You are on page 1of 273

PROCESS DESCRIPTION

KHANNA
NEW DIP LINE 300 BDMT/24h
PRINTING - WRITING

DPT : SAD Par/by : JLB Date : 25/08/04


Client / Customer code : 03047 Rev. Page
Command / Order ref. : 0401010 PD 0155A 00 1 / 273

39, rue de la Fontaine Ludot – BP 46 – 51302 Vitry-le-François Cedex – France


S.A.S. au capital de 3.212.420 €

Tel.: +33 (0)3.26.74.80.80 – Fax: +33 (0)3.26.72.08.33 – www.kadant.com


R.C.S. Châlons-en-Champagne
B 736120205
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

1 REVISIONS TO DOCUMENT 11

2 GENERAL 12

2.1 GENERAL DESCRIPTION...........................................................................................................12


2.2 SCOPE.........................................................................................................................................12
2.3 DE-INKED PULP PRODUCTION SET-POINTS...........................................................................13
2.3.1 Control Principle................................................................................................................13
2.3.1.1 Waste Paper Pulping tonnage ..........................................................................................13
2.3.1.2 Loop 1 production control P1-3015...................................................................................13
2.3.1.3 Loop 2 production control P2-5070...................................................................................14
2.3.1.4 Loop 3 production control P3-12005.................................................................................14
2.3.1.5 Pulp from Storage to Paper Machine................................................................................15
2.3.2 Interlocks & Production Set-Points ...................................................................................15
2.3.3 Production Flexibility, Quality Control & Pulp Production .................................................15
2.3.4 Ash control and Yield control in Pulp Production...............................................................17
2.4 DIP LINE WATER BALANCE & CONTROLS................................................................................18
2.4.1 Loop 1 Filtrate balance controls........................................................................................18
2.4.2 Loop 2 Filtrate balance controls........................................................................................19
2.4.3 Loop 3 Filtrate balance controls........................................................................................20

3 PULPING 22

3.1 DESCRIPTION.............................................................................................................................22
3.1.1 Pulping itemization............................................................................................................22
3.1.1.1 Pulping area 1...................................................................................................................22
3.1.1.2 Pulping area 2...................................................................................................................22
3.1.1.3 Equipment common to both pulping areas........................................................................23
3.1.2 Helico Pulper basics.........................................................................................................23
3.1.2.1 Helico Pulper Description..................................................................................................23
3.1.2.2 Helico Pulper Sequence....................................................................................................24
3.1.3 Dumping Poire basics.......................................................................................................24
3.1.3.1 Poire description...............................................................................................................24
3.1.3.2 Dumping Poire Sequence.................................................................................................25
3.1.4 Pulping area......................................................................................................................26
3.1.4.1 Pulping area 1...................................................................................................................26
3.1.4.2 Pulping area 2...................................................................................................................27
3.1.4.3 Buffer water tank 05CE11.................................................................................................29
3.1.4.4 Dump chest 01CPA15.......................................................................................................29
3.2 BASIC OPERATING CAPACITY..................................................................................................30
3.3 TRANSMITTERS and CONTROL LOOPS....................................................................................31
3.3.1 Pulping area 1...................................................................................................................31
3.3.2 Pulping area 2...................................................................................................................32
3.3.3 Common to both Pulper areas..........................................................................................32

GENERAL
Page 2/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

3.4 INTERLOCKINGS AND ALARMS.................................................................................................33


3.4.1 Pulping area 1...................................................................................................................33
3.4.2 Pulping area 2...................................................................................................................35
3.4.3 Common to both Pulper areas..........................................................................................38
3.5 OPERATION.................................................................................................................................40
3.5.1 Start-up 40
3.5.2 Operation 43
3.5.3 Stop 43

4 HD CLEANING AND HOLE SCREENING 45

4.1 DESCRIPTION ............................................................................................................................45


4.1.1 HD Cleaning and Holes screening Itemization..................................................................45
4.1.2 High Density Cleaner basics.............................................................................................46
4.1.2.1 HD Cleaner Description....................................................................................................46
4.1.2.2 HD Cleaner Operation.......................................................................................................46
4.1.2.3 HD Cleaner Sequence......................................................................................................47
4.1.3 Horizontal screen (CH) basics..........................................................................................47
4.1.3.1 Horizontal screen (CH) Description...................................................................................47
4.1.3.2 Horizontal screen (CH) Operation.....................................................................................48
4.1.3.3 Horizontal screen (CH) Sequence.....................................................................................48
4.1.4 Tailing screen Diabolo......................................................................................................49
4.1.4.1 Diabolo Description...........................................................................................................49
4.1.4.2 Diabolo Operation.............................................................................................................49
4.1.4.3 Diabolo Sequence.............................................................................................................50
4.1.5 HD Cleaning and Holes Screening Area ..........................................................................51
4.1.5.1 High Density Cleaning.......................................................................................................51
4.1.5.2 Pre-screening Holes 3 Stages ..........................................................................................51
4.2 BASIC OPERATING CAPACITY..................................................................................................54
4.3 TRANSMITTERS and CONTROL LOOPS....................................................................................54
4.3.1.1 High Density Cleaning.......................................................................................................54
4.3.1.2 Holes screening................................................................................................................55
4.4 INTERLOCKINGS AND ALARMS.................................................................................................57
4.5 OPERATION.................................................................................................................................63
4.5.1 Start-up 63
4.5.1.1 Water filling.......................................................................................................................63
4.5.1.2 Starting of the loop............................................................................................................63
4.5.2 Production 64
4.5.3 Operation 64
4.5.4 Stop 65

5 SLOTS PRE-SCREENING 67

5.1 DESCRIPTION.............................................................................................................................67
5.1.1 Area itemization................................................................................................................67

GENERAL
Page 3/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

5.1.2 ScreenOne basics.............................................................................................................67


5.1.2.1 ScreenOne Description.....................................................................................................67
5.1.2.2 ScreenOne operation........................................................................................................68
5.1.2.3 ScreenOne sequence.......................................................................................................68
5.1.3 Slots Pre-screening area..................................................................................................69
5.2 BASIC OPERATION CAPACITY..................................................................................................71
5.3 TRANSMITTERS AND CONTROL LOOPS..................................................................................71
5.4 INTERLOCKINGS AND ALARMS.................................................................................................73
5.5 OPERATION.................................................................................................................................75
5.5.1 Start-up 75
5.5.1.1 Fill the unit........................................................................................................................75
5.5.1.2 Starting of the loop............................................................................................................76
5.5.1.3 Production.........................................................................................................................76
5.5.2 Operation 76
5.5.3 Sequences 77
5.5.3.1 ScreenOne basket depluging............................................................................................77
5.5.3.2 ScreenOne washing..........................................................................................................77
5.5.4 Shutdown 78
5.5.4.1 Stop of production.............................................................................................................78
5.5.4.2 Stop of the loop.................................................................................................................78

6 PRIMARY FLOTATION 80

6.1 DESCRIPTION ............................................................................................................................80


6.1.1 Flotation Itemization..........................................................................................................80
6.1.2 Flotation cell (MAC) basics...............................................................................................81
6.1.3 Deinking MAC cell multi-Aeration flotation .......................................................................82
6.1.4 Deinking cell MAC Sequence............................................................................................82
6.1.5 Pre-Flotation area.............................................................................................................83
6.1.5.1 Prime MAC 03CEV02a.....................................................................................................83
6.1.5.2 Primary flotation cell MAC 03CEV02b...............................................................................85
6.2 BASIC OPERATING CAPACITY..................................................................................................88
6.3 TRANSMITTERS and CONTROL LOOPS....................................................................................88
6.3.1 Prime MAC 03CEV02a.....................................................................................................88
6.3.2 Primary flotation cell MAC 03CEV02b...............................................................................89
6.4 INTERLOCKINGS AND ALARMS.................................................................................................90
6.5 OPERATION.................................................................................................................................94
6.5.1 Start up 94
6.5.1.1 Water filling.......................................................................................................................94
6.5.1.2 Starting of loop..................................................................................................................95
6.5.1.3 Production.........................................................................................................................96
6.5.2 Operation 96
6.5.3 Stop 97

GENERAL
Page 4/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

6.5.3.1 Stop of loop.......................................................................................................................97


6.5.3.2 Stop of the Deinking cells..................................................................................................97

7 CLEANING 100

7.1 DESCRIPTION...........................................................................................................................100
7.1.1 Area Itemization..............................................................................................................100
7.1.2 Basics Cleaners System.................................................................................................100
7.1.2.1 Cleaners description.......................................................................................................100
7.1.2.2 Cleaners operation..........................................................................................................102
7.1.3 Cleaners system sequence.............................................................................................103
7.1.4 Area description..............................................................................................................104
7.2 BASIC OPERATING CAPACITY................................................................................................108
7.3 TRANSMITTERS AND CONTROL LOOPS................................................................................108
7.4 INTERLOCKINGS AND ALARMS...............................................................................................111
7.5 OPERATION...............................................................................................................................115
7.5.1 Start-Up 115
7.5.1.1 Starting of the loop..........................................................................................................115
7.5.1.2 Production.......................................................................................................................116
7.5.2 Operation 116
7.5.3 Shutdown 116
7.5.3.1 Stop of production...........................................................................................................116
7.5.3.2 Stop of the loop...............................................................................................................116

8 LOOP 1 DISC FILTER & WATER DISTRIBUTION 118

8.1 DESCRIPTION...........................................................................................................................118
8.1.1 Area itemization..............................................................................................................118
8.1.2 Disc Filter basics.............................................................................................................118
8.1.2.1 Disc Filter Description.....................................................................................................118
8.1.2.2 Disc Filter operation principle..........................................................................................121
8.1.3 Area description..............................................................................................................123
8.1.3.1 Loop 1 Disc Filter............................................................................................................123
8.1.3.2 Loop 1 water distribution.................................................................................................123
8.2 BASIC OPERATING CAPACITY................................................................................................125
8.3 TRANSMITTERS AND CONTROL LOOPS................................................................................125
8.4 INTERLOCKINGS AND ALARMS...............................................................................................126
8.4.1 Loop 1 Disc Filter 05FDQ01............................................................................................126
8.4.2 Loop 1 water distribution.................................................................................................127
8.5 OPERATION...............................................................................................................................130
8.5.1 Start-up 130
8.5.1.1 Water tanks filling............................................................................................................130
8.5.1.2 Disc Filter 05FDQ01 start................................................................................................130
8.5.1.3 Production.......................................................................................................................131

GENERAL
Page 5/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

8.5.2 Operation 131


8.5.3 Shutdown 132
8.5.3.1 Stop of production...........................................................................................................132
8.5.3.2 Disc Filter 05FDQ01 stop................................................................................................132
8.5.3.3 Loop 1 Water distribution................................................................................................132

9 LOOP1 THICKENING, KNEADING AND OXYDATIVE BLEACHING


AREA 134

9.1 DESCRIPTION ..........................................................................................................................134


9.1.1 Area Itemization..............................................................................................................134
9.1.2 MC Pump basics.............................................................................................................134
9.1.3 Screw Press basics.........................................................................................................134
9.1.4 Basics Kneader type TL .................................................................................................136
9.1.4.1 Kneader description........................................................................................................136
9.1.4.2 Kneader Counter-pressure control & Pneumatic Panel ..................................................136
9.1.4.2.1 Kneader Counter-pressure control & Pneumatic Panel ...........................................136
9.1.4.2.2 Kneader Absorbed Power control: Counter-pressure...............................................137
9.1.5 Basics Pollcon Tower......................................................................................................137
9.1.5.1 Pollcon tower description................................................................................................137
9.1.5.2 Pollcon tower operation...................................................................................................138
9.1.6 Dispersion and Bleaching description.............................................................................140
9.1.6.1 Transfer MC pump 05PMC10.........................................................................................140
9.1.6.2 Recirculation chest 07CPA11..........................................................................................140
9.1.6.3 Screw Press 06PVS01....................................................................................................141
9.1.6.4 Kneader 06TL02.............................................................................................................142
9.1.6.5 Pollcon Tower 07CPA01.................................................................................................144
9.2 BASIC OPERATING CAPACITY................................................................................................145
9.3 TRANSMITTERS AND CONTROL LOOPS................................................................................146
9.4 INTERLOCKINGS AND ALARMS...............................................................................................147
9.4.1 Transfer MC pump 05PMC10.........................................................................................147
9.4.2 Recirculation chest 07CPA11.........................................................................................148
9.4.3 Screw Press 06PVS01....................................................................................................150
9.4.4 Kneader 06TL02.............................................................................................................150
9.4.5 0xidative bleaching tower 07CPA01................................................................................152
9.4.6 ALARMS 157
9.5 OPERATION...............................................................................................................................158
9.5.1 Start-up 158
9.5.1.1 Starting of the loop..........................................................................................................158
9.5.1.2 Production.......................................................................................................................159
9.5.2 Operation 159
9.5.3 Shutdown 160
9.5.3.1 Stop of production...........................................................................................................160
9.5.3.2 Stop of the loop...............................................................................................................160

GENERAL
Page 6/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

10 FINE SCREENING 162

10.1 DESCRIPTION.........................................................................................................................162
10.1.1 Area itemization............................................................................................................162
10.1.2 ScreenOne basics.........................................................................................................162
10.1.2.1 ScreenOne Description.................................................................................................162
10.1.2.2 ScreenOne Operation...................................................................................................162
10.1.2.3 ScreenOne sequence...................................................................................................162
10.1.3 Fine screening area......................................................................................................163
10.2 BASIC OPERATION CAPACITY..............................................................................................165
10.3 TRANSMITTERS AND CONTROL LOOPS..............................................................................165
10.4 INTERLOCKINGS AND ALARMS.............................................................................................167
10.5 OPERATION.............................................................................................................................169
10.5.1 Start-up 169
10.5.1.1 Fill the unit.....................................................................................................................169
10.5.1.2 Starting of the loop........................................................................................................170
10.5.1.3 Production.....................................................................................................................170
10.5.2 Operation 170
10.5.3 Sequences....................................................................................................................171
10.5.3.1 ScreenOne basket depluging........................................................................................171
10.5.3.2 ScreenOne washing......................................................................................................171
10.5.4 Shutdown 172
10.5.4.1 Stop of production.........................................................................................................172
10.5.4.2 Stop of the loop.............................................................................................................172

11 POST-FLOTATION 174

11.1 DESCRIPTION .........................................................................................................................174


11.1.1 Post-Flotation Itemization..............................................................................................174
11.1.2 Flotation cell (MAC) basics...........................................................................................174
11.1.3 Deinking cell MAC Sequence........................................................................................174
11.1.4 Post-Flotation area........................................................................................................175
11.2 BASIC OPERATING CAPACITY..............................................................................................178
11.3 TRANSMITTERS and CONTROL LOOPS................................................................................178
11.4 INTERLOCKINGS AND ALARMS.............................................................................................179
11.5 OPERATION.............................................................................................................................182
11.5.1 Start up 182
11.5.1.1 Water filling...................................................................................................................182
11.5.1.2 Starting of loop..............................................................................................................182
11.5.1.3 Production.....................................................................................................................183
11.5.2 Operation 183
11.5.3 Stop 184
11.5.3.1 Stop of loop...................................................................................................................184
11.5.3.2 Stop of the Deinking cell...............................................................................................184

GENERAL
Page 7/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

12 LOOP 2 DISC FILTER & WATER DISTRIBUTION 186

12.1 DESCRIPTION.........................................................................................................................186
12.1.1 Area itemization............................................................................................................186
12.1.2 Disc Filter basics...........................................................................................................186
12.1.3 Area description...........................................................................................................187
12.1.3.1 Desaeration chest 10CPA01.........................................................................................187
12.1.3.2 Loop 2 Disc Filter..........................................................................................................187
12.1.3.3 Loop 2 water distribution...............................................................................................188
12.2 BASIC OPERATING CAPACITY..............................................................................................190
12.3 TRANSMITTERS AND CONTROL LOOPS..............................................................................190
12.4 INTERLOCKINGS AND ALARMS.............................................................................................191
12.4.1 Desaeration chest 10CPA01.........................................................................................191
12.4.2 Loop 2 Disc Filter 10FDQ04..........................................................................................192
12.4.3 Loop 2 water distribution...............................................................................................193
12.5 OPERATION.............................................................................................................................197
12.5.1 Start-up 197
12.5.1.1 Water tanks filling..........................................................................................................197
12.5.1.2 Disc Filter 10FDQ04 start..............................................................................................197
12.5.1.3 Production.....................................................................................................................198
12.5.2 Operation 198
12.5.3 Shutdown 199
12.5.3.1 Stop of production.........................................................................................................199
12.5.3.2 Disc Filter 10FDQ04 stop..............................................................................................199
12.5.3.3 Loop 3 Water distribution..............................................................................................199

13 REDUCTIVE BLEACHING 201

13.1 DESCRIPTION.........................................................................................................................201
13.1.1 Reductive bleaching itemization....................................................................................201
13.1.2 Heating screw...............................................................................................................201
13.1.3 MC Pump basics...........................................................................................................201
13.1.4 Reductive bleaching description...................................................................................202
13.1.4.1 Heating screw...............................................................................................................202
13.1.4.2 MC pump and reactive tubes........................................................................................202
13.1.4.3 Recirculation chest 07CPA11........................................................................................203
13.2 BASIC OPERATION CAPACITY..............................................................................................204
13.3 TRANSMITTERS AND CONTROL LOOPS..............................................................................204
13.4 INTERLOCKINGS AND ALARMS.............................................................................................205
13.5 OPERATION.............................................................................................................................208
13.5.1 Start-up 208
13.5.1.1 Start of the Loop...........................................................................................................208
13.5.1.2 Production.....................................................................................................................208

GENERAL
Page 8/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

13.5.2 Operation 208


13.5.3 Shutdown 209

14 LOOP 2 DISPERSING SYSTEM 211

14.1 DESCRIPTION .........................................................................................................................211


14.1.1 Area Itemization............................................................................................................211
14.1.2 Dispersing system.........................................................................................................211
14.1.3 Area description............................................................................................................212
14.1.3.1 Dispersing system.........................................................................................................212
14.1.3.2 Storage tower 12CPA03...............................................................................................216
14.2 BASIC OPERATING CAPACITY..............................................................................................218
14.3 TRANSMITTERS AND CONTROL LOOPS..............................................................................218
14.4 INTERLOCKINGS AND ALARMS.............................................................................................220
14.4.1 Dispersing system.........................................................................................................220
14.4.2 Storage tower 12CPA03...............................................................................................224
14.5 OPERATION.............................................................................................................................227
14.5.1 Start-up 227
14.5.1.1 Starting of the loop........................................................................................................227
14.5.1.2 Production.....................................................................................................................229
14.5.2 Operation 229
14.5.3 Shutdown 229
14.5.3.1 Stop of production.........................................................................................................229
14.5.3.2 Stop of the loop.............................................................................................................229

15 WASHING & FINAL STORAGE 232

15.1 DESCRIPTION.........................................................................................................................232
15.1.1 Area Itemization............................................................................................................232
15.1.2 Washer basics..............................................................................................................233
15.1.2.1 DNT Washer Description..............................................................................................233
15.1.3 DNT Washer operation.................................................................................................234
15.1.4 Area description............................................................................................................235
15.1.4.1 Washing area feed and by-pass....................................................................................235
15.1.4.2 Washing feed pump 13PPC01......................................................................................235
15.1.4.3 DNT washers................................................................................................................236
15.1.4.4 Transfer MC pump 14PMC11.......................................................................................237
15.1.4.5 Final Storage tower 14CPA04.......................................................................................238
15.2 BASIC OPERATING CAPACITY..............................................................................................240
15.3 TRANSMITTERS AND CONTROL LOOPS..............................................................................241
15.4 INTERLOCKINGS AND ALARMS.............................................................................................243
15.4.1 Transfer chest 12CPA06...............................................................................................243
15.4.2 Washers feed pump 13PPC01......................................................................................244
15.4.3 Washer 13LAV02..........................................................................................................245

GENERAL
Page 9/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

15.4.4 Washer 13LAV03..........................................................................................................247


15.4.5 Common to both Washers............................................................................................250
15.4.6 Transfer MC pump 14PMC11.......................................................................................251
15.4.7 Storage tower 14CPA04...............................................................................................253
15.5 OPERATION.............................................................................................................................255
15.5.1 Start-up 255
15.5.1.1 Start of the loop.............................................................................................................255
15.5.1.2 Production.....................................................................................................................256
15.5.2 Operation 257
15.5.3 Shutdown 257
15.5.3.1 Stop of production.........................................................................................................257
15.5.3.2 Stop of the loop.............................................................................................................257

16 LOOP 3 WATER DISTRIBUTION & MICRO-FLOTATION 260

16.1 DESCRIPTION.........................................................................................................................260
16.1.1 Itemization....................................................................................................................260
16.1.2 Microflotator PPM basics..............................................................................................261
16.1.2.1 Microflotator PPM Description.......................................................................................261
16.1.2.2 Microflotator PPM operation..........................................................................................261
16.1.3 Area description............................................................................................................264
16.1.3.1 Loop 3 Water distribution..............................................................................................264
16.1.3.2 Micro-flotation..............................................................................................................265
16.2 BASIC OPERATING CAPACITY..............................................................................................267
16.3 TRANSMITTERS AND CONTROL LOOPS..............................................................................267
16.4 INTERLOCKINGS AND ALARMS.............................................................................................268
16.5 OPERATION.............................................................................................................................272
16.5.1 Start-up 272
16.5.1.1 Water tanks filling..........................................................................................................272
16.5.1.2 Start up the Microflotator ..............................................................................................272
16.5.1.3 Production.....................................................................................................................272
16.5.2 Operation 273
16.5.3 Shutdown 273
16.5.3.1 Micro-Flotation..............................................................................................................273
16.5.3.2 Loop 3 water tanks........................................................................................................273

GENERAL
Page 10/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

1 REVISIONS TO DOCUMENT

Rev Date Author Description/pages modified

00 23/0904 JLV 1st ISSUE.

GENERAL
Page 11/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

2 GENERAL

NB: General remarks for all sequence timers.


All timers noted “operator screen “have to be adjusted by operator.
All the others need (for process reasons) to be adjustable but with a different
access level.

2.1 GENERAL DESCRIPTION

The new KHANNA DIP line comprises the installation of a 3 loops deinking pulp
line complete from waste paper to pulp storage, including variable washing -
deashing and DIP water processes.

The deinking grade produce is PRINTING/WRITING made with deinking pulp


from this line and from an existing modified line.

The capacity of this deinking line is 300 BDMT/24h into the storage.

This document is to serve as basis for the program of the DCS control software,
a guide for operation of the line and training of the operators.

The area considered here is fully controlled from by a Distributed Control System
(DCS), with local controls for a limited number of applications, for regulations,
interlocks, sequences and group-start/group-stop.

2.2 SCOPE

We review in this document the global process layout and main control
parameters.

Chemical Storage and distribution, Sludge Thickening, Paper Machine systems


are excluded from the scope of this document.

For each area, the process is outlined with a definition of the main sub-systems,
basic operating data and main control relations to other process areas.

All items used hereafter (for equipment, valves and instrumentation) correspond
to Flow-Sheet N° FS5232.

GENERAL
Page 12/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

2.3 DE-INKED PULP PRODUCTION SET-POINTS

2.3.1 Control Principle

The object of the Line production control will be to maintain all intermediate pulp
storage volumes stable (Dump Chest, Bleaching Towers) and maintain Storage
Tower at required level.

Differences in actual tonnage processed in the different loops, resulting either


from instrument error or process variation, are corrected by operator following the
evolutions of the levels in the intermediate capacities

The operator determines the production set points for the line as described
hereunder.

2.3.1.1 Waste Paper Pulping tonnage

Pulper system takes water from Pulper Water Tank 05CE11 and dumps stock
into Pulper Dump Chest 01CPA15.

The Pulper production follows the level in Pulper Dump Chest 01CPA15.

2.3.1.2 Loop 1 production control P1-3015

Loop 1 takes pulp from Pulper Dump Chest 01CPA15 and delivers Pulp to Loop
1 Bleaching Tower 07CPA01 - with water recirculating from Loop 1 Disc Filter &
Screw-press to Loop 1 Water tanks.

Loop 1 Pre-screening Slots production is set as set-point to P1-3015.

As transmitter NT3015 continuously measures the consistency of this flow, flow


in m3/h can be calculated and adjusted automatically through Flowmeter
FIC3020.

Pre-Screen slots 02SC19 accept flow is forwarded from Constant level box
02CP20.
Then the flow accepted from Stage 1 Pre-Screen slots 02SC19, in excess from
the flow controlled by FIC3020, flows back to Slots screening Feed Chest
02CPA16. The operation of ScreenOne is not affected by changes in throughput.

The Loop 1 Pre-screening accept tonnage is adjusted by checking Loop 1


Bleaching Tower 07CPA01 level LIS6070.

In practice, the residence time of 2 hours in the Loop 1 Pollcon Tower operated
at 80% level with an average 25-35% consistency, leaves time to avoid
overflowing or emptying the Tower.

Operation with stable Bleaching Tower level is recommended for stable


Bleaching operation.

GENERAL
Page 13/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

2.3.1.3 Loop 2 production control P2-5070

Loop 2 takes pulp from Loop 1 Bleaching Tower 07CPA01 and delivers pulp to
Loop 2 Storage Tower 12CPA03 - with water recirculating from Loop 2 Disc Filter
& Screw-press to Loop 2 Water tanks.

Loop 2 Production is adjusted with Flowmeter FIC8010 on post-flotation stock


feed pipe.

This adjustment has a direct repercussion on Loop 2 screening feed chest


07CPA08 level control LIC6120 with valve LCV-6120 regulating delivery flow
from Bleaching tower 07CPA01 extraction pump 07PPC07.

Then Loop 2 production P2-5070 is calculated from Flowmeter FI6115 (bleaching


tower 07CPA01 extracted flow) and consistency controller NRC6095.

Operator must check and correct Flowmeter FIC8010 set-point in order to keep
constant level in Bleaching Tower 07CPA01.

In order to keep constant Storage tower 12CPA03 level LIS11045, Loop 2


tonnage P2-5070 should vary relatively to Deashing system throughput P3-12005
and to Final Storage tower 14CPA04 level LIS15040 (when DNT washers are by-
passed).

2.3.1.4 Loop 3 production control P3-12005

Loop 3 takes pulp from Loop 2 Storage Tower 12CPA03 and delivers pulp to
Storage Tower 14CPA04 - with water recirculating from Loop 3 DNT Washers to
Loop 3 Water tanks.

Deashing stock feed production is set as set-point to P3-12005.


As the consistency of this flow is continuously measured & controlled by
regulation loop NIC11075, set flow in m3/h can be calculated and adjusted
automatically through Flowmeter FIC12005.

Moreover a washing by-pass line allows to transfer pulp from Storage Tower
12CPA03 directly to Storage Tower 14CPA04 via extraction pump 12PPC05.
Consistency at this point is continuously measured by regulation loop NIC11050,
set flow in m3/h can then be calculated and adjusted automatically through
Flowmeter FIC15095.

Total stock production required from Loop 2 is the sum of Washing feed
production and washing by-pass production.

The Loop 3 Production control P3-12005 and washing by-pass quantity can be
adjusted by checking Storage tower 14CPA04 level LIS15040 and Loop 2
Bleaching tower 12CPA03 level LIS11045.

Operation with stable Storage Tower level is recommended for stable water
balance.

GENERAL
Page 14/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

2.3.1.5 Pulp from Storage to Paper Machine

Paper Machine area Controller adjusts the remote set-point of FIC-15060


controlling extracted flow from Storage Tower 14CPA04.

This transfer production is calculated through Flowmeter FIC15060 and


consistency controller NRC15045.

2.3.2 Interlocks & Production Set-Points

Operation of the process equipment will prevail on production control through


control interlocks to maintain continuity of operations on the line.

These interlocks are detailed in the applicable paragraph for each process area.

However Operators are required to check all Pulp Bleaching and Storage Towers
level trends regularly in operation and to adjust Production set-points accordingly.

Note: for all systems operated at a stable hydraulic load (flotation cells, cleaners),
no interlocks protect against operation in sub-optimal conditions, if a pulp flow is
applied superior to the design capacity.

Setting a production flow above the design values may lead to sub-optimal
performances or production disruption.

2.3.3 Production Flexibility, Quality Control & Pulp Production

The line production configuration possibilities described hereunder allow full


flexibility regarding final requirement for bleaching profit and final ash content.

In case of off-specification pulp production due to either Waste Paper


contamination or transitory process upsets, the possibilities proposed allow
proper handling of the off-spec pulp produced.

Bleaching steps series

According to waste paper characteristics and final desired quality, the following
bleaching steps can be adjusted:
- Loop 1 oxidative bleaching in Pollcon tower 07CPA01.
- Loop 2 Reductive bleaching through Heating Screw 14VIT01 and reactive
Tube 14BLT07a & 14BLT07b.
- If required, this Reductive bleaching is achieved in KRIMA dispersion system
(through Disperser 11KR06).

GENERAL
Page 15/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Deashing system

Ash content in deinked pulp is proportional to production ratio sent to washing


system (and then to filtrate flow to be treated by Micro-flotation).
Feed production to Loop 3 washing is adjustable through Flowmeter FIC12005,
commanding stock extraction from Transfer chest 12CPA06 (and then from Loop
2 Storage Tower 12CPA03). (Production can be calculated with consistency
measured with NIC11075).
Washing by-pass production is adjustable through Flowmeter FIC15095 (and
calculated with stock consistency measured NRC11050).

The sum of Washing feed and By-pass productions gives the stock quantity to be
processed by the 2 upstream deinking loops.

Case Loop 1 Accept pulp recycling to Start Chest

In the case the Pulp quality obtained at the Loop 1 Disc Filter Outlet is
unacceptable, or during transitory start-up conditions, the Pulp accepted from
Loop 1 Disc Filter may be pumped back from MC Pump 05PMC10 to Start Chest
07CPA11 (and then pumped back to Dump Chest 01CPA15) with On/Off valve
AV6010 forced closed and On/Off valve AV6006 open.

In this case, the Pulp Flow to Loop 2 is closed.

Case Loop 1 Dispersion system By-pass

In the case of malfunction of equipment in Dispersion system, or during special


operating conditions, the Pulp accepted from Loop 1 Disc Filter may be sent
directly to oxidative bleaching tower 07CPA01 with On/Off valve AV6015 forced
closed (with On/Off valve AV6150 open) at Screw Press 06PVS01 inlet.

The upstream Loop 1 process throughput remains controlled as described above.

Case Loop 2 Accept pulp recycling to Start Chest

In the case the Pulp quality obtained at the Loop 2 Disc Filter Outlet is
unacceptable, or during transitory start-up conditions, the Pulp accepted from
Loop 2 Disc Filter may be pumped back from MC Pump 14PMC03 to Start Chest
07CPA11 (and then pumped back to Dump Chest 01CPA15) with On/Off valve
AV15035 forced closed and On/Off valve AV9015 open.

In this case, Reductive Bleaching is inactive:


 Heating Screw .14VIT01 is only used for stock conveying and steam
feed must be closed.
 Reductive chemicals injection must be closed.

Then the Pulp Flow to KRIMA dispersion is closed, the upstream Loop 1 & Loop
2 process throughputs remain controlled as described above.

GENERAL
Page 16/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Case Loop 2 Hot Dispersion system By-pass

Same as in Loop 1, in the case of malfunction of an equipment in KRIMA Hot


Dispersion system, or during special operating conditions, the Pulp accepted
from Loop 2 Disc Filter may be sent directly to Loop 2 reductive MC pump feed
tank 12PMC02.

The downstream Loop 1 & Loop 2 process throughputs remain controlled as


described above.

2.3.4 Ash control and Yield control in Pulp Production

The Ash & Fines content in the Pulp produced and related DIP Line Yield are
controlled by the following process parameters:

- % of total production sent to Loop 3 washing. Then, as a consequence, % of


Washers filtrates processed on Micro-flotation.

- % of Pre Flotation foam re-introduction to Prime Mac feed.

- % of Post Flotation foam re-introduction to Prime Mac feed.

- % of Micro-Flotation sludge re-introduction to Prime Mac feed.

GENERAL
Page 17/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

2.4 DIP LINE WATER BALANCE & CONTROLS

The DIP Line water is structured in 3 circulation Loops.

- Loop 1: from Waste Paper Pulping to Loop 1 Bleaching Tower;


- Loop 2: from extraction of Loop 1 Bleaching Tower to Loop 2 Tower.
- Loop 3: from extraction of Loop 2 Bleaching Tower to DNT Washers and
Storage Tower.

For each loop, the filtrates produced by the thickening equipment are used for
dilution of the thick stock entering the loop.

For loops 1-2-3, the operation of the line requires a filtrate make-up to balance
water exportation through rejects and stock flows.

The Paper Machine process generates an excess of filtrates, which is used to


cover the required make-up to DIP Line.

The object of Filtrate and Water controls is to:


- Obtain a stable operation on the DIP Line filtrate & water flows,
- Allow smooth start-up & shut-down,
- Control water balance through all process variations without Low level or
overflows.

Water process control for each loop are detailed in each corresponding
paragraph.

2.4.1 Loop 1 Filtrate balance controls

The Loop 1 dilution water tanks are the following:


- Clear Filtrate Tank 05CE03, with level controller LIS5055, used for Cleaners
and Loop1 dilution pumps and overflowing into:

- Cloudy Filtrate Tank 05CE02, with level controller LIS5045, used for
Flotation dilution and overflowing into

- Pulper Water tank 05CE04, with level controller LIC5010, used as transfer to

- Buffer Water tank 05CE11, with level controller LIS5000, used for Pulpers
dilution (occurring high discontinuous flows). This tank has a big volume
capacity in order to store water during transitory phases (for example
shutdown of Loop 1 when filtrate generated by thickening is no more
consumed for Loop 1 process dilutions).

The make-up to Loop 1 is obtained from pump 10PPC09 (Loop 2 Periodic


Filtrates pump), through level controller LIC5010 (level decreasing in tank 05C04)
commanding control valve LCV-5010.

The make-up from Loop 2 to Loop 1 Clear filtrate tank 05CE03 covers the water
losses through the cleaning, screening and flotation processes.
Design flow is to allow minimum for start-up & variations.

GENERAL
Page 18/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Note: The Clear Filtrate Tank 05CE03 level controller LIS5055 and Cloudy
Filtrate Tank 05CE02 level controller LIS5045 will be adjusted as to respond
rapidly to any variation in level.
The Pulper Water tank 05CE04 level controller LIC5010 will be adjusted to act
slowly to keep the Pulper Water Tank level trend stable.

The Water tank 05CE11 serves as buffer tank, and its level oscillates following
the batch operation of the Pulper.

Normal variations in operation

When Dump Chest level goes down, either voluntarily or because of process
variation, the volume of water pumped out of Dump Chest flows to Loop 1 Filtrate
tanks. This constitutes an excess of filtrate that ends up in Loop 1 Buffer Water
Tank 05CE11.

To avoid overflow, it is required to have in operation enough storage available in


Water Tank: i.e. the lowest water volume in Pulper Water Tank 05CE11.

On the other hand, when Dump Chest level goes up, i.e. on starting the DIP Line,
the volume filling the Dump Chest will be supplied from Buffer Water Tank
05CE11. For a smooth start-up, it is required to have a sufficient level in Buffer
Water Tank.

Repetition of strong variations in Dump Chest level should be avoided, as this will
have the effect of filling up the Buffer Water chest with Loop 2 water with
additional call of PM White Water into the DIP Line.

2.4.2 Loop 2 Filtrate balance controls

The Loop 2 dilution tanks are the following:


- Loop 2 Clear Filtrate Tank 10CE06, with level controller LIS9055,
overflowing into:

- Loop 2 Cloudy Filtrate Tank 10CE05, with level controller LIC9050.

The water make-up to Loop 2 is obtained from pump 13PPC09 (Loop 3 dilution
pump), through control valve LCV-9050 to Clear water tank 10CE06, controlled
by level controller LIC9050.
Then make-up water feeds Clear filtrate tank 10CE06 and overflows to tank
10CE05.

The make-up from Loop 3 to Loop 2 covers the Loop 1 & Loop 2 water losses
through the cleaning, screening and flotation processes.
Design flow is to allow minimum for start-up & variations.

In case of Microflotator not used for deashing process (DNT washers stopped),
then Loop 2 Clear Filtrate can be pumped through 10PPC10 to DAF feed tank
13CE07. After being processed by Poseidon, clarified filtrate flow back to Loop 2
through transfer pump 13PPC11.

GENERAL
Page 19/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Normal variations in operation

When Loop 1 Bleaching Tower level goes down, either voluntarily or because of
process variation, the volume of water pumped out will be negligible compared to
global water flows.

Operational priority will be to maintain level in Loop 2 filtrates tanks to smooth out
all process variations.

2.4.3 Loop 3 Filtrate balance controls

The Loop 3 water tanks are the following:


- Poseidon Feed tank 13CE07 with level controller LIC13010, recovering by
gravity the Filtrates accepted from Filtrates from DNT Washers or filtrates
transferred from Loop 2 (in case DNT washers are not used).

- Loop 3 dilution tank 13CE08 with level controller LIC13005, recovering


accepted from Poseidon and PM water make-up. This tank is used for Loop 3
dilutions and make-up water.

Pump 13PPC10 feeds the Poseidon Clarifier at a controlled & fixed flow (in direct
relation with level controller LIC13010 in order to operate Poseidon accordingly to
DNT filtrates flow).

The make-up to Loop 3 is obtained from PM Clarified Water, through level


controller LIC13005 acting on valve LCV-13005 commanding complement flow to
Loop 3 tank 13CE08.

If required, pump 13PPC19 allows transferring filtrate from tank 13CE07 to


another micro-flotation system in a parallel line (called existing VOITH line).
In order to maintain a stable water balance in the whole system, the same water
quantity must be repatriated from VOITH line in water tank 13CE08.

The make-up from PM Clarified Water to Loop tank 13CE08 covers the Loop 1,
Loop 2 & Loop 3 water losses through the cleaning, screening and flotation
processes.
Design flow is to allow minimum for start-up & variations.

Normal variations in operation

When Loop 2 Bleaching Tower level goes down, either voluntarily or because of
process variation, the volume of water pumped out of will be negligible compared
to global water flows.

Operational priority will be to maintain level in Loop 3 filtrates tanks to smooth out
all process variations.

When Storage Tower 14CPA04 level goes down, either voluntarily or because of
process variation, the volume of water pumped out of Storage Tower flows to
Loop 3 Washer Filtrate tank 13CE07. This constitutes an excess of Loop 3
filtrate.

GENERAL
Page 20/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

PROCESS DESCRIPTION

KHANNA
NEW DIP LINE 300 BDMT/24h
PRINTING - WRITING

PULPING AREA

PULPING
Page 21/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

3 PULPING

3.1 DESCRIPTION

Waste Paper Repulping system repulps the Waste Paper with DIP Line filtrates,
with possible chemicals addition; the coarse contaminants are removed in the
Dumping Poire.

The area process structure is as follows:

Pulping area is divided in two parallels identical systems complete from Waste
papers conveyor to dumping pump and able to run independently except for:
- Dilution water is pumped from a common water tank 05CE11.
- Pulped stock is sent to a common dump chest 01CPA15.

3.1.1 Pulping itemization

3.1.1.1 Pulping area 1


 Waste paper conveyor ............................................................................01TAP01
 Helico Pulper ..............................................................................01PH02
 Hood for Helico Pulper ..............................................................................01HT03
 Pulper vapour exhaust fan......................................................................................
01ASP04
 Hot water tank wit steam injectors..........................................................................
01CE05
 Dumping Poire ..............................................................................01PV06
 Dump pump ............................................................................01PPC07
 Water dilution pump ............................................................................05PPC12
 Dosing tank Peroxide H202....................................................................................
40CC29
 Dosing tank Silicate Na2SIO3.................................................................................
40CC30
 Dosing tank Caustic Soda NaOH............................................................................
40CC31
 Dosing tank DTPA ..............................................................................40CC32
 Dosing tank Soap ..............................................................................40CC37

3.1.1.2 Pulping area 2


 Waste paper conveyor ............................................................................01TAP08
 Helico Pulper ..............................................................................01PH09
 Hood for Helico Pulper ..............................................................................01HT10

PULPING
Page 22/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

 Pulper vapour exhaust fan......................................................................................


01ASP11
 Hot water tank wit steam injectors..........................................................................
01CE12
 Dumping Poire ..............................................................................01PV13
 Dump pump ............................................................................01PPC14
 Water dilution pump ............................................................................05PPC13
 Dosing tank Peroxide H202....................................................................................
40CC33
 Dosing tank Silicate Na2SIO3.................................................................................
40CC34
 Dosing tank Caustic Soda NaOH............................................................................
40CC35
 Dosing tank DTPA ..............................................................................40CC36
 Dosing tank Soap ..............................................................................40CC38

3.1.1.3 Equipment common to both pulping areas


 Dump chest ............................................................................01CPA15
 Dump chest agitator ..............................................................................01AG16
 Transfer pump to continuous chest.........................................................................
01PPC17
 Pulper water tank ..............................................................................05CE11

3.1.2 Helico Pulper basics

3.1.2.1 Helico Pulper Description

The KADANT Helico Pulper consists of:


- A stainless steel Pulper Vat, with support legs according to size.
A Pulper Hood generally covers the Pulper Vat with extraction pipe to contain mist
and steam generated by the filtrates used in the Pulper.
- An accept chamber with accept stock outlet
- A cast stainless steel High consistency Helico turbine machined and treated
according to the application. The rotor is driven in rotation by the vertical shaft
of the mechanism.
- A complete rotating mechanism driving the screen rotor, with a vertical shaft
and a water lubricated packed gland seal, running in two grease-lubricated
bearings and depending on the Pulper size a mechanical gear drive or pulleys
and V-belt drive.

The Pulper turbine remains in operation continuously during the Pulper operating
cycle.

PULPING
Page 23/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

ATTENTION: THE PULPER SHOULD NOT BE FED WITH FIBER WITHOUT A


PRIOR PARTIAL FILLING OF FILTRATES. NON-OBSERVANCE WILL LEAD TO
BLOCK THE PULPER DRIVE OR TO A RISK OF OVER-HEATING OF THE RAW
MATERIAL & RELATED FIRE HAZARD.

ATTENTION: THE MAXIMUM WEIGHT LOAD OF RAW MATERIAL TO THE


PULPER SHOULD NOT BE EXCEEDED NON OBSERVANCE MAY LEAD TO
OVERLOAD THE PULPER DRIVE, LEAD TO DISRUPTION OF OPERATIONS.

ATTENTION: RUNNING THE PULPER WITH A WATER LOAD (WITHOUT


FIBER) IN EXCESS OF THE DESIGN 25% FIRST FILLING VOLUME MAY LEAD
TO SPILLAGE OF WATER or FILTRATES. IN CASE OF HOT OR CAUSTIC
FILTRATES, INJURY MAY RESULT IF NON OBSERVANCE.

ATTENTION: MAINTENANCE PERSONNEL OR OPERATOR INTERVENTION


ON THE PULPER MOVING PARTS OR IN/ABOVE THE PULPER VAT WILL BE
DONE ACCORDING TO THE ADEQUATE SECURITY PROCEDURES,
INCLUDING ISOLATION & LOCKING OF THE MCC FEEDER TO PULPER
DRIVE, FILTRATES TO PULPER FEED PUMP, ISOLATION OR LOCKING OF
FILTRATES FEED VALVES. INJURY MAY RESULT IF NON OBSERVANCE.

ATTENTION: WHERE APPLICABLE, SECURITIES & ALARMS ON DRIVE


HYDRAULICS MUST BE IMPLEMENTED ACCORDING TO KADANT or
HYDRAULICS SUPPLIER RECOMMENDATIONS AND OBSERVED
RIGOROUSLY. FAILURE TO DO SO MAY LEAD TO DESTRUCTION OF THE
DRIVE. STOPPING & RESTARTING REPEATEDLY THE PULPER DRIVE IS
SUBJECT TO THE LIMITATIONS ON PULPER DRIVE MOTOR.

3.1.2.2 Helico Pulper Sequence

See Associated Grafcet (will be supplied by Kadant).

3.1.3 Dumping Poire basics

3.1.3.1 Poire description

The KADANT Dumping Poire consists of:


- A stainless steel Dump screen body comprising a large reject chamber, fitted
with a bolted front-end door-lid.
- A screen plate with perforations as per application.
- A Rotor -rotating in front of the perforated plate - with hydrofoils effect arranged
specifically for the application considered. The rotor is driven in rotation by the
horizontal shaft of the mechanism.
- A complete rotating mechanism driving the rotor, with a horizontal shaft running
in two grease-lubricated bearings and a water lubricated packed gland seal,
pulleys and V-belt drive.

PULPING
Page 24/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

- A supporting base for the Dump screen body and mechanism.

The Dumping Poire starts and stops at each Pulper discharge cycle.

3.1.3.2 Dumping Poire Sequence

See Associated Grafcet (will be supplied by Kadant).

PULPING
Page 25/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

3.1.4 Pulping area

3.1.4.1 Pulping area 1

Waste paper loading to Pulper

Waste paper bales are dewired manually & dumped as Loose Paper on Pulper
Conveyor 01TAP01.

The batches put on the conveyor are previously weighted by WIRS1045 to check
the weight of materials going into the Pulper.

In general, the Waste Paper Handling system is controlled locally (local control
panel with PLC, interfaced with DCS) for bales reception and de-wiring, waste
paper controls for the system downstream. (To be checked and corrected with
exact situation).

Afterwards, waste papers are dumped in the Pulper 01PH02 running & filled (25%
level) with hot water and necessary chemicals.

Pulper 01PH02

The hot water tank 01CE05 receives the quantity of filtrate necessary for the next
batch pulping from the distribution water (via pump 05PPC12).
Level controller LIS1075 measures this tank level. High threshold LSH1075 closes
filling On/Off valve AV-1070.
Then filtrate is heated by mean of direct steam: Steam injection quantity (via
control valve TCV-1065) is adjusted through controller TIC1065 and must be
adapted according to required temperature inside Water tank 01CE05.

From this water tank 01CE05, a line brings filling water into Pulper vat via
automatic valve AV-1080. A hand valve MV-1066 is located upstream for
adjustment of the filling water flow.

The volume of Filtrates is completed to the amount required for operation of the
Pulper at a design of 14-16% operating consistency, and the Pulper operates for
the Pulping time required for a proper dispersion of the fibers.

After the set Pulping time, if Dump chest 01CPA15 has enough room, the Dumping
Poire 01PV06 cycle is set to ON.

Pulper 01PH02 rotor is driven in rotation with a gearbox equipped with security
alarms FSAL1050 (cooling water flow Low alarm) and TSAH1055 (Gearbox
temperature alarm).

The Pulper turbine remains in operation continuously during the Pulper operating
cycle. The Dump screen starts and stops at each Pulper discharge cycle.

PULPING
Page 26/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Dumping Poire 01PV06

When the Dump Poire 01PV06 is running, the Pulper discharge proceeds.
A manifold brings the water used to dilute the stock during this dumping sequence:
the largest portion (about 60 to 70 %) is introduced directly at the Dump Poire inlet
(via valve AV-1100), a further quantity goes into the Pulper tub (valve AV-1085),
lastly a small quantity is sent through the tub bottom under the rotor to avoid stock
building up there (valve AV-1095).
The water quantities are measured by Flowmeter FIQS1106 to control the proper
operation and regularity of the different phases of these dumping sequences.

Diluted pulp is pumped out of the Pulper vat towards the dump tank 01CPA15
through the Dump Poire 01PV06 by the Pulper dump pump 01PPC07 at a 4,5-
5,0% consistency.

At the discharge of pump 01PPC07, a regulating command valve HIC1115 is


installed to allow 3 different flows:
- -A closed position to avoid pulp return.
- -An open position for complete closing of the flow to the tank.
- -A selected half close position used during Dumping Poire screen washing
step.

The flow through the Dump Poire is an important factor to ensure the equipment’s
proper operation and efficiency. Too fast, it will carry through more contaminants.
Too slow, it will effect dumping time.
After a set time, if the Dump screen has not been set to Thickening step (auto
alarm or manual), the Pulper Discharge proceeds to Thickening and Emptying, and
the cycle re-starts.

When the Pulper Discharge valve AV-1060 closes, Dumping Poire 01PV06
sequence goes to Rejects Thickening, Draining, Rejects Dumping and Water
Filling.
The Poire motor stops if the Pulper is not in Discharge step.

During the dumping of rejects (Flap valve AV-1105 opens), the regulating valve
HCV-1115 has to be shut to prevent from discharge of the pulp contained in the
feed pipe of tank 01CPA15.

A motor amp-load high intensity alarm JISH1110 helps to detect an eventual


malfunction during Dumping Poire 01PV06 operation.

3.1.4.2 Pulping area 2

Waste paper loading to Pulper

Waste paper bales are dewired manually & dumped as Loose Paper on Pulper
Conveyor 01TAP08.

The batches put on the conveyor are previously weighted by WIRS1345 to check
the weight of materials going into the Pulper.

PULPING
Page 27/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

In general, the Waste Paper Handling system is controlled locally (local control
panel with PLC, interfaced with DCS) for bales reception and de-wiring, waste
paper controls for the system downstream. (To be checked and corrected with
exact situation).

Afterwards, waste papers are dumped in the Pulper 01PH09 running & filled (25%
level) with hot water and necessary chemicals.

Pulper 01PH09

The hot water tank 01CE12 receives the quantity of filtrate necessary for the next
batch pulping from the distribution water (via pump 05PPC13).
Level controller LIS1375 measures this tank level. High threshold LSH1375 closes
filling On/Off valve AV-1370.
Then filtrate is heated by mean of direct steam: Steam injection quantity (via
control valve TCV-1365) is adjusted through controller TIC1365 and must be
adapted according to required temperature inside Water tank 01CE12.

From this water tank 01CE12, a line brings filling water into Pulper vat via
automatic valve AV-1380. A hand valve MV-1379 is located upstream for
adjustment of the filling water flow.

The volume of Filtrates is completed to the amount required for operation of the
Pulper at a design of 14-16% operating consistency, and the Pulper operates for
the Pulping time required for a proper dispersion of the fibers.

After the set Pulping time, if Dump chest 01CPA15 has enough room, the Dumping
Poire 01PV13 cycle is set to ON.

Pulper 01PH09 rotor is driven in rotation with a gearbox equipped with security
alarms FSAL1350 (cooling water flow Low alarm) and TSAH1355 (Gearbox
temperature alarm).

Dumping Poire 01PV13

When the Dump Poire 01PV13 is running, the Pulper discharge proceeds.
A manifold brings the water used to dilute the stock during this dumping sequence:
the largest portion (about 60 to 70 %) is introduced directly at the Dump Poire inlet
(via valve AV-1400), a further quantity goes into the Pulper tub (valve AV-1390),
lastly a small quantity is sent through the tub bottom under the rotor to avoid stock
building up there (valve AV-1395).
The water quantities are measured by Flowmeter FIQS1405 to control the proper
operation and regularity of the different phases of these dumping sequences.

Diluted pulp is pumped out of the Pulper vat towards the dump tank 01CPA15
through the Dump Poire 01PV13 by the Pulper dump pump 01PPC14 at a 4,5-
5,0% consistency.

At the discharge of pump 01PPC14, a regulating command valve HIC1420 is


installed to allow 3 different flows:
- -A closed position to avoid pulp return.
- -An open position for complete closing of the flow to the tank.

PULPING
Page 28/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

- -A selected half close position used during Dumping Poire screen washing
step.

The flow through the Dump Poire is an important factor to ensure the equipment’s
proper operation and efficiency. Too fast, it will carry through more contaminants.
Too slow, it will effect dumping time.
After a set time, if the Dump screen has not been set to Thickening step (auto
alarm or manual), the Pulper Discharge proceeds to Thickening and Emptying, and
the cycle re-starts.

When the Pulper Discharge valve AV-1360 closes, Dumping Poire 01PV13
sequence goes to Rejects Thickening, Draining, Rejects Dumping and Water
Filling.
The Poire motor stops if the Pulper is not in Discharge step.

During the dumping of rejects (Flap valve AV-1410 opens), the regulating valve
HCV-1420 has to be shut to prevent from discharge of the pulp contained in the
feed pipe of tank 01CPA15.

A motor amp-load high intensity alarm JISH1415 helps to detect an eventual


malfunction during Dumping Poire 01PV13 operation.

3.1.4.3 Buffer water tank 05CE11

This tank is filled with filtrate by pump 05PPC05 connected on water tank 05CE04.

From this tank, pump 05PPC12 ensure Pulper 01PH02 dilution and pump
05PPC13 ensures Pulper 01PH09 dilution.

Water tank 05CE11, additionally to being a buffer for the discontinuous Pulper
Water consumption, is used to absorb variation in water needs on the DIP Line
related to Pulp Storage levels. (See § 2.4.1 - Loop 1 Filtrate balance controls).

Controller LIS5000 measures tank 05CE11 level continuously.


Low level in tank 05CE11 must be adjusted in order to always assume a minimum
reserve volume of water corresponding to a water total quantity required for a
dumping cycle.
Level set-point must correspond to normal operating level on the Pulper Water
Tank. This level will oscillate at the rhythm of the Pulper batch cycles, and the
controller long integration will ensure that on a 15 minutes period, the Water taken
out by the Pulper is smoothly made-up.

3.1.4.4 Dump chest 01CPA15

The Dumping Chest 01CPA15 has a volume sufficient to ensure storing between
this first step of the process, which is sequential, and the following steps, which are
continuous.
Controller LIS1425 measures chest level continuously.

Pump 01PPC17 transfers pulp stock to downstream Holes screening.

PULPING
Page 29/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

3.2 BASIC OPERATING CAPACITY

Pulpers: 2 x PH35
On the basis of a Pulper PH 35 m3 feed 5200 BDkg/batch, (i.e. 14 to 16% pulping
consistency), and sequence time at design 30 to 40 minutes, the basic operating
capacity of the sub-system is 200-250 BDt/24h.

Then basic operating capacity of Pulper area (2 x PH35 in parallel) is 400-450


BDt/24h.

Dumping Poire: 2 x PV3/3 with perforated plate (holes 6 mm)

PULPING
Page 30/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

3.3 TRANSMITTERS AND CONTROL LOOPS

3.3.1 Pulping area 1

Alarms Scale-0-
Item Function Description 100%
LL L H HH Value unit
L H
LIS 1000 Soap dosing tank 40CC37 level 0–300 lit
(1) (1)
L H
LIS 1005 Peroxide dosing tank 40CC29 level 0–150 lit
(1) (1)
Silicate Na2SIO3 dosing tank 40CC30 L H
LIS 1015 0–700 lit
level (1) (1)
Caustic Soda NaOH dosing tank 40CC31 L H
LIS 1025 0–300 lit
level (1) (1)
L H
LIS 1035 DTPA dosing tank 40CC32 level 0–100 lit
(1) (1)
Waste Paper weighing on Pulper L H
WIRS 1045 6500 0-7000 kg
conveyor 01TAP01 (1) (1)
Pulper 01PH02 gear cooling water flow
FSAL 1050 L
alarm
TSAH 1055 Pulper 01PH02 gear temperature alarm H
Pulper 01PH02 sealing water Low flow
FSA 20140 L Digital alarm
alarm
Hot water tank 01CE05 heating
TIC 1065 40 70 20-100°C
temperature control
L H1 H2 HH
LIS 1075 Hot water tank 01CE05 level control 0-35m3
(1) (1) (1) (1)
LL L H HH
LIS 1090 Pulper 01PH02 vat level control 0-35m3
(1) (1) (1) (1)
Pulper dumping water dilution flow 0-1000 m3/h
FIQS 1106 99%
counter %
JISH 1110 Dumping Poire 01PV06 drive Amp Load 95% 100% 0-150%
Dumping Poire 01PV06 sealing water
FSA 20145 L Digital alarm
Low flow alarm
Dump pump 01PPC07 delivery flow
HIC 1115 0-100%
control
(1) Values to be adjusted on start-up (according to process conditions & overall installation)

PULPING
Page 31/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

3.3.2 Pulping area 2


Alarms Scale-0-
Item Function Description 100%
LL L H HH Value unit
LIS 1300 Soap dosing tank 40CC38 level L (1) H (1) 0–300 lit

LIS 1305 Peroxide dosing tank 40CC33 level L (1) H (1) 0–150 lit

LIS 1315 Na2SIO3 dosing tank 40CC34 level L (1) H (1) 0–700 lit
LIS 1325 NaOH dosing tank 40CC35 level L (1) H (1) 0–300 lit
LIS 1335 DTPA dosing tank 40CC36 level L (1) H (1) 0–100 lit
Waste Paper weighing on Pulper
WIRS 1345 L (1) H (1) 6500 0-7000 kg
conveyor 01TAP08
Pulper 01PH09 gear cooling water flow
FSAL 1350 L
alarm
TSAH 1355 Pulper 01PH09 gear temperature alarm H
Pulper 01PH09 sealing water Low flow
FSA 20150 L Digital alarm
alarm
Hot water tank 01CE12 heating
TIC 1365 40 70 20-100°C
temperature control
L H1 H2 HH
LIS 1375 Hot water tank 01CE12 level control 0-35m3
(1) (1) (1) (1)
LL L H HH
LIS 1385 Pulper 01PH09 vat level control 0-35m3
(1) (1) (1) (1)
Pulper dumping water dilution flow
FIQS 1405 99% 0-1000 m3/h%
counter
JISH 1415 Dumping Poire 01PV13 drive Amp Load 95% 100% 0-150%
Dumping Poire 01PV13 sealing water
FSA 20155 L Digital alarm
Low flow alarm
HIC 1420 Dump pump 01PPC14 flow control 0-100%
(1) Values to be adjusted on start-up (according to process conditions & overall installation)

3.3.3 Common to both Pulper areas


Alarms Scale-0-
Item Function Description 100%
LL L H HH Value unit
L H1 H2 HH
LIS 1425 Dumping chest 01CPA15 level control 0-600 m3
(1) (1) (1) (1)
L LL H HH
LIS 5000 Pulper water tank 05CE11 level control 0-500 m3
(1) (1) (1) (1)
(1) Values to be adjusted on start-up (according to process conditions)

PULPING
Page 32/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

3.4 INTERLOCKINGS AND ALARMS

Interlocks are designed to avoid situations leading to disruption of operations or


damage to equipment. These securities are not absolute and KADANT
recommendations for operation are to be respected.

3.4.1 Pulping area 1

1- PULPER 01PH02 & GEARBOX ALARMS

If The gearbox oil temperature is High (TSAH1055) or the oil flow is Low
(FSAL1050)

Then If Pulper 01PH02 motor is stopped: it can't start


If Pulper 01PH02 motor is running: it stops

2- PULPER WATER TANK 01CE05 LEVEL LIS1075 & TEMPERATURE


TIC1065 TO STEAM VALVE TCV-1065

If Temperature TIC1065 is High-High


Or Water tank 01CE05 level LIS1075 is Low

Then Steam valve TCV-1065 is forced closed (Hard interlock).

If Temperature TIC1065 is High (High = set-point+ 5°C)


Then Steam Valve TCV-1065 in Auto is closed (Soft interlock).

If Temperature TIC1065 is Low (Low= set-point- 5°C)


Then Steam Valve TCV-1065 in Auto is opened (Soft interlock).

3- PULPER WATER TANK 01CE05 LEVEL LIS1075, PULPER WATER


PUMP 05PPC12 TO MAKE-UP VALVE AV-1070

If Water tank 01CE05 level LIS1075 is High-High


Or Pulper Water Pump 05PPC12 is not running

Then Make-up valve AV-1070 is forced closed (Hard interlock).

If Water tank 01CE05 level LIS1075 is not High-High


And Pulper Water Pump 05PPC12 is running

Then Make-up valve AV-1070 is allowed to Open (according to


Pulping sequence).

PULPING
Page 33/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

4- PULPER 01PH02 FILLING VALVE AV-1080 & DUMP VALVE AV-1060

If Pulper 01PH02 Filling Valve AV-1080 is not closed


Then Pulper 01PH02 Dump Valve AV-1060 is forced Closed

If Pulper 01PH02 Dump Valve AV-1060 is not closed


Then Pulper 01PH02 Filling Valve AV-1080 is forced Closed

5- PULPER WATER PUMP 05PPC12 INTERLOCK TO DILUTION VALVES

If Pulper Water Pump 05PPC12 is not running (On delay T=10s)

Then Pulper Top dilution Valve AV-1085 is forced closed


And Pulper Bottom dilution Valve AV-1095 is forced closed
And Poire dilution Valve AV-1100 is forced closed

Reset interlock On-delay=10s after pump is running.

6- DUMPING POIRE 01PV06 to PULPER DUMP PUMP 01PPC07

If Dumping Poire 01PV06 is not running

Then Stop Pulper dump pump 01PPC07

7- DUMP CHEST 01CPA15 LEVEL LIS1425 to PULPER PUMP 01PPC07

If Dump chest 01CPA15 level LIS1425 is High

Then Stop Pulper dump pump 01PPC07

8- PULPER DUMP VALVE AV-1060 & DUMP POIRE REJECT VALVE AV-
1105

If Pulper Dump Valve AV-1060 is not closed


Then Dump Poire Reject Valve AV-1105 is forced Closed

If Dump Poire Reject Valve AV-1105 is not closed


Then Pulper Dump Valve AV-1060 is forced Closed

PULPING
Page 34/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

9- PULPER DUMP PUMP 01PPC07 TO SLAVE VALVE HCV-1115

If Pulper dump pump 01PPC07 is not running


Then Control valve HCV-1115 is forced closed (Hard interlock)

If HD Pulper pump 01PPC07 is running


Then With on delay T=5s, Control valve HCV-1115 is opened (Soft interlock)

10- (RESERVE)

11- (RESERVE)

ALARMS

12- PULPER 01PH02 SEALING WATER ALARM

If Pulper 01PH02 main drive is running


And Sealing water flow FSA20140 is on Alarm Low

Then Set Pulper 01PH02 sealing water alarm

13- DUMPING POIRE 01PV06 SEALING WATER ALARM

If Dumping Poire 01PV06 motor is running


And Sealing water flow FSA20145 is on Alarm Low

Then Set Poire 01PV06 sealing water alarm

14- (RESERVE)

3.4.2 Pulping area 2

15- PULPER 01PH09 & GEARBOX ALARMS

If The gearbox oil temperature is High (TSAH1355) or the oil flow is Low
(FSAL1350)

Then If Pulper 01PH09 motor is stopped: it can't start


If Pulper 01PH09 motor is running: it stops

PULPING
Page 35/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

16- PULPER WATER TANK 01CE12 LEVEL LIS1375 & TEMPERATURE


TIC1365 TO STEAM VALVE TCV-1365

If Temperature TIC1365 is High-High


Or Water tank 01CE12 level LIS1375 is Low

Then Steam valve TCV-1365 is forced closed (Hard interlock).

If Temperature TIC1365 is High (High = set-point+ 5°C)


Then Steam Valve TCV-1365 in Auto is closed (Soft interlock).

If Temperature TIC1365 is Low (Low= set-point- 5°C)


Then Steam Valve TCV-1365 in Auto is opened (Soft interlock).

17- PULPER WATER TANK 01CE12 LEVEL LIS1375, PULPER WATER


PUMP 05PPC13 TO MAKE-UP VALVE AV-1370

If Water tank 01CE12 level LIS1375 is High-High


Or Pulper Water Pump 05PPC13 is not running

Then Make-up valve AV-1370 is forced closed (Hard interlock).

If Water tank 01CE12 level LIS1375 is not High-High


And Pulper Water Pump 05PPC13 is running

Then Make-up valve AV-1370 is allowed to Open (according to


Pulping sequence).

18- PULPER 01PH09 FILLING VALVE AV-1380 & DUMP VALVE AV-1360

If Pulper 01PH09 Filling Valve AV-1380 is not closed


Then Pulper 01PH09 Dump Valve AV-1360 is forced Closed

If Pulper 01PH09 Dump Valve AV-1360 is not closed


Then Pulper 01PH09 Filling Valve AV-1380 is forced Closed

19- PULPER WATER PUMP 05PPC13 INTERLOCK TO DILUTION VALVES

If Pulper Water Pump 05PPC13 is not running (On delay T=10s)

Then Pulper Top dilution Valve AV-1390 is forced closed


And Pulper Bottom dilution Valve AV-1395 is forced closed
And Poire dilution Valve AV-1400 is forced closed

Reset interlock On-delay=10s after pump is running.

PULPING
Page 36/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

20- DUMPING POIRE 01PV13 to PULPER DUMP PUMP 01PPC14

If Dumping Poire 01PV13 is not running

Then Stop Pulper dump pump 01PPC14

21- DUMP CHEST 01CPA15 LEVEL LIS1425 to PULPER PUMP 01PPC14

If Dump chest 01CPA15 level LIS1425 is High

Then Stop Pulper dump pump 01PPC14

22- PULPER DUMP VALVE AV-1360 & DUMP POIRE REJECT VALVE AV-
1410

If Pulper Dump Valve AV-1360 is not closed


Then Dump Poire Reject Valve AV-1410 is forced Closed

If Dump Poire Reject Valve AV-1410 is not closed


Then Pulper Dump Valve AV-1360 is forced Closed

23- PULPER DUMP PUMP 01PPC14 TO SLAVE VALVE HCV-1420

If Pulper dump pump 01PPC14 is not running


Then Control valve HCV-1420 is forced closed (Hard interlock)

If HD Pulper pump 01PPC14 is running


Then With on delay T=5s, Control valve HCV-1420 is opened (Soft interlock)

24- (RESERVE)

25- (RESERVE)

ALARMS

26- PULPER 01PH09 SEALING WATER ALARM

If Pulper 01PH09 main drive is running


And Sealing water flow FSA20150 is on Alarm Low

Then Set Pulper 01PH09 sealing water alarm

PULPING
Page 37/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

27- DUMPING POIRE 01PV13 SEALING WATER ALARM

If Dumping Poire 01PV13 motor is running


And Sealing water flow FSA20155 is on Alarm Low

Then Set Poire 01PV06 sealing water alarm

28- (RESERVE)

3.4.3 Common to both Pulper areas

29- DUMP CHEST 01CPA15 LEVEL LIS1425 to EXTRACTION PUMP


01PPC17

If Dump chest level LIS1425 is Low


Then Stop Transfer Pump 01PPC17

If Tank level LIS1425 is Low


Then Inhibit start of Transfer Pump 01PPC17

30- DUMP CHEST LEVEL LIS1425 TO AGITATOR 01AG16

If Dump chest level LIS1425 is Low-Low


Then Stop Agitator 01AG16

If Dump chest level LIS1425 is Low


Then Inhibit Start Agitator 01AG16

If Dump chest level LIS1425 is not Low


And Agitator 01AG16 in DCS Auto mode

Then Start Agitator 01AG16

31- TRANSFER PUMP 01PPC17 AUTO-START & INTERLOCK FROM


SCREENING FEED CHEST 02CPA01 LEVEL LICS2005

If Feed Chest Level LICS2005 is High-High


Then Stop Transfer Pump 01PPC17

PULPING
Page 38/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

ALARMS

32- SEALING WATER

If Pulper area is in operation


And Main line Sealing water flow is on Alarm FSA20135 Low for T=30 s

Then Active the ALARM

33- COMPRESSED AIR

If Pulper area is in operation


And Compressed Air pressure PIA19202 is on Alarm Low

Then Active the ALARM

34- BUFFER TANK 05CE11 LEVEL LIS5000

If Buffer tank 05CE11 level LIS5000 is High-High

Then Active the ALARM

35- (RESERVE)

PULPING
Page 39/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

3.5 OPERATION

Notes: Both Pulper areas work in parallel and then refer to the identical Start-up
and shutdown sequences. Only one sequence of each is described hereunder but
is applicable to both areas.

The following sequences are an explanation going with function charts describing
all Pulping area operation. Programming must be done in priority with
Function charts (supplied separately by Kadant).

3.5.1 Start-up

Basic conditions:
- Sealing water main line is under pressure and Flow switch
FSA20135 is not alarm Low.
- Compressed air system is under pressure (pressure PIA19202 not on Alarm
Low).
- Pulper water tank 05CE04 level LIC5010 is not Low.

Fill buffer tank 05CE11 through feed pump 05PPC05 up to a sufficient level in
order to start a Pulper cycle.

Open sealing water valves for Pulpers (SV-19314 for 01PH02 and SV-19318 for
01PH09) and Dumping Poire (SV-19316 for 01PV06 and SV-19320 for 01PV13).

Pulper filling tanks 01CE05 & 01CE12


If tank 01CE05 (or 01CE12) is empty, start Pulper water pump 05PPC12 (or
05PPC13) in order to fill the tank up to High level.

Then Heating controller TIC1065 (or TIC1365) is enabled.

Waste paper conveyor loading


Loading of the selected quantity of waste paper on the conveyor 01TAP01 (or
01TAP08) by controlling the indicated weight WIRS1045 (or WIRS1345).

Pulper filling (Refer to associated Grafcet)

Start of hood exhaust fan 01ASP04 (or 01ASP11).

Start of motors of cooling blower 01PH02c (or 01PH09c), re-circulation pump


01PH02b (or 01PH09b), and then of main Pulper drive 01PH02a (or 01PH09a).

Opening of valve AV-1080 (or AV-1380) for filling the Pulper with water.

As soon as a minimum volume (about 25 %) has been reached, starting of


conveyor for introduction of paper. The conveyor stops automatically after a pre-
set time or after no presence of waste paper on the conveyor.

PULPING
Page 40/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Introduction of chemicals:
- Peroxide H2O2
- Silicate Na2SIO3
- Soda NaOH
- DTPA
- Soap

As soon as the Pulper is filled with the whole water quantity: closing of filling valve
AV-1080 (or AV-1380).

Pulping (Refer to associated Grafcet)


As soon as the Pulper is correctly filled (water, chemicals and paper): countdown
of pulping time.

At the end of pulping time:


 If there is enough volume available in the dump Chest 01CPA15: Pulper
is emptied through the Dump Poire 01PV06 (or 01PV13).
 If there is not enough volume available in dump Chest 01CPA15: waiting
time = 5 minutes. If after these 5 minutes, there is still not enough volume
available, the Helico Pulper motor stops and only starts again when there
is sufficient volume in the tank.

Pulper dumping (Refer to associated Grafcet)


Water filling of Dumping Poire via the dilution valve at the unit inlet (AV-1100 for
01PV06 and AV-1400 for 01PV13).

Start of Dumping Poire motor.

Opening of Pulper dump valve (AV-1060 for 01PV06 and AV-1360 for 01PV13).

Start of Pulper pump 01PPC07 (or 01PPC14) and control valve HCV-1115 (or
HCV-1420) opens to pre-set position.

Opening of dilution valves AV-1085 and AV-1095 for Pulper 01PH02 (AV-1390 and
AV-1395 for Pulper 01PH09).

Pulper dumping time is controlled through timer.

At the end of dumping time, closing of dilution valves AV-1085 and AV-1095 for
Pulper 01PH02 (AV-1390 and AV-1395 for Pulper 01PH09).

Discharge of the water remaining in the Pulper bottom (phase called


“ Exhaustion ”).

Closing of Pulper dump valve (AV-1060 for 01PV06 and AV-1360 for 01PV13).

Once the valve is shut, the Pulper cycle can restart without waiting for the end of
the Dumping Poire cycle.

PULPING
Page 41/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Washing of contaminants (Refer to associated Grafcet)


Water valve at the inlet of the Dumping Poire (AV-1100 for 01PV06 and AV-1400
for 01PV13) is still open, and then the water washes the contaminants to rid them
of residual fibers.

Closing of the Dumping Poire’s water valve (AV-1100 for 01PV06 and AV-1400 for
01PV13).

Exhaustion by the pump 01PPC07 (or 01PPC14) of most of the water remaining in
the Dumping Poire.

Stop of Pulper dump pump 01PPC07 (or 01PPC14) and closing the valve HCV-
1115 (or HCV-1420).

Discharge of contaminants (Refer to associated Grafcet)


Opening of Dump Poire reject valve (AV-1105 for 01PV06 and AV-1410 for
01PV13): the contaminants are carried away by the water volume remaining in the
Dumping Poire.

Closing of the reject valve (AV-1105 for 01PV06 and AV-1410 for 01PV13) after a
pre-set time.

Remark:
In case of overload of the Dumping Poire motor (perhaps from a too large quantity
of contaminants or from clogging), one goes directly over to the washing of the
contaminants of the Dump Poire. In that case, at the end of the Dumping Poire
cycle, another cycle will automatically be re-launched to complete Pulper dumping.

PULPING
Page 42/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

3.5.2 Operation
The different steps run off automatically.
Monitoring only consists in checking the correct course of these cycles:
- Monitoring of cycle times,
- Monitoring of consistencies.
- Check if no fiber in Compactor outlet.
- Monitoring of inlet and outlet pressures of Cleaner if used.

3.5.3 Stop

Refer to associated Grafcet.

On requesting the stop of automatic operation, pulping, chemicals dosing systems


and dumping are carried out normally, the Pulper and Dump screen only stopping
at cycle end.

Remark:
All steps are controlled by delay times or thresholds to be defined on DCS during
the start-up or optimising phases according to raw materials with the exception of
the Pulper dumping delay which is set on.

PULPING
Page 43/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

PROCESS DESCRIPTION

KHANNA
NEW DIP LINE 300 BDMT/24h
PRINTING - WRITING

HD CLEANING &
HOLES SCREENING AREA

HD CLEANING – HOLES SCREENING


Page 44/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

4 HD CLEANING AND HOLE SCREENING

4.1 DESCRIPTION

4.1.1 HD Cleaning and Holes screening Itemization

 Holes screening feed tank......................................................................................


02CPA01
 Holes screening feed tank agitator..........................................................................
02AG02
 Holes screening feed pump....................................................................................
02PPC03
 High-density cleaner 1 ............................................................................02EPE04
 High-density cleaner 2 ............................................................................02EPE05
 High-density cleaner 3 ............................................................................02EPE06
 HD Cleaners dilution pump.....................................................................................
02PPC07
 Stage 1 Horizontal screen 1....................................................................................
02CH08
 Stage 1 Horizontal screen 2....................................................................................
02CH09
 Holes screening reject tank.....................................................................................
02CPA10
 Holes screening reject tank agitator........................................................................
02AG11
 Stage 2 screening feed pump.................................................................................
02PPC12
 Stage 2 Horizontal screen.......................................................................................
02CH13
 Auxiliary holes screen Diabolo................................................................................
02DIA14
 Constant level box ..............................................................................02CP15

HD CLEANING – HOLES SCREENING


Page 45/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

4.1.2 High Density Cleaner basics

4.1.2.1 HD Cleaner Description

The High-Density Cyclone is a centrifugal cleaner, or hydro-cyclone, designed for


the elimination of heavy contaminants (specific gravity superior to 1) from a stock
flow of up to 4,5% consistency. It protects the downstream equipment from
abrasion-related wear and deterioration by those contaminants.

The Heavy contaminants considered here are staples, paper clips and metal
fragments, sands, glass, …

4.1.2.2 HD Cleaner Operation

Figure: HD Cleaner Principle

Accept flow

Inlet flow

The Cleaner head with tangential stock inlet impels a rotating downward
movement to the stock flow. The heavy contaminants are centrifuged against the
wall of the cleaner cone and flow downward to the cleaner reject trap, where they
are collected. The clean stock flows back upwards at the centre of the cyclone to
the accept nozzle of the cleaner.

HD CLEANING – HOLES SCREENING


Page 46/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

The counter-pressure pressure water flow (continuous clear filtrates, or water)


recovers the fiber captured with the heavy contaminants and contributes to the
control of the cyclone vortex at the bottom of the cleaner. Proper setting of the
counter-pressure pressure water flow is required for optimal operation.

The Reject trap at the bottom of the Cleaner collects the Heavy rejects.
Periodically, the Reject trap is isolated from the cleaner by a sliding gate-valve for
flushing of the accumulated rejects according to a set-time sequence

During the flushing cycle, the feeding of the HD Cleaners remains uninterrupted;
with rejects accumulating for a short time in the lower part of the cleaner cone.

High Density Cleaner requires a backpressure of 10 mWC on the accepted flow.

A H.D. Cleaner is characterized by its pressure loss curve against flow in given
conditions: for adequate operation, the pressure differential across the cleaners
is 12-18 mWC.

4.1.2.3 HD Cleaner Sequence

See Associated Grafcet (will be supplied by Kadant).

4.1.3 Horizontal screen (CH) basics

4.1.3.1 Horizontal screen (CH) Description

The CH Horizontal screen operates continuously up to 4,0%.


The perforation size and operating consistency depends on the process
application.

The KADANT CH Screen consists of:


- A stainless steel horizontal cylindrical body, fitted with a bolted front end door-
lid and a back-end spiral-shaped reject chamber;
- A screen basket with fine perforations, with micro-vortex surface;
- A Rotor -rotating on interior of basket- fitted with hydrofoils arranged
specifically for the application considered. The rotor is driven in rotation by the
horizontal shaft of the mechanism;
- A complete rotating mechanism driving the screen rotor, with a horizontal
shaft running in two grease-lubricated bearings and a water lubricated packed
gland seal, pulleys and V-belt drive;
- A supporting base for the screen body and mechanism.

HD CLEANING – HOLES SCREENING


Page 47/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

4.1.3.2 Horizontal screen (CH) Operation

The 3,0-3,5% stock is introduced in the CH Screen at the top and front of the
screen body, tangentially to the wall of the screen body. The pulp flows towards
the screen basket and rotor.

The screen perforation allows the passage of the fiber in the stock to the
ACCEPTS compartment of the screen. Contaminants do not pass the
perforations, and continue their flow downward towards the REJECTS spiral
chamber & outlet.

The rotating rotor foils generate a rotating local pressure pulsation on the screen:
first a light pressure pushing the pulp through the basket, second a strong
depression generating a local counter flow, which frees the basket surface from
potential plugging.

Horizontal CH Screen Overview:

Stock Stock
inlet Accept

Basket    
Rejects
Rotor    

Body  

Rejects dilution Rejects dilution


- Rejects Chamber to CH"T" Pipe

The CH screen requires a backpressure of 10 mWC on the accepted flow.

The reject flow is the main operating control parameter.

The pressure differential across the screen basket (Accept/Inlet) is 3-5 mWC in
normal operating conditions. The value is checked for verification of the proper
operation of the screen.

4.1.3.3 Horizontal screen (CH) Sequence

See Associated Grafcet (will be supplied by Kadant).

HD CLEANING – HOLES SCREENING


Page 48/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

4.1.4 Tailing screen Diabolo

4.1.4.1 Diabolo Description

The DIABOLO screen operates with accumulation of the rejects and periodic
discharge, with Holes or Slots perforation depending on the application. The
operating consistency (1,5-2,0%) depends of the process application.

The KADANT DIABOLO Tailing Screen consists of:


- A stainless steel Diabolo body comprising a large reject chamber, fitted with a
bolted front end door-lid;
- A Rotor -rotating on interior of basket for basket Diabolo; rotating in front of
the perforated plate for standard Diabolo- fitted with hydrofoils arranged
specifically for the application considered. The rotor is driven in rotation by the
horizontal shaft of the mechanism;
- A complete rotating mechanism driving the screen rotor, with a horizontal
shaft running in two grease-lubricated bearings and a water lubricated packed
gland seal, pulleys and V-belt drive;
- A supporting base for the screen body and mechanism.

4.1.4.2 Diabolo Operation

KADANT Diabolo Tailing Screen


Inlet Accept

Washing

Basket

Rotor

De-aeration

Reject Chamber

Accept Chamber

Rejects Accept
periodic Draining

HD CLEANING – HOLES SCREENING


Page 49/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

The Diabolo is the Tailing screen, last stage of the Pre-Screening system
ensuring a very Low fiber loss in the rejects through its washing cycle prior to
discharge of the rejects.

The 2-2,5% screening rejects are introduced in the Diabolo Screen at the top and
front of the screen body, tangentially to the wall of the screen body. The pulp
flows towards the screen basket and rotor.

The screen perforation allows the passage of the fiber in the diluted stock to the
ACCEPTS compartment of the screen. Contaminants do not pass the
perforations, and are accumulated in the REJECTS chamber.

The rotating rotor foils generate a rotating local pressure pulsation on the screen
plate or basket: first a light pressure pushing the pulp through the basket, second
a strong depression generating a local counter flow, which frees the perforated
plate or basket surface from potential plugging.

Periodically or in case of accept low pressure alarm, or in case of drive overload


alarm, the accumulated rejects are washed and dumped according to a set-time
flushing sequence (See Grafcet)

After the Dumping cycle, the Diabolo fills up on filtrates through the Wash valve
(20-40 seconds) and resumes screening operation. The Diabolo drive operates
continuously during the sequence.

The Diabolo screen requires a backpressure of 5-10 mWC on the accepted flow.

The Diabolo screen is operated without any other regulation than the start-up
setting of the manual valves on the equipment, and trigger of the rejects dumping
step according to Screen differential pressure or drive overload alarm.

The pressure differential across the Diabolo screen basket (Accept/Inlet) is 3-4
mWC in normal working conditions. The value is monitored to trigger the Rejects
dumping step on alarm high.

The Diabolo drive load is monitored to trigger the Rejects dumping step on alarm
high.

4.1.4.3 Diabolo Sequence

See Associated Grafcet (will be supplied by Kadant).

HD CLEANING – HOLES SCREENING


Page 50/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

4.1.5 HD Cleaning and Holes Screening Area

The area process structure is as follows:

From the dumping tank 01CPA15, pump 01PPC17 feeds the stock chest
02CPA01 that is a constant level working chest.
The level control LICS2005 commands the stock quantity required upstream the
system.

4.1.5.1 High Density Cleaning

Pump 02PPC03 on Holes screening chest 02CPA01 feeds the 3 parallel HD


Cleaners (02EPE04, 02EPE05 and 02EPE06) with the pulped stock at a
controlled consistency (through regulation loop NRC2010) of 3,0-4,0%.

HD Cleaners heavy rejects flow by gravity periodically through an automatic


sequence.

The following pressures are obtained from pressure transmitters:

Item Inlet Pressure Accept Pressure Differential


Pressure
02EPE04 PIS2030 PIS2045 PdIS2050
02EPE05 PIS2075 PIS2090 PdIS2095
02EPE06 PIS2130 PIS2145 PdIS2150

HD Cleaners accepted stock feed directly the 2 parallel Horizontal screens


02CH08 and 02CH09 at a pressure adjusted by control loop PIC2125 with control
valve PCV-2125 on pulp pipe recycling to feed chest 02CPA01.
This configuration of circuit enables HD Cleaners operation at constant rating,
whatever the production. Malfunctions or possible problems are thus more easily
detected.

Counter-pressure & trap filling water to the HD Cleaners is obtained from Booster
Pump 02PPC07. Dilution pressure is continuously checked by PIS2020.

4.1.5.2 Pre-screening Holes 3 Stages

The Pre-screening system processes the 3,0-4,0% pulp on a 3-stage screen


holes system.

Stage 1 Screens 02CH08 & 02CH09:

The Stage 1 is composed of 2 Horizontal screens (02CH08 and 02CH09)


working in parallel.

Screen 02CH08 inlet and accept pressures are respectively measured by


transmitters PIS2305 and PIS2320. Then differential pressure PdIS2325 is
calculated and helps to check proper operation of Horizontal screen.

HD CLEANING – HOLES SCREENING


Page 51/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Idem for Horizontal Screen 02CH09: inlet pressure is measured by transmitter


PIS2355, accept pressure by PIS2365 and differential pressure PdIS2370 is then
deduced.

Stage 1 screening accepted pulp flow to Constant Level Box 02CP15.


Accept flow from each screen is adjustable through a hand-command control
valve (HIC2330 for 02CH08 and HIC2380 for 02CH09) and measured by FI2335
for 02CH08 and FI2375 for 02CH09.

Constant level box 02CP15 feeds Slots pre-screening area. An overflow


connected to Screening feed chest 02CPA01 enables the whole area operation
at constant rating, whatever the production variations.

After being diluted in line (through On/Off valves AV-2340 for 02CH08 and AV-
2385 for 02CH09), Stage 1 screens rejects are routed to Reject chest 02CPA10.
Reject flow from each screen are regulated with flow controllers (FFIC2345 for
02CH08 and FFIC2390 for 02CH09) whose set-points are calculated in direct
ratio with accept flows and accordingly to a pre-set reject rate in %.

Reject chest 02CPA10:

Rejects chest 02CPA10 collects:


 Primary Screens 02CH08 & 02CH09 reject pulp.
 By-pass of Diabolo 02DIA14 infeed.
 Accepted stock from Diabolo 02DIA14.
 Tertiary accept A3 from downstream ScreenOne 02SC19.
 Complement dilution water.

The level in Rejects chest 02CPA10 is controlled by LICS2395 and kept


constant through control valve LCV-2395 on periodic filtrates from Pump
05PPC08.

Stage 2 Screen 02CH13:

Secondary Horizontal Screen 02CH13 is fed with pulp from pump 02PPC12
connected on Rejects chest 02CPA10.

Screen 02CH13 inlet and accept pressures are respectively measured by


transmitters PIS2470 and PIS2480. Then differential pressure PdIS2485 is
calculated and helps to check proper operation of Horizontal screen.

Stage 2 screening accepted pulp is routed in forward to Constant Level Box


02CP15 at a flow regulated with controller FFIC2500 whose set-point can be
calculated in direct ratio with Primary screens accept flows and accordingly to an
pre-set production repartition between primary and secondary stage.

After being diluted in line through On/Off valve AV-2490, Screen 02CH13 rejects
are processed on last stage Diabolo 02DIA14.
Flowmeter FI2460 continuously measures this reject flow.

HD CLEANING – HOLES SCREENING


Page 52/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Diabolo 02DIA14:

Diabolo 02DIA14 works in sequences, i.e., alternating working phases along with
wash and contaminant removal phases (See Grafcet).

Diabolo 02DIA14 inlet and accept pressures are respectively measured by


transmitters PIS2425 and PIS2415. Then differential pressure PdIS2430 is
deduced and helps to check proper operation of the unit.

Over working phases, the unit is fed via valve AV-2450. The flow through the unit
is adjusted by means of manual valve MV-2411, installed on the accept piping,
connected to the unit’s top part.

The Diabolo accepts are sent backward to reject chest 02CPA10.

An eventual plugging of Diabolo basket will be detected by accept pressure low


alarm PSL2415 and/or motor amp-load High pressure Alarm JISH2405. Then
Diabolo automatic sequence triggers Washing and dumping phases.

During the Dumping cycle (outside working phases), the stock sent to the Diabolo
screen flows directly to Rejects chest 02CPA10 for a Dumping cycle duration of #
1-2 minutes over a working time of 5-30 minutes depending on the application.
The flow is then adjusted (via a manual by-pass valve MV-2456) to the same
value as accept flow over the working phase to avoid variations in the primary
screen.

Diabolo rejects are flushed periodically.

HD CLEANING – HOLES SCREENING


Page 53/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

4.2 BASIC OPERATING CAPACITY

HD Cleaners: 3 x LA250/3900
Inlet flow 702 m3/h at consistency 3 to 3.8%.

Stage 1 Holes screens: 2 x Horizontal screen CH7


Accept flow 420 m3/h at consistency 3%.
Perforated holes of 1,2 mm

Stage 2 Holes screen: Horizontal screen CH7


Accept flow 225 m3/h at consistency 2,7%.
Perforated holes of 1,2 mm

Stage 3 Holes screen: Diabolo screen DT3


Average accept flow: 85 m3/h at consistency 2-2,5 %
Perforated holes of 1,4 mm

Screening Area nominal capacity: 450 BDT/24h (at CH accept).

4.3 TRANSMITTERS AND CONTROL LOOPS

4.3.1.1 High Density Cleaning

Alarms Scale-0-
Item Function Description 100%
LL L H HH Value unit
Constant level chest 02CPA01 level
LICS 2005 5% 15% 85% 95% 0-70m3
control
NRC 2010 H.D. Cleaning feed consistency control 3 to 5%
H.D. Cleaners counter-pressure water
PIS 2020 3,5 0–10 Bars
pressure indication
H.D. Cleaner 02EPE04 feed pressure
PIS 2030 2 4 0–5 Bars
indication
H.D. Cleaner 02EPE04 accept pressure
PIS 2045 1 3 0–5 Bars
indication
H.D. Cleaner 02EPE04 differential 0–3 Bars
PdIS 2050 1,3 1,9
pressure indication Software only
H.D. Cleaner 02EPE05 feed pressure
PIS 2075 2 4 0–5 Bars
indication
H.D. Cleaner 02EPE05 accept pressure
PIS 2090 1 3 0–5 Bars
indication
H.D. Cleaner 02EPE05 differential 0–3 Bars
PdIS 2095 1,3 1,9
pressure indication Software only
…/…

HD CLEANING – HOLES SCREENING


Page 54/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Alarms Scale-0-
Item Function Description 100%
LL L H HH Value unit
H.D. Cleaner 02EPE06 feed pressure
PIS 2130 2 4 0–5 Bars
indication
H.D. Cleaner 02EPE06 accept pressure
PIS 2145 1 3 0–5 Bars
indication
H.D. Cleaner 02EPE06 differential 0–3 Bars
PdIS 2150 1,3 1,9
pressure indication Software only
H.D. Cleaning stock outlet pressure
PIC 2125 0–5 Bars
control

4.3.1.2 Holes screening

Alarms Scale-0-
Item Function Description 100%
LL L H HH Value unit
Primary Horizontal screen 02CH08 inlet
PIS 2305 1 3 3,5 0–5 Bars
pressure indication
Primary Horizontal screen 02CH08
PIS 2320 0,5 3 3,5 0–5 Bars
accept pressure indication
Primary Horizontal screen 02CH08 0–2,5 Bars
PdIS 2325 0,6 1
differential pressure indication Software only
Primary Horizontal screen 02CH08
HIC 2330 0-100%
accept flow command
Primary Horizontal screen 02CH08
FI 2335 0-250 m3/h
accept flow indication
Primary Horizontal screen 02CH08
FFIC 2345 0-100 m3/h
rejects flow control
Primary Horizontal screen 02CH08
FSA 20160 L Digital alarm
sealing water Low flow alarm
Primary Horizontal screen 02CH09 inlet
PIS 2355 1 3 3,5 0–5 Bars
pressure indication
Primary Horizontal screen 02CH09
PIS 2365 0,5 3 3,5 0–5 Bars
accept pressure indication
Primary Horizontal screen 02CH09 0–2,5 Bars
PdIS 2370 0,6 1
differential pressure indication Software only
Primary Horizontal screen 02CH09
HIC 2380 0-100%
accept flow command
Primary Horizontal screen 02CH09
FI 2375 0-250 m3/h
accept flow indication
Primary Horizontal screen 02CH09
FFIC 2390 0-100 m3/h
rejects flow control
…/…

HD CLEANING – HOLES SCREENING


Page 55/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Alarms Scale-0-
Item Function Description 100%
LL L H HH Value unit
Primary Horizontal screen 02CH09
FSA 20165 L Digital alarm
sealing water Low flow alarm
LICS 2395 Rejects chest 02CPA10 level control 5% 15% 85% 95% 0-20m3
Secondary Horizontal screen 02CH13
PIS 2470 1 3 3,5 0–5 Bars
inlet pressure indication
Secondary Horizontal screen 02CH13
PIS 2480 0,5 3 3,5 0–5 Bars
accept pressure indication
Secondary Horizontal screen 02CH13 0–2,5 Bars
PdIS 2485 0,6 1
differential pressure indication Software only
Secondary Horizontal screen 02CH13
FFIC 2500 0-250 m3/h
accept flow control
Secondary Horizontal screen 02CH13
FI 2460 0-100 m3/h
reject flow indication
Secondary Horizontal screen 02CH13
FSA 20170 L Digital alarm
sealing water Low flow alarm
JISH 2405 Diabolo 02DIA14 drive Amp Load 95% 100% 0-150%

PIS 2425 Diabolo 02DIA14 inlet pressure indication 1 3 3,5 0–5 Bars
Diabolo 02DIA14 accept pressure
PIS 2415 0,5 3 3,5 0–5 Bars
indication
Diabolo 02DIA14 differential pressure 0–2,5 Bars
PdIS 2430 0,6 1
indication Software only
Diabolo 02DIA14 sealing water Low flow
FSA 20175 L Digital alarm
alarm

HD CLEANING – HOLES SCREENING


Page 56/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

4.4 INTERLOCKINGS AND ALARMS

36- PULPED STOCK TRANSFER PUMP 01PPC17 TO HOLES


SCREENING FEED CHEST LEVEL LICS2005

If Dump Tank Pump 01PPC17 is not running

Then Chest feed control valve LCV-2005 is forced closed.

37- HOLES SCREENING FEED CHEST LEVEL LICS2005 TO AGITATOR


02AG02

If Chest level LICS2005 is Low-Low


Then Stop Agitator 02AG02

If Chest level LICS2005 is Low


Then Inhibit Start Agitator 02AG02

If Chest level LICS2005 is not Low


And Agitator 02AG02 in DCS Auto mode

Then Start Agitator 02AG02

38- INTERLOCKS TO HOLES SCREENING FEED PUMP 02PPC03

If Holes Screening Feed Chest level LICS2005 is Low-Low


Or Stage 1 Horizontal screen 02CH08 is not running
Or Stage 1 Horizontal screen 02CH09 is not running

Then Holes screening feed pump 02PPC03 is stopped.

If Continuous Water pump 05PPC07 is not running


Or Booster water pump 02PPC07 is not running
Or Holes Screening Feed Chest level LICS2005 is Low

Then Inhibit start Holes screening feed pump 02PPC03

HD CLEANING – HOLES SCREENING


Page 57/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

39- HOLES SCREENING FEED PUMP 02PPC03 TO SLAVE VALVE AV-


2015

If Holes screening feed pump 02PPC03 is not running


Then Valve AV-2015 is forced closed (Hard interlock)

If Holes screening feed pump 02PPC03 is running


Then With on delay T=5s, Valve AV-2015 in Auto opens (air exhaust limit to
open 15s)

40- INTERLOCKS FROM HOLES SCREENING FEED PUMP 02PPC03

If Holes screening feed pump 02PPC03 is not running

Then Consistency controller NRC2010 is disabled with control valve NCV-


2010 forced closed.
And HD Cleaners (02EPE04, 02EPE05 & 02EPE06) sequence is suspended.

The interlock is released when the pump is running with On-delay T=5s. In Auto,
NRC2010 is then enabled; HD Cleaners sequences are ON proceed.

41- INTERLOCKS CONTINUOUS WATER PUMP 05PPC07 to HD


CLEANERS FEED CONSISTENCY CONTROLLER NRC2010

If Continuous Water pump 05PPC07 is not running

Then Consistency controller NRC2010 is disabled


With valve NRC2010 forced closed (Hard interlock)

42- HD CLEANER 02EPE04 TRAP TOP VALVE AV-2055 & TRAP


BOTTOM VALVE AV-2060

If HD Cleaner 02EPE04 Trap Top Valve AV-2055 is not Closed


Then HD Cleaner 02EPE04 Trap Bottom Valve AV-2060 is forced Closed

If HD Cleaner 02EPE04 Trap Bottom Valve AV-2060 is not Closed


Then HD Cleaner 02EPE04 Trap Top Valve AV-2055 is forced Closed

43- HD CLEANER 02EPE05 TRAP TOP VALVE AV-2105 & TRAP


BOTTOM VALVE AV-2110

If HD Cleaner 02EPE05 Trap Top Valve AV-2105 is not Closed


Then HD Cleaner 02EPE05 Trap Bottom Valve AV-2110 is forced Closed

If HD Cleaner 02EPE05 Trap Bottom Valve AV-2110 is not Closed


Then HD Cleaner 02EPE05 Trap Top Valve AV-2105 is forced Closed

HD CLEANING – HOLES SCREENING


Page 58/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

44- HD CLEANER 02EPE06 TRAP TOP VALVE AV-2160 & TRAP


BOTTOM VALVE AV-2165

If HD Cleaner 02EPE06 Trap Top Valve AV-2160 is not Closed


Then HD Cleaner 02EPE06 Trap Bottom Valve AV-2165 is forced Closed

If HD Cleaner 02EPE06 Trap Bottom Valve AV-2165 is not Closed


Then HD Cleaner 02EPE06 Trap Top Valve AV-2160 is forced Closed

45- INTERLOCKS to STAGE 1 SCREENS ACCEPT CONTROL VALVES

If Holes screening feed pump 02PPC03 is not running


Or Stage 1 Pre-Screen Holes 02CH08 is not running

Then Controller HIC2330 is disabled with valve HCV-2330 forced closed

If Holes screening feed pump 02PPC03 is not running


Or Stage 1 Pre-Screen Holes 02CH09 is not running

Then Controller HIC2380 is disabled with valve HCV-2380 forced closed

46- INTERLOCKS PERIODIC WATER PUMP 05PPC08 to REJECTS


CHEST WATER CONTROL VALVE LCV-2395

If Periodic Water pump 05PPC08 is not running

Then Rejects chest level controller LICS2395 is disabled


With valve LCV-2395 forced closed

47- REJECTS CHEST 02CPA10 LEVEL LICS2395 TO AGITATOR 02AG11

If Rejects chest level LICS2395 is Low-Low


Then Stop Agitator 02AG11

If Rejects chest level LICS2395 is Low


Then Inhibit Start Agitator 02AG11

If Rejects chest level LICS2395 is not Low


And Agitator 02AG11in DCS Auto mode

Then Start Agitator 02AG11

HD CLEANING – HOLES SCREENING


Page 59/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

48- INTERLOCKS TO SECONDARY SCREEN FEED PUMP 02PPC12

If Rejects chest level LICS2395 is Low


Or Stage 2 Horizontal screen 02CH13 is not running

Then Secondary screen feed pump 02PPC12 is stopped.

If Continuous Water pump 05PPC07 is not running


Or Rejects chest level LICS2395 is Low

Then Inhibit start Secondary screen feed pump 02PPC12

49- SECONDARY SCREEN FEED PUMP 02PPC12 TO SLAVE VALVE AV-


2397

If Secondary screen feed pump 02PPC12 is not running


Then Valve AV-2397 is forced closed (Hard interlock)

If Secondary screen feed pump 02PPC12 is running


Then With on delay T=5s, Valve AV-2397 in Auto opens (air exhaust limit to
open 15s)

50- INTERLOCKS to STAGE 2 SCREEN 02CH13 ACCEPT VALVES

If Secondary screen feed pump 02PPC123 is not running


Or Stage 2 Screen 02CH13 is not running

Then Accept ON/Off valve AV-2495 is forced closed


And Flow controller FFIC2500 is disabled with valve FCV-2500 forced closed

51- TAILING SCREEN DIABOLO 02DIA14 FLUSHING

If Amp load JIS2405 is on alarm High for T=5 s

Then Blockage alarm is set to alarm (reset by operator acknowledge)


And Diabolo Holes sequence is forced to Step Washing

52- TAILING SCREEN DIABOLO 02DIA14 INLET & REJECT VALVE

If Diabolo 02DIA14 reject valve AV-2435 is not Closed

Then Diabolo 02DIA14 inlet valve AV-2450 is forced Closed (Hard int.)

53- (RESERVE)

HD CLEANING – HOLES SCREENING


Page 60/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

54- (RESERVE)

ALARMS

55- HD CLEANERS DILUTION WATER PRESSURE

If HD Cleaners dilution pump 02PPC07 is running


And Outlet pressure PIS2020 is on Alarm Low

Then Set HD Cleaners dilution pressure alarm

56- HORIZONTAL SCREEN 02CH08 SEALING WATER ALARM

If Stage 1 Pre-Screen Holes 02CH08 is running


And Sealing water flow FSA20160 is on Alarm Low

Then Set Stage 1 Pre-Screen Holes 02CH08 sealing water alarm

57- HORIZONTAL SCREEN 02CH09 SEALING WATER ALARM

If Stage 1 Pre-Screen Holes 02CH09 is running


And Sealing water flow FSA20165 is on Alarm Low

Then Set Stage 1 Pre-Screen Holes 02CH09 sealing water alarm

58- SECONDARY SCREEN 02CH13 SEALING WATER ALARM

If Secondary screen 02CH13 is running


And Sealing water flow FSA20170 is on Alarm Low

Then Set Secondary screen 02CH13 sealing water alarm

59- TAILING SCREEN DIABOLO 02DIA14 SEALING WATER ALARM

If Diabolo 02DIA14 is running


And Sealing water flow FSA20175 is on Alarm Low

Then Set Diabolo 02DIA14 sealing water alarm

60- REJECT CHEST 02CPA10 LEVEL HIGH-HIGH

If Rejects chest level LIC2395 is High-High


Then Active the ALARM

Note: This alarm doesn’t stop upstream screens 02CH08 & 02CH09 but Operator
action is required to solve the problem that could lead to chest overflow.

HD CLEANING – HOLES SCREENING


Page 61/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

61- SEALING WATER

If HD Cleaning & Holes Screening area is in operation


And Main line Sealing water flow is on Alarm FSA20135 Low for T=30 s

Then Active the ALARM

62- COMPRESSED AIR

If HD Cleaning & Holes Screening area is in operation


And Compressed Air pressure PIA19202 is on Alarm Low

Then Active the ALARM

63- (RESERVE)

HD CLEANING – HOLES SCREENING


Page 62/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

4.5 OPERATION

4.5.1 Start-up

HD Cleaning & Holes screening area is to begin after Pulping.

4.5.1.1 Water filling.

Starting up the Pre-screening area begins with the filling phase of the units (refer
to associated Function charts):

Basic conditions:
- Sealing water main line is under pressure and Flow switch FSA20135 is not
alarm Low.
- Compressed air system is under pressure (pressure PIA19202 not on Alarm
Low).
- Loop 1 Clear Filtrate tank 05CE03 level LIS5055 is not Low.
- Periodic water pump 05PPC08 must be running.
- Continuous water pump 05PPC07 must be running.

Open sealing water valves:


 SV-19330 for St. 1 Horizontal Screen 02CH08.
 SV-19332 for St. 1 Horizontal Screen 02CH09.
 SV-19337 for St. 2 Horizontal Screen 02CH13.
 SV-19338 Diabolo 02DIA14.

Start of the cycle of the high density cleaners 02EPE04, 02EPE05 & 02EPE06
whose first step is the filling phase. (Dilution pump 02PPC07 start is obtained
from HD Cleaners sequence).

Start of the cycles of Horizontal Screens 02CH08, 02CH09 and 02CH13, which
each first step is the filling phase.

Start of Diabolo 02DIA14 cycle, whose first step is also the filling phase.

The units working in cycles (high density cleaners and Diabolo tailing screen) will
automatically go over to the working configuration at the end of filling times.
The filling time of the different units is controlled by delay times set on start-up of
the installation. They take account of the size of units and of pressures and flow
rates available in the water circuits.

4.5.1.2 Starting of the loop

Once the units are filled, the Pre-screening loop is enabled to start:

If dump chest 01CPA15 level is sufficiently filled with stock, start transfer pump
01PPC17 to fill Holes screening feed chest 02CPA01 up to 60%.

Start of Primary screens 02CH08 and 02CH09 motors.

Start of Holes screening feed pump 02PPC03.

HD CLEANING – HOLES SCREENING


Page 63/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

As soon rejects chest 02CPA10 level has reached a minimum height (usually
40%):

Start of Secondary screen 02CH13 motor.

Start of Secondary screen feed pump 02PPC12.

NB 1: It is not necessary to wait for the end of Diabolo filling. Indeed, when it fills,
its feed valve AV-2450 is shut, but its by-pass valve AV-2455 is open. The Pre
screening loop can work, the rejects of Secondary screen 02CH13 will simply be
sent directly into the rejects chest 02CPA10.

NB 2: Through interlocks, all regulation controllers will be enabled and will


proceed to Auto with associated equipment start-up.

4.5.2 Production

The process block can run few minutes in full recycling mode via constant level
box 02CP15.

The stock is bled downstream of the constant level box 02CP15 when required
by slots Pre-screening chest 02CPA16 level controller LIC2605.

4.5.3 Operation
The different steps run off automatically.
To be monitored during the operation of the installation:
- Correct course of cycles of the sequence-working units. In particular, whether
the time of working phases does correspond to the quantities of contaminants
to be removed will have to be checked.
- Inlet and accepts pressures of cleaners and in the different screening stages.
- Consistencies.
- Flows through screening units.

HD CLEANING – HOLES SCREENING


Page 64/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

4.5.4 Stop

Stop of Holes screening feed pump 02PPC03.

Stop of High-density cleaner cycles.

Stop of Primary screens 02CH08 and 02CH09 motors after a delay to flush the
screen.

Stop of Secondary screen feed pump 02PPC12.

Stop of Secondary screen 02CH13 motor after a delay to flush the screen.

Stop of Diabolo 02DIA14cycle.

The working phases of the units with sequences discontinue bring their cycle to
an end normally. They stop in idle position.

Note: After a shut during which the HD Cleaner have been emptied, the operator
must fill up the HD Cleaner with the HD Cleaner sequence prior to
starting Pump 02PPC03. Failure to do so may generate a pressure
shock in the HD Cleaner piping and valve system.

HD CLEANING – HOLES SCREENING


Page 65/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

PROCESS DESCRIPTION

KHANNA
NEW DIP LINE 300 BDMT/24h
PRINTING - WRITING

SLOTS PRE-SCREENING AREA

SLOTS PRE-SCREENING
Page 66/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

5 SLOTS PRE-SCREENING

5.1 DESCRIPTION

5.1.1 Area itemization

 Slots Pre-screening feed chest...............................................................................


02CPA16
 Fine screening feed agitator....................................................................................
02AG17
 Fine screen feed pump............................................................................02PPC18
 Fine slots screen (ScreenOne)...............................................................................
02SC19
 Accept constant level box.......................................................................................
02CP20

5.1.2 ScreenOne basics

5.1.2.1 ScreenOne Description

ScreenOne is an integrated three stage screen. It is a self contained fine slot


screening plant with a very low reject rate, energy consumption for a very low
overall investment.

ScreenOne basically consists of a tank sealed with a cover and positioned


vertically. Inside there is a screen basket that allows the stock to be filtered as
the result of the action of a rotor.
The rotor is supported and driven by a mechanism that is actuated by a belt
drive.

Primary coarse screen (ScreenOne) connections:


 1 inlet pipe
 3 accept pipes
 3 water dilution pipes
 1 reject pipe
 1 heavy rejects pipe (used as a drain)
 1 sealing water inlet (to avoid eventual damage on internal elements).

SLOTS PRE-SCREENING
Page 67/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

5.1.2.2 ScreenOne operation

The pulp is fed from the bottom into the first stage, which is sized and designed
to get the full use of the total basket length.

Thanks to Kadant’s new patented concept, the “Intermediate De-flocculation


Device” with Dilution (ID3), the stage one reject reaches the second zone under
ideal conditions to optimise the screening operation in 1terms of throughput and
efficiency.

The same principle is applied with a second ID3 between the second and third
zone. Thanks to ID3, separation between fiber and contaminants is extremely
efficient.

The screen cylinder is a multi-life rigid cage cylinder with easily removable
elements, allowing high flexibility in configuration.

The machine is fitted with a specifically designed rotor for high sticky removal
and very low energy consumption.

5.1.2.3 ScreenOne sequence

See Associated Grafcet (will be supplied by Kadant).

SLOTS PRE-SCREENING
Page 68/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

5.1.3 Slots Pre-screening area

Stock flows by gravity from Holes Screening accept constant box 02CP15 up to
feed chest 02CPA16 that is a constant level working chest.
The level control LIC2605 commands the stock quantity required upstream the
system via control valve LCV-2605 on stock feed pipe.

ScreenOne 02SC19 receives stock from pump 02PPC18 with stock at


consistency 3-3,5% regulated by controller NRC2610 with control valve NCV-
2610 on dilution pipe fed with filtrates from Water tank 05CE03 via pump
05PPC07.

Pressure regulation loop PIC2705 (with control valve PCV-2705 on recirculating


pipe back to feed chest 02CAP16) keeps constant ScreenOne feed pressure in
order to avoid shocks (that could cause internal damages) during transitory
phases (on ScreenOne start-up when automatic valve AV-2620 opens or during
washing and unplugging sequences).
We recommend inlet automatic valve AV-2620 to open slowly.

Transmitter PIS2640 continuously controls screen inlet pressure.

Accepted stock A1 (from first slotted screening zone) is routed to accept constant
level box 02CP20.
Flow can be adjusted by controller FIC2690 and pressure is continuously
controlled by transmitter PIS2650.
An accidental plugging will be detected by differential pressure alarm PDIS2645
(ratio between inlet and accept A1 pressures).

Rejects from this first zone are diluted (via manual valve MV-2626) with white
water. This dilution flow is measured by loop FIC2625.

Accepted stock A2 (from second slotted screening zone) is also routed to


Constant level box 02CP20.
Flow is adjusted by controller FFIC2685 in ratio with accept A1 flow (FIC2690)
and according to required reject rates between each screening zones.
Stock pressure from accept A2 is continuously controlled by instrumentation loop
PIS2660.
An accidental plugging in 2nd screening zone will be detected by differential
pressure alarm PDIS2655 (ratio between inlet and accept A2 pressures).

A water connection allows stock dilution between second and third screening
zones. This dilution flow is indicated by loop FI2630 and may be adjusted at start-
up with manual valve MV-2631.

Accepted stock A3 (from third slotted screening zone) is sent in backward pre-
screening process:
 Either to feed chest 02CPA16 through On/Off valve AV-2681.
 Or Holes reject chest 02CPA10 through On/Off valve AV-2682
Final pipe direction choice is to be made in order to stabilize ScreenOne feed
consistency during stabilized operation.

SLOTS PRE-SCREENING
Page 69/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

A3 accept Flow is adjusted by controller FFIC2680 in ratio with accept A1 flow


(FIC2690) and according to required reject rates between each screening zones.
Stock pressure from accept A3 is continuously controlled by instrumentation loop
PIS2670.
An accidental plugging in 3rd screening zone will be detected by differential
pressure alarm PDIS2665 (ratio between inlet and accept A3 pressures).

Rejected stock from the third screening zone is also diluted before being directed
to sewer.
Reject dilution water flow is indicated by loop FI2635 and may be adjusted at
start-up with manual valve MV-2636.

Stock rejected flow is adjusted by controller FFIC2675 in ratio with accept A1 flow
(FIC2690) and according to required reject rates.

Dilution controller FIC2625 adds up all water dilution flows to ScreenOne and
adjusts the total (sum of measured flows FT-2625 + FT-2630 + FT-2635)
according to operating dilution Set-Point (adjusted on start-up) by regulating
opening value of control valve FCV-2625.
The Low Flow Alarm for total water dilution calculations (i.e. measured total flow
< 0,5 x set point) indicates a ScreenOne operation problem and is used to launch
a Washing Sequence (see § 5.5.3.2 – Page 77).

In case of differential pressure alarm (for 1st screening zone, for the 2nd and for
the 3rd) or in case of drive overload alarm (JISH2700), appropriate sequences are
launched in order to clean the ScreenOne basket (See § 5.5.3 – Page 77).

Controller SIC2695 allows to adjust (manual set-point before start-up) and control
speed of ScreenOne drive motor from DCS according to screen working
conditions and then to save power consumption.

Stock outlet from constant level box 02CP20 is routed to downstream process
(Pre-flotation).
An overflow pipe from constant box 02CP20 to Feed chest 02CPA16 enables
ScreenOne operation at constant rating (in flow and pressure), whatever the
production variations.

SLOTS PRE-SCREENING
Page 70/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

5.2 BASIC OPERATION CAPACITY

ScreenOne: Size SO8


- Area 1: Slots 0,20mm. Accept flow = ~550 m3/h at consistency 2,5-3%.
- Area 2: Slots 0,18mm. Accept flow = ~120 m3/h at consistency 2-2,5%.
- Area 3: Slots 0,20mm. Accept flow = ~30 m3/h at consistency 2%.

Total accept production (A1 + A2) = 430 BDT/24h

5.3 TRANSMITTERS AND CONTROL LOOPS

Alarms Scale-0-
Item Function Description 100%
LL L H HH Value unit
LICS 2605 Feed chest 02CPA16 level control 5% 15% 85% 95% 0-70 m3
Slots pre-screening feed consistency
NRC 2610 2,5 to 5%
control
ScreenOne 02SC19 feed pressure
PIC 2705 0–4 Bars
control
FIC 2625 ScreenOne 02SC19 dilution flow control
FT-2625: intermediate dilution flow
0-100 m3/h
measurement (between 1st & 2nd zones)
FC-2625: ScreenOne total water dilution
flow controller L
0-150 m3/h
(1)
= Σ (FT-2625 + FT-2630 + FT-2635)
FCV-2625: total dilution flow valve 0-150 m3/h
ScreenOne 02SC19 intermediate dilution
FI 2630 flow indication (between 2nd & 3rd 0-75 m3/h
screening zones)
ScreenOne 02SC19 reject dilution flow
FI 2635 0-75 m3/h
indication
ScreenOne 02SC19 inlet pressure 3
PIS 2640 0–4 Bars
indication (1)
ScreenOne 02SC19 differential pressure
0,4 0,6
PdIS 2645 1 indication 0–2 Bars
(1) (1)
(Difference between Accept A1 & inlet)
ScreenOne 02SC19 Accept A1 pressure 1
PIS 2650 0–4 Bars
indication (1)

…/…

SLOTS PRE-SCREENING
Page 71/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Alarms Scale-0-
Item Function Description 100%
LL L H HH Value unit
ScreenOne 02SC19 differential pressure
0,4 0,6
PdIS 2655 2 indication 0–2 Bars
(1) (1)
(Difference between Accept A2 & inlet)
ScreenOne 02SC19 Accept A2 pressure 1
PIS 2660 0–4 Bars
indication (1)
ScreenOne 02SC19 differential pressure
0,4 0,6
PdIS 2665 3 indication 0–2 Bars
(1) (1)
(Difference between Accept A3 & inlet)
ScreenOne 02SC19 Accept A3 pressure 1
PIS 2670 0–4 Bars
indication (1)
FFIC 2675 ScreenOne 02SC19 reject flow control 0-50 m3/h
ScreenOne 02SC19 Accept A3 flow
FFIC 2680 0-100 m3/h
control
ScreenOne 02SC19 Accept A2 flow
FFIC 2685 0-250 m3/h
control
ScreenOne 02SC19 Accept A1 flow
FIC 2690 0-750 m3/h
control
ScreenOne 02SC19 drive motor speed
SIC 2695 0-100%
control
JISH 2700 ScreenOne 02SC19 drive Amp Load 95% 100% 0-150%

(1) Values to be adjusted on start-up (according to process conditions & overall installation)

SLOTS PRE-SCREENING
Page 72/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

5.4 INTERLOCKINGS AND ALARMS

64- SLOTS PRE- SCREENING FEED CHEST LEVEL LIC2605 TO


AGITATOR 02AG17

If Slots Screening feed chest level LIC2605 is Low-Low


Then Stop Agitator 02AG17

If Slots Screening feed chest level LIC2605 is Low


Then Inhibit Start Agitator 02AG17

If Slots Screening feed chest level LIC2605 is not Low


And Agitator 02AG17 in DCS Auto mode

Then Start Agitator 02AG17

65- INTERLOCKS TO FINE SCREENING FEED PUMP 02PPC18

If Slots Screening feed Chest level LIC2605 is Low


Or ScreenOne 02SC19 is not running
Or Loop 1 Continuous water dilution pump 05PPC07 is not running

Then Screening feed pump 02PPC18 is stopped.

If Slots Screening feed Chest level LIC2605 is Low

Then Inhibit start of Screening feed pump 02PPC18

66- INTERLOCKS FROM SLOTS SCREENING FEED PUMP 02PPC18 TO


SLAVE VALVE AV-2620

If Screening feed pump 02PPC18 is not running

Then On/Off slave valve AV-2620 is forced closed

67- INTERLOCKS TO CONSISTENCY CONTROL NRC2610

If Screening feed pump 02PPC18 is not running


Or Continuous water dilution pump 05PPC07 is not running

Then Consistency controller NRC2610 is disabled with control valve NCV-


2610 forced closed.

SLOTS PRE-SCREENING
Page 73/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

68- (RESERVE)

69- (RESERVE)

ALARMS

70- SEALING WATER

If Slots Pre-screening area is in operation


And Main line Sealing water flow is on Alarm FSA20135 Low for T=30 s

Then Active the ALARM

71- COMPRESSED AIR

If Slots Pre-screening area is in operation


And Compressed Air pressure PIA19202 is on Alarm Low

Then Active the ALARM

72- (RESERVE)

SLOTS PRE-SCREENING
Page 74/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

5.5 OPERATION

5.5.1 Start-up

Slots Pre-screening area is to begin after Holes screening area.

5.5.1.1 Fill the unit

Starting up the Slots Pre-screening loop begins with the filling phase of the unit:

Basic conditions:
- Sealing water main line is under pressure and Flow switch FSA20135 is not
alarm Low
- Compressed air system is under pressure (pressure PIA19202 not on Alarm
Low).
- Level control LIS5055 of water tank 05CE03 is not Low.

If not already running, start Loop 1 Continuous water pump 05PPC07.

Open ScreenOne sealing water valve SV-19342.

Start of ScreenOne cycle, whose first step is the filling phase (refer to specific
Function Chart). :
 Open reject valve FCV-2675 up-to its “X%" opening value. This
position must allow water filling with a moderate pressure inside
ScreenOne.
 Open water dilution valve FCV-2625 during a pre-set time (to be
adjusted at start-up, usually 30 seconds).
 Start of ScreenOne 02SC19 motor.

Note: The unit working in cycle automatically go over to the working configuration
at the end of filling time (controlled by timer set on start-up of the installation and
taking account of the size of the unit and of pressures and flow rates available in
the water circuits).

SLOTS PRE-SCREENING
Page 75/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

5.5.1.2 Starting of the loop

Activation of level controller LIC2605 in order to fill feed chest 02CPA16 with
pulp.

When a sufficiently level is reached (usually higher than 40%):

 Start ScreenOne feed pump 02PPC18 with activation of pressure


controller PIC2705.
Note 1: As long inlet valve AV-2620 is not open, pulp pumped by
02PPC18 flows back to feed chest 02CPA16 via control valve
PCV-2705 fully open.
Note 2: With interlocks, consistency controller NRC2610 is set on
automatic.
 Open slowly ScreenOne inlet valve AV-2620.
 Reject flow control loop FFIC2675 is activated (valve FCV-2675 moves
from full opening to operating value).
 Accept A3 flow control loop FFIC2680 is activated.
 Accept A2 flow control loop FFIC2685 is activated.
 Accept A1 flow control loop FFIC2690 is activated.

5.5.1.3 Production

The process block can run few minutes in full recycling mode via constant level
box 02CP20.

DIP line Loop 1 starts in production when the stock is bled downstream of the
constant level box 02CP20 to Pre-Flotation with opening of weight valve FCV-
3020.

5.5.2 Operation

To be monitored during the operation of the installation:


 Inlet and accepts pressures of ScreenOne.
 All inlet and outlet consistencies.
 Regularity of flows through ScreenOne.
 Regularity of the power absorbed by the ScreenOne.

SLOTS PRE-SCREENING
Page 76/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

5.5.3 Sequences

This chapter hereunder is only for description.


Please refer to associate Function Chart (to be supplied by Kadant) for exact
sequences to be programmed.

5.5.3.1 ScreenOne basket depluging

This sequence is launched in case of Differential pressure High alarm on


threshold 1 (PDSH2645 for 1st screening zone, PDSH2655 for the 2nd and
PDSH2665 for the 3rd) for T= 5 to 10 seconds.

 Open reject valve FCV-2675 to its “X%" opening value.


 Close Accept control valve at screening stage in Alarm and Accept
control valve at eventual downstream stages.

Examples:
On Alarm PDSH2665, cleaning of basket 3rd zone will close control
valve FCV-2680 for the 3rd stage.
On Alarm PDSH2655, cleaning of basket 2nd zone will close control
valves FCV-2685 for the 2nd stage and valves FCV-2680 for the 3rd
stage.
On Alarm PDSH2645, cleaning of basket 1st zone will close control
valves FCV-2690 for the 1st stage, FCV-2685 for the 2nd stage and
valves FCV-2680 for the 3rd stage.

 After a pre-set timer (adjusted during start-up, usually 60 seconds):


reject valve FCV-2675 and accept control valves come back to their
automatic position.

5.5.3.2 ScreenOne washing

During ScreenOne normal operation, this sequence is launched in case of:


 An overload of the ScreenOne motor, detected by alarm JISH2700 for
T= 5 to 10 seconds.
 OR a differential pressure High-High alarm on threshold 2 (PDSHH2645
for 1st screening zone, PDSHH2655 for the 2nd and PDSHH2665 for the
3rd) for T= 5 to 10 seconds.
 OR a Low alarm of total dilution water flow to ScreenOne (calculated by
controller FC2625 < 0,5 x set point) during T=5 to 10s.
 OR a ScreenOne stop request in AUTOMATIC mode.
 OR an Operator manual request (key “WASH”)

 Close stock feed valve AV-2620.


 Close accept flow valves (FCV-2690 for accept A1, FCV-2685 for
accept A2 & FCV-2680 for accept A3).
 Open reject valve FCV-2675 to its “X%" opening value.
 After a pre-set timer (usually 30 seconds), sequence proceeds either
back to working operation or to stop (if requesting in AUTO mode).

SLOTS PRE-SCREENING
Page 77/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

5.5.4 Shutdown

5.5.4.1 Stop of production

The process bloc stops in production when no more pulp required in downstream
Flotation area, with closing of weight valve FCV-3020 on accept constant level
box 02CP20 outlet pipe.

5.5.4.2 Stop of the loop

Please refer to associated function chart (will be supplied by Kadant) including


“stop step” for ScreenOne:

 A Washing sequence is launched (See § 5.5.3.2 – Page 77)


At the end of this sequence, inlet valve AV-2620 remains closed and
reject valve FCV-2675 remains to its “X%" opening value.
 Stop feed pump 02PPC18 motor.
With interlocks, consistency controller NRC2610 is disabled.
 Closing (slowly with a ramp) of accept A1 valve FCV-2690.
 Closing (slowly with a ramp) of accept A2 valve FCV-2685.
 Closing (slowly with a ramp) of accept A3 valve FCV-2680.
 Stop of ScreenOne motor.
 Closing of water valve FCV-2625.

SLOTS PRE-SCREENING
Page 78/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

PROCESS DESCRIPTION

KHANNA
NEW DIP LINE 300 BDMT/24h
PRINTING - WRITING

PRE-FLOTATION AREA

PRE-FLOTATION
Page 79/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

6 PRIMARY FLOTATION

6.1 DESCRIPTION

6.1.1 Flotation Itemization

 Prime MAC cell feed stand tube..............................................................................


03CE12
 Prime MAC cell 03CEV02a feed pump...................................................................
03PPC01
 Prime MAC cell ..........................................................................03CEV02a
 Pre-flotation cell 03CEV02b 1st aeration feed pump...............................................
03PPC03
 Pre-flotation cell 03CEV02b 2nd aeration feed pump.............................................
03PPC04
 Pre-flotation cell 03CEV02b 3rd aeration feed pump..............................................
03PPC05
 Pre-flotation cell 03CEV02b 4th aeration feed pump..............................................
03PPC06
 Pre-Flotation cell (MAC)..........................................................................................
03CEV02b
 Pre-flotation accept constant level box....................................................................
03CP07
 Foam tank (collecting compartment).......................................................................
03CPA08
 Recirculation foam pump to Prime MAC feed.........................................................
03PPV10
 Foam tank (definitive transfer compartment)...........................................................
03CPA09
 Deinking foam transfer pump to treatment..............................................................
03PPC11

PRE-FLOTATION
Page 80/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

6.1.2 Flotation cell (MAC) basics

The Flotation process consists of:

- An Aeration phase during which Air is introduced in the 1-1,4% consistency


stock processed.
This is done in the Auto-Clean Injectors, mounted in canisters-see figure
below.

Figure-Injector Canisters: Washing


Water

INLET OUTLET

Air

The size of canisters depending on the construction, their throughput will only
depend on their inlet pressure. Each canister of injectors features:
 A stock inlet,
 An outlet for the stock/air mix,
 A washing water inlet to fill the canister of injectors during start-up,
shutdown or washing,
 An inlet for air injected into the stock and also used for the discharge to
sewer of the washing water.

The size of air bubbles, the air percentage, and stock chemistry are important
parameters.

- A Collection phase during which the ink or particles to be removed are


collected by the air bubbles rising through the stock.

- A Separation phase, during which the air bubbles with the particles collected
are separated from the stock.

- A Foam washing: water is injected at the top of deinking cell and flows back
from 1st aeration outlet to 1st stage feed pump.

Collection and separation proceed in the Flotation cell.

PRE-FLOTATION
Page 81/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

6.1.3 Deinking MAC cell multi-Aeration flotation

Prime MAC cell with 3 stages in parallel

The 3/3 aerations Primary flotation cell (MAC) is composed of 3 superimposed


elementary cells, each operating an Aeration phase, a Collection phase and a
separation phase.

Fed by a common pump, the processed stock is processed successively in the 3


parallel cells.

Stock accepted from each cell is collected in a common level tank at the top of
the cell maintaining the cell slightly pressurized.

Deinking MAC cell with 4 stages in cascade

The 4 aerations Primary flotation cell (MAC) is composed of 4 superimposed


elementary cells, each operating an Aeration phase, a Collection phase and a
separation phase (See above).

The processed stock is processed successively in the 4 cells.

The stock is pumped through the first aeration injectors to the first cell, disposed
on the top of the cell. The stock accepted from the first cell is pumped through
the Second aeration injectors, until the last cell accept flows to a constant level
box.

The Air separated from each elementary cell rises through the stock flow feeding
the previous cell, leading to a full counter-current flow of air relatively to the fiber
flow.

The constant level box maintains the cell slightly pressurized.

Deinking foam

The Flotation Foam (separated Air bubbles with collected particles) is blown out
via a control valve under action of the cell pressure. By its mechanical action on
the foam, the control valve allows a good air-liquid separation of the foam in the
foam tank.

The Foam control valve is used to control the Foam level in the cell, and by this,
to control the operating conditions of the cell (quantity of foam).

The foam control valve is the main control on the operating conditions of the cell:
Foam consistency, Ash content in Foam, Brightness & speck elimination, loss
control in Total solids and Fiber-see figure below.

6.1.4 Deinking cell MAC Sequence

See Associated Grafcet (will be supplied by Kadant).

PRE-FLOTATION
Page 82/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

6.1.5 Pre-Flotation area

6.1.5.1 Prime MAC 03CEV02a

Prime MAC cell feed

The stock coming from the constant level box 02CP20 is pumped to flotation cell
MAC through 1st aeration pump 03PPC01 connected on water tank 05CE02 to
ensure necessary dilution.

Flowmeter FIC3020 adjusts flotation stock feed flow.


Control valve FCV-3020 is the basis weight valve for 1 st loop of deinking line: its
opening fixes the production rate of Loop 1.

As transmitter NI3015 also continuously measures consistency at this point, then


instantaneous Loop 1 production (P1-3015) can be calculated and checked (and
corrected if necessary through FIC3020 set-point) by operator.

A chemicals injection (surfactant), connected at pump 03PPC01 suction, allows


adjusting flotation operation according to process conditions and required
efficiency.

Pump 03PPC01 feeds the 3 parallel canisters of injectors, at the pressure


required (1,4 bars normally) to ensure air suction and mixing of bubbles in the
stock.
Manual valve MV-3021 at the pump discharge is meant to adjust the inlet
pressure and thus the operating flow of the cell.
Inlet pressure of each injectors canister are measured by transmitters PIS3065,
PIS3085 and PIS3105. Then eventual problems can be more easily detected.

The canister’s washing water connection nipples have automatic isolating valves
used during the various operating sequences.

Stock aerated in this way flows inside the cell where separation of air bubbles
from the stock takes place.

Prime MAC accept stock

Stock accepted from each stage flow to a common tank on top of the cell and
from where pump 03PPC03 directly connected on outlet pipe feeds flotation cell
03CEV02b.

In order to balance Prime MAC 03CEV02a stock accept flow and Deinking cell
03CEV02b feed flow, an overflow outlet sends stock excess flow back to Prime
MAC feed pump 03PPC01 suction, through a stand tube 03CE12 used to avoid
air suction into pump 03PPC01.
Stand Tube 03CE12 is equipped with a water injection (through On/Off valve AV-
3136) in order to break foam bubbles that could eventually pile-up there.

PRE-FLOTATION
Page 83/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Prime MAC cell foam

Foam level is regulated by level controller LIC3145 together with pressure


transmitters LT1-3145, LT2-3145 and PT3150 (refer to regulation principle in
Kadant Function Charts).

The cell level means the stock level in the cell, i.e., the position of the interface
between the stock (at the lower part) and the foam (at the top part).

Foam from the flotation at each aeration stage flows together in the cell’s top part
to fill it entirely.

Prime MAC is equipped with a foam washing device, allowing to “wash” ink foam
collected at cell top part and then to regulate deinking losses with washing flow
controller FIC3135.

Foam tank 03CPA09

Foam is discharged through piping from cell top part. This piping is fitted with
control valve LCV-3145, ensuring both level control in the cell and relaxing of
foam, which is thus discharged as liquid to sludge tank 03CPA09 and transferred
to treatment (outside DIP line) through foam pump 03PPC11.

Pump 03PPC11 is equipped with a variable speed motor in order to adapt foam
transfer flow to Foam tank 03CPA08 level LICS3155.
Moreover, as foam flow to be transferred can vary in a large margin (not easily
compatible with a standard pump curve flow/pressure), pressure regulation loop
PIC3160 (with control valve PCV-3160 on recirculating pipe back to foam tank
03CPA09) helps for this recirculation when flow to be transferred is lower.

Principle:
Foam pump 03PPC11 operating range flow is between a limited margin (could be
between 50 to 100% design flow).
In case all foam flow extracted from pre-flotation cell 03CEV02b is recirculated to
Prime MAC feed pump 03PPC01 (via pump 03PPV10). Then tank 03CPA09
receives only foam from Prime Mac cell 03CEV02a and pump 03PPC11 has to
transfer a lower flow (could be less then 50% of pump 03PPC11 design flow).
In order to maintain level in Foam tank, level controller LICS3150 will enable
pressure controller PIC3160 with opening of valve PCV-3160 in parallel with
regulation to pump motor speed control SC3155.

In case tank 03CPA09 receives foam flow extracted from Prime Mac cell
03CEV02a and from pre-flotation cell 03CEV02b and if flow to be transferred to
treatment is acceptable for pump 03PPC11 design curve, then level controller
LICS3150 will regulate tank 03CPA09 level with pump motor speed control
SC3155 (and pressure controller PIC3160 can be disabled with closing of valve
PCV-3160).

PRE-FLOTATION
Page 84/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Foam tank 03CPA08 and foam recirculation to Prime MAC

The main benefit of Prime MAC use is the opportunity to re-introduce a part or
the totality of DIP line deinking foam and micro-flotation sludge, in order to
reduce fiber losses and increase plant yield.
Of course this re-introduction flow must be adjustable in relation with required
pulp final quality.

Tank 03CPA08 receives:


- Totality of foam flow extracted from pre-flotation cell 03CEV02b.
- A part or totality of micro-flotation sludge flow transferred by pump 13PPC16
and according to adjustment of recirculation flow control FIC14085 (see §
16.1.3.2 - Micro-flotation – Page 265).

Note: Post-Flotation foam recycled flow is sent directly to Prime MAC feed pump
03PPC01 suction.

Volumetric pump 03PPV10 transfers foam to be reintroduced from tank 03CPA08


to Prime MAC feed pump 03PPC01.
Operator gives set-point of this transfer flow through pump motor speed controller
SC3125. (One main characteristic of a volumetric pump is that motor speed is
directly proportional to delivery flow. Then transfer flow is obtained with pump
curve and motor speed value).

Recirculated foam can be re-introduced either at pump 03PPC01 suction


(through On/Off valve AV-3028) or at outlet (through On/Off valve AV-3027).
Final choice to be done according to piping installation and resulting pressures
available in the circuit).

Foam tank 03CPA08 level is controlled by LICS3150 in order to stop extraction


pump 03PPV10 in case of Low level.

In case recirculated foam flow (set through pump 03PPV10) is nil or lower than
foam extracted from Cell 03CEV02b, excess flow overflow to tank 03CPA09 and
is pumped by 03PPC11 to sludge treatment.

6.1.5.2 Primary flotation cell MAC 03CEV02b

The stock accepted from Prime MAC 03CEV02a is pumped to flotation cell MAC
02CEV02b through 1st aeration pump 03PPC03.

1st aeration pump 03PPC03 feeds canister of injectors of the cell’s first stage, at
the pressure required (1,4 bars normally), and continuously measured by
transmitter PIS3365, to ensure air suction and mixing of bubbles in the stock.
Manual valve MV-3372 at the pump discharge is meant to adjust the inlet
pressure and thus the operating flow of the cell.

Stock aerated in this way flows in the first stage in the top of the cell where
separation of air bubbles from the stock takes place.

PRE-FLOTATION
Page 85/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Multi-aeration principle

Stock is then taken up in a pipe in the central barrel to flow out at the cell’s lower
part so as to feed the 2nd aeration.

2nd aeration pump 03PPC04 feeds 2nd canister of injectors, identical to the
previous one.
Hand valve MV-3353 at the pump discharge enables to adjust the inlet pressure
of the 2nd aeration canister of injectors (pressure is continuously measured by
transmitter PIS3345). Stock flows in the cell at a level lower than the one of the
previous stage.

Stock will circulate in the same way for the subsequent aeration steps:
- 3rd aeration pump 03PPC05 (with inlet pressure
measured by PIS3325).
- 4th aeration pump 03PPC06 (with inlet pressure
measured by PIS3305).

Accept constant level box

After the last aeration stage at the lower part of the cell, stock goes up to
constant level box 03CP07 at a higher level than the top of the cell. Thus the cell
is statically and steadily pressurized and floated stock flows out freely.

From this constant level box, stock is routed by gravity to a further process stage.
Constant level box can also send the stock back to the suction of prime MAC
feed pump 03PPC01.
This recycling flow is adjusted by HIC3005 during normal operation (where
recirculating flow is to be set between 0 and 15% maxi of Flotation design flow).
Moreover a parallel bigger pipe, equipped with On/Off Valve AV-3006, allows to
recirculate back all flotation accept flow from constant box 03CP07 if needed by a
transitory phase (for example adjustment on start-up or an eventual incident).

This configuration of circuit enables Flotation operation at constant rating,


whatever the production in downstream process.

The flow through injectors being set by the inlet pressure required for their proper
operation, the flow through the cell is firm.

Due to its principle and inner construction, the Primary flotation cell (MAC)’s
production is only fixed by the feed pump. The other aeration pumps can run or
be turned off without affecting the production flowing through the cell. They only
affect stock quality insofar as their role is just limited to aerating stock via the
injectors.

Deinking cell 03CEV02b foam

MAC cell 03CEV02b foam level is regulated by level controller LIC3390 with
PIS3390 (refer to regulation principle in Kadant Function Charts).
The cell level means the stock level in the cell, i.e., the position of the interface
between the stock (at the lower part) and the foam (at the top part).

PRE-FLOTATION
Page 86/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Foam from the flotation at each aeration stage flows together in the cell’s top part
to fill it entirely.

Foam is discharged through piping at the cell’s lower part. This piping is fitted
with control valve LCV-3390, ensuring both level control in the cell and relaxing of
foam, which is thus discharged as liquid to sludge tank 03CPA08.

PRE-FLOTATION
Page 87/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

6.2 BASIC OPERATING CAPACITY

Prime MAC cell: MAC3/3W1488


Inlet flow 1488 m3/h at consistency 1,35% (i.e. 480
BDMT/24h)

Primary flotation MAC cell 4 aerations: MAC4A1456

6.3 TRANSMITTERS AND CONTROL LOOPS

6.3.1 Prime MAC 03CEV02a

Alarms Scale-0-
Item Function Description 100%
LL L H HH Value unit
Control of deinking cell 03CEV02B
HIC 3005 0-100%
accept recycling
NI 3015 Flotation feed consistency indication 2 to 5%

FIC 3020 Flow control of stock sent to flotation 0-700 m3/h


DIP line Loop 1 production indication
P1 3015 Software only
(Calculation with NI3015 & FIC3020)
Prime MAC 03CEV02a inlet 1 pressure
PIS 3065 1 2 0–3 Bars
indication
Prime MAC 03CEV02a inlet 2 pressure
PIS 3085 1 2 0–3 Bars
indication
Prime MAC 03CEV02a inlet 3 pressure
PIS 3105 1 2 0–3 Bars
indication
Flow control of Prime MAC cell foam
FIC 3135 0-75 m3/h
washing water
Prime MAC 03CEV02a inside pressure
PIS 3145 1 0–3 Bars
indicator
Prime MAC 03CEV02a inside foam level
LIC 3145 0-100%
control
LIC 3150 Foam tank 03CPA08 level control 5% 15% 85% 95% 0-30m3
Foam recirculating pump 03PPV10 motor
SC 3125 0-100%
speed control
LIC 3155 Foam tank 03CPA09 level control 5% 15% 85% 95% 0-20m3
Foam transfer pump 03PPC11 motor
SC 3155 0-100%
speed control
Foam transfer pump 03PPC11 outlet
PIC 3160 0–4 Bars
pressure control

PRE-FLOTATION
Page 88/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

6.3.2 Primary flotation cell MAC 03CEV02b

Alarms Scale-0-
Item Function Description 100%
LL L H HH Value unit
Pre-flotation cell 03CEV02b Stage 1 feed
PIS 3365 1 2 0–3 Bars
pressure indication
Pre-flotation cell 03CEV02b Stage 2 feed
PIS 3345 1 2 0–3 Bars
pressure indication
Pre-flotation cell 03CEV02b Stage 3 feed
PIS 3325 1 2 0–3 Bars
pressure indication
Pre-flotation cell 03CEV02b Stage 4 feed
PIS 3305 1 2 0–3 Bars
pressure indication
Pre-flotation cell 03CEV02b inside
PIS 3390 1 0–3 Bars
pressure indicator
Pre-flotation cell 03CEV02b inside foam
LIC 3390 0-100%
level control

PRE-FLOTATION
Page 89/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

6.4 INTERLOCKINGS AND ALARMS

73- INTERLOCKS to PRIME MAC FEED PUMP 03PPC01

If Water tank 05CE02 level controller LIS5045 is low


Or Prime MAC cell inside pressure is High (LIC3145 level High)

Then Prime MAC feed pump 03PPC01 is stopped.

74- PRIME MAC FEED PUMP 03PPC01 to DEINKING CELL LEVEL


CONTROLLERS PIS3145 & LIC3145

If Prime MAC feed pump 03PPC01 is not running

Then Controllers PIS3145 & LIC3145 are disabled with LCV-3145 forced
open.

75- PRIME MAC FEED PUMP 03PPC01 to SLAVE ON/OFF VALVE AV-
3022

If Prime MAC feed pump 03PPC01 is not running


Then On/Off Valve AV-3022 is forced closed

If Prime MAC feed pump 03PPC01 is running


Then With on delay T=5s, On/Off Valve AV-3022 in Auto is opened (air
exhaust limit to open 15s)

76- OTHER INTERLOCKS from PRIME MAC FEED PUMP 03PPC01

If Prime MAC feed pump 03PPC01 is not running

Then Stock feed control valve FCV-3020 is forced closed


And Flotation accept constant box 03CP07 recycling control valve HCV-3005
and On/Off Valve AV-3006 are forced closed
And Pre-flotation foam recirculating pump 03PPV10 is forced stopped
And On/Off valve AV-3140 on Post-flotation foam recirculating pipe is forced
stopped (if running, all post-flotation foam flow to sludge treatment with
pump 09PPV07).
And Chemicals supply to feed pump suction is disabled
And On/Off Valve AV-3022 (at pump outlet) is forced closed

77- FOAM TANK 03CPA08 LEVEL LICS3150 to EXTRACTION PUMP


03PPV10

If Foam tank 03CPA08 level LICS3150 is Low

PRE-FLOTATION
Page 90/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Then Stop foam recycling pump 03PPV10

78- SECURITY INTERLOCKS FROM VOLUMETRIC PUMP 03PPV10 TO


OUTLET ON/OFF VALVES

If On/Off valve AV-3027 is not open (Open limit switch not activated)
Then On/Off valve AV-3028 is not allowed to Close

If On/Off valve AV-3028 is not open (Open limit switch not activated)
Then On/Off valve AV-3027 is not allowed to Close

If On/Off valve AV-3027 is closed


And On/Off valve AV-3028 is closed

Then Volumetric pump 03PPV10 is forced stopped

79- FOAM TANK 03CPA09 LEVEL LICS3155 to EXTRACTION PUMP


03PPC11

If Sludge tank 03CPA09 level LICS3155 is Low

Then Stop sludge transfer pump 03PPC11

80- FOAM PUMP 03PPC11 to REGULATIONS ON DELIVERY PIPE

If Foam transfer pump 03PPC11 is not running

Then Outlet pressure controller PIC3160 is disabled with valve PCV-3160


forced closed.
And Control valve LCV-3155 (on delivery pipe) is forced closed

81- CELL 03CEV02b 1st AERATION FEED PUMP 03PPC03 to DEINKING


CELL LEVEL CONTROLLERS PIS3390 & LIC3390

If 1st aeration pump 03PPC03 is not running

Then Controllers PIS3390 & LIC3390 are disabled with LCV-3390 forced
open.

PRE-FLOTATION
Page 91/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

82- CELL 03CEV02b 1st AERATION FEED PUMP 03PPC03 to SLAVE


ON/OFF VALVE AV-3373

If 1st aeration pump 03PPC03 is not running


Then On/Off Valve AV-3373 is forced closed

If 1st aeration pump 03PPC03 is running


Then With on delay T=5s, On/Off Valve AV-3373 in Auto is opened (air
exhaust limit to open 15s)

83- INTERLOCKS to CELL OTHER AERATION FEED PUMPS

If 1st aeration pump 03PPC03 is not running

Then 03PPC04 is forced stopped (2nd Aeration)


Then 03PPC05 is forced stopped (3rd Aeration)
Then 03PPC06 is forced stopped (4th Aeration)

If Deinking Cell level LIC3390 is Low (meaning Cell inlet pressure is High)

Then Inhibit start of pump 03PPC04 (2nd Aeration)


Then Inhibit start of pump 03PPC05 (3rd Aeration)
Then Inhibit start of pump 03PPC06 (4th Aeration)

84- (RESERVE)

85- (RESERVE)

ALARMS

86- SEALING WATER

If Pre-Flotation area is in operation


And Main line Sealing water flow is on Alarm FSA20135 Low for T=30 s

Then Active the ALARM

PRE-FLOTATION
Page 92/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

87- COMPRESSED AIR

If Pre-Flotation area is in operation


And Compressed Air pressure PIA19202 is on Alarm Low

Then Active the ALARM

88- (RESERVE)

PRE-FLOTATION
Page 93/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

6.5 OPERATION

6.5.1 Start up

6.5.1.1 Water filling

Basic conditions:
- Sealing water main line is under pressure and Flow switch FSA20135 is not
alarm Low
- Compressed air system is under pressure (pressure PIA19202 not on Alarm
Low).
- Prime MAC cell 03CEV02a foam valve LCV-3145 must be open
- Pre-flotation cell 03CEV02b foam valve LCV-3390 must be open
Water tank 05CE02 level controller LIS5045 must be high
Stock valve FCV-3020 is closed
Recycling valve HCV-3005 is closed

Prime MAC 03CEV02a filling:

 Vent valve AV-3165 on the top of the Prime MAC cell is normally open.
 Start Prime MAC feed pump 03PPC01. (With Interlocks valve AV-3022
after T=5 sec).
 Water valves AV-3120, AV-3100 and AV-3080 (on parallel canisters of
injectors) open during T=15 sec and close.

When the cell is full, detected by level controller LIC3145 High:

Primary flotation cell MAC 03CEV02b filling:

 Vent valve AV-3385 on the top of the deinking cell is normally open.
 Start 1st aeration pump 03PPC03. (With Interlocks valve AV-3373 after
T=5 sec).
 Water valve AV-3380 of the 1st stage canister of injectors opens
during T=15 sec and closes.

When the cell is full, detected by level controller LIC3390 High:


 Close vent valve AV-3385 on the top of the deinking cell 03CEV02b.
 Stop 1st aeration pump 03PPC03. (With Interlocks valve AV-3373
closes automatically).
 Close vent valve AV-3165 on the top of the Prime MAC cell.
 Stop Prime MAC feed pump 03PPC01. (With Interlocks valve AV-3022
closes automatically).

PRE-FLOTATION
Page 94/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

6.5.1.2 Starting of loop

Prime MAC 03CEV02a start:

 Start Prime MAC feed pump 03PPC01. (With Interlocks valve AV-3022
after T=5 sec).
 Open air valves AV-3115, AV-3095 and AV-3075 for Prime MAC.
 Water valves AV-3120, AV-3100 and AV-3080 (of the parallel canisters
of injectors) open during T=15 sec and close.
 Set to AUTO mode Prime MAC cell level regulation LIC3145.

Primary flotation cell MAC 03CEV02b start:

Aeration 4:
 Start 4th aeration feed pump 03PPC06
 Open air valve AV-3315 for 4th aeration of cell 03CEV02b
 Water valve AV-3320 of the 4th stage canister of injectors opens
during T=15 sec and closes.

Aeration 3:
 Start 3rd aeration feed pump 03PPC05
 Open air valve AV-3335 for 3rd aeration of cell 03CEV02b
 Water valve AV-3340 of the 3rd stage canister of injectors opens
during T=15 sec and closes.

Aeration 2:
 Start 2nd aeration feed pump 03PPC04
 Open air valve AV-3355 for 2nd aeration of cell 03CEV02b
 Water valve AV-3360 of the 2nd stage canister of injectors opens
during T=15 sec and closes.

Aeration 1:
 Start 1st aeration feed pump 03PPC03
 Open air valve AV-3375 for 1st aeration of cell 03CEV02b
 Water valve AV-3380 of the 1st stage canister of injectors opens
during T=15 sec and closes.

Set to AUTO mode flotation cell 03CEV02b level regulation LIC3390

PRE-FLOTATION
Page 95/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

6.5.1.3 Production

Foam transfer pump 03PPC11 can start (if allowed through interlocks)

Set to AUTO mode: flotation stock feeding flow controller FIC3020.

Deinking foam washing controller FIC3135 can be set in Auto (flow set-point to
be adjusted according to desired Fiber content in deinking foam) after a timer to
be pre-set before start-up.

Set in “AUTO” mode foam tank 03CPA08 level controller LICS3150.


If required (for example through a specific mode “With Pre-flotation foam
recirculation” selected), start of foam recirculation pump 03PPV10 (with motor
speed SC3125 at the pre-set value).

6.5.2 Operation

Monitoring of inlet pressures within the canisters of injectors.


Monitoring of consistencies of inlet stock, accept stock and deinking foam for
each cell.

Regularly at a rate that will be determined by the operation:


 Open level control valves LCV-3145 and LCV-3390 to raise the level
within each cell and clean the upper part of the cell. This operation will
last a few seconds after which level controller will take its normal course
of operation.

 Flush each canister of injectors successively, for a few seconds, against


possible stock deposits.

PRE-FLOTATION
Page 96/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

6.5.3 Stop

6.5.3.1 Stop of loop

If required (for example through a specific mode “With Pre-flotation foam


recirculation” selected), stop of foam recirculation pump 03PPV10.

Disable foam washing flow controller with closing of valve FCV-3135.

Close the Flotation feed stock valve FCV-3020 at the outlet of constant level box
02CP20.

6.5.3.2 Stop of the Deinking cells

Execute the washing sequences for each injectors canister on both deinking cells
(Prime MAC 03CEV02a and flotation cell 03CEV02b) (on operator order).

Primary flotation cell MAC 03CEV02b stop:

Aeration 1:
 Close air valve AV-3375 for 1st aeration of cell 03CEV02b.
 Water valve AV-3380 on canister of injectors opens during T=15 sec
and closes.
 Stop 1st aeration feed pump 03PPC03

Set to MANU mode flotation cell 03CEV02b level regulation LIC3390 and open
fully foam valve LCV-3190.

Open vent valve AV-3385 on the top of the deinking cell.

Aeration 2:
 Close air valve AV-3355 for 2nd aeration of cell 03CEV02b
 Water valve AV-3360 on canister opens during T=15 sec and closes.
 Stop 2nd aeration feed pump 03PPC04

Aeration 3:
 Close air valve AV-3335 for 3rd aeration of cell 03CEV02b
 Water valve AV-3340 on canister opens during T=15 sec and closes.
 Stop 3rd aeration feed pump 03PPC05

Aeration 4:
 Close air valve AV-3315 for 4th aeration of cell 03CEV02b
 Water valve AV-3320 on canister opens during T=15 sec and closes.
 Stop 4th aeration feed pump 03PPC06

PRE-FLOTATION
Page 97/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Prime MAC 03CEV02a stop:

 Close air valves AV-3115, AV-3095 and AV-3075 for Prime MAC.
 Water valves AV-3120, AV-3100 and AV-3080 (on parallel canisters of
injectors) open during T=15 sec and close.
 Stop Prime MAC feed pump 03PPC01. (With Interlocks valve AV-3022
after T=5 sec).

Set to MANU mode Prime MAC cell 03CEV02a level regulation LIC3145 and
open fully foam valve LCV-3145.

Open vent valve AV-3165 on the top of the Prime MAC cell.

PRE-FLOTATION
Page 98/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

PROCESS DESCRIPTION

KHANNA
NEW DIP LINE 300 BDMT/24h
PRINTING - WRITING

FINE CLEANING

CLEANING
Page 99/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

7 CLEANING

7.1 DESCRIPTION

7.1.1 Area Itemization

 Cleaners 1st stage – Canister 1...............................................................................


04CLR04A
 Cleaners 1st stage – Canister 2...............................................................................
04CLR04B
 Cleaners feed pump stage 2...................................................................................
04PPC05
 Cleaners 2nd stage ............................................................................04CLR06
 Cleaners feed pump stage 3...................................................................................
04PPC07
 Cleaners 3rd stage ............................................................................04CLR08
 Cleaners feed pump stage 4...................................................................................
04PPC09
 Cleaners 4th stage ............................................................................04CLR10

7.1.2 Basics Cleaners System

7.1.2.1 Cleaners description

Kadant ELP Cleaners

The Kadant ELP Cleaners are cyclonic cleaners, which remove by centrifuge
effect HEAVY particles from a dilute (<1%) stock flow.

The stock is introduced into the Cleaner through the cleaner head with an
integrated spiral deflector, which impels a rotating movement to the stock flow.
The heavy particles are centrifuged against the wall of the cleaner, and, due to
the shape of the conical cleaner wall, progress towards the REJECT end of the
cleaner.

Multi-stage systems

The Reject flow obtained on one stage with optimal reject elimination contains
fiber, which must be recovered.

The Cleaners are therefore assembled is successive stages. Each stage rejects
flow to the next stage; each stage accepts flow back to the previous stage. The

CLEANING
Page 100/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

consistency of the stock decreases from one stage to the next, with successive
dilutions at the feed of each stage.

CLEANING
Page 101/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Canister/Battery assembly

For the high number of cleaners ELP136 required in the 1st/2nd/3rd stages for a
high efficiency cleaning, an optimal mounting arrangement of the cleaners is in
Canisters. The Feed to the cleaners flows though the Inlet compartment. The
Accepts and Rejects flow through the Accept and the Reject compartment.

The reject flow is diluted in the Reject compartment by a manually set filtrate

ELP 136 Canister Assembly

Reject

Inlet Accept

flow.

The last stage is composed of ELP440 cleaners mounted in bank, with common
Inlet, Accepts and Rejects headers.

7.1.2.2 Cleaners operation

A cleaner is characterized by its pressure loss curve against flow in given


conditions: for adequate operation, the pressure differential across the cleaners
is 15 mWC.

On start-up, the manual valves on the Cleaner feed pumps, Accept lines and
Reject lines will be set as to obtain the adequate differential pressure on all
Cleaner stages.

CLEANING
Page 102/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Where these settings are implemented with control valves, the adequate control
valve positions are memorized as fixed opening set-point in the DCS.
In operation, operator on DCS monitors the differential pressures on all cleaner
stages. The Cleaner settings do not change in normal operation.

ATTENTION: In operation, deviation on any stage of the Cleaner differential


pressure required to obtain an adequate Cleaner differential pressure indicate
either 1) a modification of the Cleaner manual valve settings, 2) a plugging on a
certain number of cleaners.

This may result in sub-optimal operation of the Cleaner system, with increase in
stock Cleaning consistency and stock back-flows to the Filtrate tank.

The operator is to control these deviations to ensure the operation of the Cleaner
system remains optimal.

The manual valve settings should not be modified without a proper verification
that the operating conditions obtained are adequate.

7.1.3 Cleaners system sequence

See Associated Grafcet (will be supplied by Kadant).

CLEANING
Page 103/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

7.1.4 Area description

The 4-Stage Cleaners System consists in 3 of ELP136 canisters and 1 bank of


ELP440 (for last stage).

Desaeration Chest 04CPA01

Stock accepted from Pre-Flotation is accepted by gravity from Level Box 03CP07
into Desaeration chest 04CPA01.

Desaeration chest 04CPA01 is operated at constant level via level controller


LICS4005 with control valve LCV-4005 on water addition pipe provided by Loop 1
Periodic Clarified pump 05PPC08.
A parallel filtrate pipe with a bigger diameter is used for chest filling on start-up.
Filling On-Off valve AV-4006 is also interlocked with level controller LICS-4005.

Desaeration chest 04CPA01 allows the air remaining in stock pulp to escape and
is equipped with an agitator 04AG02.

Cleaners are of hydro-cyclone type and must always run at their design flow. The
battery’s inlet and accept are fitted with manual control and with pressure
measuring for adjusting the operating flow rate and detect any variation.

Stage 1 Cleaners 04CLR04A & 04CLR04B

Stage 1 Cleaners is composed of 2 identical and parallel canisters 04CLR04A &


04CLR04B.

Stage 1 Cleaners pump 04PPC03 feeds dilute stock to Stage 1 Cleaners, with
On/Off valve AV-4110 operating as slave valve to the pump.

The following pressures are obtained from instruments mounted on Canister and
connected pipes:
For canister 04CLR04A:
- Inlet Pressure PIS4030
- Accept Pressure PIS4020.
- Differential pressure 1 PDIS4035 (calculated by DCS from difference
between inlet and accept pressure).
- Rejects Pressure PIS4045.
- Differential pressure 2 PDIS4050 (calculated by DCS from difference
between inlet and reject pressure).

For canister 04CLR04B:


- Inlet Pressure PIS4080
- Accept Pressure PIS4070.
- Differential pressure 1 PDIS4085 (calculated by DCS from difference
between inlet and accept pressure).
- Rejects Pressure PIS4095.
- Differential pressure 2 PDIS4100 (calculated by DCS from difference
between inlet and reject pressure).

1st stage Cleaners Reject feed the second stage of Cleaners.

CLEANING
Page 104/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

The Stage 1 reject dilution flow is set on start-up by manual valves on top of each
canister, switched on by common On/Off valve AV-4215 on Loop 1 Continuous
filtrates.

The Stage 1 Sealing chamber degassing valves AV-4060 (for canister


04CLR04A) and AV-4105 (for canister 04CLR04B) open on start of feed pump
03PPC03, and closes after 30s.

1st stage Cleaners accepted stock directly feeds downstream Loop 1 Disc Filter at
the required pressure.

To maintain differential pressure on stage 1 Cleaners in different hydraulic


conditions, regulation loop PIC4010 controls the accept pressure with 2 control
valves PCV-4010A and PCV-4010B on 2 parallel recirculation pipes to Cleaners
feed pump 04PPC03 suction:
- The smallest diameter valve PCV-4010A will be enabled with controller
PIC4010 during normal operation (when pressure recirculation flow not
exceeds 120m3/h).
- The biggest diameter valve PCV-4010B will be used during transitory phases
(like start-up) requiring a bigger pressure recirculation (even a total
recirculation).

This configuration of circuit enables Cleaners system operation at constant


rating, whatever the production. Malfunctions or possible problems are thus more
easily detected.

Stage 2 Cleaners 04CLR06:

Stage 2 Cleaners pump 04PPC05 feeds dilute stock to Stage 2 Cleaners


04CLR06, with On/Off valve AV-4160 operating as slave valve to the pump.

The following pressures are obtained from instruments mounted on Canister and
connected pipes:
- Inlet Pressure PIS4130
- Accept Pressure PIS4120.
- Differential pressure 1 PDIS4135 (calculated by DCS from difference
between inlet and accept pressure).
- Rejects Pressure PIS4145.
- Differential pressure 2 PDIS4150 (calculated by DCS from difference
between inlet and reject pressure).

2nd stage Cleaners Accept flow back to Stage 1 pump 04PPC03 suction

2nd stage Cleaners Reject feed the third stage of Cleaners.

The Stage 2 reject dilution flow is set on start-up by manual valve MV-4156 on
top of canister.

The Stage 2 Sealing chamber degassing valve AV-4155 opens on start of feed
pump 04PPC05, and closes after 30s.

CLEANING
Page 105/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Stage 3 Cleaners 04CLR08:

Stage 3 Cleaners pump 04PPC07 feeds dilute stock to Stage 3 Cleaners


04CLR08, with On/Off valve AV-4210 operating as slave valve to the pump.

The following pressures are obtained from instruments mounted on Canister and
connected pipes:
- Inlet Pressure PIS4180
- Accept Pressure PIS4170
- Differential pressure 1 PDIS4185 (calculated by DCS from difference
between inlet and accept pressure).
- Rejects Pressure PIS4195
- Differential pressure 2 PDIS4200 (calculated by DCS from difference
between inlet and reject pressure).

3rd stage Cleaners Accept flow back to Stage 2 pump 04PPC05 suction

3rd stage Cleaners Reject feed the last stage of Cleaners.

The Stage 2 reject dilution flow is set on start-up by manual valve MV-4206 on
top of canister.

The Stage 3 Sealing chamber degassing valve AV-4205 opens on start of feed
pump 04PPC07, and closes after 30s.

Stage 4 Cleaners 04CLR10:

Stage 4 Cleaners pump 04PPC09 feeds dilute stock to Stage 4 Cleaners


04CLR10. On/Off valve AV-4220 operates as slave valve to the pump.

The following pressures are obtained:


- Inlet Pressure PIS-4250
- Accept Pressure PIS-4235
- Differential pressure PDIS4255 (calculated by DCS from difference between
inlet and accept pressure).

4th stage Cleaners Accept flow back to Stage 3 pump 04PPC07 suction.

The Stage 4 reject dilution flow is set on start-up by manual valve MV-4224 and
switched on by On/Off valve AV-4225 on Fresh Water line.

Common Stages 1-4 Cleaners

The suctions of Cleaners feed pumps 04PPC05 (stage 2), 04PPC07 (Stage 3)
and 04PPC09 (Stage 4) are connected to Loop 1 Clear Filtrate tank 05CE03,
whose constant level ensures a constant head on the pumps and the dilution of
the successive stock flows between each stage. Low level LIS5055 alarm will
stop the pumps.

CLEANING
Page 106/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

The dilution flow to Rejects compartment of Stages 1-2-3 Cleaners is switched on


by On/Off valve AV-4215, on a line from Loop 1 Continuous Clear Filtrates pump
05PPC07. On/Off valve AV-4215 is forced closed if 05PPC07 is not running.

The Stages 1-2-3 Cleaners canisters Sealing chambers are fed through On/Off
valve AV-4013. 402-HS-6264 is switched on when 3rd stage pump 04PPC07
starts and remains open.
Water for canisters Sealing chambers are provided either from Fresh Water
(through manual valve MV-4257) or from Loop 3 dilution water (through manual
valve MV-4259).

Note: In case the reject dilutions are not set properly, blockage may occur in the
reject lines going from the Canisters back to the Cleaner feed pumps. In this
case, this blockage occurs typically above the manual valve used to adjust
counter-pressure on reject line. In the first weeks of operation, or after having
changed the valves settings, the reject lines of the Cleaner system will usefully
be routinely checked by operator: a blockage will be detected by 1) an increase
in reject compartment pressure, and 2) cold pipe line. In case of an onset of
blockage, opening and closing the manual valve easily remove the blockage.

CLEANING
Page 107/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

7.2 BASIC OPERATING CAPACITY

Cleaners stage 1: 2 x Canisters size H7 with 108 Cleaners ELP136 in each.


Inlet flow 2160 m3/h at consistency 1% (i.e. 550
BDMT/24h)

Cleaners stage 2: 1 Canister size H6 with 72 Cleaners ELP136


Inlet flow 680 m3/h at consistency 1% (i.e. 155
BDMT/24h)

Cleaners stage 3: 1 Canister size H4 with 24 Cleaners ELP136


Inlet flow 230 m3/h at consistency 0,8% (i.e. 40
BDMT/24h)

Cleaners stage 4: 1 Bank of 3 Cleaners ELP440 BC


Inlet flow 80 m3/h at consistency 0.5% (i.e. 10 BDMT/24h)

7.3 TRANSMITTERS AND CONTROL LOOPS

Alarms Scale-0-
Item Function Description 100%
LL L H HH Value unit
Desaeration chest 04CPA01 level
LICS 4005 5% 15% 85% 95% 0-150 m³
controller
PIC 4010 Cleaners accepts pressure control 0–4 Bars
St. 1 Cleaners 04CLR04A inlet pressure
PIS 4030 1 4 0–5 Bars
indicator
St. 1 Cleaners 04CLR04A Accept
PIS 4020 0,5 3 0–5 Bars
pressure indicator
St. 1 Cleaners 04CLR04A differential
0–3 Bars
PDIS 4035 pressure 1 indicator 0,8 2
Software only
(Difference between inlet & accept)
St. 1 Cleaners 04CLR04A Reject
PIS 4045 0,6 0–5 Bars
pressure indicator
St. 1 Cleaners 04CLR04A differential
0–3 Bars
PDIS 4050 pressure 2 indicator
Software only
(Difference between inlet & reject)
St. 1 Cleaners 04CLR04B inlet pressure
PIS 4080 1 4 0–5 Bars
indicator
St. 1 Cleaners 04CLR04B Accept
PIS 4070 0,5 3 0–5 Bars
pressure indicator
St. 1 Cleaners 04CLR04B differential
0–3 Bars
PDIS 4085 pressure 1 indicator 0,8 2
Software only
(Difference between inlet & accept)

CLEANING
Page 108/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

St. 1 Cleaners 04CLR04B Reject


PIS 4095 0,6 0–5 Bars
pressure indicator
…/…

CLEANING
Page 109/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Alarms Scale-0-
Item Function Description 100%
LL L H HH Value unit
St. 1 Cleaners 04CLR04B differential
0–3 Bars
PDIS 4100 pressure 2 indicator
Software only
(Difference between inlet & reject)
St. 2 Cleaners 04CLR06 inlet pressure
PIS 4130 1 4 0–5 Bars
indicator
St. 2 Cleaners 04CLR06 Accept pressure
PIS 4120 0,5 3 0–5 Bars
indicator
St. 2 Cleaners 04CLR06 differential
0–3 Bars
PDIS 4135 pressure 1 indicator 0,8 2
Software only
(Difference between inlet & accept)
St. 2 Cleaners 04CLR06 Reject pressure
PIS 4145 0,6 0–5 Bars
indicator
St. 2 Cleaners 04CLR06 differential
0–3 Bars
PDIS 4150 pressure 2 indicator
Software only
(Difference between inlet & reject)
St. 3 Cleaners 04CLR08 inlet pressure
PIS 4180 1 4 0–5 Bars
indicator
St. 3 Cleaners 04CLR08 Accept pressure
PIS 4170 0,5 3 0–5 Bars
indicator
St. 3 Cleaners 04CLR08 differential
0–3 Bars
PDIS 4185 pressure 1 indicator 0,8 2
Software only
(Difference between inlet & accept)
St. 3 Cleaners 04CLR08 Reject pressure
PIS 4195 0,6 0–5 Bars
indicator
St. 3 Cleaners 04CLR08 differential
0–3 Bars
PDIS 4200 pressure 2 indicator
Software only
(Difference between inlet & reject)
St. 4 Cleaners 04CLR10 inlet pressure
PIS 4250 1 4 0–5 Bars
indicator
St. 4 Cleaners 04CLR10 Accept pressure
PIS 4235 0,5 3 0–5 Bars
indicator
St. 4 Cleaners 04CLR10 differential
0–3 Bars
PDIS 4255 pressure indicator 0,8 2
Software only
(Difference between inlet & accept)

CLEANING
Page 110/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

7.4 INTERLOCKINGS AND ALARMS

89- DESAERATION CHEST LEVEL LICS4005 TO AGITATOR 04AG02

If Desaeration chest level LICS4005 is Low-Low


Then Stop Agitator 04AG02

If Desaeration chest level LICS4005 is Low


Then Inhibit Start Agitator 04AG02

If Desaeration chest level LICS4005 is not Low


And Agitator 04AG02 in DCS Auto mode

Then Start Agitator 04AG02

90- INTERLOCKS LOOP 1 PERIODIC WATER PUMP 05PPC08 to


DESAERATION CHEST WATER VALVES

If Loop 1 Periodic Water pump 05PPC08 is not running

Then Desaeration Chest level controller LICS4005 is disabled


With control valve LCV-4005 forced closed
And filling On/Off valve AV-4006 forced closed

91- INTERLOCKS TO CLEANERS STAGE 1 FEED PUMP 04PPC03

If Disc Filter 05FDQ01 is not running


Or Cleaners stage 2 pump 04PPC05 is stopped
Or Desaeration chest 04CPA01 level controller LICS4005 is Low-Low
Or St. 1 Cleaners 04CLR04A inlet Pressure PIS4030 is on alarm High-High
(>4,0 Bar g) for 15 s
Or St. 1 Cleaners 04CLR04B inlet Pressure PIS4080 is on alarm High-High
(>4,0 Bar g) for 15 s

Then Stage 1 Cleaners feed pump 04PPC03 is stopped.

If Desaeration chest 04CPA01 level controller LICS4005 is Low


Or Loop 1 Disc Filter 05FDQ01 is NOT Ready

Then Inhibit Start of Stage 1 Cleaners feed pump 04PPC03.

CLEANING
Page 111/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

92- INTERLOCKS FROM STAGE 1 CLEANERS FEED PUMP 04PPC03

If Stage 1 Cleaners Feed Pump 04PPC03 is not running

Then On/Off slave valve AV-4110 is forced closed


And Accept pressure controller PIC4010 is disabled with control valves PCV-
4010A and PCV-4010B forced closed.

If Stage 1 Cleaners Feed Pump 04PPC03 is running

Then With On-Delay T=5s, Open slave valve AV-4110 (air exhaust limit to
open 15s)

93- INTERLOCKS TO CLEANERS STAGE 2 FEED PUMP 04PPC05

If Cleaners stage 3 pump 04PPC07 is stopped


Or Water tank 05CE03 level controller LIS5055 is Low
Or St. 2 Cleaners inlet Pressure PIS4130 alarm High-High (>3,0 Bar g) for
15 s

Then Stage 2 Cleaners Feed Pump 04PPC05 is stopped.

94- INTERLOCKS FROM STAGE 2 PUMP 04PPC05 To SLAVE VALVE

If Stage 2 Cleaners Feed Pump 04PPC05 is not running


Then On/Off slave valve AV-4160 is forced closed

If Stage 2 Cleaners Feed Pump 04PPC05 is running


Then With On-Delay T=5s, Open slave valve AV-4160 (air exhaust limit to
open 15s)

95- INTERLOCKS TO CLEANERS STAGE 3 FEED PUMP 04PPC07

If Cleaners stage 4 pump 04PPC09 is stopped


Or Water tank 05CE03 level controller LIS5055 is Low
Or St. 3 Cleaners inlet Pressure PIS4180 alarm High-High (>3,0 Bar g) for
15 s

Then Stage 3 Cleaners feed pump 04PPC07 is stopped.

CLEANING
Page 112/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

96- STAGE 3 CLEANERS FEED PUMP 04PPC07 TO SLAVE VALVE AV-


4210

If Stage 3 Cleaners Feed Pump 04PPC07 is not running


Then On/Off slave valve AV-4210 is forced closed

If Stage 3 Cleaners Feed Pump 04PPC07 is running


Then With on delay T=5s AV-4210 in Auto is opened (air exhaust limit to open
15s)

97- INTERLOCKS TO CLEANERS STAGE 4 FEED PUMP 04PPC09

If Water tank 05CE03 level controller LIS5055 is Low


Or St. 4 Cleaners inlet Pressure PIS4250 alarm High-High (>3,0 Bar g) for
15 s

Then Stage 4 Cleaners Feed Pump 04PPC09 is stopped.

98- STAGE 4 CLEANERS FEED PUMP 04PPC09 TO SLAVE VALVE AV-


4220

If Stage 4 Cleaners Feed Pump 04PPC09 is not running


Then On/Off slave valve AV-4220 is forced closed

If Stage 4 Cleaners Feed Pump 04PPC09 is running


Then With on delay T=5s AV-4220 in Auto is opened (air exhaust limit to open
15s)

99- INTERLOCKS FROM LOOP 1 CONTINUOUS WATER PUMP 05PPC07

If Loop 1 Continuous Water pump 05PPC07 is not running


Then St. 1-2-3 reject dilution On/Off valve AV-4215 is forced closed.

If Loop 1 Continuous Water pump 05PPC07 is not running


Then Inhibit start of stage 3 Cleaners Feed Pump 04PPC07.

100- FRESH WATER AVAILABLE INTERLOCKS

If Fresh Water is not available (Process value to be identified)

Then St. 4 reject dilution On/Off valve AV-4225 is forced closed


And Inhibit start of stage 4 Cleaners Feed Pump 04PPC09

CLEANING
Page 113/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

And St. 1-2-3 canisters sealing chambers filling main On/Off valve AV-4013
is forced closed (if fed by Fresh Water through manual valve MV-4527).

101- LOOP 3 WATER AVAILABLE TO ON/OFF VALVE AV-4013

If Loop 3 water dilution pump 13PPC09 is not running

Then St. 1-2-3 canisters sealing chambers filling main On/Off valve AV-4013
is forced closed (if fed by Loop 3 Water through manual valve MV-4529).

102- (RESERVE)

103- (RESERVE)

ALARMS

104- SEALING WATER

If Cleaning area is in operation


And Main line Sealing water flow is on Alarm FSA20135 Low for T=30 s

Then Active the ALARM

105- DILUTION WATER TANK 05CE03

If Water tank 05CE03 level controller LIS5055 is Low

Then Active the ALARM

106- COMPRESSED AIR

If Cleaning area is in operation


And Compressed Air pressure PIA19202 is on Alarm Low

Then Active the ALARM

107- (RESERVE)

CLEANING
Page 114/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

7.5 OPERATION

7.5.1 Start-Up

Starting the Fine-Cleaning system should be done after having started Loop 1
Disc Filter 05FDQ01.
Feeding forward from the Stage 1 Cleaners will remain forbidden until Disc Filter
is running, but there is no interlock preventing to start the 2-3-4 stage Cleaners
independently from the rest of the line, provided filtrates are available in Loop 1
Filtrate Tank.

The following sequences are an explanation going with function charts describing
all Cleaning area operation. Programming must be done in priority with
Function charts (supplied separately by Kadant).

7.5.1.1 Starting of the loop

Basic conditions:
- Sealing water main line is under pressure and Flow switch FSA20135 is not
alarm Low.
- Compressed air system is under pressure (pressure PIA19202 not on Alarm
Low).
- Fresh water is available.
- Level control LIS5055 of water tank 05CE03 must be at least 85%.
- Desaeration chest 04CPA01 level LICS4005 is not on alarm Low (this chest
to be filled with water on first start-up).
- Disc Filter 05FDQ01 is ready to start (READY status)

If not already running, start Filtrate pumps:


 Loop 1 Periodic white water pump 05PPC08.
 Loop 1 Continuous white water pump 05PPC07.
 Loop 3 water dilution pump 13PPC09 if St. 1-2-3 canisters sealing
chambers fed by Loop 3 Water through manual valve MV-4529.

Start Stage 4 Cleaners feed pump 04PPC09


When running status obtained, wait 10s and proceed.

Start Stage 3 Cleaners feed pump 04PPC07


When running status obtained, wait 10s and proceed.

Start Stage 2 Cleaners feed pump 04PPC05


When running status obtained, wait 10s and proceed.

Start Stage 1 Cleaners feed pump 04PPC03


When running status obtained, wait 10s and proceed.

Note 1: On/Off valves on water circuits are to be opened as described in


associated Function Charts.

Note 2: All regulations and other On/Off valves will be enabled and set to
Automatic position through interlocks.

CLEANING
Page 115/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

7.5.1.2 Production

Fine screening area starts in production with the flotation bloc (Once the stock is
bled downstream of the constant level box 02CP20 via control valve FCV-3020).

Accepted stock from Pre-Flotation area feeds Desaeration chest 04CPA01


through constant level box 03CP07.

Stock feed can proceed to Cleaners when the Loop 1 Disc Filter is Ready.

NB: The process block can run few minutes in water mode if the flotation loop is
running into water mode.

7.5.2 Operation
To be monitored during the operation of the installation:
 Inlet, accept and differential pressures of cleaner.
 Consistencies.
 The absence of fibers rejected in the cleaner rejects.

7.5.3 Shutdown

7.5.3.1 Stop of production

The process bloc stops in production with the Flotation, by closing of the valve
FCV-3020 at the outlet of the constant level box 02CP20.
Over a few minutes, the circuit is left running with water to dilute the stock in the
flotation and Cleaning loops.

NB: The process block can run few minutes in water mode if the flotation loop is
running into water mode.

7.5.3.2 Stop of the loop

Once the units are clean, the Fine cleaning loop is stopped:

Stop the stage 1 cleaners feed pump 04PPC03.


Wait T=10s then proceed,

Stop the stage 2 cleaners feed pump 04PPC05.


Wait T=10s then proceed,

Stop the stage 3 cleaners feed pump 04PPC07.


Wait T=10s then proceed,

Stop the stage 4 cleaners feed pump 04PPC09.

Note On/Off valves on water circuits are to be closed as described in associated


Function Charts.

CLEANING
Page 116/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

PROCESS DESCRIPTION

KHANNA
NEW DIP LINE 300 BDMT/24h
PRINTING - WRITING

LOOP 1 DISC FILTER


& WATER DISTRIBUTION

LOOP 1 DISC FILTER & WATER DISTRIBUTION


Page 117/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

8 LOOP 1 DISC FILTER & WATER DISTRIBUTION

8.1 DESCRIPTION

8.1.1 Area itemization

 Disc Filter ............................................................................05FDQ01


 Clear filtrate tank ..............................................................................05CE03
 Cloudy filtrate tank ..............................................................................05CE02
 Pulper water tank ..............................................................................05CE04
 Pulper water transfer pump ....................................................................................
05PPC05
 Disc Filters showers feed pump .............................................................................
05PPC06
 Loop 1 continuous water dilution pump ..................................................................
05PPC07
 Loop 1 periodic water dilution pump ......................................................................
05PPC08

8.1.2 Disc Filter basics

8.1.2.1 Disc Filter Description

Filter rotor
The filter is built around a horizontal shaft with internal axial filtrate channels
leading to one end of the shaft (or both ends if the filtrate quantities are very
large).
A number of filter discs are mounted on the shaft, each disc consisting of 20
sectors, connected to corresponding flow channels in the shaft.
Approx. 70% of the disc area is submerged in a vat, containing the suspension to
be filtered.
The open end of the shaft is connected to a filtrate valve, which opens and closes
the flow channels to a vacuum created by means of a barometric leg of the clear
filtrate pipe.
The disc filter drive set includes a shaft-mounted bevel planetary gearbox, which
accepts a flanged motor into a hollow input. A torque arm is provided to restrain
the shaft mounted gearbox for transmitting the drive.

Filter segments
The rotor consists of a set of circular discs mounted on a centre shaft in welded
and bolted construction.
Each disc accommodates 20 sectors. The sectors are fabricated in stainless
steel construction and covered with a 420-micron polyester filter cloth. The filter
cloth is replaceable.

LOOP 1 DISC FILTER & WATER DISTRIBUTION


Page 118/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

The special design of the sectors enables forming a strong basket design, as well
as minimized inside volume for reaching an optimum filtrate discharge. The
filtrate drained through the discs is led to the outer filtrate channels welded on the
periphery of the centre shaft. The filtrate channels are sloped towards the end
and carry the filtered water to the filtrate valve and from there through the outlet
pipes.

Filter vat
The vat is in welded stainless steel construction and provided with outside
reinforcements at both ends.
The bottom of the vat is provided with drainage connection. A level transmitter
installed on the vat enables automatic control of the rotor speed based on the
level inside the vat and the inlet flow to the filter.

Filtrate Valve
Between the rotating "spider" on the centre shaft and the fixed filtrate valve a set
of renewable wear plates in UHMWPE are installed.
The wear plates are bolted to the filtrate valve and kept pressed against the face
of the rotating centre shaft by three adequately sized pressure springs supported
by mounting bolts.
A sealing arrangement around the wear plate is provided for preventing leakage
between the shaft and the valve.

The filtrate valve at the end is equipped with two filtrate outlets: one for cloudy
and other for clear filtrate. Proportion of the clear filtrate could be adjusted by
varying the position of a special filtrate split device inside the filtrate valve. An
adequately sized manhole with lid is provided on the filtrate valve for accessing
this adjustment device.

Inlet feed box


The inlet feed box is welded on the vat side and equipped with inspection/service
covers.
The feed box is provided inside with floating louvers and weirs, giving a uniform
distribution of incoming stock along the filter length. The louvers float along with
the liquid level in the vat thereby preventing entrapment of air into the feed liquid
due to turbulence.

Filter hood
The disc filter is provided with a welded stainless steel construction hood with
adequate number of inspection covers on either side as well as on top side for
observation of performance as well as for ease of maintenance.
The covers along the sides are open able.
The shower pipe assemblies are mounted and supported inside the hood.
The removable side covers also provide access for maintenance of the showers
and nozzles.

Showers
Oscillating shower
This consists of a main distributing header with branch pipes, oscillating between
the discs.
Each branch pipe is provided with four water jets for cleaning either side of the
disc, efficiently washing the filter segments on the discs.

LOOP 1 DISC FILTER & WATER DISTRIBUTION


Page 119/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Special “C” nozzles are provided for discharging the water jets. Each nozzle can
deliver a flow of 16 LPM at 7 bar (g) pressure. The “C” nozzles enable any
clogging or choking to be cleared easily just by a twist of the handle.
Dismantling of the water jets is not necessary.
Oscillating drive arrangement includes a gear motor and a crank arrangement.
Clear filtrate from the filter is used as washing water.

Knock-off shower
This consists of a main distributing header with branch pipes between the discs.
Each branch pipe is provided with one water jet on either side of the disc,
efficiently discharging the fiber mat formed on the disc surface. Same “C” nozzles
are provided for this also as detailed above.
Clear filtrate from the filter is used as knock-off water.

Sluicing shower
This consists of a main distributing header with branch pipes between the discs.
Each branch pipe is provided with one water jet, to aid in the proper flow of the
discharged fiber mat through the collecting boxes. Same “C” nozzles are
provided for this also as detailed above.
Clear filtrate from the filter is used as knock-off water.

Stock Collecting Boxes


The stock collecting boxes are in welded stainless steel construction and located
inside the vat and uniformly arranged between the adjacent discs.
These collecting boxes are so strategically placed to receive the knocked-off fiber
mat from the discs and convey it to the discharge screw mounted below the
trough.

Discharge Screw
The recovered stock falls into a discharge screw mounted at the bottom of the
trough.
The discharge screw is built around a hollow stainless steel pipe and provided
with end shafts running over roller bearings.
The drive set consists of a gear box with hollow output and a flanged motor
directly mounted.
The discharge screw flight is cut and folded at intervals and also provided with
paddles at the discharge end to break-up the fiber mat and feed the stock
uniformly through the outlet nozzle.

LOOP 1 DISC FILTER & WATER DISTRIBUTION


Page 120/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

8.1.2.2 Disc Filter operation principle

The fiber suspension enters the filter via the inlet feed box A and is uniformly
distributed across the entire length of the trough.
The inlet box has a float arrangement B that moves up and down with the level of
the stock in the trough thereby eliminating air entrapment in the liquid.

As the centre shaft C and discs D rotate, initial filtration takes place by gravity
and the pulp mat starts to form on the disc sectors, ensuring optimal dewatering
characteristics.
At this stage, the water removal takes place by physical filtration through the filter
bags on the disc sectors. The filtrate is drained via the open grid segments to the
corresponding outer channels E that forms the cloudy filtrate, which gets
extracted through the nozzle F on the filtrate vale.

As the discs rotate further, clear filtrate gets extracted through the portion of the
spider coming under vacuum due to the barometric drop leg and this water also
flows through the flow channels to the filtrate valve G and out through another
nozzle H.
Clear filtrate is formed under negative pressure when the filtration takes place
through the fiber mat already formed on the discs. When the segments emerge
from the suspension they are drained and the pulp mat is dewatered under
negative pressure.

The fiber mat is knocked-off at the top by means of knock-off nozzles I and falls
through the collecting boxes J directly into the discharge screw trough K.

The filter cloths are cleaned by oscillating nozzles L before the filtration
procedure starts over again.

The shower headers are supported inside a hood N, which also serves to cover
the whole disc filter.

The cleaning shower nozzles are mounted on the oscillating shower header M,
which is driven by a geared motor O through an oscillating mechanism. The disc
filter rotor is rotated by a main drive consisting of a planetary gear box P and
electric motor run through a variable frequency drive.

The repulper at the bottom of the trough is driven by a gearbox / motor Q directly
mounted on repulper shaft.

The entire disc filter equipment is provided with an MS fabricated base frame R,
which supports the equipment on a civil foundation.

The normal barometric leg recommended for a good installation would be 7M


from the top of the water level in seal pit to the centreline of the filtrate valve.
For an optimum filtration / thickening efficiency of the disc filter, the barometric
leg is of paramount importance, as this decides the amount of vacuum available
for the dewatering process.
The vacuum in the clear filtrate leg would be around 350 to 400 mm Hg for good
dewatering performance.

LOOP 1 DISC FILTER & WATER DISTRIBUTION


Page 121/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

The disc filter rotates at a maximum speed of 2 RPM.


The speed could vary between 0.5 to 2 RPM that would be automatically
controlled based on the trough liquid level by the variable frequency drive on the
main motor. The customer’s DCS or PLC system should be programmed to
achieve the above control loop based on level transmitter readings.

Disc Filter Overview

LOOP 1 DISC FILTER & WATER DISTRIBUTION


Page 122/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

8.1.3 Area description

8.1.3.1 Loop 1 Disc Filter

The Loop 1 Disc Filter 05FDQ01 thickens the pulp flow accepted from the Fine-
Cleaning system, from 1% to 10-12%.

Brightness on feed to Loop 1 Disc Filter is measured by transmitter AIR5015 and


displayed/recorded.

Pulp pH on feed to Loop 1 Disc Filter is measured by transmitter AIR5005 and


displayed/recorded.

The Disc Filter main drive speed controller SIC5025 maintains the level LIC5020
in Disc Filter 05FDQ01 vat.

This is the only control on the Disc Filter:


- When the hydraulic through-put fed to the disc filter increases, leading to
increase the pulp level in the vat, the Disc filter drive speed increases.
- When the hydraulic through-put fed to the disc filter decreases, leading to
increase the pulp level in the vat, the Disc filter drive speed decreases.

The filtrate supply to the Disc Filter showers, from its own Clear filtrates for both
oscillating showers and Knock-off showers, is switched on by actuating On/Off
valve AV-5035.
Pressure indicator PI5040 on filtrates supply line to Knock-off shower ensures the
adequate pressure is available.
The respective shower flows are adjusted by setting of manual valves.

Transmitter PI5050 measures vacuum available for Disc Filter operating in Clear
filtrate barometric leg.

A speed switch SS5030 supervises the Repulping Screw 05FDQ01b rotation.

The accepted 10-12% stock falls in stand pipe of MC pump 05PMC10 feeding-
Screw-press & Dispersing 1.

The Shower pump 05PPC06 ensures the cleaning & unplugging of the Disc Filter
sectors wire, using the Disc Filter's own clear filtrates.

8.1.3.2 Loop 1 water distribution

The Loop 1 Filtrate distribution system ensures the filtrate requirements for Loop
1 are covered.

Clear Filtrate tank 05CE03


This tank receives:
 Clear filtrate extracted from Disc Filter 05FDQ01.
 Complement water from loop 2 water pump 10PPC09 (through control
valve LCV-5010).
 Tank filling water also from loop 2 water pump 10PPC09 (through
On/Off valve AV-5051).

LOOP 1 DISC FILTER & WATER DISTRIBUTION


Page 123/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

The level is measured by LIS5055.

Tank 05CE03 is used to feed:


 Loop 1 Continuous white water pump 05PPC07
 Loop 1 Periodic white water pump 05PPC08
 Disc Filter showers pump 05PPC06
 Cleaners feed pumps 04PPC05 (Stage 2), 04PPC07 (Stage 3) and
04PPC09 (Stage 4).

A continuous overflow to Cloudy water tank 05CE02 allows a constant level of


water and then avoids pressure variations at connected pump suctions, and
transfers complement to downstream water tanks.

Cloudy Filtrate tank 05CE02


This tank receives:
 Cloudy filtrate extracted from Disc Filter 05FDQ01.
 Loop 1 Screw-press 06PVS01 filtrates.
 Overflow from Clear Water tank 05CE03.

The level is measured by LIS5045.

Tank 05CE02 is used for dilution of Pre-flotation feed pump 03PPC01.

Cloudy filtrates in excess overflow by gravity from to Pulper water tank 05CE04
and allow complement to downstream water tanks.

Pulper water tank 05CE04


Pump 05PPC05 connected to this tank transfers Loop 1 filtrate to Buffer tank
05CE11 for:
 Dilution of Pulping area.
 Storage of excess filtrate during transitory phases (for example
shutdown of Loop 1 when filtrate generated by thickening is no more
consumed for Loop 1 process dilutions)

Level of tank 05CE04 is controlled by loop LIC5010 acting on control valve LCV-
5010 on make-up water from Loop 2 Periodic Filtrates pump 10PPC09, falling in
Clear Filtrate tank 05CE03 and overflowing successively to tank 05CE03 and
finally to tank 05CE04.
This configuration enables Low levels LIS5045 and LIS5055 to call also for water
complement in case of water deficit in corresponding water tank.

LOOP 1 DISC FILTER & WATER DISTRIBUTION


Page 124/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

8.2 BASIC OPERATING CAPACITY

Disc Filter: Ø 5200mm


Inlet flow 1850 m3/h at consistency 0,9% (i.e. 410
BDMT/24h)

8.3 TRANSMITTERS AND CONTROL LOOPS

Alarms Scale-0-
Item Function Description 100%
LL L H HH Value unit
AIR 5005 PH indication of Disc Filter feed pulp 5 to 11
Brightness indication of Disc Filter feed
AIR 5015
pulp
LIC 5020 Disc Filter 05FDQ01 vat level control 50% 95% 100% 0-100%
Disc Filter 05FDQ01 main drive motor
SIC 5025 0-100%
speed control
Disc Filter 05FDQ01 main drive zero
SS 5027 * Digital alarm
speed alarm
SS 5030 Disc Filter Repulper zero speed alarm * Digital alarm
Disc Filter 05FDQ01 shower header
PI 5040 3,2 7 0–8 Kg/cm2g
pipe pressure indication
Disc Filter 05FDQ01 Clear Filtrate - 600 to 0 mm
PI 5050 200 275
vacuum indication HG
LIC 5010 Pulper water tank 05CE04 level control 10% 15% 80% 90% 0-60 m3
Cloudy filtrate tank 05CE02 level
LIS 5045 10% 25% 0-60 m³
control
LIS 5055 Clear filtrate tank 05CE03 level control 10% 25% 0-60 m³

LOOP 1 DISC FILTER & WATER DISTRIBUTION


Page 125/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

8.4 INTERLOCKINGS AND ALARMS

8.4.1 Loop 1 Disc Filter 05FDQ01

108- MC PUMP 05PMC10 TO DISC FILTER 05FDQ01

If MC pump drive 05PMC10 is stopped

Then Disc Filter Repulping Screw is stopped.

109- INTERLOCKS TO DISC FILTER REPULPER SCREW 05FDQ01b

If Disc Filter Repulping screw 05FDQ01b is running with start-up override


T=5s
And Speed switch SS5030 is alarm (zero)

Then Disc Filter Repulping screw 05FDQ01b is stopped and alarm generated.

110- DISC FILTER OUTLET SCREW MOTOR TO SHOWERS WATER


PUMP

If Motor (M6043) of Disc Filter discharge screw is running

Then Showers water pump 05PPC06 is allowed to start

111- SHOWERS PUMP 05PPC06 TO SHOWER OSCILLATING DEVICE


MOTOR

If Showers water pump 05PPC06 is not running or tripped

Then Filter oscillating shower device motor (M6044) is forced to stop

112- INTERLOCKS TO DISC FILTER MAIN MOTOR

If Filter oscillating shower device (M6044) is not running or tripped

Then Disc Filter main motor (M6042) is forced to stop

If Repulper drive motor (M6043) is not running or tripped

Then Disc Filter main motor (M6042) is forced to stop

If Main Motor (M6042) of Disc Filter is running


AND Filter zero speed switch “SS-5027” is on alarm Low

LOOP 1 DISC FILTER & WATER DISTRIBUTION


Page 126/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Then Stop main motor (M6042) of Disc Filter

113- INTERLOCKS FROM DISC FILTER 05FDQ01

If Disc Filter Main Motor “M6042” is tripped during running

Then Filter vat level controller “LICA-5020” is DISABLED


AND Stock feeding pump “04PPC03” to cleaners is forced to STOP

114- (RESERVE)

8.4.2 Loop 1 water distribution

115- INTERLOCKS TO PULPER WATER TRANSFER PUMP 05PPC05

If Pulper water tank 05CE04 level LIC5010 is Low-Low


Or Buffer tank 05CE11 level LIS5000 is High

Then Pulper water transfer pump 05PPC05 is stopped.

If Pulper water tank 05CE04 level LIC5010 is Low


Then Inhibit start of Pulper water transfer pump 05PPC05

116- TRANSFER PUMP 05PPC05 TO SLAVE VALVE AV-5014

If Pulper water transfer pump 05PPC05 is not running


Then On/Off slave valve AV-5014 is forced closed

If Pulper water transfer pump 05PPC05 is running


Then With on delay T=5s, On/Off slave valve AV-5014 in Auto opens

117- INTERLOCKS TO SHOWERS WATER PUMP 05PPC06

If Clear filtrate tank 05CE03 level LIS5055 is Low-Low


Or Disc Filter 05FDQ01 main motor is not running

Then Disc Filter shower pump 05PPC06 is stopped.

If Clear filtrate tank 05CE03 level LIS5055 is Low


Then Inhibit start of Disc Filter shower pump 05PPC06

LOOP 1 DISC FILTER & WATER DISTRIBUTION


Page 127/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

118- SHOWERS WATER PUMP 05PPC06 TO DELIVERY VALVE AV-5035

If Disc Filter shower pump 05PPC06 is not running


Then On/Off slave valve AV-5035 is forced closed

If Disc Filter shower pump 05PPC06 is running


Then With on delay T=5s, On/Off slave valve AV-5035 in Auto opens (air
exhaust limit to open 15s)

119- INTERLOCKS TO LOOP 1 CONTINUOUS WATER PUMP 05PPC07

If Clear filtrate tank 05CE03 level LIS5055 is Low-Low


Then Continuous water pump 05PPC07 is stopped.

If Clear filtrate tank 05CE03 level LIS5055 is Low


Then Inhibit start of Continuous water pump 05PPC07

120- LOOP 1 CONTINUOUS WATER PUMP 05PPC07 TO SLAVE VALVE


AV-5090

If Continuous water pump 05PPC07 is not running


Then On/Off slave valve AV-5090 is forced closed

If Continuous water pump 05PPC07 is running


Then With on delay T=5s, On/Off slave valve AV-5090 in Auto opens (air
exhaust limit to open 15s)

121- INTERLOCKS TO LOOP 1 PERIODIC WATER PUMP 05PPC08

If Clear filtrate tank 05CE03 level LIS5055 is Low-Low


Then Periodic water pump 05PPC08 is stopped.

If Clear filtrate tank 05CE03 level LIS5055 is Low


Then Inhibit start of Periodic water pump 05PPC08

LOOP 1 DISC FILTER & WATER DISTRIBUTION


Page 128/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

122- LOOP 1 PERIODIC WATER PUMP 05PPC08 TO SLAVE VALVE AV-


5085

If Periodic water pump 05PPC08 is not running


Then On/Off slave valve AV-5085 is forced closed

If Periodic water pump 05PPC08 is running


Then With on delay T=5s, On/Off slave valve AV-5085 in Auto opens (air
exhaust limit to open 15s)

123- (RESERVE)

ALARMS

124- SEALING WATER

If Loop 1 Disc Filter & water distribution area is in operation


And Main line Sealing water flow is on Alarm FSA20135 Low for T=30 s

Then Active the ALARM

125- COMPRESSED AIR

If Loop 1 Disc Filter & water distribution area is in operation


And Compressed Air pressure PIA19202 is on Alarm Low

Then Active the ALARM

126- (RESERVE)

LOOP 1 DISC FILTER & WATER DISTRIBUTION


Page 129/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

8.5 OPERATION

8.5.1 Start-up

Loop 1 water distribution is the first area to start in Loop 1, in order to store
necessary water for all equipment start-up and dilution.

Basic conditions:
- Sealing water main line is under pressure and Flow switch FSA20135 is not
alarm Low
- Compressed air system is under pressure (pressure PIA19202 not on Alarm
Low).
- Loop 2 filtrate tanks levels LIC9050 and LIS9055 are not Low

8.5.1.1 Water tanks filling

If water tanks are empty (for example on first start-up):

Open On/Off water valve AV-5051 for filling of Clear filtrate tank 05CE03 with
Loop 2 filtrates provided by pump 10PPC09.

Other tanks 05CE02 and 05CE04 in cascade are filled with successive overflows.

When allowed through interlocks, start pump 05PPC05 to fill Buffer tank 05CE11
up to sufficient level to launch pulping sequences.

As soon as water tank levels are up to Low level, connected water pumps can
start if required by the sub-systems or in manual by operator.

8.5.1.2 Disc Filter 05FDQ01 start

Basic conditions:
- Clear Filtrate tank 05CE03 level LIS5055 is not Low.
- MC Pump 05PMC10 stand pipe level LICS5065 is not High

For start-up of sequence, the clear filtrate seal chamber should be filled with
either clear filtrate or fresh water up to the maximum level of this chamber so that
overflow occurs into the clear filtrate tank.

Start Loop 1 Disc Filter Repulping screw 05FDQ01b.

Start Disc Filter Shower Pump 05PPC06 and open its delivery valve AV-5035.

Start Oscillating shower drive 05FDQ01c.

Start Loop 1 Disc Filter Main Drive 05FDQ01.

When running status obtained for both, set Disc Filter status to READY.

LOOP 1 DISC FILTER & WATER DISTRIBUTION


Page 130/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

8.5.1.3 Production

The process bloc starts in production with the flotation bloc and cleaning bloc
(Once the stock is bled downstream of the constant level box 02CP20 via control
valve FCV-3020).

Cleaners feed pump 04PPC03 is allowed to start with Disc Filter READY status.

When feed pump 04PPC03 is started:


Put the Disc Filter trough level controller LIC5020 in AUTO Mode.

NB: The process block can run few minutes in water mode if the flotation loop
and cleaning & fines screening loop are running into water mode.

8.5.2 Operation

The different steps run off automatically.

 Monitoring of HP shower water pressure.


 Monitoring of consistencies (Water and stock).
 Monitoring of operating vacuum

LOOP 1 DISC FILTER & WATER DISTRIBUTION


Page 131/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

8.5.3 Shutdown

8.5.3.1 Stop of production

The process bloc stops in production with the flotation bloc and the cleaning loop,
by closing of the control valve FCV-3020 outlet of the constant level box 02CP20.

Loop 1 Disc Filter stops in production with stop of feed pump 04PPC03.

8.5.3.2 Disc Filter 05FDQ01 stop

Reset Disc Filter status to Not READY

Stop the disc filter main motor after time delay of 10 minutes to ensure that as
much of fiber is recovered as possible from the liquid in the trough.

Stop Loop 1 Disc Filter Oscillating shower drive 05FDQ01c.

Stop Disc Filter Shower Pump 05PPC06 and close its delivery valve AV-5035.

Stop the stock repulper screw drive after time delay of 5 minutes, to ensure that
stock does not remain in the screw trough during stoppage.

CAUTION!
It would be preferable to operate the Disc Filter system for 5-10 minutes with just
showers water for internal cleaning prior to any medium duration stoppage (up to
4 hours).

For stoppages exceeding 4 hours, it would be preferable to clean the internal


system and have the trough drained fully. The contents of the trough should be
drained very slowly and gradually to avoid physical damage to the internal
components of the trough and rotor due to build-up of vacuum caused by
excessively rapid draining (siphon effect). Use of wire cleaning showers to clean
the filter fabrics is recommended. The inside of the hood and the showers pipes
should also be cleaned with water hose under pressure.

8.5.3.3 Loop 1 Water distribution

Filtrate pumps 05PPC05, 05PP07 & 05PPC08 are stopped when no more
required by any Loop 1 sub-systems.

LOOP 1 DISC FILTER & WATER DISTRIBUTION


Page 132/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

PROCESS DESCRIPTION

KHANNA
NEW DIP LINE 300 BDMT/24h
PRINTING - WRITING

LOOP 1 THICKENING -
KNEADING &
OXIDATIVE BLEACHING

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 133/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

9 LOOP1 THICKENING, KNEADING AND OXYDATIVE BLEACHING AREA

9.1 DESCRIPTION

9.1.1 Area Itemization

 Stand Pipe ..............................................................................14CE02


 MC pump ...........................................................................05PMC10
 Recirculation chest ............................................................................07CPA11
 Recirculation chest agitator.....................................................................................
07AG12
 Recirculation chest extraction pump.......................................................................
07PPC13
 Screw press ............................................................................06PVS01
 Kneader ...............................................................................06TL02
 Bleaching tower ............................................................................07CPA01
 Bleaching tower vertical agitator ............................................................................
07AG02
 Bleaching tower rotating extraction mixer...............................................................
07AG03
 Bleaching tower extraction pump............................................................................
07PPC07

9.1.2 MC Pump basics

The MC-Pump system consists of

- A stand pipe for Pump feeding with thick stock.

- The MC Pump itself, with a special pulp impeller that fluidises the pulp.

For more details, please refer to supplier documentation.

9.1.3 Screw Press basics

Screw press is composed of the following elements mounted on a base frame:


- Press screw with conical-cylindrical shape and screw pitch reduced from inlet
to outlet of the press;
- Press screen system, with Inlet screen (half cylinder), Draining section &
Compression section screen plates supported in half cylinder mantles;
- Counter-pressure cone

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 134/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

For more details, please refer to supplier documentation.

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 135/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

9.1.4 Basics Kneader type TL

9.1.4.1 Kneader description

The pulp introduced into the Kneader is subjected to shear forces between stator
& rotor, which conveys the pulp through the kneading zone, with a controlled
counter-pressure maintained at the outlet of the Kneader.

The KADANT Kneader type TL is a single shaft Kneader, comprising the


following elements:
- Inlet & accept casing and support for inlet side/accept side bearing, base-
frame;
- Cylindrical body, with connection for thick stock inlet, thick stock outlet, and
nozzles for steam injection. In Kneading zone, the mantled body supports the
individual stator kneading fingers constituting the Kneader Stator.
- Rotating shaft, equipped with a conical screw in Feeding zone, and with
rotating kneading fingers in Kneading zone, constituting the Kneader Rotor.
- Counter-pressure system, with pneumatically actuated flap on thick stock
outlet (local pneumatic panel with pressure control, remote set-point).

The Kneader is equipped with a mechanical gear-drive & motor coupled to the
Kneader drive shaft. The Kneader is operated at fixed speed.

The thick stock to be processed in fed by gravity into the Kneader stock inlet, and
is carried forward by the screw in the Feeding zone into the kneading zone.

The kneading action takes place between the interpenetrating rows of fingers:
rotating (rotor) and stationary (stator). As the pulp is forced forward through the
area between the fingers, it is subjected to intense friction & shear, which
determine the kneading effect on the pulp.

The main process parameter to control the kneading effect is the specific
energy absorbed by the stock. The absorbed kW load is controlled by the
pneumatic counter-pressure applied on the stock outlet.

The counter-pressure system comprises of a pneumatically actuated flap


mounted against the stock outlet. The pneumatic pressure applied to stock outlet
flap is controlled from local pneumatic panel, with remote set point used to
control absorbed kW on the Kneader.

The energy absorbed by the stock in the Kneader leads to a significant


temperature increase. Steam injection into the Kneader, controlled by
temperature measurement on the accepted stock, ensures an optimal accepted
stock temperature optimal for bleaching as required.

9.1.4.2 Kneader Counter-pressure control & Pneumatic Panel

9.1.4.2.1 Kneader Counter-pressure control & Pneumatic Panel

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 136/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

The Kneader local pneumatic panel comprises a pressure control of the


Compressed air feed to the Kneader counter-pressure pneumatic actuator, with
remote set point and On/Off release of air-pressure.

The counter-pressure system (abbreviated CP) is integrated into the process


system using the following features:
Counter-Pressure On/Off: the Kneader counter-pressure is put on or released
at once by closing/opening of a solenoid valve.

Note: the local panel solenoid is Fail-open (1 to close).

Kneader Counter-Pressure set point: the set point to the pneumatic counter-
pressure (= local controller JT-6030) is obtained from DCS controller JICS6030
(DCS output to local servo valve).

The process value input to JICS6030 controller is the Amp load feedback
(expressed in kW).

9.1.4.2.2 Kneader Absorbed Power control: Counter-pressure

Kneader CP is to be set ON by operator. If Kneader CP is OFF, the Power


controller is disabled with minimum counter-pressure set point to Kneader
pneumatic panel, solenoid valve open to release pressure.

If Kneader High-High Amp load alarm, or in case of interlocks downstream to


Kneader, reset Kneader CP to OFF.

When enabled by operator, the DCS Power controller JICS6030 controls the
Counter-pressure local controller of the Kneader, at the Amp Load (or kW) set-
point entered by operator:
- If measured Amp load JICS6030 increases to above set-point, DCS controller
reduces counter-pressure;
- If measured Amp load JICS6030 decreases to below set point, DCS
controller increases counter-pressure.

Note: the controlled value is absorbed kW - NOT specific absorbed kW. The set-
point to the power controller will need to be adapted by operator taking into
account the through put of the line.

The Kneader absorbed Power is monitored by operator. Activating CP Absorbed


Power control using Kneader CP ON remains an operator decision.

9.1.5 Basics Pollcon Tower

9.1.5.1 Pollcon tower description

The POLLCON High Consistency Bleaching Tower consists of the following


elements:

Top part:

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 137/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

- Support structure & bottom agitator drive, with torque transmitter (4-20 mA)
integrated to gear-drive;
- Manhole & maintenance opening;
- 4 openings for High Consistency Stock inlet;

Bottom Part:
- Bottom agitator 07AG02 with 4 branches and dilution ramps, bottom support;
- Connections to rotating dilution ramps and to central dilution box;
- Annular dilution ring with valve & injectors to tower base;
- Rotating extraction mixer 07AG03, with drive & dilution;
- Level transmitter flange.

9.1.5.2 Pollcon tower operation

The Ox Bleaching Tower is fed with pulp at 30% from Kneader.

The pulp bleaching proceeds at high consistency, for the residence time of the
pulp in the Bleaching Tower.

In the lower dilution zone of the Tower, the high consistency pulp is diluted to 4-
5% through the following nozzles:
- Dilution A: through annular dilution ring and injectors around the base of the
Tower;
- Dilution B: through central dilution box
- Dilution C: through rotating dilution ramps fixed on the agitator branches.
- Dilution D: to Extraction Mixer zone.

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 138/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Figure: POLLCON HC Bleaching Tower

Agitator drive

Dilutions

Dilutions
A
- to Bottom Dilution to
Periphery Extraction Mixer
D
- to Central B
dilution Box
- to Rotating Agitator
C
Stock Extracted

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 139/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

9.1.6 Dispersion and Bleaching description

9.1.6.1 Transfer MC pump 05PMC10

Note: The following description for MC pump operation & associated regulations
correspond with a Sulzer pump type.
This paragraph is to be adapted and/or corrected in case of any other supplier.

Stock at 10-12% falls by gravity from the Loop 1 Disc Filter 05FDQ01 Repulping
screw outlet into the MC Pump Stand-Pipe 14CE02.

Dilution water is injected to the stand-pipe at the top by HCV-5060 and to the
base by LCV-5065. Both valves can be operated in manual or in Automatic.

The pump drive speed is controlled by SIC5068.

The level in the MC Pump Stand-Pipe is controlled by LICS5065 operating on


MC pump motor speed controller SIC5068.

In addition, LICS5065 controls valves LCV-5065 & HCV-5060 dilution valves to


Stand-pipe, opening the level dilution valves when the level rises.

In Manual mode, Top dilution valve HCV-5060 and bottom dilution valve LCV-
5065 can be opened at any time.

In Auto mode, Top dilution valve HCV-5060 is opened at operator defined


opening set-point + controlled value related to deviation of LICS5065 from set-
point.
Bottom dilution valve LCV-5065 is normally closed, and opens to operator set
value when LICS5065 measure is greater than 30% above set-point and MC
Pump is running.

The MC Pump 05PMC10 pumps the stock forward to downstream process.


Consistency measurement via NI5110 has been added at the MC pump outlet
just to be able to monitor the outlet consistency of the stock.

9.1.6.2 Recirculation chest 07CPA11

During transitory phase (like on start-up or during an eventual incident in


downstream process), a recirculation line from MC pump 05PMC10 outlet
(through On/Off valve AV-6006 open and with On/Off valve AV-6010 closed)
allows recirculation of Loop 1 Accepted stock back to intermediate chest
07CPA11.

This pulp transferred to chest 07CPA01 is diluted in line with filtrates from pump
10PPC13 and through On/Off valve AV-6160 in order to decrease consistency
from 10 to 4-5%.

Chest 07CPA011 is equipped with a horizontal agitator 07AG12 and level is


controlled by LIC6007 acting on control valve LCV-6007 at extraction pump
07PPC13 outlet.

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 140/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Extraction pump 07PPC13 transfers stock to Dump Chest 01CPA15.

Then when operator activates loop 1 accept stock recirculation to Dump chest, a
sequence automatically:
 Starts filtrate pump 10PPC13
 Opens filtrate valve AV-6160
 Opens by-pass valve AV-6006 and closes opposite valve AV-6010
 Sets in Auto mode level controller LIC6007
 Enables start of agitator 07AG12 and extraction pump 07PPC13
(motors start depend also on interlocks).

Recirculation chest 07CPA11 can also by fed Loop 2 Disc Filter accepted stock
through MC pump 14PMC03.

9.1.6.3 Screw Press 06PVS01

The Screw-Press 06PVS01 thickens the 10-12% pulp (from Loop 1 Disc Filter via
MC pump 05PMC10) to 30-35% consistency required for Kneading.

Transmitter PIS6005 measures screw-Press 06PVS01 feed pressure and a by-


pass line (through On/Off valve AV-6150 with opposite On/Off valve AV-6015
closed) can send pulp directly to downstream bleaching tower 07CPA01.

Screw Press torque is controlled by JICS6020.

Screw press is equipped with a variable speed motor controlled by SIC6021.

These operating parameters (torque set-point/ operating speed range/ counter-


pressure) of the screw press need to be adjusted on start-up to achieve adequate
outlet consistency.

The consistency of thick stock at the outlet of the Screw Press results of the
Torque JICS6020 and counter-pressure applied to the press, taking into account
the type of pulp, the throughput, the inlet consistency.

Screw press speed control & Torque controller:

Inputs:
Process value: Taken from the frequency converter and scaled to Nm.
Set point: Operator controlled parameter.
SP Ramp: 5 Nm per second.
Auto/Manual: Default “Auto”.
PV filter: 4s. Filter to flatten the process value signal.
To be applied either in frequency converter
or in control system.
Maximum output: This is to be set at 100%.
Minimum output: To be set at 0%.
Maximum SP: 50%.

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 141/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Minimum SP: 0%.


HHAL: 70%.
HAL: 60%.

Output:
Output from controller forwarded frequency converter speed reference input.

Function:
Process value < Set point makes output decrease.
Process value > Set point makes output increase.

Refer to Screw Press supplier documentation for further operating description.

The filtrates extracted from the Screw press flow by gravity to Cloudy Filtrate
Tank 05CE02.

The 30-35% consistency stock accepted from the Screw press feeds directly
Kneader 06TL02.

9.1.6.4 Kneader 06TL02

Pulp falls directly from Screw Press 06PVS01 to Kneader 06TL02.

Necessary chemicals for oxidative bleaching are also introduced into the
Kneader infeed hopper.
Notes:
 Chemicals flow should be proportional to line production.
 The supply of chemicals MUST be interlocked (hard) to the operation
of the Kneader and downstream equipment, and to the presence of
stock in the Kneader (indicated by Kneader CP-Status ON).

The pulp introduced into the Kneader 06TL02 is subjected to shear forces
between stator & rotor, which conveys the pulp through the kneading zone, with a
controlled counter-pressure maintained at the outlet of the Kneader.

Kneader 06TL02 rotor is driven in rotation with a gearbox equipped with security
alarms FSAL6135 and TSAH6050 (Gearbox temperature alarm).

Torque controller JICS6030 receives as process value input the Amp load %
measured by the MCC and copied to DCS, and controls the set-point to local
pneumatic panel counter-pressure local controller to Kneader counter pressure.

Operator sets the set-point to JICS6030; there is no remote set-point for specific
energy control provided for at this stage.

Pulp into Kneader is heated with direct steam injection.


The steam control valve TCV-6025 is controlled by the temperature loop TIC6025
measured on the thick stock accepted from the Kneader (TT on Kneader) in

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 142/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

order to obtain a required bleaching temperature T= 80-95°C at outlet of Kneader


(depends on operating conditions).

The thick stock accepted from Kneader falls by gravity into Bleaching Tower
07CPA01.

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 143/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

9.1.6.5 Pollcon Tower 07CPA01

The thick stock fall from Kneader into Bleaching tower 07CPA01 at consistency
30-35%.

The pulp bleaching proceeds at high consistency. Tower volume has been sized
adequately to the required residence time of the pulp.

Bleaching tower 07CPA01 level is measured by LIS6070.

High Level LIS6070 is one of the main levels on the line, to be monitored by
operator to control the production & stability on loop 1 by acting on Loop 1
production set-point (through command FIC3020 regulating stock feed to Pre-
Flotation area).

The Ox Bleaching tower must have a minimum level of filtrates or stock prior to
feeding thick stock - to prevent block agitator or extracting system. This requires
pre-filling on filtrates prior to start the line. Operator does this filling manually from
DCS.

Operation with stable Bleaching Tower level is recommended for stable


Bleaching operation.

Bottom agitator 07AG02 is equipped with a torque alarm XS6080 to detect an


eventual blockage of agitator.

The Bottom agitator 07AG02 torque JIC6085 controls the flow to Dilutions A-
Annular ring & B-Central box through control valve FCV-6085.

The dilution C flow is controlled by FIC6060 through control valve FCV-6060, with
set-point in remote could be proportional to stock flow FI6115 extracted from
Tower bottom to downstream fine screening.

In Extraction Mixer 07AG03, the Pulp is fluidised and further diluted by DILUTION
D flow, controlled by measured consistency NRC6095 through control valve
NCV-6095 in order to reach 4,5%.

All these dilution flows are fed with Loop 2 filtrates from pump 10PPC08.

Pump 07PPC07 extracts the stock from Bleaching tower to downstream Loop 2
process (i.e. Fine Screening feed chest 07CPA08).
Flowmeter FI6115 measures this transfer flow.

Then Loop 2 production P2-5070 can be calculated from Flowmeter FI6115 and
consistency controller NRC6095.

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 144/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

9.2 BASIC OPERATING CAPACITY

Screw press:
Inlet 175 m3/h at consistency 10% (i.e. 400 BDMT/24h)
Accept at consistency 30-35%

Kneader: TL3
Installed Power: 1200 kW
Specific energy: 80-85 kW/BDT

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 145/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

9.3 TRANSMITTERS AND CONTROL LOOPS

MC Pump and Screw Press control loops to be checked with corresponding


supplier.

Alarms Scale-0-
Item Function Description 100%
LL L H HH Value unit
Manual control valve of dilution water to
HIC 5060 0-100%
top of Stand Pipe 14CE02
MC Pump Stand Pipe 14CE02 level
LICS 5065 5% 15% 85% 95% 0-100%
control
MC Pump 05PMC10 motor speed
SIC 5068 0-100%
Control
Consistency indication of Loop 1
NI 5110 0 to 15%
thickening - Bleaching
Recirculation chest 07CPA11 level
LIC 6007 5% 15% 85% 95% 0-30 m³
control
Screw Press 06PVS01 feed pressure
PIS 6005 0–5 Bars
indication
JICS 6020 Screw Press 06PVS01 torque control 0-700 m3/h
Screw Press 06PVS01 motor speed
SIC 6021 0-100%
Control
TIC 6025 Kneader 06TL02 temperature control 0-150°C
KW scale/MCC
JICS 6030 Kneader 06TL02 Amp-load control 20% 70% 90% And unit 0-100%
Kneader 06TL02 gear drive cooling water
FSAL 6135 L Digital alarm
flow alarm
Kneader 06TL02 gear drive temperature
TSAH 6050 H Digital alarm
alarm
Oxidative bleaching tower 07CPA01 level
LIS 6070 5% 15% 85% 95%
control
Tower 07CPA01 Bottom agitator 07AG02
JICS 6085 70% 90% 0-100%
drive Torque controller
Tower 07CPA01 Bottom agitator 07AG02
XS 6080 H Digital alarm
drive Torque High switch
Oxidative bleaching tower 07CPA01
FIC 6060 0-200 m3/h
dilution flow control (to rotating agitator)
Oxidative bleaching tower 07CPA01
NRC 6095 0–5%
extracted pulp consistency control
Oxidative bleaching tower 07CPA01
FI 6115 0-500 m3/h
extracted pulp flow indication
DIP line Loop 2 production indication
P2 5070 Software only
(Calculation with NT-6095 & FT-6115)

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 146/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

9.4 INTERLOCKINGS AND ALARMS

MC Pump and Screw Press interlocks and alarms to be corrected and/or


corrected with corresponding supplier.

9.4.1 Transfer MC pump 05PMC10

127- INTERLOCKS TO MC PUMP 05PMC10

If Bleaching Tower 07CPA01 level LIS6070 is alarm High-High for T=5s


Or MC pump Stand Pipe level LICS5065 is Low-Low for 30s
Or Screw Press 06PVS01 is not running when required (On/Off valves AV-
6010 & AV-6015 open, On/Off valves AV-6066 & AV-6150 closed)

Then MC Pump 05PMC10 is stopped

128- MC PUMP 05PMC10 INTERLOCKS TO CONTROLS & VALVES

If MC Pump 05PMC10 is not running

Then Level controller LICS5065 is disabled


And Control valve HCV-5060 if in Auto is closed
And Control valve LCV-5065 if in Auto is closed
And Slave On/Off valve AV-5080 is forced closed

If MC Pump 05PMC10 is running (On delay T=20s)

Then Level controller LICS5065 is enabled to speed controller


SIC5068
And Output to valve LCV-5065 is enabled
(HCV-5060 output is enabled on motor start-order)
And Slave On/Off valve AV-5080 opens

129- LOOP 2 DILUTION WATER INTERLOCK TO MC PUMP WATER


CONTROL VALVES

If Loop 2 periodic water pump 10PPC09 is not running


Then Control valves HCV-5060 and LCV-5065 are forced closed.

If Loop 2 periodic water pump 10PPC09 is not running


And MC Pump 05PMC10 is running

Then Alarm dilution to MC Pump is generated.

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 147/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

130- (RESERVE)

9.4.2 Recirculation chest 07CPA11

131- RECIRCULATION CHEST 07CPA11 LEVEL LIC6007 TO AGITATOR


07AG12

If Chest level LIC6007 is Low-Low


Then Stop Agitator 07AG12

If Chest level LIC6007 is Low


Then Inhibit Start Agitator 07AG12

If Chest level LIC6007 is not Low


And Agitator 07AG12 in DCS Auto mode

Then Start Agitator 07AG12

132- INTERLOCKS TO EXTRACTION PUMP 07PPC13

If Recirculation chest level LIC6007 is Low-Low


Or Dumping chest 01CPA15 level LIS1425 is High-High

Then Extraction pump 07PPC13 is stopped.

If Recirculation chest level LIC6007 is Low

Then Inhibit start Extraction pump 07PPC13

133- EXTRACTION PUMP 07PPC13 TO SLAVE VALVE LCV-6007

If Extraction pump 07PPC13 is not running


Then Control valve LCV-6007 is forced closed (Hard interlock)

If Extraction pump 07PPC13 is running


Then With on delay T=5s, control valve LCV-6007 in Auto opens

134- (RESERVE)

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 148/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 149/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

9.4.3 Screw Press 06PVS01

135- INTERLOCKS TO SCREW PRESS 06PVS01

If Kneader 06TL02 is not running (On-delay T=10s).


Or OFF (computer) is activated (broken circuit).
Or Emergency stop or service switch is activated (broken circuit).
Or Slow speed limit switch is not activated (low speed = broken circuit).

Then Screw Press 06PVS01 is stopped.

136- INTERLOCKS TO SCREW PRESS 06PVS01 COUNTER PRESSURE


CONE

If Screw Press 06PVS01 is not running.


Or Open (computer) is selected (broken circuit).
Or Pulp feed pump 05PMC10 is not running on delay T=30s.
Or Screw Press speed Torque controller JICS6020 is on Alarm High

Then Counter pressure cone in Screw Press opens (solenoid valve


energized).

137- INTERLOCKS TO SCREW PRESS 06PVS01 SEALING WATER


VALVE

If Screw Press 06PVS01 is not running.


Then Sealing water On/Off valve closes

If Screw Press 06PVS01 is running.


Then Sealing water On/Off valve opens

138- (RESERVE)

139- (RESERVE)

TO BE COMPLETED AND/OR CORRECTED IF NECESSARY

9.4.4 Kneader 06TL02

140- INTERLOCKS TO KNEADER 06TL02

If Oxidative bleaching tower 07CPA01 level is High-High for T=45s.


Or Oxidative bleaching tower 07CPA01 level is Low-Low.

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 150/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Then Kneader 06TL02 is stopped.

141- SCREW PRESS 06PVS01 & KNEADER 06TL02 RUNNING TO STEAM


HEATING TIC6025

If Kneader 06TL02 is not running (on-delay T=20s)


Or Screw Press 06PVS01 is not running (on-delay T=20s)
Or Temperature TIC6025 is alarm High-High (on-delay T=20s)

Then Temperature controller TIC6025 is disabled with valve TCV-6025 forced


closed
And Steam isolation valve AV-6140 is forced off

Note: if TIC6025 is in Auto and the interlocking conditions are set to healthy, the
controller is enabled after specified on-delays. In Manual, the controller
remains at closed value.

142- KNEADER CP & KNEADER POWER CONTROL JICS6030

Operator action only sets Kneader CP_STATUS to ON, for example with push-
button action on DCS synoptic.

If Operator resets Kneader CP_STATUS to OFF


Or Screw-Press 06PVS01 is not running
Or Kneader Amp load JICS6030 is alarm High for T=2s
Or Kneader 06TL02 is stopped
Or Oxidative bleaching tower 07CPA01 level is High

Then Kneader CP_Status is reset to OFF.

If Kneader CP_Status is OFF

Then Kneader torque controller JICS6030 is disabled


With output to local CP ctrl forced to 0%
And Kneader counter-pressure On/Off solenoid valve is forced Off

Note: Kneader CP_Status ON is required to allow Chemical dosage to Kneader.

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 151/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

143- KNEADER INTERLOCK TO OXIDATIVE CHEMICAL DOSAGE

If Kneader CP_Status is to OFF (with on-delay T=30s)

Then Chemical supply to Kneader inlet is DISABLED (to Chemical dosage


pumps).

The On-delay T=30s means that chemical supply to Kneader will remain
forbidden T=30s after the CP has been set ON.

144- (RESERVE)

9.4.5 0xidative bleaching tower 07CPA01

High level stops the Kneader 06TL02 after T=45s, while it stops the feed MC
pump 05PMC10 immediately (T=5s), allowing to stop properly the Screw press-
Kneading system.

The level setting for High-High alarm will leave room in Tower for T=45s
production.

145- TORQUE CONTROL JIC6085, TORQUE HIGH SWITCH XS6080,


FLOW CONTROL FIC6060 & AGITATOR 07AG02

If Torque controller JIC6085 is High-High


Or Torque High Switch XS6080 is alarm

Then Stop Agitator 07AG02 (Hard interlock)

Note: The agitator even if in Auto cannot restart until operator resets the alarm
manually.

If Agitator 07AG02 is not running (On-delay T=1s)


Then Torque dilution controller JIC6085 is disabled with control valve FCV-
6085 forced closed.

(Above on-delay T=1s means that the interlock is reset 1s after Agitator is
running, enabling JIC6085 if in auto 1s after running status is obtained).

If Loop 2 Continuous Filtrate Pump 10PPC08 is not running


Then Torque dilution controller JIC6085 is disabled with control valve FCV-
6085 forced closed

If Agitator 07AG02 start order


. If Torque controller JIC6085 in Auto

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 152/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

And Loop 2 Continuous Filtrate Pump 10PPC08 is


running
Then Control valve FCV-6085 is opened to 60% for T1=15s

. If Dilution flow control FIC6060 in Auto


And Loop 2 Continuous Filtrate Pump 10PPC08 is
running
Then Control valve FCV-6060 is opened to 60% for T2=15s

After T1, Agitator 07AG02 is started


(When Agitator 07AG02 is running for 15s, JIC6085 is enabled)
(When Extraction pump 07PPC07 is running for 1s, FIC6060 is enabled)

Note: There is no interlock preventing starting manually the bottom agitator


without dilution - which is a wrong manoeuvre. If the stock in the lower
part of the Tower has a high consistency, the High-High torque interlock
will stop the agitator.

146- INTERLOCKS TO DILUTION FLOW CONTROLLER FIC6060

If Extraction pump 07PPC07 is not running (On-delay T1=1s)


Then Flow dilution controller FIC6060 is disabled with control valve FCV-6060
forced closed.

If Loop 2 Continuous Filtrate Pump 10PPC08 is not running


Then Flow dilution controller FIC6060 is disabled with control valve FCV-6060
forced closed.

Note: There is no interlock preventing starting manually the pump without dilution
- which is a wrong manoeuvre. If the stock in the lower part of the
Tower has a high consistency, there is a risk to trip the mixer motor,
block pump.

147- INTERLOCKS TO CONSISTENCY CONTROLLER NRC6095

If Extraction pump 07PPC07 is not running (On-delay T1=1s)


Then Consistency dilution controller NRC6095 is disabled with control valve
NCV-6095 forced closed.

If Loop 2 Continuous Filtrate Pump 10PPC08 is not running


Then Consistency dilution controller NRC6095 is disabled with control valve
NCV-6095 forced closed.

If Mixer 07AG03 start order


With Consistency controller NRC6095 is in Auto
And Loop 2 Continuous Filtrate Pump 10PPC08 is running

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 153/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Then Consistency dilution controller NCV-6095 is opened to 60% for T2=15s


After T2=15s, Mixer 07AG03 is started
(Reset of above Extraction pump 07PPC07 interlock enables NRC6095
if in Auto)

Note: There is no interlock preventing starting manually the mixer or the pump
without dilution - which is a wrong manoeuvre. If the stock in the lower
part of the Tower has a high consistency, there is a risk to trip the mixer
motor.

148- BLEACHING TOWER LEVEL LIS6070 HIGH_HIGH INTERLOCK TO


DILUTION VALVES

If Oxidative bleaching tower 07CPA01 level is High-High

Then Torque dilution controller JIC6085 is disabled with valve FCV-6085


forced closed
And Flow dilution controller FIC6060 is disabled with valve FCV-6060 forced
closed
And Consistency controller NRC6095 is disabled with valve NCV-6095 forced
closed

Note: this interlock is designed to prevent adding dilution filtrates to a full tower,
to prevent overflowing the tower filling it with filtrates.

149- EXTRACTION PUMP 07PPC07 to SLAVE VALVE 403-HS-6250

If Extraction Pump 07PPC07 is not running


Then Slave valve 403-HS-6250 is forced closed (Hard interlock)

If Extraction Pump 07PPC07 is running


With On-delay T=5s,
Then Open Slave valve 403-HS-6250 (Hard interlock-with air exhaust limit to
open in 15s)

Note: 403-HS-6250 in Manual or in Auto always operates with 07PPC07. The


operator cannot operate the valve independently from the pump, even in
Manual. Operation of the valve independently from the pump will require
maintenance or engineer level access.

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 154/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

150- BLEACHING TOWER 07CPA01 LEVEL LIS6070 INTERLOCK TO


AGITATOR 07AG02 & MIXER 07AG03

If Bleaching tower level LIS6070 is Low-Low

Then Stop Mixer 07AG03


And Stop Agitator 07AG02

If Bleaching tower level LIS6070 is Low

Then Inhibit Start Extraction Mixer 07AG03


And Inhibit Start Agitator 07AG02

If Bleaching tower level LIS6070 is Not Low


And Agitator 07AG02 in DCS Auto mode

Then Start Agitator 07AG02

151- EXTRACTION PUMP 07PPC07 TO MIXER 07AG03

If Extraction Pump 07PPC07 is not running


And Mixer 07AG03 is running since T=300s

Then Mixer 07AG03 if running is stopped (hard interlock)

Note: this interlock stops the mixer to avoid "forgetting" the mixer running without
flow for a long period. The interlock is active only after equipment is
running to allow starting the equipment.

152- INTERLOCKS TO EXTRACTION PUMP 07PPC07

If Loop 2 Continuous Filtrate Pump 10PPC08 is not running


Then Stop Bleaching Tower extraction pump 07PPC07

If Bleaching tower level LIS6070 is Low-Low


Or Mixer 07AG03 is not running
Or Agitator 07AG02 is not running

Then Stop Bleaching Tower extraction pump 07PPC07

If Bleaching tower level LIS6070 is Low


Then Inhibit Start Bleaching Tower extraction pump 07PPC07

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 155/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

153- FINE SCREENING FEED CHEST 07CPA08 LEVEL LIC6120


INTERLOCK TO EXTRACTION PUMP 07PPC07

If Fine Screening feed chest level LIC6120 is Alarm High-High


Then Extraction pump 07PPC07 is stopped (hard interlock)

If Fine Screening feed chest level LIC6120 is Alarm High


Then Extraction pump 07PPC07 is stopped (soft interlock)

154- (RESERVE)

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 156/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

9.4.6 ALARMS

155- SEALING WATER

If Thickening - Bleaching area is in operation


And Main line Sealing water flow is on Alarm FSA20135 Low for T=30 s

Then Active the ALARM

156- COMPRESSED AIR

If Oxidative Bleaching area is in operation


And Compressed Air pressure PIA19202 is on Alarm Low

Then Active the ALARM

157- RECIRCULATION CHEST 07CPA11 LEVEL

If Recirculation chest 07CPA11 level controller LIC6007 is High

Then Active the ALARM

158- CLOUDY FILTRATE TANK 05CE02

If Loop 1 cloudy filtrate tank 05CE02 level controller LIS5045 is High

Then Active the ALARM

159- BLEACHING TOWER 07CPA01 LEVEL LIS6070

If Bleaching tower 07CPA01 level controller LIS6070 is High

Then Active the ALARM

160- (RESERVE)

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 157/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

9.5 OPERATION

9.5.1 Start-up

The Area Thickening-Kneading is the first system started in Loop 1 (after of


course Water Distribution system).
It starts only if the Ox Bleaching Tower 07CPA01 level is not High AND not Low-
Low.

Basic conditions:
- Sealing water main line is under pressure and Flow switch FSA20135 is not
alarm Low
- Compressed air system is under pressure (pressure PIA19202 not on Alarm
Low).
- Steam network under pressure
- “FRESH WATER” network under pressure
- Chemicals ready
- Loop 2 filtrate tanks Level LIC9050 & LIS9055 are not Low.
- Bleaching tower 07CPA01 level LIS6070 is not High AND not Low-Low

Note: If Bleaching Tower 07CPA01 level is Low, operator needs to pre-fill the
Tower with Loop 2 filtrates from pump 10PPC08.

9.5.1.1 Starting of the loop

The system is started by sequentially starting all elements from downstream to


upstream.

If not already running, start Loop 2 filtrate pumps 10PPC08 & 10PPC09.

Start Kneader 06TL02.


When running status is obtained, wait T=5s then proceed

Set ON Screw Press 06PVS01.

Set Screw Press Torque controller JICS6020 to MANUAL and 80% output.

Time delay 10 seconds.

Screw Press counter pressure cone solenoid valve deenergized

Start feed MC pump 05PMC10.


All attached valves and controllers of sub-system - in Auto mode - start
according to interlocks defined above:

Time delay 60 seconds.

The system is running.

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 158/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

9.5.1.2 Production

The process bloc starts in production with Flotation area: with the opening of
valve FCV-3020at the outlet of the constant level box 02CP20.

The whole LOOP1 line is then started, and when stock arrives to Bleaching
Tower 07CPA01. Operator then needs to set:
 Screw Press Torque controller JICS6020 to AUTO and standard set
point.
 Kneader Counter-pressure ON.

With Interlocks, Kneader 06TL02 heating temperature controller TIC6025 will be


enabled when allowed by Screw press 06PVS01.

Kneader CP_Status ON is required to allow Chemical dosage to Kneader.

Thanks to recirculation chest 07CPA11, it’s also possible to start Loop 1 in


production with pulp without Screw Press and Kneader system: with On/Off valve
AV-6010 closed and valve AV-6006, pulp from MC pump 05PMC10 feeds directly
chest 07CPA11 and is sent backward to Dumping chest 01CPA15 via pump
07PPC13.

9.5.2 Operation
To be monitored during the operation of the installation:
 Monitoring of stock consistencies.
 Monitoring of Steam pressure
 Monitoring of drive motors load.
 Monitoring of Kneader 06TL02 specific energy
 Checking of Bleaching Tower level 07CPA01 (one of the main
parameters in the line).

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 159/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

9.5.3 Shutdown

9.5.3.1 Stop of production

Loop 1 DIP line stops in production with the pre-flotation, fine cleaning and Disc
Filter areas, by closing of the control valve FCV-3020 outlet of the constant level
box 02CP20.

Provided there is no pulp flow to the Loop 1 Disc Filter, Thickening – Bleaching
sub-system can be stopped.
Waiting is provided to empty the system from the stock present for an adequate
planned shut.

9.5.3.2 Stop of the loop

Thickening – Bleaching area is stopped after Disc Filter area.

Stop feed MC pump 05PMC10.

Set Kneader-CP to OFF


Wait T=60s then proceed

Energize solenoid valve of Screw Press counter pressure cone

Wait approx. T=60s (Screw Press is emptied from pulp)

Stop Screw Press 06PVS01


Wait T=10s then proceed

Stop Kneader 06TL02

The system is stopped

Note: Tower extraction pump 07PPC07 is stopped when no more pulp is required
on downstream process. This action is independent from upstream process stop
sequence.

LOOP 1 THICKENING – KNEADING – OXIDATIVE BLEACHING


Page 160/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

PROCESS DESCRIPTION

KHANNA
NEW DIP LINE 300 BDMT/24h
PRINTING - WRITING

FINE SCREENING

FINE SCREENING
Page 161/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

10 FINE SCREENING

10.1 DESCRIPTION

10.1.1 Area itemization

 Fine screening feed chest.......................................................................................


07CPA08
 Fine screening feed agitator....................................................................................
07AG09
 Fine screen feed pump............................................................................07PPC10
 Fine slots screen (ScreenOne)...............................................................................
08SC01
 Accept constant level box.......................................................................................
08CP02

10.1.2 ScreenOne basics

10.1.2.1 ScreenOne Description

Refer to Loop 1 ScreenOne description (§ 5.1.2.1 – Page 67).

10.1.2.2 ScreenOne Operation

Refer to Loop 1 ScreenOne operation (§ 5.1.2.2 – Page 68).

10.1.2.3 ScreenOne sequence

See Associated Grafcet (will be supplied by Kadant).

FINE SCREENING
Page 162/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

10.1.3 Fine screening area

From the Bleaching tower 07CPA01, pump 07PPC07 feeds the stock chest
07CPA08 that is a constant level working chest.
The level control LIC6120 commands the stock quantity required upstream the
system via control valve LCV-6021 on stock feed pipe.

Feed chest 07CPA08 serves also to homogenize finely stock extracted from
Bleaching step (in consistency, air content, …).

ScreenOne 08SC01 receives stock from pump 07PPC10 with stock at


consistency ~3% regulated by controller NRC6125 and addition of Loop 2 filtrates
from pump 10PPC08.

In fact, as dilution at this point requires a relatively big flow (at least more than
acceptable for a single injection to pump suction where consistency adjustment is
better with limited flow variations), water dilution is made through controllers
QC6126 and NRC6125 as follows:
 Most part is directed (via control valve NCV-6126) towards feed chest
07CPA08.
 Remaining dilution water flow is directed (via control valve NCV-6125)
to suction of pump 07PPC10 where consistency reaches more finely
3%.

Controller QC6126 operates as a proportional ratio in order to adjust associated


valves (NCV-6125 and NCV-6126) opening values, and then the sharing of total
dilution flows (usually 70% of total flow through valve NCV-6126 and 30%
through NCV-6125).

Pressure regulation loop PIC7090 (with control valve PCV-7090 on recirculating


pipe back to feed chest 07CAP08) keeps constant ScreenOne feed pressure in
order to avoid shocks (that could cause internal damages) during transitory
phases (on ScreenOne start-up when automatic valve AV-7020 opens or during
washing and unplugging sequences).
We recommend inlet automatic valve AV-7020 to open slowly.

Screen inlet pressure is continuously controlled by control loop PIS7025.

Accepted stock A1 (from first slotted screening zone) is routed to accept constant
level box 08CP02.
Flow can be adjusted by controller FIC7085 and pressure is continuously
controlled by loop PIS7030.
An accidental plugging will be detected by differential pressure alarm PDIS7035
(ratio between inlet and accept A1 pressures).

Rejects from this first zone are diluted (via manual valve MV-7006) with white
water. This dilution flow is measured by loop FIC7005.

Accepted stock A2 (from second slotted screening zone) is also routed to


Constant level box 08CP02.
Flow is adjusted by controller FFIC7080 in ratio with accept A1 flow (FIC7085)
and according to required reject rates between each screening zones.

FINE SCREENING
Page 163/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Stock pressure from accept A2 is continuously controlled by instrumentation loop


PIS7050.
An accidental plugging in 2nd screening zone will be detected by differential
pressure alarm PDIS7055 (ratio between inlet and accept A2 pressures).

A water connection allows stock dilution between second and third screening
zones. This dilution flow is indicated by loop FI7010 and may be adjusted at start-
up with manual valve MV-7011.

Accepted stock A3 (from third slotted screening zone) is sent backwards to feed
chest 07CPA08.

A3 accept Flow is adjusted by controller FFIC7075 in ratio with accept A1 flow


(FIC7085) and according to required reject rates between each screening zones.
Stock pressure from accept A3 is continuously controlled by instrumentation loop
PIS7060.
An accidental plugging in 3rd screening zone will be detected by differential
pressure alarm PDIS7065 (ratio between inlet and accept A3 pressures).

Rejected stock from the third screening zone is also diluted before being directed
to sewer.
Reject dilution water flow is indicated by loop FI7015 and may be adjusted at
start-up with manual valve MV-7016.

Stock rejected flow is adjusted by controller FFIC7070 in ratio with accept A1 flow
(FIC7085) and according to required reject rates.

Dilution controller FIC7005 adds up all water dilution flows to ScreenOne and
adjusts the total (sum of measured flows FT-7005 + FT-7010 + FT-7015)
according to operating dilution Set-Point (adjusted on start-up) by regulating
opening value of control valve FCV-7005.
The Low Flow Alarm for total water dilution calculations (i.e. measured total flow
< 0,5 x set point) indicates a ScreenOne operation problem and is used to launch
a Washing Sequence (see § 10.5.3.2 – Page 171).

In case of differential pressure alarms (for 1st screening zone, for the 2nd and for
the 3rd) or in case of drive overload alarm (JISH7045), appropriate sequences are
launched in order to clean the ScreenOne basket (see § 10.5.3 – Page 171).

Controller SIC2695 allows to adjust (manual set-point before start-up) and control
speed of ScreenOne drive motor from DCS according to screen working
conditions and then to save power consumption.

Stock outlet from constant level box 08CP02 is routed to downstream process
(optional Post-Flotation)
An overflow pipe from constant box 08CP02 to Feed chest 07CPA08 enables
ScreenOne operation at constant rating (in flow and pressure), whatever the
production variations.

FINE SCREENING
Page 164/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

10.2 BASIC OPERATION CAPACITY

ScreenOne: Size SO8


- Area 1: Slots 0,15mm. Accept flow = ~450 m3/h at consistency 2,5-3%.
- Area 2: Slots 0,15mm. Accept flow = ~125 m3/h at consistency 2-2,5%.
- Area 3: Slots 0,15mm. Accept flow = ~30 m3/h at consistency 2%.

Total accept production (A1 + A2) = 370 BDT/24h

10.3 TRANSMITTERS AND CONTROL LOOPS

Alarms Scale-0-
Item Function Description 100%
LL L H HH Value unit
LIC 6120 Feed chest 07CPA08 level control 5% 15% 85% 95% 0-70 m3
Slots pre-screening feed consistency
NRC 6125 2,5 to 5%
control
Ratio repartition for Fine screening feed
QC 6126 0-100%
dilution water flow
ScreenOne 08SC01 feed pressure
PIC 7090 0–4 Bars
control
FIC 7005 ScreenOne 08SC01 dilution flow control
FT-7005: intermediate dilution flow
0-50 m3/h
measurement (between 1st & 2nd zones)
FC-7005: ScreenOne total water dilution
flow controller L
0-150 m3/h
(1)
= Σ (FT-7005 + FT-7010 + FT-7015)
FCV-7005: total dilution flow valve 0-150 m3/h
ScreenOne 08SC01 intermediate dilution
FI 7010 flow indication (between 2nd & 3rd 0-75 m3/h
screening zones)
ScreenOne 08SC01 reject dilution flow
FI 7015 0-75 m3/h
indication
ScreenOne 08SC01 inlet pressure 3
PIS 7025 0–4 Bars
indication (1)
ScreenOne 08SC01 differential pressure
0,4 0,6
PdIS 7035 1 indication 0–2 Bars
(1) (1)
(Difference between Accept A1 & inlet)
ScreenOne 08SC01 Accept A1 pressure 1
PIS 7030 0–4 Bars
indication (1)

…/…

FINE SCREENING
Page 165/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Alarms Scale-0-
Item Function Description 100%
LL L H HH Value unit
ScreenOne 08SC01 differential pressure
0,4 0,6
PdIS 7055 2 indication 0–2 Bars
(1) (1)
(Difference between Accept A2 & inlet)
ScreenOne 08SC01 Accept A2 pressure 1
PIS 7050 0–4 Bars
indication (1)
ScreenOne 08SC01 differential pressure
0,4 0,6
PdIS 7065 3 indication 0–2 Bars
(1) (1)
(Difference between Accept A3 & inlet)
ScreenOne 08SC01 Accept A3 pressure 1
PIS 7060 0–4 Bars
indication (1)
FFIC 7070 ScreenOne 08SC01 reject flow control 0-75 m3/h
ScreenOne 08SC01 Accept A3 flow
FFIC 7075 0-100 m3/h
control
ScreenOne 08SC01 Accept A2 flow
FFIC 7080 0-250 m3/h
control
ScreenOne 08SC01 Accept A1 flow
FIC 7085 0-500 m3/h
control
ScreenOne 08SC01 drive motor speed
SIC 7040 0-100%
control
JISH 7045 ScreenOne 08SC01 drive Amp Load 95% 100% 0-150%

(1) Values to be adjusted on start-up (according to process conditions & overall installation)

FINE SCREENING
Page 166/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

10.4 INTERLOCKINGS AND ALARMS

161- BLEACHING TOWER EXTRACTION PUMP 07PPC07 TO FINE


SCREENING FEED CHEST LEVEL LIC6120

If Bleaching tower extraction pump 07PPC07 is not running

Then Chest feed control valve LCV-6021 is forced closed.

162- FINE SCREENING FEED CHEST LEVEL LIC6120 TO AGITATOR


07AG09

If Fine Screening feed chest level LIC6120 is Low-Low


Then Stop Agitator 07AG09

If Fine Screening feed chest level LIC6120 is Low


Then Inhibit Start Agitator 07AG09

If Fine Screening feed chest level LIC6120 is not Low


And Agitator 07AG09 in DCS Auto mode

Then Start Agitator 07AG09

163- INTERLOCKS TO FINE SCREENING FEED PUMP 07PPC10

If Fine Screening feed Chest level LIC6120 is Low


Or ScreenOne 08SC01 is not running
Or Loop 2 Continuous water dilution pump 10PPC08 is not running

Then Screening feed pump 07PPC10 is stopped.

If Fine Screening feed Chest level LIC6120 is Low

Then Inhibit start of Screening feed pump 07PPC10

164- INTERLOCKS FROM FINE SCREENING FEED PUMP 07PPC10 TO


SLAVE VALVE AV-7020

If Screening feed pump 07PPC10 is not running


Then On/Off slave valve AV-7020 is forced closed

FINE SCREENING
Page 167/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

If Screening feed pump 07PPC10 is running


Then With on delay T=5s, On/Off slave valve AV-7020 in Auto opens (air
exhaust limit to open 15s)

165- INTERLOCKS TO DILUTION CONTROLLERS NRC6125 & QC6126

If Screening feed pump 07PPC10 is not running


Or Loop 2 Continuous water dilution pump 10PPC08 is not running

Then Dilution controllers NRC6125 & QC6126 are disabled with control valves
NCV-6125 & NCV-6126 forced closed.

166- (RESERVE)

167- (RESERVE)

ALARMS

168- SEALING WATER

If Fine Screening area is in operation


And Main line Sealing water flow is on Alarm FSA20135 Low for T=30 s

Then Active the ALARM

169- COMPRESSED AIR

If Fine screening area is in operation


And Compressed Air pressure PIA19202 is on Alarm Low

Then Active the ALARM

170- (RESERVE)

FINE SCREENING
Page 168/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

10.5 OPERATION

10.5.1 Start-up

Normal start-up operation will lead to start Loop 2 fine screening after Post-
Flotation.
It is possible to start Fine Screening independently of the Post-Flotation,
recirculating back from constant level box 08CP02: this will lead to overflow Feed
Chest 07CPA08.

10.5.1.1 Fill the unit

Starting up the fine screening loop begins with the filling phase of the unit:

Basic conditions:
- Sealing water main line is under pressure and Flow switch FSA20135 is not
alarm Low
- Compressed air system is under pressure (pressure PIA19202 not on Alarm
Low).
- Level control LIS9055 of water tank 10CE06 is not Low.

If not already running, start Loop 2 Continuous water pump 10PPC08.

Open ScreenOne sealing water valve SV-19382.

Start of ScreenOne cycle, whose first step is the filling phase (refer to specific
Function Chart). :
 Open reject valve FCV-7070 up-to its “X%" opening value. This
position must allow water filling with a moderate pressure inside
ScreenOne.
 Open water dilution valve FCV-7005 during a pre-set time (to be
adjusted at start-up, usually 30 seconds).
 Start of ScreenOne 08SC01 motor.

Note: The unit working in cycle automatically go over to the working configuration
at the end of filling time (controlled by timer set on start-up of the installation and
taking account of the size of the unit and of pressures and flow rates available in
the water circuits).

FINE SCREENING
Page 169/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

10.5.1.2 Starting of the loop

Start transfer pump 07PPC07 with activation of level controller LIC6120 in order
to fill feed chest 02CPA16 with pulp.

When a sufficiently level is reached (usually higher than 40%):

 Start ScreenOne feed pump 07PPC10 with activation of pressure


controller PIC7090.
Note 1: As long inlet valve AV-7020 is not open, pulp pumped by
07PPC10 flows back to feed chest 07CPA08 via control valve
PCV-7090 fully open.
Note 2: With interlocks, consistency controller NRC2610 is set on
automatic.
 Open slowly ScreenOne inlet valve AV-7020.
 Reject flow control loop FFIC7070 is activated (valve FCV-7070 moves
from full opening to operating value).
 Accept A3 flow control loop FFIC7075 is activated.
 Accept A2 flow control loop FFIC7080 is activated.
 Accept A1 flow control loop FFIC7085 is activated.

10.5.1.3 Production

The process block can run few minutes in full recycling mode via constant level
box 08CP02.

DIP line Loop 2 starts in production when the stock is bled downstream of the
constant level box 08CP02to Post-Flotation with opening of valve FCV-8010.

10.5.2 Operation

To be monitored during the operation of the installation:


 Inlet and accepts pressures of screens.
 All Consistencies.
 Regularity of Flows through ScreenOne.
 Regularity of the power absorbed by the ScreenOne.

FINE SCREENING
Page 170/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

10.5.3 Sequences

This chapter hereunder is only for description.


Please refer to associate Function Chart (to be supplied by Kadant) for exact
sequence to be programmed.

10.5.3.1 ScreenOne basket depluging

This sequence is launched in case of Differential pressure High alarm on


threshold 1 (PDSH7035 for 1st screening zone, PDSH7055 for the 2nd and
PDSH7065 for the 3rd) for T= 5 to 10 seconds.

 Open reject valve FCV-7070 to its “X%" opening value.


 Close Accept control valve at screening stage in Alarm and Accept
control valve at eventual backward stages.

Examples:
On Alarm PDSH7065, cleaning of basket 3rd zone will close control
valve FCV-7075 for the 3rd stage.
On Alarm PDSH7055, cleaning of basket 2nd zone will close control
valves FCV-7080 for the 2nd stage and valves FCV-7075 for the 3rd
stage.
On Alarm PDSH7035, cleaning of basket 1st zone will close control
valves FCV-7085 for the 1st stage, FCV-7080 for the 2nd stage and
valves FCV-7075 for the 3rd stage.

 After a pre-set timer (adjusted during start-up, usually 60 seconds):


reject valve FCV-7070 and accept control valves come back to their
automatic position.

10.5.3.2 ScreenOne washing

During ScreenOne normal operation, this sequence is launched in case of:


 An overload of the ScreenOne motor, detected by alarm JISH7045
 OR a differential pressure High-High alarm on threshold 2 (PDSHH7035
for 1st screening zone, PDSHH7055 for the 2nd and PDSHH7065 for the
3rd) for T= 5 to 10 seconds.
 OR a Low alarm of total dilution water flow to ScreenOne (calculated by
controller FC7005 < 0,5 x set point) during T=5 to 10s.
 OR a ScreenOne stop request in AUTOMATIC mode.
 OR an Operator manual request (key “WASH”)

 Close stock feed valve AV-7020.


 Close accept flow valves (FCV-7085 for accept A1, FCV-7080 for
accept A2 & FCV-7075 for accept A3).
 Open reject valve FCV-7070 to its “X%" opening value.
 After a pre-set timer (usually 30 seconds), sequence proceeds either
back to working operation or to stop (if requesting in AUTO mode).

FINE SCREENING
Page 171/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

10.5.4 Shutdown

10.5.4.1 Stop of production

The process bloc stops in production when no more pulp required in downstream
Post-Flotation area, with closing of weight valve FCV-8010 on accept constant
level box 08CP02 outlet pipe.

10.5.4.2 Stop of the loop

Please refer to associated function chart (will be supplied by Kadant) including


“stop step” for ScreenOne:

 A Washing sequence is launched (See § 10.5.3.2)


At the end of this sequence, inlet valve AV-7020 remains closed and
reject valve FCV-7070 remains to its “X%" opening value.
 Stop feed pump 07PPC10 motor.
With interlocks, dilution controllers NRC6125 & QC6126 are
disabled.
 Opening of reject valve FCV-7070 in fully opened position.
 Closing (slowly with a ramp) of accept A1 valve FCV-7085.
 Closing (slowly with a ramp) of accept A2 valve FCV-7080.
 Closing (slowly with a ramp) of accept A3 valve FCV-7075.
 Stop of ScreenOne motor.
 Closing of water valve FCV-7005.

FINE SCREENING
Page 172/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

PROCESS DESCRIPTION

KHANNA
NEW DIP LINE 300 BDMT/24h
PRINTING - WRITING

POST-FLOTATION AREA

POST-FLOTATION
Page 173/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

11 POST-FLOTATION

11.1 DESCRIPTION

11.1.1 Post-Flotation Itemization

 Deinking 1st aeration feed pump............................................................................


09PPC01
 Deinking 2nd aeration feed pump...........................................................................
09PPC03
 Deinking 3rd aeration feed pump............................................................................
09PPC04
 Deinking 4th aeration feed pump............................................................................
09PPC05
 Flotation cell (MAC) ............................................................................09CEV02
 Flotation accept constant level box.........................................................................
09CP08
 Foam tank ............................................................................09CPA06
 Deinking foam transfer pump..................................................................................
09PPV07

11.1.2 Flotation cell (MAC) basics

Refer to Pre-Flotation description (§ 6.1.2 – Page 81).

11.1.3 Deinking cell MAC Sequence

See Associated Grafcet (will be supplied by Kadant).

POST-FLOTATION
Page 174/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

11.1.4 Post-Flotation area

Deinking cell feed

The stock coming from the Fine screening constant level box 08CPA02 is
pumped to flotation cell MAC through 1st aeration pump 09PPC01 connected on
water tank 10CE05 to ensure necessary dilution.

Flowmeter FIC8010 adjusts flotation stock feed flow.


Control valve FCV-8010 is the basis weight valve for 2nd loop of deinking line: its
opening fixes the production rate of Loop 2 in concordance with stability of level
in Bleaching Tower 07CPA01.

A chemicals injection (surfactant), connected at pump 09PPC01 suction, allows


adjusting post-flotation operation according to process conditions and required
efficiency.

1st aeration pump 09PPC01 feeds canister of injectors of the cell’s first stage, at
the pressure required (1,4 bars normally), and continuously measured by
transmitter PIS8055, to ensure air suction and mixing of bubbles in the stock.
Manual valve MV-8067 at the pump discharge is meant to adjust the inlet
pressure and thus the operating flow of the cell.

The size of canisters depending on the construction, their throughput will only
depend on their inlet pressure. Each canister of injectors features:
 A stock inlet,
 An outlet for the stock/air mix,
 A washing water inlet to fill the canister of injectors during start-up,
shutdown or washing,
 An inlet for air injected into the stock and also used for the discharge to
sewer of the washing water.
The canister’s washing water connection nipples have automatic isolating valves
used during the various operating sequences.

Stock aerated in this way flows in the first stage in the top of the cell where
separation of air bubbles from the stock takes place.

Multi-aeration principle

Stock is then taken up in a pipe in the central barrel to flow out at the cell’s lower
part so as to feed the 2nd aeration.

2nd aeration pump 09PPC03 feeds 2nd canister of injectors, identical to the
previous one.
Hand valve MV-8038 at the pump discharge enables to adjust the inlet pressure
of the 2nd aeration canister of injectors (pressure is continuously measured by
transmitter PIS8045). Stock flows in the cell at a level lower than the one of the
previous stage.

Stock will circulate in the same way for the subsequent aeration steps:
- 3rd aeration pump 09PPC04.

POST-FLOTATION
Page 175/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

- 4th aeration pump 09PPC05.

Accept constant level box

After the last aeration stage at the lower part of the cell, stock goes up to
constant level box 09CP08 at a higher level than the top of the cell. Thus the cell
is statically and steadily pressurized and floated stock flows out freely.

From this constant level box, stock is routed by gravity to a further process stage.
Constant level box can also send the stock back to the suction of 1 st aeration
pump 09PPC01.
This recycling flow is adjusted by HIC8005 during normal operation (where
recirculating flow is to be set between 0 and 15% maxi of Flotation design flow).
Moreover a parallel bigger pipe, equipped with On/Off Valve AV-8006, allows to
recirculate back all flotation accept flow from constant box 09CP08 if needed by a
transitory phase (for example adjustment on start-up or an eventual incident).

This configuration of circuit enables Post-Flotation operation at constant rating,


whatever the production in downstream process.

The flow through injectors being set by the inlet pressure required for their proper
operation, the flow through the cell is firm.

Due to its principle and inner construction, the Primary flotation cell (MAC)’s
production is only fixed by the feed pump. The other aeration pumps can run or
be turned off without affecting the production flowing through the cell. They only
affect stock quality insofar as their role is just limited to aerating stock via the
injectors.

Deinking cell foam

MAC cell 09CEV02 foam level is regulated by level controller LIC8090 with
PIS8090 (refer to regulation principle in Kadant Function Charts).
The cell level means the stock level in the cell, i.e., the position of the interface
between the stock (at the lower part) and the foam (at the top part).

Foam from the flotation at each aeration stage flows together in the cell’s top part
to fill it entirely.

Post-Flotation cell MAC 09CEV02 is equipped with a foam washing device:


 A water injection controlled by flow regulation loop FIC8080 enables to
“wash” ink foam collected at cell top part and then allows to recover
residual stock fibers that could be hung on foam bubbles.
 Resulting excess flow coming out from 1st stage is recycled to 1st
aeration pump 09PPC01 suction through flow-meter FFIC8015. Of
course this excess flow is directly proportional to additional washing
flow FIC8080.

Foam is discharged through piping at the cell’s lower part. This piping is fitted
with control valve LCV-8090, ensuring both level control in the cell and relaxing of
foam, which is thus discharged as liquid to sludge tank.

POST-FLOTATION
Page 176/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Foam tank 09CPA06 and foam recirculation to Prime MAC

Post-flotation deinking foam is extracted from tank 09CPA06 with volumetric


pump 09PPV07.

As already explained for Pre-Flotation, Loop 1 Prime MAC 03CEV02A gives the
opportunity to re-introduce a part (adjustable) of deinking foam in order to reduce
fiber losses and increase plant yield.
This re-introduction flow is to be adjusted with manual valve MV-3154 (on
transfer pipe to Prime MAC feed pump 03PPC01 suction) and in relation with
required pulp final quality.

Pump 09PPV07 is equipped with a variable speed motor in order to adapt


extraction flow to Foam tank 09CPA06 level LIC8095.

Moreover pressure controller PIC8100 allows to send to sludge treatment the


remaining foam flow, which is the difference between foam flow extracted from
cell 09CEV02 MINUS flow sent back to Prime MAC (through valve MV-3154).

In order to avoid running of volumetric pump 09PPV07 with all outlet valves
closed (that could cause definitive damage to pump mechanism), manual valve
MV-3154 must be equipped with an adjustable limit switch, to be set very
carefully on start-up with a minimum opening (maybe 10%) compatible with
volumetric pump highest operating pressure.
Then this limit switch will be used to interlock the start of volumetric pump (See
Interlock N° 11.4Page 180).

And for more security, in case of operation with no recirculation to Prime MAC
(On/Off valve AV-3140 closed), control valve PCV-8100 is forced open and all
Post-Flotation foam is transferred to sludge treatment (transfer flow is then
directly regulated by tank level control LIC8095 acting on pump 09PPV07 speed
controller SC8095).

POST-FLOTATION
Page 177/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

11.2 BASIC OPERATING CAPACITY

Post-Flotation MAC cell 4 aerations: MAC 4W1456


Inlet flow 1456 m3/h at consistency 1,2% (i.e. 400
BDMT/24h)

11.3 TRANSMITTERS AND CONTROL LOOPS

Alarms Scale-0-
Item Function Description 100%
LL L H HH Value unit
Control of deinking cell 09CEV02 accept
HIC 8005 0-100%
recycling
Flow control of stock sent to Post-
FIC 8010 0-650 m3/h
flotation
Post-flotation cell 09CEV02 Stage 1 feed
PIS 8055 1 2 0–3 Bars
pressure indication
Post-flotation cell 09CEV02 Stage 2 feed
PIS 8045 1 2 0–3 Bars
pressure indication
Post-flotation cell 09CEV02 Stage 3 feed
PIS 8035 1 2 0–3 Bars
pressure indication
Post-flotation cell 09CEV02 Stage 4 feed
PIS 8020 1 2 0–3 Bars
pressure indication
Flow control of Post-flotation cell foam
FIC 8080 0-300 m3/h
washing water
Flow control of 2nd aeration stock
FFIC 8015 0-300 m3/h
recycling to 1st aeration feed pump
Pre-flotation cell 09CEV02 inside
PIS 8090 1 0–3 Bars
pressure indicator
Pre-flotation cell 09CEV02 inside foam
LIC 8090 0-100%
level control
LIC 8095 Foam tank 09CPA06 level control 5% 15% 85% 95% 0-20m3
Foam pump 09PPV07 motor speed
SIC 8095 0-100%
control
Pressure control of Post-Flotation foam
PIC 8100 0–4 Bars
transfer to sludge treatment

POST-FLOTATION
Page 178/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

11.4 INTERLOCKINGS AND ALARMS

171- INTERLOCKS to CELL 1st AERATION FEED PUMP 09PPC01

If Water tank 10CE05 level controller LIS9050 is low


Or MAC cell inside pressure is High (LIC8090 level High)

Then 1st aeration pump 09PPC01 is stopped.

172- 1st AERATION FEED PUMP 09PPC01 to DEINKING CELL LEVEL


CONTROLLERS PIS8090 & LIC8090

If 1st aeration pump 09PPC01 is not running


Then Controllers PIS8090 & LIC8090 are disabled with LCV-8090 forced
open.

173- 1st AERATION FEED PUMP 09PPC01 to SLAVE ON/OFF VALVE AV-
8068

If 1st aeration pump 09PPC01 is not running


Then On/Off Valve AV-8068 is forced closed

If 1st aeration pump 09PPC01 is running


Then With on delay T=5s, On/Off Valve AV-8068 in Auto is opened (air
exhaust limit to open 15s)

174- OTHER INTERLOCKS from 1st AERATION FEED PUMP 09PPC01

If 1st aeration pump 09PPC01 is not running

Then Stock feed control valve FCV-8010 is forced closed


And Flotation accept constant box 09CP08 recycling control valve HCV-8005
and On/Off Valve AV-8006 are forced closed
And Recycling flow controller (from 2nd stage) FFIC8015 is disabled with
control valve FCV-8015 forced closed
And Chemicals supply to feed pump suction is disabled

POST-FLOTATION
Page 179/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

175- INTERLOCKS to CELL OTHER AERATION FEED PUMPS

If 1st aeration pump 09PPC01 is not running

Then 09PPC03 is forced stopped (2nd Aeration)


Then 09PPC04 is forced stopped (3rd Aeration)
Then 09PPC05 is forced stopped (4th Aeration)

If Deinking Cell level LIC8090 is Low (meaning Cell inlet pressure is High)

Then Inhibit start of pump 09PPC03 (2nd Aeration)


Then Inhibit start of pump 09PPC04 (3rd Aeration)
Then Inhibit start of pump 09PPC05 (4th Aeration)

176- SLUDGE TANK LEVEL LIC8095 to EXTRACTION PUMP 09PPV07

If Sludge tank 09CPA06 level LIC8095 is Low

Then Stop sludge transfer pump 09PPV07

177- SECURITY INTERLOCKS FROM VOLUMETRIC PUMP 09PPV07

If On/Off valve AV-3140 is not open (Full Open limit switch not activated)
Or Manual valve MV-3154 minimum opening limit switch is not activated
(Valve opening adjustment to Low)
While MAC cell feed pump 09PPC01 is running

Then Control valve PCV-8100 is forced to fully open

If On/Off valve AV-3140 is not open (Full Open limit switch not activated)
And Control valve PCV-8100 is not fully open

Then Volumetric pump 03PPV10 is forced stopped

178- (RESERVE)

179- (RESERVE)

POST-FLOTATION
Page 180/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

ALARMS

180- SEALING WATER

If Post-Flotation area is in operation


And Main line Sealing water flow is on Alarm FSA20135 Low for T=30 s

Then Active the ALARM

181- COMPRESSED AIR

If Post-Flotation area is in operation


And Compressed Air pressure PIA19202 is on Alarm Low

Then Active the ALARM

182- (RESERVE)

POST-FLOTATION
Page 181/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

11.5 OPERATION

11.5.1 Start up

11.5.1.1 Water filling

Basic conditions:
- Compressed air system is under pressure (pressure PIA19202 not on Alarm
Low).
- Post-flotation cell 09CEV02 foam valve LCV-8090 must be open
Water tank 10CE05 level controller LIC9050 must be high
Stock feed valve FCV-8010 is closed
Recycling valve HCV-8005 is closed

Vent valve AV-8085 on the top of the cell is normally open.

Start 1st aeration pump 09PPC01. (With Interlocks valve AV-8068 after T=5 sec).

Water valve AV-8075 of the 1st stage canister of injectors opens during T=15 sec.

When the cell is full, detected by level controller LIC8090 High:

Close vent valve AV-8085 on the top of the cell.

Stop 1st aeration pump 09PPC01 (With Interlocks valve AV-8068 will close
automatically).

11.5.1.2 Starting of loop

Aeration 4:
 Start 4th aeration feed pump 09PPC05
 Open air valve AV-8025 for 4th aeration of cell 09CEV02
 Water valve AV-8030 on canister opens during T=15 sec and closes.

Aeration 3:
 Start 3rd aeration feed pump 09PPC04
 Open air valve AV-8060 for 3rd aeration of cell 09CEV02
 Water valve AV-8065 on canister opens during T=15 sec and closes.

Aeration 2:
 Start 2nd aeration feed pump 09PPC03
 Open air valve AV-8040 for 2nd aeration of cell 09CEV02
 Water valve AV-8050 on canister opens during T=15 sec and closes.

Aeration 1:
 Start 1st aeration feed pump 09PPC01
 Open air valve AV-8070 for 1st aeration of cell 09CEV02
 Water valve AV-8075 on canister opens during T=15 sec and closes.

Set to AUTO mode flotation cell 09CEV02 level regulation LIC8090.

POST-FLOTATION
Page 182/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

After some minutes of operation, successively flush each canister of injectors for
a few seconds against possible stock deposits that may appear during the start-
up phase.

11.5.1.3 Production

Foam transfer pump 03PPV07 is allowed to start through interlocks.


Note: On/Off valve AV-3140 will be enabled to open only after Prime MAC feed
pump 03PPC01 motor start.

Set to AUTO mode flotation stock feeding flow controller FIC8010.

Deinking foam washing controller FIC8080 can be set in Auto (flow set-point to
be adjusted according to desired Fiber content in deinking foam) after a timer to
be pre-set before start-up.

Simultaneously recycling Flow controller FFIC8015 is automatically set in Auto.

11.5.2 Operation

Monitoring of inlet pressures within the canisters of injectors.


Monitoring of consistencies of inlet stock, accept stock and deinking foam for
each cell.

Regularly at a rate that will be determined by the operation:


 Open level control valve LCV-8090 to raise the level within each cell
and clean the upper part of the cell. This operation will last a few
seconds after which level controller will take its normal course of
operation.

 Flush each canister of injectors successively, for a few seconds, against


possible stock deposits.

POST-FLOTATION
Page 183/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

11.5.3 Stop

11.5.3.1 Stop of loop

Disable foam washing flow controller FIC8080 with valve FCV-8080 forced
closed.
Automatically recycling Flow controller FFIC8015 is disabled with valve FCV-
8015 forced closed.

Close the Post-Flotation feed stock valve FCV-8010 at the outlet of constant level
box 02CP20.

Close recycling valve HCV-8005.

11.5.3.2 Stop of the Deinking cell

Execute the washing sequence for each injectors canister (on operator order).

Stop Aeration 1:
 Close air valve AV-8070 for 1st aeration of cell 09CEV02
 Water valve AV-8075 on canister opens during T=15 sec and closes.
 Stop 1st aeration feed pump 09PPC01

Set to MANU mode Post-Flotation MAC cell 09CEV02 level regulation LIC8090
and open fully foam valve LCV-8090.

Open vent valve AV-8085 on the top of the deinking cell.

Stop aeration 2:
 Close air valve AV-8040 for 2nd aeration of cell 09CEV02
 Water valve AV-8050 on canister opens during T=15 sec and closes.
 Stop 2nd aeration feed pump 09PPC03

Stop aeration 3:
 Close air valve AV-8060 for 3rd aeration of cell 09CEV02
 Water valve AV-8065 on canister opens during T=15 sec and closes.
 Stop 3rd aeration feed pump 09PPC04

Stop aeration 4:
 Close air valve AV-8025 for 4th aeration of cell 09CEV02
 Water valve AV-8030 on canister opens during T=15 sec and closes.
 Stop 4th aeration feed pump 09PPC05

POST-FLOTATION
Page 184/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

PROCESS DESCRIPTION

KHANNA
NEW DIP LINE 300 BDMT/24h
PRINTING - WRITING

LOOP 2 DISC FILTER


& WATER DISTRIBUTION

LOOP 2 DISC FILTER & WATER DISTRIBUTION


Page 185/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

12 LOOP 2 DISC FILTER & WATER DISTRIBUTION

12.1 DESCRIPTION

12.1.1 Area itemization

 Loop 2 Desaeration chest.......................................................................................


10CPA01
 Loop 2 Desaeration chest agitator..........................................................................
10AG02
 Loop 2 Disc Filter feed pump..................................................................................
10PPC03
 Disc Filter ............................................................................10FDQ04
 Clear filtrate tank ..............................................................................10CE06
 Cloudy filtrate tank ..............................................................................10CE05
 Pulper water transfer pump ....................................................................................
05PPC05
 Disc Filters showers feed pump .............................................................................
10PPC07
 Loop 2 continuous water dilution pump ..................................................................
10PPC08
 Loop 2 periodic water dilution pump ......................................................................
10PPC09
 Loop 2 filtrate transfer pump to Micro-flotation........................................................
10PPC10
 Dilution pump to recirculation chest 07CPA11........................................................
10PPC13

12.1.2 Disc Filter basics

Same description as Disc Filter in Loop 1 (See § 8.1.2 – Page 118).

LOOP 2 DISC FILTER & WATER DISTRIBUTION


Page 186/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

12.1.3 Area description

12.1.3.1 Desaeration chest 10CPA01

Stock accepted from Post-Flotation is accepted by gravity from Level Box


09CP08 into Desaeration chest 10CPA01.

Desaeration chest 10CPA01 is operated at constant level via level controller


LICS9005 with control valve LCV-9005 on feed pipe to Disc Filter 10FDQ04.
By this way, Disc Filter operates at the same production than Post-Flotation
accept.

Desaeration chest 10CPA01 allows the air remaining in stock pulp to escape and
is equipped with an agitator 1AG02.

12.1.3.2 Loop 2 Disc Filter

The Loop 2 Disc Filter 10FDQ04 thickens the pulp flow accepted from Post-
Flotation system, from 1% to 10-12%.

Pulp pH on feed to Loop 2 Disc Filter is measured by transmitter AIR9010 and


displayed/recorded.

Brightness on feed to Loop 2 Disc Filter is measured by transmitter AIR9015 and


displayed/recorded.

The Disc Filter main drive speed controller SIC9025 maintains the level LIC9020
in Disc Filter 10FDQ04 vat.

This is the only control on the Disc Filter:


- When the hydraulic through-put fed to the disc filter increases, leading to
increase the pulp level in the vat, the Disc filter drive speed increases.
- When the hydraulic through-put fed to the disc filter decreases, leading to
increase the pulp level in the vat, the Disc filter drive speed decreases.

The filtrate supply to the Disc Filter showers, from its own Clear filtrates for both
oscillating showers and Knock-off showers, is switched on by actuating On/Off
valve AV-9035.
Pressure indicator PI9030 on filtrates supply line to Knock-off shower ensures the
adequate pressure is available.
The respective shower flows are adjusted by setting of manual valves.

Transmitter PI9045 measures vacuum available for Disc Filter operating in Clear
filtrate barometric leg.

A speed switch SS9040 supervises the Repulping Screw 10FDQ04b rotation.

The accepted 10-12% stock feeds downstream process (i.e. Reductive


Bleaching).

LOOP 2 DISC FILTER & WATER DISTRIBUTION


Page 187/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

The Shower pump 10PPC07 ensures the cleaning & unplugging of the Disc Filter
sectors wire, using the Disc Filter's own clear filtrates.

12.1.3.3 Loop 2 water distribution

The Loop 2 Filtrate distribution system ensures the filtrate requirements for Loop
2 are covered.

Clear Filtrate tank 10CE06


This tank receives:
 Clear filtrate extracted from Disc Filter 10FDQ04.
 Complement water from loop 3 water pump 13PPC09 (through control
valve LCV-9050).
 Loop 3 filtrates (through On/Off valve AV-9085) from water pump
13PPC11, used for Loop 2 water tanks filling on start-up and for transfer
of Clarified Water (when Micro-Flotation is fed with Loop 2 filtrates).

This tank level is measured by LIS9055.

Tank 10CE06 is used to feed:


 Loop 2 Continuous water pump 10PPC08
 Loop 2 Periodic water pump 10PPC09
 Disc Filter showers pump 10PPC07
 Filtrates transfer pump 10PPC10

In case deashing system is not activated (DNT washers 13LAV02 & 13LAV03
are stopped), it is possible to operate Micro-flotation (free from DNT filtrate) with
Loop 2 filtrates:
 Pump 10PPC10 transfers Loop 2 Clear Filtrates to Loop 3 tank
13CE07 with a flow regulated by level controller LIC13010.
 From Loop 3 clarified water tank 13CE08, pump 13PPC11 transfers
back clarified water to Clear filtrate tank 10CE06.
 Make-up water to Loop 2 water system is always made from pump
13PPC09 through level control valve LCV-9050.

A continuous overflow to Cloudy water tank 10CE05 allows a constant level of


water and then avoids pressure variations at connected pump suctions, and
transfers complement to downstream water tanks.

Cloudy Filtrate tank 10CE05


This tank receives:
 Cloudy filtrate extracted from Disc Filter 10FDQ04
 Loop 2 Screw-press 11KR01 filtrates
 Overflow from Clear Water tank 10CE06

Tank 10CE05 is used for:


 Dilution of Post-flotation feed pump 09PPC01
 Feed of dilution pump 10PPC13
 Loop 2 Periodic water pump 10PPC09

LOOP 2 DISC FILTER & WATER DISTRIBUTION


Page 188/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Loop 2 Periodic water pump 10PPC09 can be fed either from Clear filtrate
10CE06 (through manual valve MV-9024) or from Cloudy filtrate tank 10CE05
(through manual valve MV-9053).
The selection between these 2 possibilities is to be done according to water
balance in Loop 2 involved by line operation process.

In case of Loop 1 or Loop 2 accept pulp recirculation to chest 07CPA11 during


transitory phase (like start-up for example), pump 10PPC13 is used to decrease
transfer stock consistency from 10 to 4-5%.
 Loop 1 pulp dilution is made through On/Off valve AV-6160 at MC
pump 05PMC10 outlet (See § 9.1.6.2 – Page 140).
 Loop 2 pulp dilution is made through On/Off valve AV-6155 at MC
pump 14PMC03 outlet (See § 13.1.4.3 – Page 203).

Level of tank 10CE05 is controlled by loop LIC9050 acting on control valve LCV-
9050 on make-up water from Loop 3 Filtrates pump 13PPC09, falling in Clear
Filtrate tank 10CE06 and overflowing to tank 10CE05.
This configuration enables Low level LIS9055 to call also for water complement
in case of water deficit water tank 10CE06.

LOOP 2 DISC FILTER & WATER DISTRIBUTION


Page 189/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

12.2 BASIC OPERATING CAPACITY

Disc Filter: Ø 5200mm


Inlet flow 1370 m3/h at consistency 1% (i.e. 370
BDMT/24h)

12.3 TRANSMITTERS AND CONTROL LOOPS

Alarms Scale-0-
Item Function Description 100%
LL L H HH Value unit
Desaeration chest 10CPA01 level
LIC 9005 10% 15% 80% 90% 0-120 m3
control
PH indication of Loop 2 Disc Filter feed
AIR 9010 5 to 11
pulp
Brightness indication of Loop 2 Disc
AIR 9015
Filter feed pulp
LIC 9020 Disc Filter 10FDQ04 vat level control 50% 95% 100% 0-100%
Disc Filter 10FDQ04 main drive zero
SS 9027 * Digital alarm
speed alarm
Disc Filter 10FDQ04 main drive zero
SIC 9025 0-100%
speed alarm
Disc Filter Repulper rotation alarm
SS 9040 * Digital alarm
Speed switch
Disc Filter 10FDQ04 shower header
PI 9030 3,2 7 0–8 Kg/cm2g
pipe pressure indication
Disc Filter 10FDQ04 Clear Filtrate - 600 to 0 mm
PI 9045 200 275
vacuum indication HG
Cloudy filtrate tank 10CE05 level
LIC 9050 10% 15% 80% 90% 0-60 m3
control
LIS 9055 Clear filtrate tank 10CE06 level control 10% 25% 0-60 m³

LOOP 2 DISC FILTER & WATER DISTRIBUTION


Page 190/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

12.4 INTERLOCKINGS AND ALARMS

12.4.1 Desaeration chest 10CPA01

183- DESAERATION CHEST LEVEL LIC9005 TO AGITATOR 10AG02

If Desaeration chest level LIC9005 is Low-Low

Then Stop Agitator 10AG02

If Desaeration chest level LIC9005 is Low

Then Inhibit Start Agitator 10AG02

If Desaeration chest level LIC9005 is not Low


And Agitator 10AG02 in DCS Auto mode

Then Start Agitator 10AG02

184- INTERLOCKS TO DISC FILTER 2 FEED PUMP 10PPC03

If Desaeration chest 10CPA01 level controller LIC9005 is Low-Low


Or Disc Filter 10FDQ04 is not running

Then Loop 2 Disc Filter feed pump 10PPC03 is stopped.

If Desaeration chest 10CPA01 level controller LIC9005 is Low


Or Disc Filter 10FDQ04 is NOT Ready

Then Inhibit start of Disc Filter feed pump 10PPC03.

185- INTERLOCKS FROM DISC FILTER 2 FEED PUMP 10PPC03

If Loop 2 Disc Filter feed pump 10PPC03 is not running

Then Slave control valve LCV-9005 is forced closed

If Loop 2 Disc Filter feed pump 10PPC03 is running

Then With On-Delay T=5s, Open control valve LCV-9005 (air exhaust
limit to open 15s)

LOOP 2 DISC FILTER & WATER DISTRIBUTION


Page 191/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

12.4.2 Loop 2 Disc Filter 10FDQ04

186- HEATING SCREW 14VIT01 TO DISC FILTER 10FDQ04

If Heating screw 14VIT01 is not running

Then Disc Filter Repulping Screw is stopped.

187- INTERLOCKS TO DISC FILTER REPULPER SCREW 10FDQ04b

If Disc Filter Repulping screw 10FDQ04b is running with start-up override


T=5s
And Speed switch SS9040 is alarm (zero)

Then Disc Filter Repulping screw 10FDQ04b is stopped and alarm generated.

188- DISC FILTER OUTLET SCREW MOTOR TO SHOWERS WATER


PUMP

If Motor (M6070) of Disc Filter discharge screw is running

Then Showers water pump “10PPC07” (M6072) is allowed to start

189- SHOWERS PUMP TO SHOWER OSCILLATING DEVICE MOTOR

If Showers water pump “10PPC07” is not running or tripped

Then Filter oscillating shower device motor (M6071) is forced to stop

LOOP 2 DISC FILTER & WATER DISTRIBUTION


Page 192/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

190- INTERLOCKS TO DISC FILTER MAIN MOTOR

If Filter oscillating shower device (M6071) is not running or tripped

Then Disc Filter main motor (M6069) is forced to stop

If Repulper drive motor (M6070) is not running or tripped

Then Disc Filter main motor (M6069) is forced to stop

If Main Motor (M6069) of Disc Filter is running


AND Filter zero speed switch “SS-9027” is on alarm Low

Then Stop main motor (M6069) of Disc Filter

191- INTERLOCKS FROM DISC FILTER 10FDQ04

If Disc Filter Main Motor “M6069” is tripped during running

Then Filter vat level controller “LICA-9020” is DISABLED


AND Stock feeding pump “10PPC03” is forced to STOP

192- (RESERVE)

12.4.3 Loop 2 water distribution

193- INTERLOCKS TO SHOWERS WATER PUMP 10PPC07

If Clear filtrate tank 10CE06 level LIS9055 is Low-Low


Or Disc Filter 10FDQ04 main motor is not running

Then Disc Filter shower pump 10PPC07 is stopped.

If Clear filtrate tank 10CE06 level LIS9055 is Low


Then Inhibit start of Disc Filter shower pump 10PPC07

LOOP 2 DISC FILTER & WATER DISTRIBUTION


Page 193/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

194- SHOWERS WATER PUMP 10PPC07 TO DELIVERY VALVE AV-9035

If Disc Filter shower pump 10PPC07 is not running


Then On/Off slave valve AV-9035 is forced closed

If Disc Filter shower pump 10PPC07 is running


Then With on delay T=5s, On/Off slave valve AV-9035 in Auto opens (air
exhaust limit to open 15s)

195- INTERLOCKS TO LOOP 2 CONTINUOUS WATER PUMP 10PPC08

If Clear filtrate tank 10CE06 level LIS9055 is Low-Low


Then Continuous water pump 10PPC08 is stopped.

If Clear filtrate tank 10CE06 level LIS9055 is Low


Then Inhibit start of Continuous water pump 10PPC08

196- LOOP 2 CONTINUOUS WATER PUMP 10PPC08 TO SLAVE VALVE


AV-9080

If Continuous water pump 10PPC08 is not running


Then On/Off slave valve AV-9080 is forced closed

If Continuous water pump 10PPC08 is running


Then With on delay T=5s, On/Off slave valve AV-9080 in Auto opens (air
exhaust limit to open 15s)

197- INTERLOCKS TO LOOP 2 PERIODIC WATER PUMP 10PPC09

If Clear filtrate tank 10CE06 level LIS9055 is Low-Low


While pump 10PPC09 is fed from tank 10CE06 (through manual valve
MV-9024)
Or Cloudy filtrate tank 10CE05 level LIC9050 is Low-Low
While pump 10PPC09 is fed from tank 10CE05 (through manual valve
MV-9053)

Then Periodic water pump 10PPC09 is stopped.

If Clear filtrate tank 10CE06 level LIS9055 is Low


While pump 10PPC09 is fed from tank 10CE06 (through manual valve
MV-9024)
Or Cloudy filtrate tank 10CE05 level LIC9050 is Low
While pump 10PPC09 is fed from tank 10CE05 (through manual valve
MV-9053)

LOOP 2 DISC FILTER & WATER DISTRIBUTION


Page 194/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Then Inhibit start of Periodic water pump 10PPC09

198- LOOP 2 PERIODIC WATER PUMP 10PPC09 TO SLAVE VALVE AV-


9090

If Periodic water pump 10PPC09 is not running


Then On/Off slave valve AV-9090 is forced closed

If Periodic water pump 10PPC09 is running


Then With on delay T=5s, On/Off slave valve AV-9090 in Auto opens (air
exhaust limit to open 15s)

199- INTERLOCKS TO TRANSFER WATER PUMP 10PPC10

If Clear filtrate tank 10CE06 level LIS9055 is Low-Low


Then Transfer water pump 10PPC10 is stopped.

If Clear filtrate tank 10CE06 level LIS9055 is Low


Then Inhibit start of Transfer water pump 10PPC10

200- INTERLOCKS TO RECIRCULATION CHEST DILUTION PUMP


10PPC13

If Cloudy filtrate tank 10CE05 level LIC9050 is Low-Low


Then Dilution water pump 10PPC13 is stopped.

If Cloudy filtrate tank 10CE05 level LIC9050 is Low


Then Inhibit start of Dilution water pump 10PPC13

201- DILUTION PUMP 10PPC13 TO ON/OFF VALVES AV-6155 & AV-6160

If Dilution water pump 10PPC13 is not running


Then On/Off valves AV-6155 & AV-6160 are forced closed

If Dilution water pump 10PPC13 is not running


Then With on delay T=5s, On/Off valves AV-6155 & AV-6160 in Auto open

202- (RESERVE)

LOOP 2 DISC FILTER & WATER DISTRIBUTION


Page 195/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

ALARMS

203- SEALING WATER

If Loop 2 Disc Filter & water distribution area is in operation


And Main line Sealing water flow is on Alarm FSA20135 Low for T=30 s

Then Active the ALARM

204- COMPRESSED AIR

If Loop 2 Disc Filter & water distribution area is in operation


And Compressed Air pressure PIA19202 is on Alarm Low

Then Active the ALARM

205- (RESERVE)

LOOP 2 DISC FILTER & WATER DISTRIBUTION


Page 196/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

12.5 OPERATION

12.5.1 Start-up

Loop 2 water distribution is the first area to start in Loop 2, in order to store
necessary water for all equipment start-up and dilution.

Basic conditions:
- Sealing water main line is under pressure and Flow switch FSA20135 is not
alarm Low
- Compressed air system is under pressure (pressure PIA19202 not on Alarm
Low).
- Loop 3 filtrate tank 13CE08 level LIC13005 is not Low

12.5.1.1 Water tanks filling

If water tanks are empty (for example on first start-up):

Open On/Off water valve AV-9085 for filling of Clear filtrate tank 10CE06 with
Loop 3 filtrates provided by pump 13PPC11.

Cloudy filtrate tank 10CE05 in cascade is filled through overflow.

As soon as water tank levels are up to Low level, all connected water pumps can
start if required by the sub-systems or in manual by operator.

12.5.1.2 Disc Filter 10FDQ04 start

Basic conditions:
- Clear Filtrate tank 10CE06 level LIS9055 is not Low.
- Downstream Heating screw 14VIT01 is running.

For start-up of sequence, the clear filtrate seal chamber should be filled with
either clear filtrate or fresh water up to the maximum level of this chamber so that
overflow occurs into the clear filtrate tank.

Start Loop 1 Disc Filter Repulping screw 10FDQ04b.

Start Disc Filter Shower Pump 10PPC07 and open its delivery valve AV-9035.

Start Oscillating shower drive 10FDQ04c.

Start Loop 1 Disc Filter Main Drive 10FDQ04.

When running status obtained for both, set Disc Filter status to READY.

LOOP 2 DISC FILTER & WATER DISTRIBUTION


Page 197/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

12.5.1.3 Production

The process bloc starts in production with the Post-flotation bloc (Once the stock
is bled downstream of the constant level box 08CP02 via control valve FCV-
8010).

Feed pump 10PPC03 is allowed to start with Disc Filter READY status.

When feed pump 10PPC03 is started:


Put the Disc Filter trough level controller LIC9020 in AUTO Mode.

12.5.2 Operation

The different steps run off automatically.

 Monitoring of HP shower water pressure.


 Monitoring of consistencies (Water and stock).
 Monitoring of operating vacuum

LOOP 2 DISC FILTER & WATER DISTRIBUTION


Page 198/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

12.5.3 Shutdown

12.5.3.1 Stop of production

The process bloc stops in production with the Post-flotation bloc by closing of the
control valve FCV-8010 outlet of the constant level box 08CP02.

Loop 2 Disc Filter stops in production with stop of feed pump 10PPC03.

12.5.3.2 Disc Filter 10FDQ04 stop

Reset Disc Filter status to Not READY

Stop the disc filter main motor after time delay of 10 minutes to ensure that as
much of fiber is recovered as possible from the liquid in the trough.

Stop Loop 2 Disc Filter Oscillating shower drive 10FDQ04c.

Stop Disc Filter Shower Pump 10PPC07 and close its delivery valve AV-9035.

Stop the stock repulper screw drive after time delay of 5 minutes, to ensure that
stock does not remain in the screw trough during stoppage.

CAUTION!
It would be preferable to operate the Disc Filter system for 5-10 minutes with just
showers water for internal cleaning prior to any medium duration stoppage (up to
4 hours).

For stoppages exceeding 4 hours, it would be preferable to clean the internal


system and have the trough drained fully. The contents of the trough should be
drained very slowly and gradually to avoid physical damage to the internal
components of the trough and rotor due to build-up of vacuum caused by
excessively rapid draining (siphon effect). Use of wire cleaning showers to clean
the filter fabrics is recommended. The inside of the hood and the showers pipes
should also be cleaned with water hose under pressure.

12.5.3.3 Loop 3 Water distribution

All Filtrate pumps are stopped when no more required by any depending sub-
systems (Loop 1 & Loop 2 dilutions, Micro-flotation feed if required through pump
10PPC10).

LOOP 2 DISC FILTER & WATER DISTRIBUTION


Page 199/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

PROCESS DESCRIPTION

KHANNA
NEW DIP LINE 300 BDMT/24h
PRINTING - WRITING

REDUCTIVE BLEACHING

REDUCTIVE BLEACHING
Page 200/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

13 REDUCTIVE BLEACHING

13.1 DESCRIPTION

13.1.1 Reductive bleaching itemization

 Heating Screw ..............................................................................14VIT01


 Stand Pipe ..............................................................................14CE02
 MC pump ...........................................................................14PMC03
 Reactive tube 1 ..........................................................................14BLT07A
 Reactive tube 2 ..........................................................................14BLT07B

13.1.2 Heating screw

The heating screw is a simple system, operating at fixed speed.


It is composed by:
-A metallic body with steam injectors.
-A conveying screw

The Heating screw is a simple system, operating at fixed speed, with steam
injection into the pulp agitated & transported by the screw.

13.1.3 MC Pump basics

The MC-Pump system consists of

- A stand pipe for Pump feeding with thick stock.

- The MC Pump itself, with a special pulp impeller that fluidises the pulp.

For more details, please refer to supplier documentation.

REDUCTIVE BLEACHING
Page 201/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

13.1.4 Reductive bleaching description

13.1.4.1 Heating screw

The Heating screw is a simple system, operating at fixed speed, with steam
injection into the pulp agitated & transported by the screw.

It receives the 10-12% accept pulp from Loop 2 Disc Filter 10FDQ04.

Heated pulp temperature is measured and controlled by TIC15005 by actuating


valve TCV-15005 on 3 Bars g Steam, to achieve a constant temperature of pulp
at the outlet of Heating Screw.

Heating temperature set-point (i.e. steam quantity to be injected) must be


adapted according to type of chemicals used and to pulp required temperature
during reaction in order to reach adequate conditions for the best reductive
bleaching efficiency.

A minimum pulp flow is required to enable steam injection by temperature


controller TIC15005, to avoid excessive steam exhaust. MC-Pump level controller
LICS15020 output is used for this signal: if level controller output is less than
10%, the steam valve TCV-15005 is forced closed.

Heating Screw 14VIT01 rotation is monitored by speed switch SS15010 allowing


detecting an eventual incident in this transfer screw.

Heated pulp falls by gravity from the Heating Screw to the MC Pump stand-pipe
14CE02.

13.1.4.2 MC pump and reactive tubes

Note: The following description for MC pump operation & associated regulations
correspond with a Sulzer pump type.
This paragraph is to be adapted and/or corrected in case of another supplier.

Dilution water is injected to the stand pipe base through control valve LCV-15020
and to the top part with hand regulated command HIC15015.

The pump drive speed is controlled by SIC15025.

The level in the MC Pump Stand-Pipe is controlled by LICS15020 operating on


MC pump motor speed controller SIC15025.

In addition, LICS15020 controls valves LCV-15020 & HCV-15015 dilution valves


to Stand-pipe, opening the level dilution valves when the level rises.

In Manual mode, Top dilution valve HCV-15015 and bottom dilution valve LCV-
15020 can be opened at any time.

REDUCTIVE BLEACHING
Page 202/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

In Auto mode, Top dilution valve HCV-15015 is opened at operator defined


opening set-point + controlled value related to deviation of LICS15020 from set-
point.
Bottom dilution valve LCV-15020 is normally closed, and opens to operator set
value when LICS15020 measure is greater than 30% above set-point and MC
Pump is running.

The MC-Pump 14PMC03 act as a Chemical mixer for the required chemicals,
dosed from Chemical Distribution system proportionally to the pulp tonnage.

Reductive Bleaching agent can be injected into the base of the stand pipe near
suction flange of the MC pump or through the chemicals injection connection on
the MC pump casing.
The proper dosing proportional factor is checked by observation of the pH value
measured off-line on pulp sampled from MC-Pump delivery or with final pH
measurement AIR15070 at Storage Tower 14CPA04 outlet.

The MC Pump 14PMC03 pumps the stock forward to:


 Reactive tubes 14BLT07A and 14BLT07B feeding downstream
process (dispersing system).
 Or Recirculation chest 07CPA11.

The pulp bleaching proceeds at medium consistency and reactive tubes are
doubled (in parallel) in order to get a sufficient residence time of the pulp to
achieve a proper bleaching efficiency.

13.1.4.3 Recirculation chest 07CPA11

During transitory phase (like on start-up or during an eventual incident in


downstream process), a recirculation line from MC pump 14PMC03 outlet
(through On/Off valve AV-9015 open and with On/Off valve AV-15035 closed)
allows recirculation of Loop 2 Accept stock back to intermediate chest 07CPA11.

This pulp transferred to chest 07CPA01 is diluted in line with filtrates from pump
10PPC13 and through On/Off valve AV-6155 in order to decrease consistency
from 10 to 4-5%.

When operator activates loop 2 accept stock recirculation to Dump chest, a


sequence automatically:
 Starts filtrate pump 10PPC13
 Opens filtrate valve AV-6155
 Opens by-pass valve AV-9105 and closes opposite valve AV-15035
 Sets in Auto mode level controller LIC6007
 Enables start of agitator 07AG12 and extraction pump 07PPC13
(motors start depend also on interlocks).

REDUCTIVE BLEACHING
Page 203/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

13.2 BASIC OPERATION CAPACITY

- Nominal MC Pump delivery 360 BDT/d at 8-12%

13.3 TRANSMITTERS AND CONTROL LOOPS

MC Pump control loops to be checked with corresponding supplier.

Alarms Scale-0-
Item Function Description 100%
LL L H HH Value unit
Temperature control of pulp in Heating
TIC 15005 0-150°C
screw 14VIT01
Heating screw 14VIT01 rotation alarm
SS 15010 * Digital alarm
Speed switch
Manual control valve of dilution water to
HIC 15015 0-100%
top of Stand Pipe 14CE02
MC Pump Stand Pipe 14CE02 level
LICS 15020 5% 15% 85% 95% 0-100%
control
MC Pump 14PMC03 motor speed
SIC 15025 0-100%
Control

REDUCTIVE BLEACHING
Page 204/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

13.4 INTERLOCKINGS AND ALARMS

206- INTERLOCK TO HEATING SCREW 14VIT01

If MC pump 14PMC03 is not running


Or MC pump Stand Pipe level LICS15020 is High-High for 15 s

Then Heating screw 14VIT01 is stopped

207- ROTATION SWITCH SS15010 TO HEATING SCREW 14VIT01

If Rotation switch SS15010 is alarm zero rotation


And Heating screw 14VIT01 is running with start up override T=5s

Then Heating screw 14VIT01 is stopped

208- INTERLOCKS TO STEAM HEATING TIC15005

If Heating Screw 14VIT01 is not running (on-delay T=20s)


Or Loop 2 Disc Filter feed pump 10PPC03 is not running (on-delay T=30s)
Or MC pump 14PMC03 is not running (on-delay T=20s)
Or MC pump Stand Pipe level LICS15020 is High-High for 15 s
Or MC pump Stand Pipe level LICS15020 output is less than 10% for T=5s
(on-delay T=20s)
Or TIC15005 is alarm High-High for T=10s (on-delay T=20s)

Then Temperature controller TIC15005 is disabled with valve TCV-15005


forced closed

Interlock is released after the on-delay T=20s of healthy status & enables
controller.

209- REDUCTIVE CHEMICALS DOSAGE

If MC pump 14PMC03 is not running


Or MC pump Stand Pipe level LICS15020 is Low-Low
Or MC pump Stand Pipe level LICS15020 output is less than 10% for T=5s
(on-delay T=20s)

Then Chemicals dosage to MC Pump is forced closed


(Action to be identified, chemicals study is out of KADANT scope)

REDUCTIVE BLEACHING
Page 205/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

210- STAND PIPE INTERLOCK TO MC PUMP 14PMC03

If MC pump Stand Pipe level LICS15020 is Low-Low for 30s

Then MC Pump 14PMC03 is stopped

211- DISPERSING SYSTEM INTERLOCK TO MC PUMP 14PMC03

While Pulp Recirculation to chest 07CPA11 is not activated, meaning by-pass


On/Off valve AV-9105 closed and opposite On/Off valve AV-15035
open.
If Storage Tower 12CPA03 level LIS11045 is alarm High-High for 30s
Or Screw Press Dispersing system is not running when required (On/Off
valves AV-10115 & AV-10120 open, On/Off valves AV-10125 & AV-
10130 closed)
Or MC pump Stand Pipe level LICS15020 is Low-Low for 30s

Then MC Pump 14PMC03 is stopped

212- MC PUMP 14PMC03 INTERLOCKS TO CONTROLS & VALVES

If MC Pump 14PMC03 is not running

Then Level controller LICS15020 is disabled


And Control valve HCV-15015 if in Auto is closed
And Control valve LCV-15020 if in Auto is closed

If MC Pump 14PMC03 is running (On delay T=20s)

Then Level controller LICS15020 is enabled to speed controller


SIC15025
And Output to valve LCV-15020 is enabled
(HCV-15015 output is enabled on motor start-order)

213- LOOP 3 DILUTION WATER INTERLOCK TO MC PUMP WATER


CONTROL VALVES

If Loop 3 dilution pump 13PPC09 is not running


Then Control valves HCV-15015 and LCV-15020 are forced closed.

If Loop 3 dilution pump 13PPC09 is not running


And MC Pump 14PMC03 is running

Then Alarm dilution to MC Pump is generated.

REDUCTIVE BLEACHING
Page 206/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

214- (RESERVE)

215- (RESERVE)

ALARMS

216- SEALING WATER

If Reductive Bleaching area is in operation


And Main line Sealing water flow is on Alarm FSA20135 Low for T=30 s

Then Active the ALARM

217- STORAGE TOWER 12CPA03 LEVEL LIS11045

If Storage tower 12CPA03 level controller LIS11045 is High

Then Active the ALARM

218- COMPRESSED AIR

If Reductive Bleaching area is in operation


And Compressed Air pressure PIA19202 is on Alarm Low

Then Active the ALARM

219- (RESERVE)

REDUCTIVE BLEACHING
Page 207/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

13.5 OPERATION

13.5.1 Start-up

Reductive Bleaching area is started after Downstream Dispersing system or pulp


will have to be recirculated to chest 07CPA11.

13.5.1.1 Start of the Loop

Basic conditions:
- Storage tower 12CPA03 level LIS11045 is not High alarm
- Sealing water main line is under pressure and Flow switch FSA20135 is not
alarm Low
- Compressed air system is under pressure (pressure PIA19202 not on Alarm
Low).
- Steam network under pressure
- Loop 3 clarified water tank 13CE08 level LIC13005 is not Low.
- Screw Press in downstream dispersing system (if used) is running
- Chemicals ready

If not already running, start Loop 3 dilution pump 13PPC09.

Start MC-Pump 14PMC03 (start order with Dispersion System sequence if used
– See § 14.5.1.1 – Page 227).

Start Heating Screw 14VIT01

All items of sub-system - in Auto mode - start according to interlocks defined


above:
- Dilution to Stand-pipe opens by interlock on MC Pump start-order;
- Controller LICS15020 & SIC15025 are enabled when MC-Pump is running;

13.5.1.2 Production

The process bloc starts in production start of feed pump 10PPC03.


Then Heating screw is fed with pulp from Loop 2 Disc Filter.

Pulp heating controller TIC15005 is enabled on delay after stock feed pump
10PPC03 start.

13.5.2 Operation

To be monitored during the operation of the installation:


 Monitoring of Steam pressure
 Monitoring of Chemicals feeding

REDUCTIVE BLEACHING
Page 208/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

13.5.3 Shutdown

Normal stop operation will lead to stop Red Bleaching MC-Pump after stopping
Loop 2 Disc Filter area.
It is strongly advised against stopping MC-Pump while Heating screw is running
- except in case of emergency.

The process bloc stops in production with closing of the control valve FCV-8010
outlet of the constant level box 08CP02 and with pump 10PPC03 motor stop.

Stop Heating Screw 14VIT01

Stop MC-Pump 14PMC03 (start order with Dispersion System sequence if used –
See § 14.5.3.2 – Page 229).
All actuators revert to required position through interlock action. The dilution
valves may be opened manually thereafter for flushing if required.

REDUCTIVE BLEACHING
Page 209/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

PROCESS DESCRIPTION

KHANNA
NEW DIP LINE 300 BDMT/24h
PRINTING - WRITING

LOOP 2 DISPERSING SYSTEM

LOOP 2 DISPERSING SYSTEM


Page 210/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

14 LOOP 2 DISPERSING SYSTEM

14.1 DESCRIPTION

14.1.1 Area Itemization

 Screw press ..............................................................................11KR01


 Plug screw ..............................................................................11KR02
 Shredder ..............................................................................11KR03
 Preheater ..............................................................................11KR04
 Infeeder ..............................................................................11KR05
 Disperser ..............................................................................11KR06
 Storage tower ............................................................................12CPA03
 Storage tower agitator ..............................................................................12AG04
 Storage tower extraction pump...............................................................................
12PPC05

14.1.2 Dispersing system

Dispersing system consists of succession of the following equipment:

- Screw press
- Plug Screw
- Shredder
- Preheater
- Infeeder
- Disperser

For more details, please refer to supplier documentation.

LOOP 2 DISPERSING SYSTEM


Page 211/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

14.1.3 Area description

14.1.3.1 Dispersing system

Note: The following description for Dispersing system must be checked and
completed by supplier.

Screw Press 11KR01

Screw-Press 11KR01 thickens the 10-12% pulp (from Reductive Bleaching via
MC pump 14PMC03) to 30-35% consistency required for Dispersing.

By-pass lines on each reactive tube outlet (through On/Off valve AV-10130 for
tube 14BLT07a and AV-10125 for tube 14BLT07b) can send pulp directly to
downstream storage tower 12CPA03.
By this way, deinking line can operate without this dispersion step.

Screw press mechanism is equipped with a packing box and monitoring alarms
(FS10095 and PS10100) helping to protect internal elements.

Screw press drive is equipped with a variable speed motor controlled by


SIC10010 and screw rotation is monitored by speed switch SSL10011 allowing
detecting an eventual incident.

The filtrates extracted from the Screw press flow by gravity to Loop 2 Cloudy
Filtrate Tank 10CE05.

The 30-35% consistency stock accepted from the Screw press feeds directly
Plug Screw 11KR02.

Reductive chemicals can be injected in Screw Press outlet chute if required for a
best pulp bleaching efficiency.

Screw press speed control & Torque controller:

Inputs:
Process value: Taken from the frequency converter and scaled to Nm.
Set point: Operator controlled parameter.
SP Ramp: 5 Nm per second.
Auto/Manual: Default “Auto”.
PV filter: 4s. Filter to flatten the process value signal.
To be applied either in frequency converter
or in control system.
Maximum output: This is to be set at 100%.
Minimum output: To be set at 0%.
Maximum SP: 50%.
Minimum SP: 0%.
HHAL: 70%.
HAL: 60%.

LOOP 2 DISPERSING SYSTEM


Page 212/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Output:
Output from controller forwarded frequency converter speed reference input.

Function:
Process value < Set point makes output decrease.
Process value > Set point makes output increase.

Plug Screw 11KR02

Plug screw transfers Screw Press outlet pulp to Shredder 11KR03.

Plug screw rotation is monitored by speed switch SSL10012 allowing detecting


an eventual incident.

Temperature there is measured by TIC10015.

Shredder 11KR03

Shredder 11KR03 transfers pulp from Plug Screw to Preheater 11KR04.

Shredder rotation is monitored by speed switch SSL10013 allowing detecting an


eventual incident.

Shredder mechanism is equipped with a packing box and monitoring alarms


(FS10085 and PS10090) helping to protect internal elements.

Part of Steam required from Preheater heating controller TIC10020 can be


injected there.

Preheater 11KR04

It receives the 30-35% accept pulp from upstream shredder.

Preheater mechanism is equipped with 2 packing boxes and monitoring alarms


(FS10085 and PS10090) helping to protect internal elements.

Preheater 11KR04 rotation is monitored by speed switch SSL10014 allowing


detecting an eventual incident in this transfer screw.

Temperature & Steam pressure control

Heated pulp temperature is measured and controlled by TIC10020 and PIC10020


by actuating valve PCV-10020 on Steam supply pipe, to achieve a constant
temperature of pulp at the outlet of Preheater.
Steam injection is adjustable through manual valves on each steam pipe
connected to shredder 11KR03 and Preheater 11KR04.

Heating temperature set-point (i.e. steam quantity to be injected) must be


adapted according to type of chemicals used and to pulp required temperature

LOOP 2 DISPERSING SYSTEM


Page 213/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

during reaction in order to reach adequate conditions for the best reductive
bleaching efficiency.

Interlocks:
 If emergency stop is activated (broken circuit), the valve is forced
closed.
 If the pulp feed is shut off, the steam valve is forced closed.
 If the temp. transmitter on the plug screw cone indicates high temp, i.e.
approx. 10°C above normal pulp temp), the valve is forced closed.

Operation:
 Pressure controller PIC10020 is the primary controller.
 Temperature controller TIC10020 is the secondary controller.
 Pressure controller operates the valve by its output value.
 Temp. controller output controls the set point value of the pressure
controller as a cascade control.
 Pressure set point range: 0-1,5bar.
 Temp. set point range: 90-120ºC.

Auto:
 Temp. Process Value < Set Point makes steam pressure Set Point
bigger.
 Pressure Process Value < Set Point makes valve output increase.
 Temp. Process Value > Set Point makes steam pressure Set Point
smaller.
 Pressure Process Value > Set Point makes valve output decrease.

Infeeder 11KR05

Infeeder 11KR05 transfers pulp from Preheater to Disperser 11KR06.

Infeeder screw rotation is monitored by speed switch SSL10016 allowing


detecting an eventual incident.

Infeeder mechanism is equipped with a packing box and monitoring alarms


(FS10085 and PS10090) helping to protect internal elements.

Disperser 11KR06

The pulp introduced into the Disperser is subjected to shear forces between
stator & rotor.

Disperser mechanism is equipped with a packing box and monitoring alarms


(FS10065 and PS10070) helping to protect internal elements.

Lubricating system for Disperser 11KR06 drive is equipped with an oil cooler
monitored by alarms FS10075 and PS100870.

LOOP 2 DISPERSING SYSTEM


Page 214/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

The thick stock in Disperser is diluted in outlet zone in concordance with set-point
consistency of controller NIC10045, acting on control valve NCV-10045 on Loop
3 filtrates provided through pump 13PPC18.

Water dilution and Disperser stock outlet pressures are controlled respectively
through PIC10055 and PIC10060 with their associated control valves on
corresponding pipe.

Disperser 10KR06 outlet stock falls directly in storage tower 12CPA03.

Backpressure control

Interlocks:
 Forced open 100% if steam control valve is closed.
 Valve output must be min. limited (approx. 20-30%).
 Set point range: 1.5-2.0 bar

Operation (auto):
 Backpressure Process Value < Set Point makes valve output decrease.
 Backpressure Process Value > Set Point makes valve output increase.

Consistency control NIC10045 (after Disperser)

Interlocks:
 Control valve forced closed when Disperser motor is not running.
 Should have a mini limit of 20% when in automatic mode.

Operation:
 Set point range: 9-11%

Auto:
 Consistency Process Value < Set Point makes valve output decrease.
 Consistency process Value > Set Point makes valve output increase.

Disc gap control (adjustment of operating gap from computer)

Interlocks:
 Gap set point to be limited to 0,10mm minimum gap.
 Gap set point to 1,20mm if steam control valve closes.

Disc gap adjustment from computer shall not work when:


 Switch for disc gap control is in local position on the Panel.
 Hydraul/Lubepump is not running.
 Discs is in rear position.

Disc gap set to rear position (solenoid MV1 energized) if:


 Emergency stop or service switch is activated (broken circuit - valid only
for computer).

LOOP 2 DISPERSING SYSTEM


Page 215/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

 Disc gap - backwards (panel/computer) is selected.

Operation:
 The control loop is fed with an analog input (4-20 mA=0-10 mm). The
controller sets one of two digital outputs that increases or decreases the
disc gap. (Energizing two relays in local panel).

Auto:
 Disc gap process value < set point gives a constant signal at increase -
output.
 Disc gap process value > set point gives a constant signal at decrease -
output.

NOTE!
 A span of ±0.03 mm should be used to avoid that the controller is
continuously searching for the right gap.
 If the respond from the process value into the controller is too slow, a
recommendation is to give pulses of 0,5 seconds to the output, when
gap reaches ±0.20 mm from set point.

14.1.3.2 Storage tower 12CPA03

The thick stock falls from Disperser into Storage tower 12CPA03 at consistency 5
to 10% according to controller NIC10045 set-point.

Bleaching tower 12CPA03 level is measured by LIS11045.

High Level LIS11045 is one of the main levels on the line, to be monitored by
operator to control the production & stability on loop 2 by acting on Loop 2
production set-point (through flow controller FIC8010 regulating stock feed to
Post-Flotation area) or on Loop 3 production set-point (through flow controller
FIC12005 regulating stock feed to Washing).

Modification of Loop 2 production set-point will have also a repercussion on


Bleaching tower 07CPA01 level and will lead operator to adjust Loop 1 set-point
(through Pre-Flotation feed controller FIC3020).

The Storage tower must have a minimum level of filtrates or stock prior to feeding
thick stock - to prevent block agitator or extracting system. This requires pre-
filling on filtrates prior to start the line. Operator does this filling manually from
DCS.

Storage tower 12CPA03 is equipped with a horizontal agitator 12AG04.

Pump 12PPC05 extracts the stock from Storage tower to downstream process:
 Through On/Off valve AV-11110 to Washing system if required by Loop
3 feed controller FIC12005.
 And / Or through On/Off valve AV-11105 directly to Final Storage tower
14CPA04 if required by Loop 3 feed controller FIC15095.

LOOP 2 DISPERSING SYSTEM


Page 216/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

(See more detailed Description in § 15.1.4.1 - Washing area feed and by-pass –
Page 235).

Tower extracted pulp consistency is controlled by NRC11050 and adjusted with


addition of Loop 3 Filtrates (from pump 13PPC18) in tower 12CPA03.
Most part of this dilution flow is directed (via control valve QCV-11055) to Tower
12CPA03 bottom diluting zone in order to reduce consistency to around approx.
5%.
Remaining dilution water flow is directed (via control valve NCV-11050) to suction
of pump 12PPC05 where consistency reaches more finely 4-4,5%.
Controller QC11055 operates as a proportional ratio in order to adjust associated
valves (QCV-11055 and NCV-11050) opening values and then the sharing of
total dilution flows (usually 70% of total flow through valve QCV-11055 and 30%
through NCV-11050).

Extraction pump 12PPC05 outlet pressure is controlled via PIC11060 and


adjusted with control valve PCV-11060 or On/Off valve AV-11100 on 2 parallel
recirculation pipes back to Storage tower bottom.
- The smallest diameter valve PCV-11060 will be enabled with controller
PIC11060 during normal operation (when pressure recirculation flow is
limited).
- The biggest diameter On/Off valve AV-11100 will be used during transitory
phases (like start-up) requiring a bigger pressure recirculation (even a total
recirculation).

During start-up, the recirculation at the bottom of the tower is turned on in order
to reach an appropriate consistency before feeding downstream chest 12CPA06:
 On/Off valve AV-11100 opens.
 Control valve LCV11070 on transfer pipe is forced closed.

When desired consistency is obtained; and stabilized, the full recirculation is shut
down:
 On/Off valve AV-11100 closes
 Pump 12PPC05 outlet pressure is controlled by PIC11060 in AUTO
mode and through control valve PCV-11060.
 Pulp is sent downstream.

Brightness of extracted pulp from Tower 12CPA03 is measured by transmitter


AIR11065 and displayed/recorded.

LOOP 2 DISPERSING SYSTEM


Page 217/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

14.2 BASIC OPERATING CAPACITY

Dispersing System:

- Outlet Production of Dispersing System 350 BDT/d at 5-10%

Refer to supplier for system operating capacity of each equipment.

14.3 TRANSMITTERS AND CONTROL LOOPS

Note: The following control loops must be checked and completed by supplier.

Alarms Scale-0-
Item Function Description 100%
LL L H HH Value unit
Screw Press 11KR01 rotation alarm
SSL 10011 * Digital alarm
Speed switch
Screw Press 11KR01 motor speed
SIC 10010 0-100%
Control
Flow alarm switch on system for Screw
FS 10095 Digital alarm
Press 11KR01 packing box
Pressure alarm switch on system for
PS 10100 Digital alarm
Screw Press 11KR01 packing box
Plug Screw 11KR02 rotation alarm
SSL 10012 * Digital alarm
Speed switch
Temperature indication inside Plug
TIC 10015
Screw 11KR02
Shredder 11KR03 rotation alarm Speed
SSL 10013 * Digital alarm
switch
Flow alarm switch on system for packing
FS 10085 boxes of Infeeder, Preheater (x2) and Digital alarm
Shredder
Pressure alarm switch on system for
PS 10090 packing boxes of Infeeder, Preheater Digital alarm
(x2) and Shredder
Temperature control inside Preheater
TIC 10020
11KR04
Pressure control of steam injection inside
PIC 10020
Preheater 11KR04
Preheater 11KR04 rotation alarm Speed
SSL 10014 * Digital alarm
switch

…/…

LOOP 2 DISPERSING SYSTEM


Page 218/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Alarms Scale-0-
Item Function Description 100%
LL L H HH Value unit
Infeeder 11KR05 rotation alarm Speed
SSL 10016 * Digital alarm
switch
Flow alarm switch on system for
FS 10075 Digital alarm
Disperser 11KR06 oil cooler
Pressure alarm switch on system for
PS 10080 Digital alarm
Disperser 11KR06 oil cooler
Flow alarm switch on system for
FS 10065 Digital alarm
Disperser 11KR06 packing box
Pressure alarm switch on system for
PS 10070 Digital alarm
Disperser 11KR06 packing box
Consistency control of stock outlet of
NIC 10045
Disperser 11KR06
Pressure control of dilution water to
PIC 10055
Disperser 11KR06 outlet
Pressure control of stock outlet of
PIC 10060
Disperser 11KR06

LIS 11045 Storage tower 12CPA03 level control 5% 15% 85% 95% 0-200 m³

Storage tower 12CPA03 extracted pulp


NRC 11050 0 to 5%
consistency control
Ratio repartition for Storage tower
QC 11055 0-100%
12CPA03 pulp dilution water flow
Storage tower 12CPA03 extracted pulp
PIC 11060 0–4 Bars
pressure control
Brightness indication of Storage tower
AIR 11065
12CPA03 extracted pulp

LOOP 2 DISPERSING SYSTEM


Page 219/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

14.4 INTERLOCKINGS AND ALARMS

14.4.1 Dispersing system

Dispersing system interlocks and alarms to be corrected and/or corrected with


corresponding supplier.

220- INTERLOCKS TO DISPERSER 11KR06 HYDRAUL / LUBEPUMP

If OFF (panel/computer) is activated (broken circuit).


Or Disperser 11KR06 is not running within 240 sec.
Or Disperser 11KR06 stops. Time delay 240 sec.

Then Disperser 11KR06 Hydraul/Lubepump stops.

221- INTERLOCKS TO DISPERSER 11KR06

If OFF (panel/computer) is activated (broken circuit).


Or Emergency stop or service switch is activated (broken circuit).
Or Hydraulic pressure switch is not activated (low pressure = broken circuit,
hardwired to motor control cabinet).
Or Lubrication oil flow switches are not activated (low flow = broken circuit,
hardwired to motor control cabinet).
Or Disperser 11KR06 Hydraul/Lubepump is not running
Or Sealing & oil cooling water On/Off valve AV-10105 is not open.
Or Storage tower 12CPA03 level is High-High for T=45s.
Or Oxidative bleaching tower 12CPA03 level is Low-Low.

Then Disperser 11KR06 stops.

222- INTERLOCKS TO INFEEDER 11KR05

If OFF (computer) is activated (broken circuit).


Or Emergency stop or service switch is activated (broken circuit).
Or Slow speed limit switch SS10016 is not activated (low speed = broken
circuit).
Or Disperser 11KR06 is not running
Or Dilution water pump 13PPC18 is not running
Or Control valve PCV-10055 on dilution water pipe is closed
Or Pressure switch for dilution water is not activated, i.e. pressure is below
2 bars for more than 5 sec. (low pressure = broken circuit).

Then Infeeder 11KR05 stops.

LOOP 2 DISPERSING SYSTEM


Page 220/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

223- INTERLOCKS TO PREHEATER 11KR04

If OFF (computer) is activated (broken circuit).


Or Emergency stop or service switch is activated (broken circuit).
Or Slow speed limit switch SS10014 is not activated (low speed = broken
circuit).
Or Infeeder 11KR05 is not running

Then Preheater 11KR04 stops.

224- INTERLOCKS TO TEMPERATURE & STEAM PRESSURE


CONTROLLERS

If Emergency stop or service switch is activated (broken circuit).


Or Screw Press 11KR01 torque controller is not in Auto mode.
Or Feed pump 14PMC03 is not running (with on-delay T=120s)
Or Temperature TIC10020 is alarm High-High (on-delay T=20s)
Or Temperature TIC10015 on the Plug Screw 11KR02 indicates High
Temperature (i.e. approx. 10°C above normal pulp temperature)

Then Temperature (TIC10020) & Steam pressure (PIC10020) controllers are


disabled with valve PCV-10020 forced closed

Note: If TIC10020 is in Auto and the interlocking conditions are set to healthy, the
controller is enabled after specified on-delays. In Manual, the controller
remains at closed value.

225- INTERLOCKS TO SHREDDER 11KR03

If OFF (computer) is activated (broken circuit).


Or Emergency stop or service switch is activated (broken circuit).
Or Slow speed limit switch SS10013 is not activated (low speed = broken
circuit).
Or Preheater 11KR04 is not running

Then Shredder 11KR03 stops.

LOOP 2 DISPERSING SYSTEM


Page 221/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

226- INTERLOCKS TO PLUG SCREW 11KR02

If OFF (computer) is activated (broken circuit).


Or Emergency stop or service switch is activated (broken circuit).
Or Slow speed limit switch SS10012 is not activated (low speed = broken
circuit).
Or Shredder 11KR03 is not running

Then Plug Screw 11KR02 stops.

227- INTERLOCKS TO SCREW PRESS 11KR01

If OFF (computer) is activated (broken circuit).


Or Emergency stop or service switch is activated (broken circuit).
Or Slow speed limit switch SS10011 is not activated (low speed = broken
circuit).
Or Plug Screw 11KR02 is not running

Then Screw Press 11KR01 stops.

228- INTERLOCKS TO SCREW PRESS 11KR01 COUNTER PRESSURE


CONE

If Screw Press 11KR01 is not running.


Or Open (computer) is selected (broken circuit).
Or Pulp feed pump 14PMC03 is not running on delay T=30s.
Or Screw Press speed Torque controller is on Alarm High

Then Counter pressure cone in Screw Press opens (solenoid valve


energized).

229- INTERLOCKS TO SEALING AND COOLING WATER VALVE

If Hydraul/Lubepump is not running.


Then Sealing water and Cooling water On/Off valve closes

If Hydraul/Lubepump is running.
Then Sealing water and Cooling water On/Off valve opens

LOOP 2 DISPERSING SYSTEM


Page 222/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

230- INTERLOCKS TO DISC GAP

If Disc gap – backwards (panel/computer) is selected


Then Disc gap set to rear position

If Hydraul/Lubepump is running.
And Selector switch (local panel) for disc gap control is set to remote mode

Then Disc gap can be set to rear or operating position (valid for computer)

If Steam control valve PCV-10020 closes


Then Disc gap set-point to 1,20mm

If Steam control valve PCV-10020 closes


Then Disc gap set-point to 1,20mm

231- INTERLOCKS TO DRAINAGE VALVE

If Dilution water pump 13PPC18 is not running.


Then Drainage On/Off valve opens

If Dilution water pump 13PPC18 is running.


Then Drainage On/Off valve closes

232- INTERLOCKS TO OUTLET CONSISTENCY CONTROL NIC10045

If Disperser 11KR06 is not running


Or Loop 3 dilution pump 13PPC18 is not running

Then Controllers QC11055 and NRC11050 are disabled with control valves
QCV-11055 and NCV-11050 forced closed.

233- SCREW PRESS INTERLOCK TO CHEMICAL DOSAGE

If Screw Press 11KR01 is not running (with on-delay T=30s)


Or Feed pump 14PMC03 is not running (with on-delay T=30s)

Then Chemical supply to Dispersing System is DISABLED (to Chemical


dosage pumps).

The On-delay T=30s means that chemical supply will remain forbidden T=30s
after the interlock has been released.

234- (RESERVE)

LOOP 2 DISPERSING SYSTEM


Page 223/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

235- (RESERVE)

14.4.2 Storage tower 12CPA03

236- STORAGE TOWER LEVEL LIS11045 TO AGITATOR 12AG04

If Storage tower 12CPA03 level LIS11045 is Low


Then Stop Agitator 12AG04

If Storage tower 12CPA03 level LIS11045 is Low


Then Inhibit Start Agitator 12AG04

If Storage tower 12CPA03 level LIS11045 is not Low


And Agitator 12AG04 is DCS Auto mode

Then Start Agitator 12AG04

237- LEVEL LIS11045 HIGH_HIGH INTERLOCK TO DILUTION VALVES

If Storage tower 12CPA03 level LIS11045 is High-High

Then Controllers QC11055 and NRC11050 are disabled with control valves
QCV-11055 and NCV-11050 forced closed

Note: this interlock is designed to prevent adding dilution filtrates to a full tower.

238- INTERLOCKS TO TOWER EXTRACTION PUMP 12PPC05

If Storage tower 12CPA03 level LIS11045 is Low


Or Agitator 12AG04 is stopped

Then Pump 12PPC05 is stopped.

If Storage tower 12CPA03 level LIS11045 is Low


Then Inhibit start of pump 12PPC05.

(This interlock prevents tripping the pump motor on start-up by extracting pulp
that is not properly agitated & homogenized in the bottom of the Tower).

LOOP 2 DISPERSING SYSTEM


Page 224/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

239- TOWER EXTRACTION PUMP 12PPC05 TO REGULATIONS ON


DELIVERY PIPES

If Tower extraction pump 12PPC05 is not running

Then Chest 12CPA06 feed control valve LCV-11070 is forced closed.


And Control valve FCV-15095 on by-pass line is forced closed.

240- INTERLOCKS TO CONSISTENCY CONTROLS NRC11050 & QC11055

If Tower extraction pump 12PPC05 is not running


Or Loop 3 dilution pump 13PPC18 is not running

Then Controllers QC11055 and NRC11050 are disabled with control valves
QCV-11055 and NCV-11050 forced closed.

241- INTERLOCKS TO PRESSURE CONTROL PIC11060

If Tower extraction pump 12PPC05 is not running

Then Controller PIC11060 is disabled with control valve PCV-11060 and


On/Off valve AV-11100 forced closed.

242- (RESERVE)

ALARMS

243- SEALING WATER

If Loop 2 dispersing system area is in operation


And Main line Sealing water flow is on Alarm FSA20135 Low for T=30 s

Then Active the ALARM

244- COMPRESSED AIR

If Loop 2 dispersing system area is in operation


And Compressed Air pressure PIA19202 is on Alarm Low

Then Active the ALARM

LOOP 2 DISPERSING SYSTEM


Page 225/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

245- BLEACHING TOWER 12CPA03 LEVEL LIS11045

If Bleaching tower 12CPA03 level controller LIS11045 is High

Then Active the ALARM

246- (RESERVE)

LOOP 2 DISPERSING SYSTEM


Page 226/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

14.5 OPERATION

Note: This paragraph is based on supplier information.


(To be checked and completed if necessary).

14.5.1 Start-up

The Loop 2 Dispersing System is the first pulp system started in Loop 2.
It starts only if the Storage Tower 12CPA03 level is not High AND not Low-Low.

Basic conditions:
- Sealing water main line is under pressure and Flow switch FSA20135 is not
alarm Low
- Compressed air system is under pressure (pressure PIA19202 not on Alarm
Low).
- Steam network under pressure
- Chemicals ready
- Loop 3 filtrate tank 13CE08 Level LIC13005 is not Low.
- Storage Tower 12CPA03 level LIS11045 is not High AND not Low-Low
- Selection of operation with Dispersing System. Position of MC pump
14PMC03 outlet valves:
 Valve AV-9105 closed (to recirculation chest 07CPA11
 Screw Press By-pass valves AV-10125 & AV-10130 closed
 Valves AV-15035, AV-15040, AV-15045, AV-10115 & AV-10120 open

Note: If Storage Tower 12CPA03 level is Low, operator needs to pre-fill the
Tower with Loop 3 filtrates from pump 13PPC18.

14.5.1.1 Starting of the loop

The system is started by sequentially starting all elements from downstream to


upstream.

Disperser 11KR06 Hydraul / Lubepump ON.

Backpressure control valve PCV-10060 100% open

Disperser discs in opening position (solenoid valve de-energized).


Time delay 10 seconds.

Check that Discgap is > 1,20mm (If Less send Increase signal)

Wait until gap is > 1,20mm (When bigger stop Increase signal)

Disperser discs in rear position (solenoid valve energized).

Receive signal from back out limit switch


Time delay 10 seconds.

LOOP 2 DISPERSING SYSTEM


Page 227/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Disperser 11KR06 main motor on.


Time delay 10 seconds.

If not already running, start Loop 3 filtrates pump 13PPC18.

Consistency transmitter activated and controller NIC10045 in Auto mode.

Disperser discs in operating position (solenoid valve de-energized).


Time delay 5 seconds.

Infeeder 11KR05 ON
Time delay 3 seconds.

Preheater 11KR04 ON
Time delay 3 seconds.

Shredder 11KR03 ON
Time delay 3 seconds.

Plug Screw 11KR02 ON


Time delay 3 seconds.

Screw press 11KR01 ON

Torque controller to Manual and 80% output.


Time delay 10 seconds.

Screw Press counter pressure cone solenoid valve de-energized.

Start feed MC pump 14PMC03.


Time delay 120 seconds.

Torque controller to automatic and standard set-point.

Steam temperature controller in Auto mode (if required by bleaching sequences).

Backpressure controller in Auto mode.

Wait until the pulp temperature is > 80°C (if required by bleaching sequences).

Decrease the disc gap within the range 0,10 – 0,50 mm.

The system is running.

LOOP 2 DISPERSING SYSTEM


Page 228/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

14.5.1.2 Production

The whole Loop 2 starts in production with Post-Flotation area: with the opening
of valve FCV-8010 at the outlet of the constant level box 08CP02.

The whole LOOP2 line is then started, and when stock arrives to Storage Tower
12CPA03.

Chemical dosage is allowed through interlocks.

14.5.2 Operation
To be monitored during the operation of the installation:
 Monitoring of stock consistencies.
 Monitoring of Steam pressure
 Monitoring of drive motors load.
 Monitoring of Bleaching efficiency
 Checking of Storage Tower 12CPA03 (one of the main parameters in
the line).

14.5.3 Shutdown

14.5.3.1 Stop of production

Loop 2 DIP line stops in production with closing of the Post-Flotation feed control
valve FCV-8010 at outlet of the constant level box 08CP02.

Provided there is no pulp flow to the Loop 2 Disc Filter, Dispersing system sub-
system can be stopped.

14.5.3.2 Stop of the loop

Dispersing system is stopped after Loop 2 Disc Filter area.

Send increase the Disc Gap signal until Disc Gap is > 1,20mm.

Stop feed MC pump 14PMC03.

Energize solenoid valve of Screw Press counter pressure cone

Wait approx. T=180s (The whole is emptied from pulp)

Discs movers to rear position (solenoid valve energized).

Stop Screw Press 11KR01


Time delay 3 seconds.

LOOP 2 DISPERSING SYSTEM


Page 229/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Stop Plug Screw 11KR02


Time delay 3 seconds.

Stop Shredder 11KR03


Time delay 3 seconds.

Stop Preheater 11KR04


Time delay 3 seconds.

Stop Infeeder 11KR05


Time delay 5 seconds.

If no more required by any other sub-system, stop Loop 3 filtrates pump


13PPC18.

Time delay 3 seconds.

Stop Disperser 11KR06

The system is stopped

Note: Tower extraction pump 12PPC05 is stopped when no more pulp is required
on downstream process. This action is independent from upstream process stop
sequence.

LOOP 2 DISPERSING SYSTEM


Page 230/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

PROCESS DESCRIPTION

KHANNA
NEW DIP LINE 300 BDMT/24h
PRINTING - WRITING

WASHING
FINAL STORAGE

WASHING & FINAL STORAGE


Page 231/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

15 WASHING & FINAL STORAGE

15.1 DESCRIPTION

15.1.1 Area Itemization

 Washing feed chest ............................................................................12CPA06


 Washing feed chest agitator ...................................................................................
12AG07
 Washing feed chest extraction pump......................................................................
12PPC08
 Washing feed pump ............................................................................13PPC01
 DNT Washer 1 ............................................................................13LAV02
 DNT Washer 2 ............................................................................13LAV03
 Washer Medium pressure showers feed pump.......................................................
13PPC05
 Washer High pressure showers feed pump............................................................
13PPC06
 Stand Pipe ..............................................................................14CP10
 Transfer MC pump to Storage tower.......................................................................
14PMC11
 Final storage tower ............................................................................14CPA04
 Final storage tower agitator ....................................................................................
14AG05
 Final storage tower extraction pump.......................................................................
14PPC06

WASHING & FINAL STORAGE


Page 232/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

15.1.2 Washer basics

15.1.2.1 DNT Washer Description

The washer thickener DNT 200 is a high-speed double nip thickener machine,
using a synthetic wire for efficient removal of ink, clay and other contaminants.

The DNT consists of an enclosed endless wire running on two cantilevered rolls
(driven couch roll, breast roll with grooves), driven by pulley and V-belts with
variable frequency drive, with the following elements:

- The stock inlet connection to DNT & pressurized flow distribution Head-box;
- Breast roll, grooved;
- Couch roll, smooth, driven by V-belt & variable speed drive;
- Oscillating Stock discharge doctor;
- Accept stock discharge screw conveyor & drive;
- Oscillating HP shower (needle-30 Bars);
- Fixed MP shower (Fan-8 bars).

DNT Overview:

Stock inlet Stock Accept


0,8-2,5% 8-12%

          Oscillating 
HP Shower
          Fixed 
MP Shower

DNT Head-box 
  
Breast Roll  
     
(with grooves)
Accept Screw 
  
Couch Roll    
Filtrates Outlet 
 

WASHING & FINAL STORAGE


Page 233/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

15.1.3 DNT Washer operation

The DNT Washer consists of a flow distribution nozzle, two rolls and a synthetic
wire, which acts as the dewatering media.

The DNT Washer operates by feeding stock from the flow distribution nozzle into
the nip formed by the breast roll and the wire. The stock is fed at a high velocity
into this nip for effective dewatering and high capacities for a relatively small roll
width.
The breast roll is grooved to provide high capacity and also eliminates the need
for the doctor blade.

After the feed nip, the wire continues around the breast roll where the stock
continues to be dewatered. As the wire separates from the breast roll, a stock
mat has been formed.
This stock mat travels with the wire to the couch roll where it undergoes
additional dewatering.

The stock mat is then doctored into the repulper screw conveyor where it is
removed from the DNT Washer at approximately 10-12% consistency.

A cowling encloses the DNT Washer and allows the white water from the unit to
be collected and discharged at one central location.
This cowling also eliminates splashing from the unit and makes the operation
clean and safe. White water consistency from the DNT Washer depending on the
ash content and fiber length on the stock and operating conditions.

The wire is guided by two V-guides resting on both tending & drive sides of the
couch & breast rolls. The wire tension is adjusted mechanically by hand-wheel &
gear screw jack on tending side and checked locally on load-cell, with low & high
tension alarms.

The MP Shower (Fan) & HP oscillating high-pressure (needle) shower clean the
wire continuously after thick stock discharge.

Applications for the DNT Washer include deashing of stock for tissue production
as well as dispersed ink removal for tissue, newsprint, and fine papers.

WASHING & FINAL STORAGE


Page 234/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

15.1.4 Area description

15.1.4.1 Washing area feed and by-pass

From the Storage tower 12CPA03, pump 12PPC05 feeds the stock chest
12CPA06 that is a constant level working chest.
Chest 12CPA06 level is controlled by LIC11070 commanding the stock quantity
required upstream the system via control valve LCV-11070 on stock feed pipe.

Moreover, washing area design capacity allows a complementary pulp


production, transferred from parallel deinking line (called “Existing VOITH line”)
and collected in transfer chest 12CPA06.

Transfer chest 12CPA06 serves also to homogenize finely stock extracted from
Bleaching step (in consistency, air content, …).

From this chest, extraction pump 12PPC08 transfers pulp to Washing area at
consistency ~4% regulated by controller NIC11075 and addition of Loop 3
filtrates from dilution pump 13PPC09.
This transfer flow is adjustable through Flowmeter FIC12005.
Control valve FCV-12005 is the basis weight valve for 3rd loop of deinking line:
its opening fixes the production rate of Loop 3.

As transmitter NIC11075 also continuously measures consistency at this point,


then instantaneous washing feed production (P3-12005) can be calculated and
checked (and corrected if necessary through FIC12005 set-point) at any time by
operator.

As Ash content in final deinked pulp is proportional to production ratio sent to


washing system (and then to filtrate flow to be treated by Micro-flotation), a by
pass-line from pump 12PPC05 delivery (through On-Off valve AV-11105) sends
stock directly to Final storage tower 14CPA04.
This by-pass flow is adjustable through Flowmeter FIC15095 and corresponding
production is calculated with stock consistency measured by NRC11050.

The sum of Washing feed and By-pass productions gives the stock quantity to be
processed by the 2 upstream deinking loops.
Operator checking is required to set both productions to values compatible with
Loop 1 & Loop 2 design operating capacities (by checking levels stability in
Towers 07CPA01 & 12CPA03).

15.1.4.2 Washing feed pump 13PPC01

DNT washers are fed from pump 13PPC01 connected on Loop 3 filtrate tank
13CE08.

DNT Washers feed pulp consistency has also a direct influence on ash content
removal in final stock and is adjustable through inlet flow controllers FIC1015 (for
13LAV02) and FIC12076 (for 13LAV03).

WASHING & FINAL STORAGE


Page 235/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

In fact: Water dilution flow (from pump 13PPC01 suction) is the subtraction of
thick stock feed flow FT-12005 from DNT total inlet flow (sum of measurements
FT-12015 and FT-12076).
Then DNT inlet stock consistency value can be obtained from thick stock
consistency measured by NT-11075.

DNT washers can operate with a feed stock consistency comprised between 1
and 3%.

DNT washers feed pump 13PPC01 is equipped with a variable speed motor
controller SIC12008 in order to adapt delivery flow to operating conditions,
varying in a large margin (due to feed production and DNT inlet consistency
variations – See above).

Moreover the possibility is kept to feed a third DNT (in a parallel deinking line) if
required by Paper Machine settings (in case of improved production and/or
quality).

15.1.4.3 DNT washers

Washers 13LAV02 & 13LAV03 thicken the 1-3% stock flow coming from Loop 2
storage tower 12CPA03.

The DNT Washer head-box inlet pressures are measured by PI12020 (for
13LAV02) & PI12080 (for 13LAV03).

The DNT Main drive motors are speed controlled - at fixed speed manually set
from DCS by operator, through SIC12031 (for 13LAV02) & SIC12091 (for
13LAV03).

Each washer fixed medium pressure shower is provided with water from pump
13PPC05 (at pressure 8 bars) and through On/Off valves AV-12040 (for
13LAV02) & AV-12100 (for 13LAV03).

Each washer oscillating High pressure shower is provided with water from pump
13PPC06 (at pressure 25 bars) and through On/Off valves AV-12045 (for
13LAV02) & AV-12105 (for 13LAV03).

HP showers oscillations are:


 Started by commands HS-12050 (for 13LAV02) & HS-12110 (for
13LAV03)
 Monitored by Oscillation alarm signals XS-12050 (for 13LAV02) & XS-
12110 (for 13LAV03).

Washer doctors oscillations are:


 Started by commands HS-12025 (for 13LAV02) & HS-12085 (for
13LAV03)
 Monitored by Doctor Oscillation alarm signals XS-12025 (for 13LAV02)
& XS-12085 (for 13LAV03)

WASHING & FINAL STORAGE


Page 236/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Each transversal wire movement is monitored by position detectors on Drive side


& Tending side, transmitted to DCS by Wire position alarms.
Alarms ZS-12030 (for 13LAV02) or ZS-12090 (for 13LAV03) stops the
corresponding DNT Main drive.

Each Washer wire tension is monitored by local load cell with remote alarms WS-
12065 (for 13LAV02) and WS-12125 (for 13LAV03) signal to DCS.
These Low tension alarms stop the corresponding DNT Main drive.

Each Washer Breast roll rotation is monitored by speed switches SSL-12060 (for
13LAV02) and SSL-12120 (for 13LAV03) alarm on Breast roll.
This alarm while DNT drive is running indicates a slackening of the wire tension
or V-belt drive incident, and stops the corresponding DNT Main drive.

If necessary, water lines from “FRESH WATER” to each Washer inlet (via On-Off
valves AV-12013 for 13LAV02 & AV-12075 for 13LAV03) and to washer extractor
screw (via On-Off valves AV-12035 for 13LAV02 & AV-12095 for 13LAV03) allow
washing in manual the equipment after its shut-down (for example before a
several days stop or before a maintenance intervention).

Washing filtrates flow to Micro-Flotation feed tank 13CE07.

Each accept stock screw conveyor rotation is monitored by speed switches SSL-
12055 (for 13LAV02) and SSL-12115 (for 13LAV03).
These alarms indicate a screw conveyor drive incident, and stop the
corresponding DNT Main drive and screw conveyor drive.

Washed pulp is extracted from washer outlet screw and falls into stand pipe
14CP10.

15.1.4.4 Transfer MC pump 14PMC11

Note: The following description for MC pump operation & associated regulations
correspond with a Sulzer pump type.
This paragraph is to be adapted and/or corrected in case of any other supplier.

Stock at 10-12% falls by gravity from Washers 13LAV02 and 13LAV03 Repulping
screws into the MC Pump Stand-Pipe 14CP10.

The pump drive speed is controlled by SIC15075.

The level in the MC Pump Stand-Pipe is controlled by LICS15090 operating on


MC pump motor speed controller SIC15075.

In addition, LICS15090 controls valve LCV-15090 on dilution water to Stand-pipe


provided by PM Water.

The MC Pump 14PMC11 pumps the stock to Final Storage tower 14CPA04.

WASHING & FINAL STORAGE


Page 237/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

15.1.4.5 Final Storage tower 14CPA04

Storage tower 14CPA04 collects accept pulp from washer (via MC pump
14PMC11) and pulp from washing by-pass (through controller FIC15095).

Storage tower 14CPA04 level is measured by LIS15040.

High Level LIS115040 is one of the main levels on the line, to be monitored by
operator to control the production & stability on loop 3 by acting on Loop 3
production set-point (through flow controllers FIC12005 for washing feed and
FIC15095 for washing by-pass).
Modification of Loop 3 production set-point may have also a repercussion on
Loop 2 and Loop 1 production set-points.

The Storage tower must have a minimum level of filtrates or stock prior to feeding
thick stock - to prevent block agitator or extracting system. This requires pre-
filling on filtrates prior to start the line. Operator does this filling manually from
DCS.

Storage tower 14CPA04 is equipped with a horizontal agitator 14AG05.

Pump 14PPC06 extracts the stock from Storage tower to Paper Machine area.
This transfer flow is adjustable through flow controller FIC15060.

Tower extracted pulp consistency is controlled by NRC15045 and adjusted with


addition of PM Filtrates.
Most part of this dilution flow is directed (via control valve QCV-15050) to Tower
14CPA04 bottom diluting zone in order to reduce consistency to around approx.
5%.
Remaining dilution water flow is directed (via control valve NCV-15045) to suction
of pump 14PPC06 where consistency reaches more finely 4-4,5%.
Controller QC15050 operates as a proportional ratio in order to adjust associated
valves (QCV-15050 and NCV-15045) opening values and then the sharing of
total dilution flows (usually 70% of total flow through valve QCV-15050 and 30%
through NCV-15045).

Extraction pump 14PPC06 outlet pressure is controlled via PIC15055 and


adjusted with control valve PCV-15055 or On/Off valve AV-15080 on 2 parallel
recirculation pipes back to Storage tower bottom.
- The smallest diameter valve PCV-15055 will be enabled with controller
PIC15055 during normal operation (when pressure recirculation flow is
limited).
- The biggest diameter On/Off valve AV-15080 will be used during transitory
phases (like start-up) requiring a bigger pressure recirculation (even a total
recirculation).

During start-up, the recirculation at the bottom of the tower is turned on in order
to reach an appropriate consistency before transfer to Paper Machine:
 On/Off valve AV-15080 opens.
 Control valve FCV-15060 on transfer pipe is forced closed.

WASHING & FINAL STORAGE


Page 238/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

When desired consistency is obtained; and stabilized, the full recirculation is shut
down:
 On/Off valve AV-15080 closes
 Pump 14PPC06 outlet pressure is controlled by PIC15055 in AUTO
mode and through control valve PCV-15055.
 Pulp is sent downstream.

Brightness of extracted pulp from Tower 14CPA04 is measured by transmitter


AIR15065 and displayed/recorded.

PH of extracted pulp from Tower 14CPA04 is measured by transmitter AIR15070


and displayed/recorded.

WASHING & FINAL STORAGE


Page 239/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

15.2 BASIC OPERATING CAPACITY

Washer: 2 x DNT200

For 2 DNT 200:


 Inlet flow: 1200 m3/h maximum

 Accept capacity if feed at 3%: 330 BDT/24h maximum


300 BDT/24h optimum

WASHING & FINAL STORAGE


Page 240/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

15.3 TRANSMITTERS AND CONTROL LOOPS

Alarms Scale-0-
Item Function Description 100%
LL L H HH Value unit
FIC 15095 Flow control of Washing by-pass pulp 0-350 m3/h

LIC 11070 Transfer chest 12CPA06 level control 5% 15% 85% 95% 0-40 m3
Consistency control of pulp transferred to
NIC 11075 0 to 5%
Washing area
FIC 12005 Flow control of Washing feed pulp 0-450 m3/h
Washing feed production indication
P3 12005 Software only
(Obtained from NT-11075 & FT-12005)
Washers feed pump 13PPC01 motor
SIC 12008 0-100%
speed Control

FIC 12015 Washer 13LAV02 inlet Flow control 0-800 m3/h


Washer 13LAV02 inlet pressure
PI 12020 0,5 1 0-2 Bars
indication
SIC 12031 Washer 13LAV02 motor speed Control 0-100%

XS 12025 Washer 13LAV02 oscillating doctor alarm


Washer 13LAV02 oscillating doctor ON
HS 12025
command
ZS 12030 Washer 13LAV02 wire position alarm
Washer 13LAV02 HP oscillating shower
XS 12050
alarm
Washer 13LAV02 HP oscillating shower
HS 12050
ON command
Washer 13LAV02 extraction screw
SSL 12055 *
rotation alarm Speed switch
Washer 13LAV02 Breast Roll Rotation
SSL 12060 *
alarm Speed switch
WS 12065 Washer 13LAV02 wire tension alarm

…/…

WASHING & FINAL STORAGE


Page 241/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Alarms Scale-0-
Item Function Description 100%
LL L H HH Value unit
FIC 12076 Washer 13LAV03 inlet Flow control 0-800 m3/h
Washer 13LAV03 inlet pressure
PI 12080 0,5 1 0-2 Bars
indication
SIC 12091 Washer 13LAV03 motor speed Control 0-100%

XS 12085 Washer 13LAV03 oscillating doctor alarm


Washer 13LAV03 oscillating doctor ON
HS 12095
command
ZS 12090 Washer 13LAV03 wire position alarm
Washer 13LAV03 HP oscillating shower
XS 12110
alarm
Washer 13LAV03 HP oscillating shower
HS 12110
ON command
Washer 13LAV03 extraction screw
SSL 12115 *
rotation alarm Speed switch
Washer 13LAV03 Breast Roll Rotation
SSL 12120 *
alarm Speed switch
WS 12125 Washer 13LAV03 wire tension alarm

MC Pump Stand Pipe 14CE10 level


LICS 15090 5% 15% 85% 95% 0-100%
control
SIC 15075 MC Pump 14PMC10 motor speed control 0-100%

LIS 15040 Storage tower 14CPA04 level control 5% 15% 85% 95% 0-600 m³

Storage tower 14CPA04 extracted pulp


NRC 15045 0 to 5%
consistency control
Ratio repartition for Storage tower
QC 15050 0-100%
14CPA04 pulp dilution water flow
Storage tower 14CPA04 extracted pulp
PIC 15055 0–4 Bars
pressure control
Flow control of pulp sent to Paper
FIC 15060 0-400 m3/h
Machine
Brightness indication of pulp sent to
AIR 15065
Paper Machine
PH indication of pulp sent to Paper
AIR 15070
Machine

WASHING & FINAL STORAGE


Page 242/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

15.4 INTERLOCKINGS AND ALARMS

15.4.1 Transfer chest 12CPA06

247- TRANSFER CHEST LEVEL LIC11070 TO AGITATOR 12AG07

If Transfer chest level LIC11070 is Low-Low


Then Stop Agitator 12AG07

If Transfer chest level LIC11070 is Low


Then Inhibit Start Agitator 12AG07

If Transfer chest level LIC11070 is not Low


And Agitator 12AG07 in DCS Auto mode

Then Start Agitator 12AG07

248- INTERLOCKS TO TRANSFER PUMP 12PPC08

If Transfer chest 12CPA06 level LIC11070 is Low


Or Washers feed pump 13PPC01 is not running
Or Loop 3 dilution pump 13PPC09 is not running

Then Transfer pump 12PPC08 is stopped.

If Transfer chest 12CPA06 level LIC11070 is Low

Then Inhibit start of Transfer pump 12PPC08

249- INTERLOCKS FROM TRANSFER PUMP 12PPC08 TO CONTROL


VALVE FCV-12005 ON DELIVERY PIPE

If Transfer pump 12PPC08 is not running


Then Control valve FCV-12005 is forced closed

If Transfer pump 12PPC08 is running


Then With on delay T=5s, Control valve FCV-12005 in Auto opens

WASHING & FINAL STORAGE


Page 243/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

250- INTERLOCKS TO DILUTION CONTROLLER NIC11075

If Transfer pump 12PPC08 is not running


Or Loop 3 dilution pump 13PPC09 is not running

Then Dilution controller NIC11075 is disabled with control valve NCV-11075

251- (RESERVE)

15.4.2 Washers feed pump 13PPC01

252- INTERLOCKS to WASHERS FEED PUMP 13PPC01

If Loop 3 water tank 13CE08 level controller LIS13005 is low


If DNT 13LAV02 Ready Status AND DNT 13LAV03 Ready Status NOT
READY, with On-delay T=15s

Then Washers feed pump 13PPC01 is stopped.

253- FEED PUMP 13PPC01 to DNT WASHERS INLET FLOW


CONTROLLERS

If Washers feed pump 13PPC01 is not running


Then DNT inlet control valves FCV-12015 and FCV-12076 are forced closed.

If Washers feed pump 13PPC01 is running


Then With on delay T=5s, DNT inlet control valves FCV-12015 and FCV-
12076 in Auto are opened.

254- FEED PUMP 13PPC01 to STOCK FEED FLOW CONTROLLER

If Washers feed pump 13PPC01 is not running

Then Stock feed flow control valve FCV-12005 is forced closed.

255- (RESERVE)

WASHING & FINAL STORAGE


Page 244/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

15.4.3 Washer 13LAV02

256- INTERLOCKS TO WASHER 13LAV02

If Water pump 13PPC05 for MP shower is stopped


Or Water pump 13PPC06 for HP shower is stopped
Or Tensioning wire WS12065 is not correct

Then Washer 13LAV02 is stopped.

257- MC PUMP 14PMC11 INTERLOCKS TO WASHER 13LAV02 OUTLET


SCREW

If MC pump 14PMC11 stand pipe level LICS15090 is High-High

Then Washer 13LAV02 Repulping Screw is stopped.

258- DNT WASHER 13LAV02 READY STATUS

DNT WASHER 13LAV02 Status READY allows feeding pulp to the Washer,
Status NOT READY forbids feeding pulp to the Washer.

If MC pump 14PMC11 stand pipe level LICS15090 is Not High-High


And Storage tower 14CPA04 level LIS15040 is not High-High
And DNT drive 13LAV02 is running with T=15s On-delay
And DNT extraction screw is running
And HP Shower oscillation XS12050 is NOT alarm no-oscillation
And Oscillating Shower HS12050 is ON
And Doctor oscillation XS12025 is NOT alarm no-oscillation
And Doctor oscillator HS12025 is ON
And Water pump 13PPC05 for MP shower is running
And Water pump 13PPC06 for HP shower is running

Then WASHER STATUS is set to READY

WASHING & FINAL STORAGE


Page 245/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

If MC pump 14PMC11 stand pipe level LICS15090 is High-High for T=15s


Or Storage tower 14CPA04 level LIS15040 is High-High for T=15s
Or DNT drive 13LAV02 is not running
Or DNT extraction screw is not running
Or HP Shower oscillation XS12050 is alarm no-oscillation with T=120s Off-
delay
Or Oscillating Shower HS12050 is Off with T=120s off-delay
Or Doctor oscillation XS12025 is alarm no-oscillation with T=120s Off-delay
Or Doctor oscillator HS12025 is OFF with T=120s off-delay
Or Water pump 13PPC05 for MP shower is stopped
Or Water pump 13PPC06 for HP shower is stopped

Then WASHER STATUS is set to Not READY

Notes:
- MP shower system does not interlock WASHER STATUS, only step for
group-start (Wire wetting);

259- WASHER SECURITY INTERLOCKS: WIRE TENSION & POSITION

If Washer 13LAV02 Wire Tension WS12065 is Alarm

Then Washer 13LAV02 Main drive is stopped

If Washer 13LAV02 Wire Position ZS12030 is Alarm

Then Washer 13LAV02 Main drive is stopped


And Washer outlet screw is stopped

260- WASHER SECURITY INTERLOCKS: SPEED SWITCHES

If Washer 13LAV02 Main drive is running with start-up override T=5 s


And Breast roll speed switch SSL12060 is alarm

Then Washer 13LAV02 Main drive is stopped

If Washer 13LAV02 outlet screw is running with start-up override T=5 s


And Washer screw speed switch SSL12055 is alarm

Then Washer 13LAV02 outlet screw is stopped

WASHING & FINAL STORAGE


Page 246/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

261- WASHER 13LAV02 HP SHOWER INTERLOCKS

If HP Shower oscillator HS12050 is OFF


Or HP Shower oscillation XS12050 signal is OK

Then HP Shower oscillation monitor XS12050 is set to OK.

If HP Shower oscillator HS12050 is ON with T1=5s on-delay


And HP Shower oscillation XS12050 signal is Zero with T1=5s on-delay

Then HP Shower oscillation monitor XS12050 is reset to Alarm

If DNT MP Shower pump 13PPC05 is not running with T=5s On-delay


Then MP Shower AV-12035 is forced Closed (Hard interlock)

If DNT HP Shower pump 13PPC06 is not running with T=5s On-delay


Or DNT washer 13LAV02 main drive is not running
Or XS12050 is Alarm no oscillation with T2=15s off-delay

Then HP Shower AV-12045 is forced Closed (Hard interlock)

Note: Oscillation alarm is overridden T1=5s after start of oscillation, and interlock
to shower valve is active only after T2=15s of alarm.

262- WASHER 13LAV02 DOCTOR OSCILLATION

If Doctor oscillator HS12025 is OFF


Or Doctor oscillation XS12025 signal is OK

Then Doctor oscillation monitor XS12025 is set to OK.

If Doctor oscillator HS12025 is ON with T1=5s on-delay


And Doctor oscillation XS12025 signal is Zero with T1=10s on-delay

Then Doctor oscillation XS12025 is reset to Alarm

263- (RESERVE)

15.4.4 Washer 13LAV03

WASHING & FINAL STORAGE


Page 247/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

264- INTERLOCKS TO WASHER 13LAV03

If Water pump 13PPC05 for MP shower is stopped


Or Water pump 13PPC06 for HP shower is stopped
Or Tensioning wire WS12125 is not correct

Then Washer 13LAV03 is stopped.

265- MC PUMP 14PMC11 INTERLOCKS TO WASHER 13LAV03 OUTLET


SCREW

If MC pump 14PMC11 stand pipe level LICS15090 is High-High

Then Washer 13LAV03 Repulping Screw is stopped.

266- DNT WASHER 13LAV03 READY STATUS

DNT WASHER 13LAV03 Status READY allows feeding pulp to the Washer,
Status NOT READY forbids feeding pulp to the Washer.

If MC pump 14PMC11 stand pipe level LICS15090 is Not High-High


And Storage tower 14CPA04 level LIS15040 is not High-High
And DNT drive 13LAV03 is running with T=15s On-delay
And DNT extraction screw is running
And HP Shower oscillation XS12110 is NOT alarm no-oscillation
And Oscillating Shower HS12110 is ON
And Doctor oscillation XS12085 is NOT alarm no-oscillation
And Doctor oscillator HS12085 is ON
And Water pump 13PPC05 for MP shower is running
And Water pump 13PPC06 for HP shower is running

Then WASHER STATUS is set to READY

If MC pump 14PMC11 stand pipe level LICS15090 is High-High for T=15s


Or Storage tower 14CPA04 level LIS15040 is High-High for T=15s
Or DNT drive 13LAV03 is not running
Or DNT extraction screw is not running
Or HP Shower oscillation XS12110 is alarm no-oscillation with T=120s Off-
delay
Or Oscillating Shower HS12110 is Off with T=120s off-delay
Or Doctor oscillation XS12085 is alarm no-oscillation with T=120s Off-delay
Or Doctor oscillator HS12085 is OFF with T=120s off-delay
Or Water pump 13PPC05 for MP shower is stopped
Or Water pump 13PPC06 for HP shower is stopped

Then WASHER STATUS is set to Not READY

WASHING & FINAL STORAGE


Page 248/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Notes:
- MP shower system does not interlock WASHER STATUS, only step for
group-start (Wire wetting);

267- WASHER SECURITY INTERLOCKS: WIRE TENSION & POSITION

If Washer 13LAV03 Wire Tension WS12125 is Alarm

Then Washer 13LAV03 Main drive is stopped

If Washer 13LAV03 Wire Position ZS12090 is Alarm

Then Washer 13LAV09 Main drive is stopped


And Washer outlet screw is stopped

268- WASHER SECURITY INTERLOCKS: SPEED SWITCHES

If Washer 13LAV03 Main drive is running with start-up override T=5 s


And Breast roll speed switch SSL12120 is alarm

Then Washer 13LAV03 Main drive is stopped (Hard Interlock)

If Washer 13LAV03 outlet screw is running with start-up override T=5 s


And Washer screw speed switch SSL12115 is alarm

Then Washer 13LAV03 outlet screw is stopped (Hard Interlock)

269- WASHER 13LAV03 HP SHOWER INTERLOCKS

If HP Shower oscillator HS12110 is OFF


Or HP Shower oscillation XS12110 signal is OK

Then HP Shower oscillation monitor HS12110 is set to OK.

If HP Shower oscillator HS12110 is ON with T1=5s on-delay


And HP Shower oscillation XS12110 signal is Zero with T1=5s on-delay

Then HP Shower oscillation monitor XS12110 is reset to Alarm

WASHING & FINAL STORAGE


Page 249/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

If DNT MP Shower pump 13PPC05 is not running with T=5s On-delay


Then MP Shower AV-12095 is forced Closed (Hard interlock)

If DNT HP Shower pump 13PPC06 is not running with T=5s On-delay


Or DNT washer 13LAV03 main drive is not running
Or XS12110 is Alarm no oscillation with T2=15s off-delay

Then HP Shower AV-12105 is forced Closed (Hard interlock)

Note: Oscillation alarm is overridden T1=5s after start of oscillation, and interlock
to shower valve is active only after T2=15s of alarm.

270- WASHER 13LAV03 DOCTOR OSCILLATION

If Doctor oscillator HS12085 is OFF


Or Doctor oscillation XS12085 signal is OK

Then Doctor oscillation monitor XS12085 is set to OK.

If Doctor oscillator HS12085 is ON with T1=5s on-delay


And Doctor oscillation XS12085 signal is Zero with T1=10s on-delay

Then Doctor oscillation XS12085 is reset to Alarm

271- (RESERVE)

15.4.5 Common to both Washers

272- INTERLOCK TO MP SHOWER PUMP 13PPC05

If Loop 3 dilution water pump 13PPC09 is not running

Then Stop MP Shower Pump 13PPC05

273- INTERLOCK TO HP SHOWER PUMP 13PPC06

If FRESH WATER not available (interlock to be defined)

Then Stop HP Shower Pump 13PPC06

WASHING & FINAL STORAGE


Page 250/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

274- (RESERVE)

275- (RESERVE)

15.4.6 Transfer MC pump 14PMC11

276- INTERLOCKS TO MC PUMP 14PMC11

If Storage Tower 14CPA04 level LIS15040 is alarm High-High for T=5s


Or MC pump Stand Pipe level LICS15090 is Low-Low for 30s

Then MC Pump 14PMC11 is stopped

277- MC PUMP 14PMC11 INTERLOCKS TO CONTROLS & VALVES

If MC Pump 14PMC11 is not running

Then Level controller LICS15090 is disabled


And Control valve LCV-15090 if in Auto is closed
And Slave On/Off valve AV-15100 is forced closed

If MC Pump 14PMC11 is running (On delay T=20s)

Then Level controller LICS15090 is enabled to speed controller


SIC5068
And Output to valve LCV-15090 is enabled
And Slave On/Off valve AV-15100 opens

278- PM WATER INTERLOCK TO MC PUMP WATER CONTROL VALVES

If PM WATER network not under pressure (interlock to be defined)


Then Control valve LCV-15090 is forced closed.

If PM WATER network not under pressure (interlock to be defined)


And MC Pump 14PMC11 is running

Then Alarm dilution to MC Pump is generated.

WASHING & FINAL STORAGE


Page 251/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

279- (RESERVE)

WASHING & FINAL STORAGE


Page 252/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

15.4.7 Storage tower 14CPA04

280- STORAGE TOWER LEVEL LIS15040 TO AGITATOR 14AG05

If Storage tower 14CPA04 level LIS15040 is Low


Then Stop Agitator 14AG05

If Storage tower 14CPA04 level LIS15040 is Low


Then Inhibit Start Agitator 14AG05

If Storage tower 14CPA04 level LIS15040 is not Low


And Agitator 14AG05 is DCS Auto mode

Then Start Agitator 14AG05

281- LEVEL LIS15040 HIGH_HIGH INTERLOCK TO DILUTION VALVES

If Storage tower 14CPA04 level LIS15040 is High-High

Then Controllers QC15050 and NRC15045 are disabled with control valves
QCV-15050 and NCV-15045 forced closed

Note: this interlock is designed to prevent adding dilution filtrates to a full tower.

282- INTERLOCKS TO TOWER EXTRACTION PUMP 14PPC06

If Storage tower 14CPA04 level LIS15040 is Low


Or Agitator 14AG05 is stopped

Then Pump 14PPC06 is stopped.

If Storage tower 14CPA04 level LIS15040 is Low


Then Inhibit start of pump 14PPC06.

(This interlock prevents tripping the pump motor on start-up by extracting pulp
that is not properly agitated & homogenized in the bottom of the Tower).

283- TOWER EXTRACTION PUMP 14PPC06 TO REGULATIONS ON


DELIVERY PIPES

If Tower extraction pump 14PPC06 is not running

Then Control valve FCV-15060 on delivery line is forced closed.

WASHING & FINAL STORAGE


Page 253/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

284- INTERLOCKS TO CONSISTENCY CONTROLS NRC15045 & QC15050

If Tower extraction pump 14PPC06 is not running


Or PM WATER network not under pressure (interlock to be defined)

Then Controllers QC15050 and NRC15045 are disabled with control valves
QCV-15050 and NCV-15045 forced closed

285- INTERLOCKS TO TOWER EXTRACTION PRESSURE CONTROL PIC15055

If Tower extraction pump 14PPC06 is not running

Then Controller PIC15055 is disabled with control valve PCV-15055 and


On/Off valve AV-15080 forced closed.

286- (RESERVE)

ALARMS

287- SEALING WATER

If Washing area is in operation


And Main line Sealing water flow is on Alarm FSA20135 Low for T=30 s

Then Active the ALARM

288- COMPRESSED AIR

If Washing area is in operation


And Compressed Air pressure PIA19202 is on Alarm Low

Then Active the ALARM

289- STORAGE TOWER 14CPA04 LEVEL LIS15040

If Storage tower 14CPA04 level LIS15040 is High

Then Active the ALARM

290- (RESERVE)

WASHING & FINAL STORAGE


Page 254/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

15.5 OPERATION

15.5.1 Start-up

This loop begins only if the loop “LOOP 3 WATER CLARIFICATION AND
DISTRIBUTION" is running.

15.5.1.1 Start of the loop

Basic conditions:
- Sealing water main line is under pressure and Flow switch FSA20135 is not
alarm Low
- Compressed air system is under pressure (pressure PIA19202 not on Alarm
Low)
- “PM water” network is under pressure
- “Fresh water” network is under pressure
- Continuous water pump 05PPC07 must be running
- Level control LIC13010 of filtrate tank 13CE07 must be not High
- Level control LIC13005 of dilution tank 13CE08 must be not Low
- Level control LIS15040 of Storage Tower 14CPA04 must be not High AND
not Low-Low
- For washer 13LAV02: Wire tension WS12065 is not alarm and Wire Position
ZS12030 is not alarm
- For washer 13LAV03: Wire tension WS12125 is not alarm and Wire Position
ZS12090 is not alarm

Note: If Storage Tower 14CPA04 level is Low, operator needs to pre-fill the
Tower with PM Water filtrates.

Start loop 3 dilution pump 13PPC09 if not already running.

WASHER 13LAV02

Start of Washer outlet screw motor.

Start Washer 13LAV02 main drive motor.

Start Washer 13LAV02 Doctor oscillation (by HS12025).

Start of water system for DNT showers:


 Start of MP shower water pump 13PPC05 (if not already started by
13LAV03)
 After T=5s, open MP shower On/Off valve AV-12035
 Start HP oscillator HS12050
 When HP oscillation XS12050 is OK, start of HP shower water pump
13PPC06 (if not already started by 13LAV03) and open HP shower
On/Off valve AV-12045

WASHING & FINAL STORAGE


Page 255/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

WASHER 13LAV03

Start of Washer outlet screw motor.

Start Washer 13LAV03 main drive motor.

Start Washer 13LAV03 Doctor oscillation (by HS12085).

Start of water system for DNT showers:


 Start of MP shower water pump 13PPC05 (if not already started by
13LAV02)
 After T=5s, open MP shower On/Off valve AV-12095
 Start HP oscillator HS12110
 When HP oscillation XS12110 is OK, start of HP shower water pump
13PPC06 (if not already started by 13LAV02) and open HP shower
On/Off valve AV-12105

15.5.1.2 Production

The washing area starts with start of transfer pump 12PPC08 and opening of
control valve FCV-12005 on transfer pipe from chest 12CPA06.

Transfer chest 12CPA06 should have been first filled with pulp from Tower
12CPA03 extraction pump 12PPC05 (and/or with pulp transferred from parallel
VOITH deinking line).
Through interlocks associated agitator 12AG07, pump 12PPC08 and consistency
regulation NIC11075 will be enabled to start as soon as chest level LIC11070
reaches a sufficient level.

On the other hand, if a part (even the totality) of production by-passes washing
area, pump 12PPC05 transfers pulp directly to storage tower 14CPA04 (to be
already filled with filtrates or pulp).

Stock feed can proceed to Washers when the DNT Washers are Ready: DNT
running with MP & HP showers, screw conveyor, and downstream systems.

NB: The process block can run few minutes in water mode.

Transfer MC-Pump 14PMC11 to be started when washers are fed with pulp.
All items of sub-system - in Auto mode - start according to interlocks defined
above:
- Dilution to Stand-pipe opens by interlock on MC Pump start-order
- Controller LICS15090 & SIC15075 are enabled when MC-Pump is running;

WASHING & FINAL STORAGE


Page 256/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

15.5.2 Operation

The different steps run off automatically.

 Monitoring of pressurized water pressures.


 Monitoring of consistencies (Water and stock).
 Monitoring of safety device (wire position, oscillation, speed switch, …)
 Checking of Storage Tower level 14CPA04 (one of the main
parameters in the line).

15.5.3 Shutdown

15.5.3.1 Stop of production

The process bloc stops in production with stop of transfer pump 12PPC08 and
closing of control valve FCV-12005 on transfer pipe from chest 12CPA06.

Then chest 12CPA06 feed pump 12PPC05 can be stopped (if no more required
for washing by-pass, Flow controller FIC15095 set point to 0).
Eventual pulp transfer from parallel VOITH deinking pulp is also stopped.

15.5.3.2 Stop of the loop

Reset DNT Washers status to Not READY. With Interlocks, feed pump 13PPC01
stops.

Planned stop of Washer will lead operator to first stop pulp feed closing of
control valve FCV-12005 (on transfer pipe from chest 12CPA06) and run
Washing area on Filtrates through the Washer to flush the pulp out of the system
for 5 minutes.

Note: For a planned shut superior to 2 hours, it is recommended to pay a special


attention to the cleaning time to avoid blocking the wire with dried fiber or
chemical deposits in relation with an insufficient cleaning of the wire on shut-
down.

If necessary, flush DNT inlet head boxes with opening of On-Off valves AV-
12013 for 13LAV02 & AV-12075 for 13LAV03.

If necessary, clean DNT outlet screw with opening of On-Off valves AV-12035 for
13LAV02 & AV-12095 for 13LAV03.

WASHING & FINAL STORAGE


Page 257/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

WASHER 13LAV02 STOP

Stop of water system for DNT showers:


 Close HP shower On/Off valve AV-12045
 Stop HP oscillator (with HS12050) and Stop of Washer 13LAV02
oscillating doctor (with HS12025).
 Close MP shower On/Off valve AV-12035
 Stop of showers water pumps 13PPC05 and 13PPC06 (if no more used
by 13LAV03).

Stop of Washer 13LAV02 main drive motor.

Stop of Washer outlet screw 13LAV02 motor.

WASHER 13LAV03 STOP

Stop of water system for DNT showers:


 Close HP shower On/Off valve AV-12105
 Stop HP oscillator (with HS12110) and Stop of Washer 13LAV02
oscillating doctor (with HS12085).
 Close MP shower On/Off valve AV-12095
 Stop of showers water pumps 13PPC05 and 13PPC06 (if no more used
by 13LAV02).

Stop of Washer 13LAV03 main drive motor.

Stop of Washer outlet screw 13LAV03 motor.

Transfer pump 14PMC11 is stopped through interlocks when no more pulp


comes from DNT Washers.

Note: Tower extraction pump 14PPC06 is stopped when no more pulp is required
for Paper Machine. This action is independent from upstream process stop
sequence.

WASHING & FINAL STORAGE


Page 258/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

PROCESS DESCRIPTION

KHANNA
NEW DIP LINE 300 BDMT/24h
PRINTING - WRITING

LOOP 3 WATER DISTRIBUTION


& MICRO-FLOTATION

LOOP 3 WATER DISTRIBUTION & MICRO-FLOTATION


Page 259/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

16 LOOP 3 WATER DISTRIBUTION & MICRO-FLOTATION

16.1 DESCRIPTION

16.1.1 Itemization

 Micro-flotation feed tank..........................................................................................


13CE07
 Microflotator feed pump..........................................................................................
13PPC10
 Filtrate transfer pump to Voith line..........................................................................
13PPC19
 Clarified water tank ..............................................................................13CE08
 Loop 3 water dilution pump.....................................................................................
13PPC09
 Loop 3 water transfer pump to Loop 2....................................................................
13PPC11
 Loop 2 dispersion dilution pump.............................................................................
13PPC18

 Microflotator ............................................................................13POS12
 Microflotation circulation pump................................................................................
13PPC13
 Sludge chest ............................................................................13CPA14
 Sludge chest agitator ..............................................................................13AG15
 Sludge chest extraction pump.................................................................................
13PPC16

LOOP 3 WATER DISTRIBUTION & MICRO-FLOTATION


Page 260/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

16.1.2 Microflotator PPM basics

16.1.2.1 Microflotator PPM Description

The Poseidon PPM Dissolved Air Flotator (DAF) is an open top separator
designed to clarify filtrates by removing suspended solids with dissolved air
generated micro-bubbles.

Poseidon PPM System Equipment

The Poseidon PPM consists of:

- A stainless steel parallelepedic-shaped tank, with nozzles as follows:


Inlet nozzle with mixing chamber, with
Flocculent injection nozzles;
Connection from pressurization system;
Clarified filtrates accept nozzle;
Filling nozzle;
Connection to Poseipump & pressurization system,
Top surface sludge discharge connection;
Settled sludge discharge front (Purge);
Settled sludge discharge bottom (Purge).

- An internal POSEIPACK assembly of plates, designed to intercept low


buoyancy particles and promote flock build-up;

- A mechanical Sludge Thickener on top of the unit with gear drive & finger
paddles.

- A mechanical sludge layer discharge scraper, pushing the sludge layer into
the discharge trough, with mechanically adjustable speed;

- Pressurization POSEIPUMP, with local pressurization control panel,


pressurization pipe and pressure relief valve.

16.1.2.2 Microflotator PPM operation

The adequate flocculation chemistry is added to the filtrate flow to be treated,


prior to introduction into the PPM unit.

The incoming filtrates are pumped to the unit's mixing chamber, where a
recirculating flow of dissolved air containing filtrates is mixed to the incoming
filtrates flow.

The dissolved air containing filtrate flow is obtained by recirculating of part of the
accepted filtrate flow of the unit through the pressurization & air introduction
system - with special POSEIPUMP and pressurization/air introduction control
panel.

The pressure release on the dissolved air containing filtrate flow generates micro-
bubbles, which form in and adhere to the suspended solids & flocks.

LOOP 3 WATER DISTRIBUTION & MICRO-FLOTATION


Page 261/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

At the inlet of the unit, heavy non-floatable particles settle to the bottom of the
unit in the sludge cone. A drainage pipe at the unit's lower point enable to remove
depositing heavy particles by periodic flushing.

The particles & flocks surrounded by micro-bubbles rise to the surface, and are
separated according to their buoyancy as follows:
 Big fast-rising particles rise directly to the unit's open surface,
 Small slow-rising particles are intercepted in the Poseipack collection
plates within the unit, where the plate design build-up flock size until
the increased buoyancy allows them to reach the unit's open surface.

The particles & flocks accumulating at the surface of the unit constitute the
sludge layer on the unit. A rotating scraper removes the thickened sludge to a
hopper.

Poseidon Operation

The operation of a PPM is typically set at constant & controlled hydraulic filtrates
feed flow rate.
However several sequences trim this continuous operation (see associated
Function Chart separately supplied).

The recirculating flow is adjusted on start-up to a set Poseipump delivery


pressure; the Air pressurization pressure & flow are set with the local panel
pressure reducer and flow-meter. The system operates in these fixed conditions.
A proper recirculation & aeration is controlled by observation of the flow obtained
at the discharge of manual vent valve from pressurization tube to the top of the
Poseidon unit (milky aspect).

Sludge discharge is by gravity. Sludge consistency is adjusted by the controlled


PPM unit level set point (lower level leads to higher sludge consistency).

Attention: It is required to have PPM vat with level above the plates BEFORE
FEEDING the unit, to avoid damage to the plates related to direct impact of
incoming water flow on the plates. The plate level is defined in interlocks as LOW
level VALUE.

It is forbidden to empty the PPM vat by either accept valve or Flushing valves
WARNING
with presence of thick sludge on the PPM unit surface. The weight of the Sludge
on the plates could lead to damage to the plates. The Sludge should FIRST be
removed from the unit by operating without feed for a while, or temporarily
increasing the level.

Special attention will be paid also to the possibility of leaking/passing valves,


which can lead to significant level decrease during a shut. Good practice is to
remove all sludge from system on each shut by increasing PPM500 unit
operating level prior to stopping PPM Feed pump. This operation may be
included in Group-stop.

LOOP 3 WATER DISTRIBUTION & MICRO-FLOTATION


Page 262/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

LOOP 3 WATER DISTRIBUTION & MICRO-FLOTATION


Page 263/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

16.1.3 Area description

16.1.3.1 Loop 3 Water distribution

Filtrate water tank 13CE07


Tank 13CE07 is used to feed:
 Microflotator feed pump 13PPC10 (See next paragraph describing
Microflotation sub-system)
 Pump 13PPC19 used to transfer Loop 3 filtrates to parallel “VOITH”
deinking line in case corresponding Microflotator is underused. (In that
case, same clarified water flow must be transferred back to Clarified
Water tank 13CE08).

Case 1: Microflotation processing Loop 3 filtrates


This tank receives all the filtrate water from DNT washer.

Tank level is monitored by controller LIC13010 acting on valve FCV-13015 on


Microflotator feed pump 13PPC10 delivery pipe.
Thanks to this regulation, Micro-flotation flow operating is the same than
Washers filtrates extraction flow.

Case 2: Microflotation processing Loop 2 filtrates


Washers are not in use and this tank receives filtrates transferred from Loop 2
with pump 1PPC10.

In this case Tank level is monitored by controller LIC13010 acting on valve LCV-
13010 on feed pump 10PPC10 delivery pipe.
Thanks to this regulation, tank 13CE07 calls for make-up the same flow as set to
Microflotator feed flow FIC13015.

Clarified water tank 13CE08


This tank receives:
 Clarified water accepted from Microflotator 13POS12.
 PM Clarified water make-up ensuring water complement to DIP line and
tank filling on start-up.
 Eventually clarified water from parallel “VOITH” deinking line if
simultaneously pump 13PPC19 transfers Loop 3 filtrates from tank
13CE07 to Microflotation in parallel “VOITH” deinking line.

The level is monitored by controller LIC13005 acting on valve LCV-13005 on


water complement pipe provided by PM Water filtrates.

Tank 13CE08 is used to feed:


 DNT washers feed pump 13PPC01
 Loop 3 water dilution pump 13PPC09
 Dispersing system dilution pump 13PPC18
 Water pump 13PPC11 used for transfer of clarified water to Loop 2
Clear Filtrate tank 10CE06 during start-up (tank filling) or in case Micro-
Flotation is fed with Loop 2 filtrates from pump 10PPC10.

LOOP 3 WATER DISTRIBUTION & MICRO-FLOTATION


Page 264/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

16.1.3.2 Micro-flotation

Microflotators 13POS12 is fed by pump 13PPC10 at a flow controlled by


Flowmeter FIC13015 (through an operator set-point or according to feed tank
level controller LIC13010).

PH of feed filtrates is measured by transmitter AIR13020 and displayed/recorded.

Filling the Poseidon unit is done by opening from DCS On/Off valve AV-14050 on
Fresh Water header.
The filling water inlet is positioned between Accept valve & Poseidon vat; Filling
water enters the Poseidon vat from the accept side, under the Poseidon plates.

Chemicals are added to help the work of Microflotator. (Chemicals flow should be
adjusted in proportion with Micro-Flotation filtrate feed flow, continuously
measured by FIC13015):
 Coagulant connected to suction of Microflotator feed pump 13PPC10.
 Flocculent in the pipeline feeding Microflotator (through several pipes
equipped with manual valves to be adjusted on start-up according to
Micro-Flotation required efficiency).

Microflotation circulation pump 13PPC13 is recycling to Microflotator inlet a small


part of clarified white water mixed with compressed air.
Recirculation water pressure is continuously measured by PIS14025 and is
adjusted on start-up by manual setting of the Pressure relief valve at the end of
the pressurization tube.

The Air injected into the recirculated flow can be checked in the local panel with
the Air rotameter, and is adjusted in flow by intervention in the panel on the Air
adjustment valve.

Opening in the field of manual valve on Vent line from pressurization tube to
Poseidon vat allows to check the proper air content of the Pressurized filtrate
recirculated flow. This manual vent valve should remain slightly open to avoid
accumulation of air in the pressurization tube.

Accept clarified water from each Microflotator flow to clarified tank 13CE08.
The level into Microflotator is kept constant with level controller LICS14045 and
associated control valve LCV-14045 connected on clarified water outlet pipe.

The Level in the Poseidon vat is used together with Sludge Scraper speed to
adjust the thickness of the sludge mat on the top of the unit: lower operating level
& lower operating speed gives thick mat, and gives higher consistency. The limit
is appropriate discharge of the sludge mat.

A temporary increase in level can be used to remove all sludge from the
Poseidon unit's surface, either by opening Filling valve or by setting accept valve
to manual.

Heavy sludge settling in each Microflotator is periodically removed from the vat
bottom via On/Off valves AV-14030, AV-14035 and AV-14040.

LOOP 3 WATER DISTRIBUTION & MICRO-FLOTATION


Page 265/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

Foam is continuously removed from the surface of Microflotator by a scrapping


system.

Microflotation sludge

Sludge is collected in sludge chest 13CPA14 equipped with a vertical agitator


13AG15.

Extraction pump 13PPC16 is equipped with a variable speed motor controller


SC14060 in order to adapt delivery flow to sludge chest 13CPA14 level
LICS14060.

Using a Prime MAC concept in Loop 1 Deinking line gives the opportunity to re-
introduce a part (even the totality) of micro-flotation sludge, in order to reduce
fiber losses and increase plant yield.

This re-introduction flow is adjustable through Flowmeter FIC14065 on transfer


pipe to Foam tank 03CPA08, from which recirculated sludge is pump by
03PPV10 to prime Mac 03CEV02a feed pump suction.

Remaining sludge flow (subtraction of recirculation flow FIC14065 from pump


13PPC16 delivery flow) is sent to sludge treatment and controlled by pressure
controller PIC14070 with control valve PCV-14070 (giving a necessary counter
pressure drop for Flow control FIC14064 proper operation).

Operator checking is required to monitor sludge chest level LIC14060, and to


modify if necessary recirculation flow FIC14065 set point.
This will avoid setting a recirculation flow higher than sludge flow extracted from
Microflotator.

LOOP 3 WATER DISTRIBUTION & MICRO-FLOTATION


Page 266/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

16.2 BASIC OPERATING CAPACITY

Microflotator: 1 x PPM750
Inlet design flow 750 m3/h at consistency 0,3%.

16.3 TRANSMITTERS AND CONTROL LOOPS

Alarms Scale-0-
Item Function Description 100%
LL L H HH Value unit
Clarified water tank 13CE08 level
LIC 13005 10% 15% 80% 90% 0-100 m3
control
LIC 13010 Filtrate tank 13CE07 level control 10% 15% 80% 90% 0-100 m3
Microflotator 13POS12 feed flow
FIC 13015 0-800 m3/h
control
PH indication of Microflotation feed
AIR 13020 5 to 11
filtrate
Poseipump control panel air feed From local
PSL 14005 L
pressure panel
Poseipump 13PPC13 delivery pressure
PIS 14025 5,8 0-10 bars
control
Poseipump 13PPC13 sealing water
FSA 20180 L Digital alarm
Low flow alarm
LICS 14045 Microflotator 13POS12 level control 50% 98% 100% 0-100% level

LICS 14060 Sludge chest 13CPA14 level control 10% 15% 80% 90% 0-10 m3
Sludge pump 13PPC16 motor speed
SC 14060 0-100%
control
Flow control of Microflotation sludge
FIC 14065 0-80 m3/h
transferred to Prime MAC
Pressure control of Microflotation
FIC 14070 0–4 Bars
sludge transferred to treatment

LOOP 3 WATER DISTRIBUTION & MICRO-FLOTATION


Page 267/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

16.4 INTERLOCKINGS AND ALARMS

291- INTERLOCKS TO LOOP 3 WATER DILUTION PUMP 13PPC09

If Clarified water tank 13CE08 level LIC13005 is Low-Low


Then Loop 3 water dilution pump 13PPC09 is stopped.

If Clarified water tank 13CE08 level LIC13005 is Low


Then Inhibit start of Loop 3 water dilution pump 13PPC09

292- INTERLOCKS TO DISPERSION DILUTION PUMP 13PPC18

If Clarified water tank 13CE08 level LIC13005 is Low-Low


Then Dispersion dilution pump 13PPC18 is stopped.

If Clarified water tank 13CE08 level LIC13005 is Low


Then Inhibit start of Dispersion dilution pump 13PPC18.

293- DISPERSION DILUTION PUMP 13PPC18 TO SLAVE VALVE AV-


13025

If Dispersion dilution pump 13PPC18 is not running


Then On/Off slave valve AV-13025 is forced closed

If Dispersion dilution pump 13PPC18 is running


Then With On-Delay T=5s, Open slave valve AV-13025 (air exhaust limit
to open 15s)

294- INTERLOCKS TO TRANSFER PUMP 13PPC11 TO LOOP 2

If Clarified water tank 13CE08 level LIC13005 is Low-Low


Then Transfer pump 13PPC11 is stopped.

If Clarified water tank 13CE08 level LIC13005 is Low


Then Inhibit start of Transfer pump 13PPC11.

295- INTERLOCKS TO TANK 13CE07 FEED PUMP 10PPC10

While Micro-flotation is fed with Loop 2 filtrates


If Filtrate tank 13CE07 level LIC13010 is High-High

Then Feed pump 10PPC10 is stopped.


And Control valve LCV-13010 is forced closed

LOOP 3 WATER DISTRIBUTION & MICRO-FLOTATION


Page 268/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

296- INTERLOCKS TO FILTRATES TRANSFER PUMP 13PPC19

If Filtrate tank 13CE07 level LIC13010 is Low-Low


Then Transfer pump 13PPC19 is stopped.

If Filtrate tank 13CE07 level LIC13010 is Low


Then Inhibit start of Transfer pump 13PPC19.

297- FILTRATE TANK 13CE07 LEVEL TO MICRO-FLOTATION FEED


PUMP 13PPC10

If Filtrate tank 13CE07 level LIC13010 is Low-Low


Then Micro-flotation feed pump 13PPC10 is stopped.

If Filtrate tank 13CE07 level LIC13010 is Low


Then Inhibit start of Micro-flotation feed pump 13PPC10.

298- INTERLOCKS FROM MICRO-FLOTATION FEED PUMP 13PPC10

If Micro-flotation feed pump 13PPC10 is not running

Then Control valve FCV-13015 (on delivery pipe) is forced closed


And Microflotator 13POS12 level LICS14045 is disabled with valve LCV-
14045 forced closed.

If Micro-flotation feed pump 13PPC10 is running


Then With on delay T=5s, Control valve FCV-13015 (on delivery pipe) in Auto
is opened

299- INTERLOCKS TO DOSAGE OF COAGULANT & FLOCCULENT

If Poseidon Feed pump 13PPC10 is not running


Or Poseipump 13PPC13 is not running
Or Microflotation feed flow FICA3015 is Low

Then Coagulant & Flocculent dosage to Microflotation is disabled

300- SLUDGE CHEST 13CPA14 LEVEL LICS14060 TO AGITATOR 13AG15

If Sludge chest level LICS14060 is Low-Low


Then Stop Agitator 13AG15

LOOP 3 WATER DISTRIBUTION & MICRO-FLOTATION


Page 269/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

If Sludge chest level LICS14060 is Low


Then Inhibit Start Agitator 13AG15

301- SLUDGE CHEST 13CPA14 LEVEL LICS14060 to EXTRACTION PUMP


13PPC16

If Sludge chest 13CPA14 level LICS14060 is Low


Then Stop sludge pump 13PPC16

302- SLUDGE PUMP 13PPC16 to REGULATIONS ON DELIVERY PIPE

If Sludge transfer pump 13PPC16 is not running

Then Outlet pressure controller PIC14070 is disabled with valve PCV-14070


forced closed.
And Sludge recirculation flow controller FIC14065 is disabled with valve FCV-
14065 forced closed.

303- (RESERVE)

ALARMS

304- SEALING WATER

If Loop 3 water system area is in operation


And Main line Sealing water flow is on Alarm FSA20135 Low for T=30 s

Then Active the ALARM

305- COMPRESSED AIR

If Loop 3 water system area is in operation


And Compressed Air pressure PIA19202 is on Alarm Low

Then Active the ALARM

306- CLARIFIED WATER TANK 13CE08 LEVEL LIC13005 LOW

If Clarified water tank 13CE08 level LIC13005 is Low

Then Active the ALARM

LOOP 3 WATER DISTRIBUTION & MICRO-FLOTATION


Page 270/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

307- POSEIPUMP 13PPC13 SEALING WATER ALARM

If Poseipump 13PPC13 is running


And Sealing water flow FSA20180 is on Alarm Low

Then Set Poseipump 13PPC13 sealing water alarm

308- (RESERVE)

LOOP 3 WATER DISTRIBUTION & MICRO-FLOTATION


Page 271/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

16.5 OPERATION

16.5.1 Start-up

Basic conditions:
- Fresh water pump (external of the deinking line) must be running.
- PM water pump (external of the deinking line) must be running.
- Sealing water main line is under pressure and Flow switch FSA20135 is not
alarm Low
- Compressed air system is under pressure (pressure PIA19202 not on Alarm
Low).
- Micro-flotation Chemicals ready

Starting up Loop 3 white water clarification and distribution begins with the filling
phase of the tanks and units.

16.5.1.1 Water tanks filling

If water tanks are empty (for example on first start-up), open the filling water
valve LCV-13005 from PM WATER header to fill Clarified water tank 13CE08.

16.5.1.2 Start up the Microflotator

Refer to associate Function Chart separately supplied by Kadant.

16.5.1.3 Production

As soon as water tank levels are up to Low level, connected water pumps can
start if required by the sub-systems.

Through interlocks, Micro-flotation area starts once filtrate come from DNT
washer (or when Loop 2 filtrates are transferred with pump 10PPC10 to tank
13CE07).

LOOP 3 WATER DISTRIBUTION & MICRO-FLOTATION


Page 272/273
PD0155 A 00 - JLB FIRST ISSUE
23/09/2004

16.5.2 Operation

To be monitored during the operation of the installation:


 Sludge and foam characteristics (no presence of fibers).
 Regularity of levels in Microflotators.
 Regularity of levels in water tanks.

16.5.3 Shutdown

In priority, refer to associated Function chart (supplied separately)

16.5.3.1 Micro-Flotation

Microflotation stops in production:


- With Loop 3 when no more filtrates come from DNT washer.
- Or when no more filtrates are transferred from pump 10PPC10 to tank
13CE07.

Increase the level in Poseidon to eliminate Sludge from Surface


- Force set-point for LICS14045 to 99%;
- Wait T=5 minutes;

Stop Feed to Poseidon


- Stop Poseidon feed pump 13PPC10
(Interlocks disable controllers FIC13015 & LICS14045, Coagulant &
Flocculent dosage)
- Wait for T=5 minutes, then proceed;

Close Air Injection (Close solenoid valve inside the pneumatic panel)

Stop Microflotation circulation pump 13PPC13.

Stop Microflotator sludge thickener & scraper drive.

16.5.3.2 Loop 3 water tanks

This stop sequence is the last one to be run on the Deinking line.

Each connected pump stops when no more required by depending sub-system.

LOOP 3 WATER DISTRIBUTION & MICRO-FLOTATION


Page 273/273