Yard + Chipper House

Pulp MillStock

Preparation Area

Paper machine

Finishing + Shipping

Area

• Head box level and pressure control.• Level Control of Seal Pit Tank.• Differential Pressure of Kuster in Calendar Section.• Steam Pressure control in Pre- Dryer.• Steam Pressure Control in Post-Dryer through QCS

system.• Measurement of GSM, Moisture and ash in the

paper through Smart Gauge 3000.• Hydraulic Presses and Drum Reel Hydraulic

System.• Measurement & control of Speed through Inductive

Proximity Sensor.• Photocell detector to detect Paper breakage.

4-20 mA

IP- Current to Pressure Converter

SP- Set Point

PV- Process Value

PCV- Pneumatic Control Valve

LIC- Level Indicating Controller

VFD- Variable Frequency Drive

LT- Level Transmitter

PT- Pressure Transmitter

0.2 To 1 kg/cm2Air Supply 1.4 kg/cm2

Fan Pump VFD

Head box

IP

PT

PIC

LT

LIC

LP

HP

Inlet Pulp

PCV

Air Drain

SP

4-20 mA

PV

Air from Air Receiver

Air Supply 1.4 kg/cm2

0.2 To 1 kg/cm2

4-20 m A

4-20 m A

PumpLIC

IP

White Water Inlet

SP

PV

PCV

OUTLET to Back Water Silo

PCV- Pneumatic Control Valve

IP- Current to Pressure Converter

LIC- Level Indicating Controller

LT- Level transmitter

• Inlet White water to Seal Pit is coming from the filtered pulp through wire. It is installed at the bottom of wire part. At the output a pump is used to sent white water to Silo via Pneumatic Control Valve

LTTank

Components:

GSM Radioactive material Ash X rays Moisture measurement IR sensor Edge Sensor Phase Encoder Limit Switch

Electrometer

Signal

Isotope Source

Process

Ground

High Voltage

+

-

Ion Chamber

Sensor Source (Example

ION Chamber)

Electrometer (current is amplified & converted to voltage)

ADC Intelligent Micro Controller (IMC)

RS-232 to RS-422 Converter

Raw CountsRS-422 to RS 232 Converter

Smart PC

Turbo PC/ Super PC

X-Ray Source

Process

SP

Air Supply (1.4 kg/cm2)

Close Tank

IP LIC

LT- Level Transmitter

PCV- Pneumatic control Valve

LIC- Level Indicating Controller

IP- current to pressure converter

PCV 4-20 mA

4-20 m A

LP

HP

Outlet

Inlet

LT

FIC

SP PV

PCVPCV

FTFT

Wild Flow Controlled Flow

4-20 mA

IP

1.4 kg/cm2

0.2 to 1 kg/cm2

Wild Flow X (Controlled Flow / Wild Flow)

SP =

4-20 mA Remote Transmission

220 V 50 Hz

PG1

Three Phase Motor (469 Hp)

Triple Disc Refiner

Flow Tube

Magnetic Flow indicator +Transmitter

PG3

PS1

PG4

PG2

PS2

Inlet from Buffer Chest

O/p Voltage

Interlock A

Water

Interlock B

Excitation voltage

Interlock A: if the Pressure of Inlet flow will goes below 0.5 kg/cm2 then Pressure switch PS1 unload the TDR

Interlock B: if the pressure of Water (which is acting as coolant to TDR )fall below 0.5 kg/cm2 then PS2 unload the TDR

Outlet to Refined Stock

Number of Boilers - 7

Coal Fired - 4

HP Boiler 1,2,3 & 7

Black Liquor Fired 2

ABL and JMW

Boiler # 7 (Coal

Fired) (OPP)JMW (Black

Liquor) (OPP)ABL (Black

Liquor) (NPP)

BTH

(6.2 M

W)

PRV- Pressure Reduce Valve

MP- Medium Pressure

46 kg/cm2

Header From HP steam Header (from PRV)

MPMP MP

Boiler # 1 (Coal Fired)

Boiler # 2 (Coal Fired)

Boiler # 3 (Coal Fired)

TG

(18 M

W)

PRV 46 Kg/cm2 to MP steam header

85 kg/cm2

Header

PRV- Pressure Reducing Valve

HP HP HP

PDM Tank

Deareator Tank

Feed Pump

Economiser Steam Drum

MUD Drum

Super Heater Section

Stop ValveTurbine

DM Plant

Condensate

Boiler

Deareator Tank

TG

IP

LIC

PG

IP LICSteam Inlet

Inlet from PDM tank thru Pump

PCV

Air Supply 20 psi

4-20 mA

SPLP

HP

Outlet to feed pump

SP Drain

20 psi

PCV

TG- Temperature GaugeLIC- level Indicating ControllerPT- Pressure transmitterPG- Pressure GaugePCV- Pneumatic Control ValveLT- Level TransmitterIP- Current to Pressure Converter

LTPT

Steam Flow Drum Level Water Flow

P+I

A T

P+I

A T

IP1.4 kg/cm2

To feed Water Control Valve

4-20 mA

Three Element Control...Drum Level

Types of transmitter:

Conventional Smart/Intelligent

Transmitter is a device which is used to measure physical variable i.e. transducer and to transmit signal into electrical signal in form of 4-20 mA or 1-5 V DC signal.

In this Calibration can be done after disconnecting the Transmitter from the field. In this calibration cannot be done using HART communicator. A Conventional Transmitter consists of Zero and Span Adjustment for the calibration 

Disconnect Transmitter from the field.Apply 24 V dc supply and a multi meter in series

to the transmitterApply a known Pressure through Pressure gauge or

dead weight tester.Check zero of the transmitter. For zero pressure a

transmitter gives 4 mA. If transmitter shows some zero error then calibrate it through zero adjustment.

Apply 100% Span Pressure & then adjust 20 mA from the Span adjustment.

Check mA output for mid range pressure.

• In this Calibration can be done by using HART (Highway Addressable remote transducer) Communicator. Online calibration can be performed using HART communicator. In this Sine wave frequency signal over right the Previous Calibration.

• HART is based on Frequency Shift Keying. In this 1200 Hz is equal to Binary logic 0 and 2200 Hz is equal to logic 1.

Its working principle is based on the flapper nozzle arrangement. Its input range of pressure is 20 psi or 1.4 kg/cm2. Depending upon the control signal i.e. 4-20 mA a flapper moves up and gives output in the range of 3 to 15 psi or 0.2 to 1 kg/cm2.

Flapper

Supply Pressure 20 psi Restriction

Spring

4-20 mAGap

Pressure signal 3-15 psi

Nozzle

1. Apply input pressure of 20 psi and also apply current signal from mA source (Loop Analyzer).

2. Attach a manometer or calibrated gauge at the output of IP.

3. Apply 4 mA and check output pressure to be 3 psi or 0.2 kg/cm2. If this pressure will not come then adjust using zero adjustment.

4. Apply 20 mA signal and check o/p pressure to be 15 psi or 1 kg/cm2. If this pressure will not come then adjust using span adjustment.

5. Check for mid ranges by changing control signal to 8, 12 & 16 mA.

6. If step 5 is not showing exact reading then repeat step number 4, 5 & 6.

 

Flow in any pipe is defined as velocity of liquid at certain point.

Various flow measuring techniques are available and some are enlist which are used here

1. Orifice Plate 2. Venturi Meter3. Flow Nozzle4. Vortex Flow meter5. Magnetic Flow meters1,2 & 3 are Differential Pressure type flow

meters.

PIDSteam

Pr. Control

Feed Forward

Feed Forward

PID Ash Flow Control

CPU

PID

Feed Forward

Stock Flow ControlDTC

Feed Forward

Feed Forward

QCS

Ash S.P

Moisture S.P.

BW S.P. Consistency Tx

QCS PROCESSING FLOW DIAGRAM

V=2 ∏ R N

V= D ∏ N

∏D=V/N

V= Line Speed of the Drum from the Encoder (Taken from the Drive 01-10 VDC)

N= Unwind Speed from the proximity (14 ppr)

R= Radius of the Unwind Roll

D= Diameter of the Unwind Roll

Instrumentation is the branch of science which deals with the measurement, record and control of process variable.

ABB MP-200 Series Distributed Control System in Pulp Mill

Supervisory Control And Data Acquisition System used in Stock Preparation Area at PM4 and at ABL Boiler.

Quality Control System at PM1, 4 and 5. PLC Control System at PM7 and Color

Kitchen. Various Types of Field Instruments like

Level Transmitter, Pressure Transmitter, Flow Transmitter, Conductivity Transmitter and Consistency Transmitter, Temp.Transmitter.

Various Types of Control Valve for Pressure, temperature and flow Control application like Butterfly, Globe Valve, Plug valve

Others measuring devices like RTD, Thermocouple, pH measurement, Khajani for brightness Measurement.

Hydraulic System of Press part. Vibration Monitoring.

These Instruments are Calibrated Against the ISO from ETDC.

Loop Analyzer Dead Weight Tester Vacuum Gauge Tester RTD Simulator Conductivity Jig

Governer Control System for the Turbine Generator.

Temperature and Vibration Monitoring for Safety and Tripping.

Dereator Tank Level and Pressure Control at HP Boilers.

Feed Water Flow and Steam Flow Measurement and Control at all Boilers

Three Element Drum Level Control for HP Boilers

761 controller based SCADA control system at ABL Boiler.

Various Temperature Indication, ID indication.

Various Pressure and Flow measurements and Control like Soot Blowing Pressure and Flow.

Various types of Control Valve for different application like Flow Control of Feed water, Steam flow etc.

Conductivity measurement at DM plant and Evaporator.

Thank You !