Yard +

Chipper
House

Pulp Mill

Stock
Preparati
on Area

Paper
machine

Finishing
+
Shipping
Area

Head box level and pressure control.

Level Control of Seal Pit Tank.
Differential Pressure of Kuster in Calendar Section.
Steam Pressure control in Pre- Dryer.
Steam Pressure Control in Post-Dryer through QCS
system.
Measurement of GSM, Moisture and ash in the paper
through Smart Gauge 3000.
Hydraulic Presses and Drum Reel Hydraulic System.
Measurement & control of Speed through Inductive
Proximity Sensor.
Photocell detector to detect Paper breakage.

Air from Air Receiver

LP

Head box
HP

LT

PT
Inlet Pulp

PV

4-20 mA

PCV

LI
C
SP

IP
Air Supply 1.4
kg/cm2

PI
C

Air Drain
0.2 To 1 kg/cm2

Fan
Pump
4-20 mA

IP- Current to Pressure

Converter
SP- Set Point
PV- Process Value
PCV- Pneumatic Control Valve

LIC- Level Indicating Controller

VFD- Variable Frequency Drive
LT- Level Transmitter
PT- Pressure Transmitter

VFD

White Water
Inlet
PCV- Pneumatic Control
Valve

LIC- Level Indicating

Controller

IP- Current to Pressure

Converter

LT- Level transmitter

Tank
LT
P
V
Pump
0.2 To 1
kg/cm2
PC
V
OUTLET to Back
Water Silo

4-20 m
A
LI
C

IP

S
P
4-20 m
A
Air
Supply
1.4
kg/cm2

Inlet White water to Seal Pit is

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

Components:

GSM

Ash
Moisture measurement
Edge Sensor
Phase Encoder
Limit Switch

Radioactive material

X rays
IR sensor

Electrometer

Ground

High
Voltag
e

Ion
Chamber
Signal

Process

Isotope Source

Process
X-Ray
Sourc
e

Sensor
Source

Electromet
er (current is

(Example ION

amplified &
converted to
voltage)

Chamber)

Smart PC

Turbo PC/
Super PC

RS-422 to
RS 232
Converter

ADC

Raw
Counts

Intelligent
Micro
Controller
(IMC)

RS-232 to
RS-422
Converter

Inlet
LP

Close Tank

HP

PC
V
Outle
t

LT

Air Supply
(1.4
kg/cm2)
IP

4-20 m
A

4-20 mA

LI
C

SP

LT- Level
Transmitter

LIC- Level Indicating

Controller

PCV- Pneumatic
control Valve

IP- current to
pressure converter

SP

PV

4-20 mA

FIC
1.4 kg/cm2

FT

IP

Wild Flow

PCV

0.2 to 1
kg/cm2

FT

PCV

Controlled
Flow

SP = Wild Flow X (Controlled

Flow / Wild Flow)

220 V
50 Hz

Outlet to
Refined Stock

Interloc
kA

Magnetic Flow
indicator
+Transmitter

Excitat
ion
voltag
e

PG
4

PS
1

O/p Voltage
Flow
Tube

P
G
1

P
G
3

Water

PS
2
PG
2

Three Phase
Motor (469 Hp)

Triple
Disc
Refiner

Interloc
kB

4-20 mA
Remote
Transmissio
n

Inlet from
Buffer Chest

Interlock A: if the Pressure of

Inlet flow will goes below 0.5
kg/cm2 then Pressure switch
PS1 unload the TDR
Interlock B: if the pressure of
Water (which is acting as
coolant to TDR )fall below 0.5
kg/cm2 then PS2 unload the
TDR

Number of Boilers

Coal Fired

HP Boiler 1,2,3 & 7

Black Liquor Fired

ABL and JMW

Boiler # 7
(Coal Fired)
(OPP)
MP

JMW (Black
Liquor)
(OPP)
MP

ABL (Black
Liquor)
(NPP)
MP

46 kg/cm2
Head
er

BT
H
(6.
2
MW
)

PRV- Pressure Reduce

Valve
MP- Medium Pressure

From HP steam
Header (from
PRV)

Boiler # 1
(Coal Fired)

Boiler # 2
(Coal Fired)

HP

Boiler # 3
(Coal Fired)

HP

HP
85 kg/cm2

Header

TG
(18
MW
)

PRV- Pressure Reducing Valve

PRV 46 Kg/cm2
to MP steam
header

Boiler

PDM
Tank

DM
Plant

Deareator
Tank

Turbin
e

Conde
nsate

Feed
Pump

Stop
Valve

Economis
er

Steam
Drum

Super
Heater
Section

MUD
Drum

Air Supply
20 psi

Inlet from PDM

tank thru Pump
Steam
Inlet

IP
PG

4-20 mA

LI
C

PCV

SP

PCV

LP

IP

Deareator Tank

20 psi

PT

H
P

LIC
SP

Drain

Outlet to feed
pump

T
G

LT

TG- Temperature Gauge

LIC- level Indicating Controller
PT- Pressure transmitter
PG- Pressure Gauge
PCV- Pneumatic Control Valve
LT- Level Transmitter
IP- Current to Pressure Converter

Three Element Control...Drum

Drum Level Level
Water Flow
Steam Flow

P+I

P+I

T
4-20 mA

1.4
kg/cm2

IP
To feed Water Control Valve

Transmitter is a device which is used to measure physical variable i.e.

transducer and to transmit signal into electrical signal in form of 4-20 mA
or 1-5 V DC signal.

Types of transmitter:

Conventional
Smart/Intelligent

In this Calibration can be done after

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

 Disconnect

Transmitter from the field.

Apply 24 V dc supply and a multi meter in series to
the transmitter
Apply a known Pressure through Pressure gauge or
dead weight tester.
Check zero of the transmitter. For zero pressure a
transmitter gives 4 mA. If transmitter shows some
zero error then calibrate it through zero
adjustment.
Apply 100% Span Pressure & then adjust 20 mA
from the Span adjustment.
Check mA output for mid range pressure.

In this Calibration can be done by using

HART (Highway Addressable remote
transducer) Communicator. Online
calibration can be performed using HART
communicator. In this Sine wave
frequency signal over right the Previous
Calibration.
HART is based on Frequency Shift Keying.
In this 1200 Hz is equal to Binary logic 0
and 2200 Hz is equal to logic 1.

Spring

Flapper

4-20 mA

Gap
Supply
Pressure
20 psi

Nozzle
Restriction
Pressure signal 3-15 psi

Its working principle is based on the flapper nozzle

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

1.
2.
3.

4.

5.
6.

Apply input pressure of 20 psi and also apply current

signal from mA source (Loop Analyzer).
Attach a manometer or calibrated gauge at the
output of IP.
Apply 4 mA and check output pressure to be 3 psi or
0.2 kg/cm2. If this pressure will not come then adjust
using zero adjustment.
Apply 20 mA signal and check o/p pressure to be 15
psi or 1 kg/cm2. If this pressure will not come then
adjust using span adjustment.
Check for mid ranges by changing control signal to 8,
12 & 16 mA.
If step 5 is not showing exact reading then repeat
step number 4, 5 & 6.

Flow in any pipe is defined as velocity of

liquid at certain point.
Various flow measuring techniques are
available and some are enlist which are used
here
1. Orifice Plate
2. Venturi Meter
3. Flow Nozzle
4. Vortex Flow meter
5. Magnetic Flow meters
1,2 & 3 are Differential Pressure type flow
meters.

QCS PROCESSING FLOW DIAGRAM

Feed
Forward

PID

BW
S.P.

Stock Flow
Control

DTC
Feed
Forward
Feed
Forward

PID
Moistur
e S.P.

Steam
Pr.
Control

Feed
Forward
Feed
Forward

PID
Ash S.P

QCS
CPU

Ash
Flow
Control

Consistency
Tx

V=2 R N
V= D N
D=V/N
V= Line Speed of the Drum from the Encoder (Taken from the Drive 01-10
VDC)
N= Unwind Speed from the proximity (14 ppr)
R= Radius of the Unwind Roll
D= Diameter of the Unwind Roll

Instrumentation is the branch of

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

ABB MP-200 Series Distributed Control

System in Pulp Mill
Supervisory Control And Data Acquisition
System used in Stock Preparation Area at
PM4 and at ABL Boiler.
Quality Control System at PM1, 4 and 5.
PLC Control System at PM7 and Color
Kitchen.
Various Types of Field Instruments like
Level Transmitter, Pressure Transmitter,
Flow Transmitter, Conductivity Transmitter
and Consistency Transmitter,
Temp.Transmitter.

Various Types of Control Valve for

Pressure, temperature and flow
Control application like Butterfly,
Globe Valve, Plug valve
Others measuring devices like RTD,
Thermocouple, pH measurement,
Khajani for brightness Measurement.
Hydraulic System of Press part.
Vibration Monitoring.

These Instruments are Calibrated Against

the ISO from ETDC.
Loop Analyzer
Dead Weight Tester
Vacuum Gauge Tester
RTD Simulator
Conductivity Jig

Governer Control System for the

Turbine Generator.
Temperature and Vibration Monitoring
for Safety and Tripping.
Dereator Tank Level and Pressure
Control at HP Boilers.
Feed Water Flow and Steam Flow
Measurement and Control at all Boilers
Three Element Drum Level Control for
HP Boilers

761 controller based SCADA control

system at ABL Boiler.
Various Temperature Indication, ID
indication.
Various Pressure and Flow measurements
and Control like Soot Blowing Pressure
and Flow.
Various types of Control Valve for different
application like Flow Control of Feed
water, Steam flow etc.
Conductivity measurement at DM plant
and Evaporator.

Thank You !