester D-101

• Asset Type: Continuous Digester
• Location: Unit A – Pulping
• Description: Primary continuous digester for cooking softwood chips
• Attributes to track:
  • Cooking Temperature (°C)
  • Digester Pressure (bar)
  • H-Factor (dimensionless)
  • White Liquor Flow (L/min)
  • Chip Level (%)

Feed Pump P-404

• Asset Type: Centrifugal Pump
• Location: Unit A – Pulping
• Description: High-pressure pump feeding wood chips to digester
• Attributes to track:
  • Discharge Pressure (bar)
  • Motor Amperage (A)
  • Bearing Vibration (mm/s)
  • Seal Temperature (°C)

Black Liquor Tank BL-02

• Asset Type: Storage Tank
• Location: Unit A – Pulping
• Description: Holding tank for spent cooking liquor before recovery
• Attributes to track:
  • Tank Level (%)
  • Liquor Temperature (°C)

Unit B – Screening & Cleaning

Screen S-05

• Asset Type: Screen
• Location: Unit B – Screening & Cleaning
• Description: Pressure screen for fiber separation and contaminant removal
• Attributes to track:
  • Inlet Pressure (bar)
  • Flow Rate (L/min)
  • Inspection Notes

Cleaner Pump CP-12

• Asset Type: Centrifugal Pump
• Location: Unit B – Screening & Cleaning
• Description: Centrifugal cleaner feed pump
• Attributes to track:
  • Discharge Pressure (bar)
  • Motor Amperage (A)
  • Bearing Vibration (mm/s)
  • Seal Temperature (°C)

Unit C – Paper Machine Line

Headbox HB-01

• Asset Type: Headbox
• Location: Unit C – Paper Machine Line
• Description: Stock distribution headbox for paper machine
• Attributes to track:
  • Stock Level (%)
  • Flow Rate (L/min)
  • Pressure (bar)
  • Inspection Notes

Dryer Can DC-12

• Asset Type: Paper Machine Dryer
• Location: Unit C – Paper Machine Line
• Description: Steam-heated drying cylinder in first dryer section
• Attributes to track:
  • Surface Temperature (°C)
  • Steam Pressure (bar)
  • Condensate Temperature (°C)

Felt Roll FR-07

• Asset Type: Rotary Equipment
• Location: Unit C – Paper Machine Line
• Description: Press section felt guide roller
• Attributes to track:
  • Bearing Vibration (mm/s)
  • Bearing Temperature (°C)

Press Section Drive Motor PM-03

• Asset Type: Rotary Equipment
• Location: Unit C – Paper Machine Line
• Description: Main drive motor for press section
• Attributes to track:
  • Motor Amperage (A)
  • Motor Temperature (°C)
  • Vibration (mm/s)

Unit D – Utilities

Steam Boiler B-01

• Asset Type: Recovery Boiler (simplified)
• Location: Unit D – Utilities
• Description: High-pressure steam boiler for process steam
• Attributes to track:
  • Steam Pressure (bar)
  • Flue Gas Temperature (°C)
  • Feedwater Conductivity (µS/cm)
  • Drum Level (%)

Air Compressor AC-12

• Asset Type: Air Compressor
• Location: Unit D – Utilities
• Description: Rotary screw compressor for instrument air
• Attributes to track:
  • Discharge Pressure (bar)
  • Discharge Temperature (°C)
  • Motor Amperage (A)
  • Oil Level (OK/Low)

Cooling Tower CT-03

• Asset Type: Rotary Equipment
• Location: Unit D – Utilities
• Description: Cooling tower for process cooling water
• Attributes to track:
  • Fan Vibration (mm/s)
  • Water Temperature (°C)
  • Fan Noise Level (Normal/Abnormal)

Step 4: Define Normal Operating Ranges

For each attribute, define normal operating ranges to help operators identify abnormal conditions:

Asset	Attribute	Normal Range	Alert Threshold
Digester D-101	Pressure	5.2–5.8 bar	<5.0 or >6.0 bar
Digester D-101	Temperature	165–172 °C	<160 or >175 °C
Feed Pump P-404	Vibration	<4.5 mm/s	>6.0 mm/s
Dryer Can DC-12	Surface Temp	85–95 °C	<80 or >100 °C
Steam Boiler B-01	Steam Pressure	40–45 bar	<38 or >48 bar
Air Compressor AC-12	Discharge Pressure	6.8–7.2 bar	<6.5 or >7.5 bar

Best Practice

Define normal operating ranges during asset setup. This makes it easier for operators to recognize abnormal conditions during rounds and enables automated alerting in Phase 2.

Verification

After completing asset setup, verify:

• ✅ All functional locations are created (Units A, B, C, D)
• ✅ Asset types are defined with appropriate attributes
• ✅ All 12 key assets are created and assigned to locations
• ✅ Each asset has attributes with units of measure defined
• ✅ Normal operating ranges are documented

Next Steps

Now that your asset hierarchy is established, you're ready to create operator routes. Continue to Operator Rounds to design structured inspection routes through the mill.