Function Description DS Smith Belisce PM2 BTM HB Final After Fat 13112018

Function descriptions DS Smith Belisce PM2
Bottom headbox
Automation / AUi Final After Fat 13.11.2018
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Project: BV-18001
Customer: DS Smith Belisce, Croatia
Machine: PM2
FUNCTION DESCRIPTION
BOTTOM HEADBOX
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CONTENT
1 PROCESS INSTRUMENTATION. DILUTION WATER SHORT CIRCULATION..............1
1.1 FIS-4800 DILUTION WATER SCREEN SEALING WATER FLOW SWITCH.................................................1
1.2 PDI-4801 DILUTION WATER SCREEN PRESSURE DIFFERENCE..................................................................2
2 PROCESS INSTRUMENTATION. BOTTOM HEADBOX.................................................3
2.1 PIC-4802 TOTAL HEAD..............................................................................................................................................3
2.2 SC-4802 RUSH / DRAG RATIO CONTROL AND TOTAL SLICE CHANNEL FLOW....................................7
2.3 LIC-4803 ATTENUTION TANK LEVEL..................................................................................................................9
2.4 PC-4804 AIR FEED TO ATTENUATION TANK...................................................................................................12
2.5 HIC-4805 ATTENUATION TANK OVERFLOW..................................................................................................13
2.6 HC-4806 STOCK HEADER RECIRCULATION....................................................................................................14
2.7 HIC-4807 DILUTION HEADER RECIRCULATION............................................................................................15
2.8 PDIC-4808 DILUTION WATER PRESSURE DIFFERENCE..............................................................................16
2.9 SEQ-4808 DILUTION WATER VALVES WASHING SEQUENCE....................................................................20
2.10 TIC-4809 THERMAL COMPENSATION...........................................................................................................28
2.11 FIC-4810 TS, FIC-4811 DS EDGE FLOW CONTROL.....................................................................................31
3 MACHINE AUTOMATION, HEADBOX BACK PLY........................................................35
3.1 HS-4812 TOP LIP VERTICAL ADJUSTMENT.....................................................................................................35
3.2 GIC-4813 TOP LIP VERTICAL POSITION...........................................................................................................38
3.3 HS-4814 TOP LIP HORIZONTAL ADJUSTMENT...............................................................................................43
3.4 GIC-4815 TOP LIP HORIZONTAL POSITION....................................................................................................46
3.5 HS-4816 HEADER OPENING...................................................................................................................................49
4 ELECTRIC MOTORS.......................................................................................................51
4.1 M-4900 TOP LIP VERTICAL ELECTRIC GEARMOTOR.................................................................................51
4.2 M-4901 TOP LIP HORIZONTAL ELECTRIC GEARMOTOR..........................................................................53
4.3 M-4902 THERMAL COMPENSATION WATER PUMP ELECTRIC MOTOR...............................................55
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4.4 R-4903 THERMAL COMPENSATION WATER HEATING RESISTOR..........................................................56
4.5 M-4904 HEADER OPENING HYDRAULIC PUMP ELECTRIC MOTOR.......................................................57
4.6 V-4905 HEADER OPENING HYDRAULIC DIRECTIONAL CONTROL VALVE ELECTRIC SUPPLY...57
4.7 M-4906 DILUTION WATER SCREEN ELECTRIC MOTOR.............................................................................58
4.8 M-4907 DILUTION PUMP ELECTRIC MOTOR..................................................................................................59
4.9 M-901 FAN PUMP ELECTRIC MOTOR....................................................................................................................62
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1 PROCESS INSTRUMENTATION. DILUTION WATER SHORT CIRCULATION
1.1 FIS-4800 DILUTION WATER SCREEN SEALING WATER FLOW

SWITCH
Purpose of operation
To feed and monitor sealing and lubrication water flow to dilution screen rotor
mechanical seal.
Principle of operation
Seal water flow is detected by a flow switch and adjusted manually by the
rotameter located near the screen.
Seal water pressure is adjusted by pressure reducing valve in rotameter.
Adjusted seal water pressure should be 2 bar over dilution water pressure.
Interlocks
Group controls
Information to other loops

Status signal of dilution screen seal water flow to the loops:
- M-4906 Dilution water screen motor.
Alarms
- FS1-4800 Sealing water flow NOT OK
Operator interface
DCS
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1.2 PDI-4801 DILUTION WATER SCREEN PRESSURE DIFFERENCE
To measure pressure difference between screen feed and accept flows.
Too big pressure difference indicates that screen is clogged.
Two separate pressure transmitters are used to measure the pressure of screen
feed and accept flows.
DCS calculates pressure difference between these two measurements as
follows:
Pressure difference = Inlet feed pressure PT1-4801- outlet accept pressure

PT2-4801.
Feed and accept pressure measurements and the calculated pressure difference
are shown on DCS monitor.
Interlocks
Group controls

Dilution screen feed pressure measurement value PT1-4801 to the loops:
- M-4906 Dilution screen motor.
Alarms
- Screen is clogging if pressure difference > 35 kPa (over 5 s.). High
- Screen is clogged if pressure difference > 50 kPa (over 5 s.). High High
Operator interface
DCS
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2 PROCESS INSTRUMENTATION. BOTTOM HEADBOX
2.1 PIC-4802 TOTAL HEAD
Total head control is used to get desired and most stable stock flow from
headbox onto wire.
Principle of operationTotal head is controlled with fan pump speed. This control loop is critical, if
we consider the quality of paper or board. Low frequency basis weight varia-
tion in machine direction can be reduced substantially just by tuning total head
control properly. If the total head is unstable, it causes consistency variations
and disturbances all over also in the short circulation.
However, because of huge inertial forces of fan pump, the control is limited to
low frequency area. Minimum closed loop response time for control varies
from 2 to 5 seconds. The response time depends greatly on performance of fan
pump electrical drive. Suitable scan time for DCS controller is from 50 to 200
ms.
Measurement and signal processing
Total head is measured with two pressure transmitters which are calibrated to
the same measurement range. One has been installed on the drive side of
headbox slice channel and the other on the tending side. Operator can choose
on DCS monitor, which one is used as a measurement signal for total head
controller. Operator can also choose the mean value of these two pressure
transmitters as a measurement signal to the total head controller.
If it becomes a measurement fault in that pressure transmitter which is used in

total head controller, DCS must automatically change measurement to other
transmitter, which is OK.
Direction of controller: controller output is increased, if measured pressure is

below set-point.
Fan pump speed control
Total head is controlled by the rotating speed of the fan pump. Speed controller
is located in the pump drive system. It gets set point from the total head
controller in DCS.
When total head controller is in manual mode, operator can control directly
the fan pump rotating speed. When controller is in manual mode, there is a
slow ramp in the controller output. Suitable ramp speed in this case is the same
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speed as is used during fan pump start-up ramp (120 s for pump speed range
0…100 %).
When total head controller is in auto/local mode, pressure is controlled

according to total head set point given by operator without any ramp in the
controller output. The speed change depends only on the controller tuning
parameters.
When the controller is in auto/remote (external) mode total head set point
comes from rush/drag ratio control (look at loop SC-4802, Rush/drag ratio
control).
Total head controller gives the set point for fan pump in r/min value directly to
drive system or pump inverter, where the speed controller is located. There is
not any speed controller in the DCS.
There are two alternatives for fan pump speed set point transfer from DCS to
pump drive.
Alternative 1
Bus connection between DCS and fan pump drive system can be used, if total
cycle time for controller (total head) and set point transfer is not more than 200
ms.
Alternative 2
If bus connection in not quick enough then analog control signal must be used.
The resolution of DCS analog output must be at least 12 bits, then the set point
transfer for fan pump speed control can be done with one analog signal without
any window technology. In this case the DCS analog output is scaled to
correspond whole fan pump operating speed range (for example 4…20 mA =
0…1500 r/min).
Normal control situation
Normally the total head is controlled according to rush/drag ratio. Rush/drag

calculation (loop SC-4802) sends continuously set point value to the total head
controller. This value is called Remote Set Point (RSP). If the rush/drag
calculation has been disconnected, operator can give total head set point value
directly via DCS terminal. This value is called Local Set Point (LSP).
When RSP has been selected, wire is running and fan pump is running, then
the total head follows automatically all the time the set point value calculated
by rush/drag ratio calculation. If machine has coordinated grade change
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system, the rush/drag ratio can be controlled according to grade change

automation. This control way minimises time and waste of product both in
start-up and in grade change situations.
Interlocks
The total head controller is set to auto mode, when
M-901 Fan pump is started.
The controller output must be ramped, when

M-901 Fan pump is started, and
PIC-4802 Total head measuring value < set point.
The above mentioned start-up ramp (from zero speed to normal running speed)
is done by ramping the maximum value of controller output slowly from zero
speed to maximum pump speed (ramp speed is 0…100 % in 120 seconds).
The controller output must be ramped (ramp speed is 0…100 % in 120

seconds), when
M-901 Fan pump is running, and
PIC-4802 Total head controller is in manual mode.
Total head controller local set point must be ramped (ramp speed is 0…100 %
in 120 seconds), when
PIC-4802 Total head controller is in local mode, or
Total head controller is set from local mode to remote mode.
Set point change must be done slowly and smoothly, when

PIC-4802 Total head controller is set from local mode to remote mode.
The measurement signal of total head controller must be changed from tending
side transmitter to drive side transmitter, if
PT1-4802 Total head. There is measurement fault in total head measu-
rement at tending side.
The measurement signal of total head controller must be changed from drive
side transmitter to tending side transmitter, if
PT2-4802 Total head. There is measurement fault in total head measu-
rement at drive side.
The output of total head controller is frozen and released 60 sec after all
conditions are back to normal, if
PT1-4802 Total head measurement fault in total head measurement at
tending side, and
PT2-4802 Total head measurement fault in total head measurement at
drive side.
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The output of total head controller is force controlled to zero without any
ramp, when
M-901 Fan pump is stopped.
When controller is in auto/remote mode the remote set point is copied to local
set point.
Group controls
Alarms
PT1-4802 Pressure transmitter TS measurement FAULT
PT2-4802 Pressure transmitter DS measurement FAULT
Operator interface
DCS
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2.2 SC-4802 RUSH / DRAG RATIO CONTROL AND TOTAL SLICE

CHANNEL FLOW
Purpose of operation Rush/drag ratio control is used to adjust web fibre orientation. Fibre orientation
affects to many paper and board quality items. Loop is also used to calculate
total outflow [l/s] from headbox slice channel.
Principle of operationDCS calculates total head set point according to the rush/drag ratio set point
given by operator by using the following equation:
Scaling factor k is defined during start-up by doing rush / drag ratio tests.
Normally its value is between 0.8…0.9 (0,85)
Total outflow from slice channel is calculated by using the

following equation:
QTOT = L x (H/100.0) x C x (VJET/6.0), where
QTOT = Total outflow [l/s]

L = Headbox slice channel width in decimeters = 55.50
dm (constant)
H = Slice opening [mm] (GIC-4813)
C = Contraction coefficient (normally about 0.9)
VJET = Jet speed [m/min] (= VWIRE + ∆V)
∆V = Speed difference = Vjetsp – Vwiresp [m/min]
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Speed difference
∆Vdiff = Speed difference = Vjetsp – Vwiresp [m/min]
Vjetsp = Vwiresp + ∆Vdiff [m/min]
∆Vdiff = Vjetsp - Vwiresp [m/min]
Rush/Drag ratio
Vjetsp = Vwiresp * Ratio [m/min]
Ratio = Vjetsp / Vwiresp
Vjetsp = Jetspeed setpoint [0 … 1000 m/min]

Vwiresp = Wire speed setpoint [0…1000 m/min]
∆Vdiff = Speed difference speed [-20 … +20 m/min]
Ratio = Rush/Drag ratio value [0.95 … 1.05]
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2.3 LIC-4803 ATTENUTION TANK LEVEL
Purpose of operation Attenuation tank is located in approach pipe before the headbox to cut away
the high pulsation from fan pump and machine screen before headbox. Air in
the tank is compressible and adsorbs the pulses. Pressure loss in the tank screen
plate (HDPE) also adsorbs the pulses generated by the screens and pumps.
Principle of operationAttenuation tank level is controlled by air pressure in attenuation tank air
chamber.
Level is measured by differential pressure transmitter, which includes two

separate pressure sensors.
There are two control valves in attenuation tank supply/release air pipe:
LV1-4803 Attenuation tank inlet air control valve
LV2-4803 Attenuation tank outlet air control valve
In normal control situation valves operate across to each other according to the
measurement.
When controller controls attenuation tank level up, air inlet valve closes and
air outlet valve opens. The output signal of the controller is divided and scaled
into two different output signals 4...20 mA. The operation ranges for the
control valves are as follows:
LV1-4803 Inlet air valve closes 100...0 %
Inlet air valve, controller's output 0...60 %
LV2-4803 Outlet air valve opens 0...100 %
Outlet air valve, controller's output 40...100 %
Software in DCS must be done so, that the above mentioned per cent values
(40 and 60 %) can be easily changed by automation engineer (not by operator)
also during machine is running (parameter change must be protected by
password).
Direction of controller: controller output is increased, if measured level is

below set-point.
Tank level control must be tuned to operate slower than the tank level dynamic
allows. By this way it is possible to reduce cross connection effects to the total
head control. It may allow little deviations to tank level values when changing
total head but should not make any deviations to total head when changing
tank level. Suitable response time is about 10 times slower than total head
control has. Program scan time should be about 100 ms or less.
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Attenuation tank level setpoint 1411 mm (81%)

LT1-4803 Attenuation tank level transmitter range
0…1735 mm = 4… 20 mA
Interlocks
When the fan pump M-901 is not running,
the output of the PI-controller is interlocked to 100 %:
LV1-4803 Inlet air valve closes 0 %, and
LV2-4803 Outlet air valve opens 100 %
When the fan pump M-901 is started, and tank level is < 607 mm (35 %),
the output of the PI-controller is interlocked to 100%:
LV1-4803 Inlet air valve closes 0 %, and
LV2-4803 Outlet air valve opens 100 %
When the fan pump M-901 is running, and pond level > 607 mm (35 %),
the output of attenuation tank level controller is first set to 868 mm (50 %):
LV1-4803 Inlet air valve opens about 20 %, and
LV2-4803 Outlet air valve opens about 20 %, and
LIC-4803 Controller is released to auto control according to
PI-tuning parameters.
This interlocking to fixed valve positions can be done again only when fan
pump has been stopped and started again.
Group controls
Alarms
LT1-4803 Tank level >1215 mm (70 %) >10 s, HIGH
LT1-4803 Tank level >1562 mm (90 %) >10 s, HIGH HIGH
LT1-4803 Attenuation tank level transmitter measurement FAULT
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Operator interface
DCS
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2.4 PC-4804 AIR FEED TO ATTENUATION TANK
Compressed instrument air is used for attenuation tank level control.
Air pressure must be suitable for the air inlet valve of level controller.
Air supply pressure is reduced from normal mill air pressure 600 kPa to a
value, which is about 50…100 kPa bigger than air pressure in the attenuation
tank air chamber.
Instrument air pressure is reduced in one step by manual pressure reducing
valve.
In Air supply pipe to pressure reducing valve there is also shut-off hand valve.
Air volume between manual pressure reducing valve and the tank inlet air
control valve must be big enough to avoid pressure variations in the
attenuation tank air chamber.
The distance between manual pressure reducing valve and the inlet air control
valve must be at least 1.5 m.
Interlocks
Group controls
Alarms
Operator interface
PCV1-4804 Local manual pressure reducing valve
PI1-4804 Local air pressure gauge
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2.5 HIC-4805 ATTENUATION TANK OVERFLOW
Attenuation tank overflow is used to get easier and disturbance free stock
supply from attenuation tank to headbox.
Attenuation tank overflow valve is used adjust a suitable overflow from tank
level surface to wire pit. This is to lead all impurities back to wire pit.
Attenuation tank overflow is adjusted to a suitable level by the help of control
valve.
Control valve is always in manual mode.
Operator can adjust control valves position from DCS display.
When operator opens the valve, overflow from attenuator tank to wire pit
increases and vice versa.
The attenuation tank overflow valve must be installed below the wire pit level.
Interlocks
- HCV-4805 The position of attenuation tank overflow valve is
always changed with a slow ramp,
(ramp speed 0…100 % in 120 seconds)
Overflow valve is opened automatically by a ramp to 100 % opening, when

- M-901 Fan pump is stopped
Overflow valve is controlled by a ramp to same opening it had before fan

pump was stopped (start-up interlock), when
- M-901 Fan pump is started
Group controls
Alarms
Operator interface
DCS
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2.6 HC-4806 STOCK HEADER RECIRCULATION
Recirculation valve is used to control the cross-direction pressure profile of
headbox stock header.
Stock header recirculation valve is adjusted to a suitable level by the help of
control valve.
Control valve is always in manual mode, and operator can adjust its position
from DCS display.
When operator closes recirculation valve pressure increases on the tending side
of header and vice versa (if stock is fed to header from drive side as usually).
Operator can see the pressure difference between tending and drive sides from
the sight glass located on the backside of the stock header.
The pressure difference of header is balanced when there is no flow through
the sight glass.
Interlocks
HCV-4806 The position of stock header recirculation valve is
Recirculation valve is opened automatically by a ramp to 100 % opening,

when
M-901 Fan pump is stopped
Recirculation valve is controlled by a ramp to same opening it had before fan

pump was stopped (start-up interlock), when
M-901 Fan pump is started
Group controls
Alarms
Operator interface
DCS
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2.7 HIC-4807 DILUTION HEADER RECIRCULATION
Recirculation valve is used to control the cross-direction pressure profile of
headbox dilution water header.
Dilution water header recirculation is controlled manually from DCS monitor
by operator.
When operator closes recirculation valve, pressure increases in the tending side
of dilution header and vice versa (if dilution water is fed to header from drive
side as usually).
Operator can see the pressure difference between tending and drive sides from
the positions of dilution water control valves on DCS monitor.
When the trend line of dilution water control valves is a straight horizontal
line, then the pressure of dilution water header is balanced.
If dilution control valves are more opened at drive side than at tending side, it
means that dilution header pressure is smaller at drive side and recirculation
must be opened a little and vice versa.
Interlocks
HCV-4807 The position of dilution water header recirculation valve is
Recirculation valve is opened automatically by a ramp to 100 % opening,

when
M-4907 Dilution pump is stopped
Recirculation valve is controlled by a ramp to same opening it had before

dilution pump was stopped (start-up interlock), when
M-4907 Dilution pump is started
Group controls
Alarms
Operator interface
DCS
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2.8 PDIC-4808 DILUTION WATER PRESSURE DIFFERENCE
Dilution water pressure control is used to get desired and most stable dilution
water flow to dilution water header so, that dilution water control valves can
optimally control the basis weight CD-profile of board or paper.
Dilution water pressure is controlled by the help of pressure difference
between dilution water and stock headers. Pressure difference is controlled by
the speed of dilution water feed pump. This control loop is as critical as total
head control loop when considering the quality of board or paper.
However, because of huge inertial forces of dilution water feed pump, the
control is limited to low frequency area. Minimum closed loop response time
for control varies from 2 to 5 seconds. The response time depends greatly on
performance of dilution water feed pump electrical drive. Suitable scan time
for DCS controller is from 50 to 250 ms.
Measurement and signal processing
Pressure difference between dilution water header and stock header is

measured
- PT1-4808 Dilution header pressure transmitter, DS
- PT2-4808 Stock header pressure transmitter, DS
Pressure difference between headers is calculated in DCS from these two
pressure measurement signals.
Calculation is done according to the following equation:

Pressure difference = Dilution header pressure – Stock header pressure.
Pressure measurements are not allowed to have any filtering not in the
transmitters nor in the DCS.
Dilution water feed pump speed control
Dilution header pressure is controlled by the rotating speed of the dilution

water feed pump. Speed controller is located in the pump drive system. It gets
set point from the pressure difference controller in DCS.
When pressure difference controller is in manual mode, operator can control

directly dilution water feed pump rotating speed.
When controller is in manual mode, there is a slow ramp in the controller
output. Suitable ramp speed in this case is the same speed as is used during the
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start-up ramp of dilution water feed pump (120 s for pump speed range 0…100
%).
When the pressure difference controller is in auto/local mode, dilution header

pressure is controlled according to pressure difference set point given by
operator without any ramp in the controller output. The speed change depends
only on the controller tuning parameters.
When controller is in auto/remote mode the set point of dilution header

pressure is given by DCS washing sequence of dilution water control valves.
Dilution water header pressure controller (pressure difference between dilution

header and stock header) gives the set point for dilution water feed pump in
r/min value directly to drive system or pump inverter, where the speed
controller is located. There is not any speed controller in DCS.
There are two alternatives for the set point transfer of dilution water feed pump
from DCS to pump drive.
Alternative 1
Serial bus between DCS and dilution water feed pump drive system can be
used, if total cycle time for controller (pressure difference) and set point
transfer is not more than 250 ms.
Alternative 2
If the resolution of DCS analogy output is at least 12 bits, the set point transfer
for dilution water feed pump speed control can be done with one analogy
signal without any window technology. In this case the DCS analogy output is
scaled to correspond the whole dilution water feed pump operating speed range
(for example 4…20 mA = 0…1500 r/min).
Interlocks
Pressure difference controller of dilution water header and stock header
setpoint is limited 50…120 kPa
Pressure difference controller of dilution water header and stock header is set
to auto control mode (only start-up interlock), when
M-4907 Dilution water feed pump is started
Controller output must be ramped (ramp speed is 120 s for 0…100 %) (only
start-up interlock), when
M-4907 Dilution water feed pump is started, and
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PDIC-4808 Dilution water pressure difference measurement value is <

set point
The above mentioned start-up ramp (from zero speed to normal running speed)
can be done by ramping the maximum value of controller output slowly from
zero speed to maximum pump speed (ramp speed is 120 s for 0…100 %).
Controller output must be ramped (ramp speed is 120 s for 0…100 %), when
M-4907 Dilution water feed pump is running, and
PDIC-4808 Dilution water pressure difference controller is in manual
mode
Local set point change of pressure difference controller must be ramped (ramp
speed is 120 s for 0…100 %), when
PDIC-4808 Dilution water pressure difference controller is in local
mode
Set point change must be done slowly and smoothly, when

PDIC-4808 Dilution water pressure difference controller is set from
local mode to remote mode
The output of pressure difference controller is frozen and released 60 sec after
all conditions are back to normal, if
PT1-4808 Dilution water header pressure transmitter fault, or
PT2-4808 Stock header pressure transmitter fault
The output of pressure difference controller is force controlled to zero when

M-4907 Dilution water feed pump is stopped
When controller is in auto/remote mode the remote set point is copied to local
set point.
Group controls
Alarms
Calculated pressure difference between dilution water header and stock
header is < 40 kPa, when fan pump is running
Washing sequence of dilution water short circulation and dilution water
valves is interrupted
PT1-4808 Dilution water header pressure >410 kPa High limit
PT2-4808 Stock header pressure transmitter >295 kPa High limit
PT1-4808 Dilution water header pressure transmitter fault
PT2-4808 Stock header pressure transmitter fault
Operator interface
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DCS
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2.9 SEQ-4808 DILUTION WATER VALVES WASHING SEQUENCE
It is recommended to wash dilution water valves straight away after every
machine stop (fan pump stopped). By this way it is prohibited that fibres might
dry onto the surfaces of dilution control valves and fibres block the valves.
Dilution water valves washing sequence is partly in DCS software and partly
in QCS software.
Washing sequence is started:
- Automatically when fan pump stops,
Belisce short circulation stop sequence, or
- Manually from DCS display by operator
DCS-display:
- AUTO/OFF button for automatic washing
o Automatic mode. Sequence starts automatically, when fan pump
stops
 Belisce short circulation stop sequence
- START/STOP button to start washing sequence manually by operator
o Manual mode. Operator starts sequence manually from DCS
display
Washing sequence:
- Before sequence start-up, check the set points of control loops
- Dilution circulation is started
Washing sequence start command from DCS software is a pulse, not
continuous control
- Dilution water pressure run values are saved
- Dilution water wash pressure values are set
- Dilution valves wash is started by QCS
- Dilution valves wash is stopped by QCS
After sequence started, check the control loops actual values (dilution
water pressure, etc), and do adjustments, if necessary
- Dilution water pressure run values are returned
- Dilution circulation is stopped
Dilution water valves normal machine running control loops states and
values are returned to DCS, and QCS softwares
Dilution water valves washing pressure set point 250 kPa is set by DCS
software
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Washing group can be bigger, if dilution pump capacity is big enough to

produce needed 250 kPa washing pressure over the wash group dilution valves.
Dilution valve wash in QCS are divided into groups of 10…15 valves.
When wash starts the first group at tending side of the HB is fully open and all
other valves are fully closed.
Washing time for each group is 30 s (final adjustment in start-up).
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Dilution valves manual washing sequence

Washing sequence manual start from DCS display by operator:
Start-up conditions
M-901 Fan pump is stopped, and
M-4906 Dilution water screen motor is stopped, and
M-4907 Dilution water pump is stopped, and
LIC-907 White water silo, wire pit level is >80 % of max
measurement range (level must be over dilution water
feed pump suction pipe)

- Manually from DCS display by operator
Step 1 Process devices to auto mode

Waiting time 0 s (delay before action)
Control time 5s (maximum time when action must be executed)
Actions in step:
M-4906 Dilution water screen motor to auto mode, and
M-4907 Dilution water pump to auto mode
Conditions for next step:
Controls in step are in Auto-mode
Step 2 Start-up of dilution water screen

Waiting time 5 s
Control time 10 s
Actions in step:
M-4906 Dilution water screen motor start command
If dilution screen is installed under the level of wire pit,
which means that dilution screen is filled up with water,
when wire pit is filled up
M-4906:RUN Dilution water screen run info is received
Step 3 Start-up of dilution water pump

Waiting time 5 s
Control time 120 s
Actions in step:
M-4907 Dilution water pump start command
M-4907:RUN Dilution water pump run info is received
Step 4 Dilution water pressure difference set point and control mode saving and change
Waiting time 0 s
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Control time 120 s

Actions in step:
PDIC-4808 Dilution water pressure difference controller control mode
and set point are saved into DCS memory, and
PDIC-4808 Dilution water pressure difference controller is set into
Auto/remote mode and set point value is set to 250 kPa
PDIC-4808 Dilution water pressure difference control mode is
auto/remote, and measurement value is >240 kPa, or
5 min delay after dilution pump has been started
Step 5 Washing request signal to QCS

Waiting time 0 s
Control time 300 s
Actions in step:
Washing request signal is sent from DCS to QCS
Washing/Flush complete signal is received from QCS to DCS
Step 6 Pressure difference control state back to normal

Waiting time 3 s
Control time 10 s
Actions in step:
Dilution water pressure difference controller is set back into auto/local
mode and set point value is set back to the old value it had before washing
sequence was started.
Dilution water pressure difference controller is in auto/local mode, and
Previous setpoint is returned
Step 7 Process device controls to Auto-mode

Waiting time 0 s
Control time 10 s
Actions in step:
M-4906 Dilution water screen motor to auto mode and
M-4907 Dilution water feed pump to auto mode
Controls are in auto mode.
Step 8 Stop of dilution water pump

Waiting time 5 s
Control time 10 s
Actions in step:
M-4907 Dilution water pump stop command
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M-4907:RUN Dilution water pump is stopped, run info is not received
Step 9 Stop of dilution water screen

Waiting time 5 s
Control time 10 s
Actions in step:
M-4906 Dilution water screen motor stop command
M-4906:RUN Dilution water screen motor run info is not received
Step 10 End of Sequence

Waiting time 0 s
Control time 0 s
Actions in step:
Stop of dilution valve washing sequence
Interlocks, Manual Dilution water valves washing sequence interlocks
Start-up interlocks
M-4907 Dilution water feed pump is stopped, and
LIC-907 Wire pit level is >80 % of max measurement range (level must be
over dilution water feed pump suction pipe)
Running interlocks
LIC-907 Wire pit level is >70% of max measurement range (level must be
Washing sequence is interrupted

LIC-907 Wire pit level decreases <70% of max measurement range (level
must be over dilution water feed pump suction pipe), or
M-901 Fan pump is started, or
PDIC-4808 Dilution water pressure difference between dilution header and
stock header have not reached 200 kPa within 5 minutes from the
start-up of washing sequence.
Alarms
Operator interface
DCS
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Dilution valves automatic washing sequence

Washing sequence automatic start, when fan pump stops
will be added to Belisce short circulation stop sequence
Start-up conditions
measurement range (level must be over dilution water
feed pump suction pipe), and
M-4906 Dilution water screen motor is running, and
M-4906:RUN Dilution water screen run info is received, and
M-4907 Dilution water pump is running, and

- Washing sequence automatic start, when fan pump stops
will be added to Belisce short circulation stop sequence
Step 4 Dilution water pressure difference set point and control mode saving and change
Waiting time 0 s
Control time 120 s
Actions in step:
PDIC-4808 Dilution water pressure difference controller control mode
and set point are saved into DCS memory, and
PDIC-4808 Dilution water pressure difference controller is set into
Auto/remote mode and set point value is set to 250 kPa
PDIC-4808 Dilution water pressure difference control mode is
auto/remote, and measurement value is >240 kPa, or
5 min delay after dilution pump has been started
Step 5 Washing request signal to QCS

Waiting time 0 s
Control time 300 s
Actions in step:
Washing request signal is sent from DCS to QCS
Washing/Flush complete signal is received from QCS to DCS
Step 6 Pressure difference control state back to normal

Waiting time 3 s
Control time 10 s
Actions in step:
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Dilution water pressure difference controller is set back into auto/local

mode and set point value is set back to the old value it had before washing
sequence was started.
Dilution water pressure difference controller is in auto/local mode, and
Previous setpoint is returned
Step 7 Process device controls to Auto-mode

Waiting time 0 s
Control time 10 s
Actions in step:
M-4906 Dilution water screen motor to auto mode and
M-4907 Dilution water feed pump to auto mode
Controls are in auto mode.
Step 8 Stop of dilution water pump

Waiting time 5 s
Control time 10 s
Actions in step:
M-4907 Dilution water pump stop command
M-4907:RUN Dilution water pump is stopped, run info is not received
Step 9 Stop of dilution water screen

Waiting time 5 s
Control time 10 s
Actions in step:
M-4906 Dilution water screen motor stop command
M-4906:RUN Dilution water screen motor run info is not received
Step 10 End of Sequence

Waiting time 0 s
Control time 0 s
Actions in step:
Stop of dilution valve washing sequence
Interlocks, Automatic Dilution water valves washing sequence interlocks
Start-up interlocks
measurement range (level must be over dilution water feed pump
suction pipe), and
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M-4907 Dilution water pump running, and

M-4907:RUN Dilution water pump run info is received, and
M-4907 Dilution water pump running, and
Running interlocks
LIC-907 Wire pit level is >70% of max measurement range (level must be

LIC-907 Wire pit level decreases <70% of max measurement range (level
must be over dilution water feed pump suction pipe), or
M-901 Fan pump is started, or
PDIC-4808 Dilution water pressure difference between dilution header and
stock header have not reached 200 kPa within 5 minutes from the
start-up of washing sequence.
Alarms
Operator interface
DCS
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2.10 TIC-4809 THERMAL COMPENSATION
Headbox thermal compensation is used to control the profile of base frame of
headbox.
The base frame profile affects to the basis weight CD-profile.
Two temperature measurements and also two controllers are used to control
thermal compensation.
The first sensor measures stock temperature and the second one the
temperature of thermal compensation circulation water.
Both temperatures and their difference are shown on DCS monitor.
The temperature difference controller controls the temperature difference of

stock and thermal compensation circulation water.
This used during machine’s normal run.
The temperature controller controls circulation water temperature.

This is used in in machine’s shutdown.
Direction of controllers: in both controller output is increased, if measured

temperature is below set-point.
Thermal compensation circulation water is heated with resistor.

The heating power of resistors is adjusted by connecting heating elements
(resistors) on and off according to the control signal coming from the tempera-
ture or temperature difference controller.
Power connection on and off is done with normal MCC contactor.
Both controllers themselves are normal PI-controllers.

The output of controller which is in use is divided into short pulses
These pulses are in turn used to set heating elements on and off.
Pulsing works as follows:
- The cycling time for one pulse is 120 s
- The length of the pulse depends on the value of controller output
 If controller output is 0 %, the pulse length is 0 s
 If controller output is 50 %, the pulse length is 60 s
 If the controller output is 100 %, the pulse length is 120 s
Operator can set thermal compensation on and off from DCS display
When circulation water temperature controller is in use, temperature is

controlled according to the set point given by operator.
In this case operator gives directly set point for circulation water temperature.
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The circulation water temperature controller set point is limited between 20…
60 °C.
When circulation water temperature and stock temperature difference

controller is in use, temperature difference is controlled according to the
temperature difference set point given by operator.
The temperature difference controller set point is limited between –5…+5 °C
(remote)
When the fan pump is not running, it is recommended to keep thermal com-
pensation ON due to the reason that in start-up situation it takes some hours to
warm up the lower part of the headbox.
While fan pump is not running the predicted set point (about 30 °C, max
deviation from stock temperature +/- 15 °C) is taken for water temperature
controller to control circulation water temperature.
Set point is limited so, that it doesn’t deviate more than +/- 15 °C (remote
external) from stock temperature.
Interlocks
Circulation water temperature controller is set to AUTO mode, when
TIC-4809 Thermal compensation is set ON, and
M-901 Fan pump is NOT RUNNING, and
TT2-4809 Thermal compensation circulation water temperature
transmitter is OK
Circulation water temperature controller is force controlled to MANUAL

mode and output to ZERO, when
TIC-4809 Thermal compensation is set OFF, or
M-901 Thermal compensation is set ON, and Fan pump IS
RUNNING, or
transmitter is NOT OK
Temperature difference controller is in AUTO mode, when

TIC-4809 Thermal compensation is set ON, and
M-901 Fan pump IS RUNNING, and
transmitter is OK, and
TT1-4809 Thermal compensation stock temperature transmitter is
OK
Temperature difference controller is force controlled to MANUAL mode, and

output to ZERO, when
TIC-4809 Thermal compensation is set OFF, or
M-901 Fan pump is STOPPED, or
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transmitter is NOT OK, or
TT1-4809 Thermal compensation stock temperature transmitter is
NOT OK
When fan pump is stopped, the last measured stock temperature, which was
valid before pump was stopped, is used.
Group controls

R-4903 Thermal compensation water heating resistor
M-4902 Thermal compensation water pump
Alarms
> 65 °C.
Temperature difference between circulation water and stock >10C.
Operator interface
DCS
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2.11 FIC-4810 TS, FIC-4811 DS EDGE FLOW CONTROL
FIC-4810 EDGE FLOW CONTROL, TS

FIC-4811 EDGE FLOW CONTROL DS
Purpose and principle of operation
Edge flow control effect to fibre orientation.
Side flow speed is same as slice flow

No affect to fibre orientation
Side flow speed ratio is <1
Fibres turns to towards the web middle zone
Side flow speed ratio is >1
Fibres turns to towards the web edge zones
Edge flow is measured by magnetic flow measurement tube and adjusted by
stepper motor controlled linear displacement valve. The actuator consists of a
feedback signal to get precise valve position.
Flow controller control direction: controller output is increased when

measurement is below the set-point.
When controller is in manual mode operator can control directly the edge flow
valve opening.
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When controller is in auto/local mode edge flow is controlled by set point

given [l/s] by operator.
When controller is in auto/remote flow side flow is controlled by ratio set point
(0.7…1.2) and DCS calculates flow set point (l/s).
Both DS and TS edge flow controllers consist of two PID-controllers. First one
controls the flow amount and second one valve position.
First PID-controller: flow controller
Setpoint: Normally setpoint for sideflow is calculated from ratio and

headbox total flow by following formula: Qesp = Rsp x Qe
Qesp= Set point for edge flow (side flow, see equation below) [l/s]
Rsp = Set point for edge flow ratio, 0.7 … 1.2 (set by operator)
Qe = Total flow in edge zone of turbo generator with same speed as in
middle zone
Normally controller is in auto/remote-mode where setpoint comes from actual
headbox outflow and operator set edge flow ratio Rsp. When controller is in
manual-mode operator can set flow amount directly
Measured value: actual measured value from magnetic flow meter

PID-output: required valve position, this signal is directed to second PID-
controller.
Second PID-controller: valve position controller
Setpoint: comes directly from flow control PID-output. This setpoint acts as a
setpoint value for valve position
Controller is always in auto-mode and hidden from operator.
Measured value: actual measured value from valve position

PID-output: not used
To control the sideflow-valve there must be comparison of setpoint and

measured-value in DCS from second PID-controller. If setpoint is lower than
measured value then binary output CLOSE is put on until setpoint reaches
measured value. If setpoint is higher than measured value then binary output
OPEN is put on until setpoint reaches measured value.
OPEN or CLOSE –signal to valve is switched off when difference between

setpoint and measured position is <0.5 %. Control is started again when
difference between setpoint and measured position is >0.5 %.
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When controller is in auto/remote mode operator gives edge flow ratio set
point Rsp [0,7…1,2] and DCS then calculates flow controller set point [l/s]
according to following equations:
Total outflow (Qtot) from slice channel is calculated by using the equation in
loop: SC-4802 RUSH / DRAG RATIO CONTROL AND TOTAL SLICE
CHANNEL FLOW
Qe = Qtot x 5,991 x 10-3
Qe = Total flow in edge zone of turbo generator with same speed as in

middle zone [ l/s ]
This Qe shows total flow in edge area - in one column area of turbo pipes. It
has same speed as in middle area. However there is need to control this flow
value smaller or greater in respect to middle area. Therefore there is
arrangement a ratio factor by which the edge flow is controlled. The ratio
factor Rsp is designed to values 0,7 … 1,2. The set point of edge flow can
calculate from formula:
Qesp = Rsp x Qe, where
Qesp= Set point for edge flow (side flow) [ l/s ]

Rsp = Set point for edge flow ratio, 0.7 … 1.2.
When edge flow ratio Rsp =1.0, it means that the edge flow speed [m/s] is the
same as jet speed VJET [m/s]. In this case edge flow doesn’t affect so much to
web fibre orientation.
The flow area of headbox is; 500…1000 l/s.

By applying formulas above we can get value area of Qesp = 2,99…5,99 l/s.
When edge flow ratio is < 1.0 or > 1.0 then edge flow affects to web fibre
orientation according to the table on the previous page.
Interlocks
The edge flow controller is set to AUTO mode and controller is released to
normal PI-control, when
M-XXXX Thick stock feed pump (stock feed into the off-machine silo).
run info is received
The edge flow controller is set to MANUAL mode and output is forced to 98
%, when
M-XXXX Thick stock feed pump (stock feed to the off-machine silo)
run info is NOT received
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Edge flow ratio set point is limited between 0,7…1,2.
Edge flow control TS is forced to manual mode and valve remains in its
current position, when
- FV-4810_ZT
Edge flow valve TS position transmitter measurement fault,
or
- FT-4810 Edge flow transmitter TS measurement fault, or
Edge flow control DS is forced to manual mode and valve remains in its
current position, when
- FV-4811_ZT
Edge flow valve DS position transmitter measurement fault,
or
- FT-4811 Edge flow transmitter DS measurement fault, or
The output of edge flow controller is limited between 2…98 %.
Alarms
- FV-4810_ZT
Edge flow valve TS position transmitter measurement fault
- FT-4810 Edge flow transmitter TS measurement fault
- FV-4811_ZT
Edge flow valve DS position transmitter measurement fault
- FT-4811 Edge flow transmitter DS measurement fault
Operator interface
DCS and QCS display
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3 MACHINE AUTOMATION, HEADBOX BACK PLY
3.1 HS-4812 TOP LIP VERTICAL ADJUSTMENT
Top lip vertical adjustment change lip opening and thus effect to the headbox
total outflow and stock consistency. Stock consistency affect to some paper or
board quality values, for example to formation.
Total outflow from slice channel calculation

- See chapter 2.2 SC-4802 Rush/Drag ratio control and total slice channel
flow
By adjusting top lip vertical position operator can adjust total stock outflow
and stock consistency.
When operator opens slice, total stock outflow increases and stock consistency
decreases.
By adjusting the consistency of headbox outflow, operator can affect to some
paper or board quality values, for example to formation.
Top lip position is measured by linear position transmitter and controlled by
inverter, gear motor, intermediate shaft and displacement screw.
Top lip position can be read from the DCS operation display or from local
digital display on the control box TS, or from the mechanical pointer on the
headbox side wall TS.
Vertical position transmitter as well as horizontal position tramsmitter are

located in safety and clean place inside headbox.
Transmitters do not measure directly the top lip position values.
Right values are calculated in DCS according to the equations in loop
GIC-4813 Top lip vertical position.
Top lip moving extreme limits are detected by inductive limit switches.
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Local control
Local control is selected from control box located at the tending side of
headbox side
Local control is used in machine shut down.
In local control operator moves top lip manually by push button with selected
constant slow/fast speed.
Constant speeds are adjusted in DCS software.
Because of the headbox mechanical construction the moving of the top lip in
horizontal direction affects to position of vertical direction and vice versa.
Operator has to control the vertical direction if he want to keep it in previous

position after horizontal position change and vice versa.
Interlocks
Top lip can be controlled locally Downwards Slow or Fast speed, if
HS1-4812 Top lip Slow or Fast speed selected, and
HS2-4812 Top lip adjustment Local selected, and
HS3.2-4812 Top lip vertical Down pushed, and
GS1.1-4812 Top lip vertical NOT in Down limit switch, NC=1, and
GS1.2-4812 Top lip vertical NOT in Down limit switch, NO=0, and
GS1-4812 Top lip vertical Down limit switch OK, no measurement
fault, and
GT1-4813 Top lip vertical position > 11 mm
Top lip can be controlled locally Upwards Slow or Fast speed, if

HS3.1-4812 Top lip vertical Up pushed, and
GS2.1-4812 Top lip vertical NOT in Up limit switch, NC=1, and
GS2.2-4812 Top lip vertical NOT in Up limit switch, NO=0, and
GS2-4812 Top lip vertical Up limit switch OK, no measurement fault,
and
GT1-4813 Top lip vertical position < 74 mm
Group controls

M-4900 Top lip vertical motor
GIC-4813 Top lip vertical position
Alarms
GS1-4812 Top lip vertical Down limit switch measurement fault
Contacts NO and NC are in the same state at the same time.
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Alarm has 0.5 s delay, when limit switch state is changed

(limit on -> off or vice versa)
GS2-4812 Top lip vertical Up limit switch measurement fault.
(limit on -> off or vice versa)
Operator interface
Local control box CB-301
Remote control
See loop: GIC-4813 Top lip vertical position
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3.2 GIC-4813 TOP LIP VERTICAL POSITION
Top lip vertical position change affect to the headbox total outflow and stock
consistency. Stock consistency affect to some paper or board quality values,
for example to formation.
digital display on the control box or from the mechanical pointer on the
headbox side wall.
Vertical position transmitter as well as horizontal position tramsmitter are

Position transmitters do not measure directly the top lip position values.
Right values are calculated in DCS according to the equations in item
Calculation in loop GIC-4813 Top lip vertical position.
Local control
Loop HS-4812
Remote control
In remote mode top lip position is controlled by set point given by operator
from DCS display, or by operator from QCS.
Vertical position controller in is activated if deviation absolute value between

set point and measurement value is bigger than dead band (> 0.1 mm).
Movement is stopped, when deviation absolute value decreases under dead
band (0.1 mm).
When deviation is positive (deviation = set point – measurement value), top lip
is moved upwards (= slice opens).
With negative deviation (deviation = set point – measurement value), top lip is
moved downwards (= slice closes).
horizontal direction affects to position of vertical direction and vice versa.
DCS takes care of these position change affects.
Interlocks
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Top lip vertical controller is force controlled to auto mode, and measurement
value is copied to set point value, if
HS2-4812 Top lip adjustment Remote control is selected
Top lip vertical controller is force controlled to manual mode, if

HS2-4812 Top lip adjustment Local control is selected
Top lip vertical controller is activated by deviation, if

HS2-4812 Top lip adjustment Remote control selected, and
GT1-4813 Vertical position measurement OK, and
GT1-4813 Vertical position controller set point is changed
OR
GT1-4813 Vertical position measurement OK, and
M-4901 Horizontal position motor run info received (set point
changed), and
GT1-4813 Vertical position measurement changed
Top lip can be controlled remote Downwards, if

HS2-4812 Top lip adjustment Top lip Remote selected, and
GS1-4812 Top lip Down limit switch OK, no measurement fault, and
GT1-4813 Top lip vertical position transmitter OK, no measurement
fault, and
GT1-4813 Top lip vertical position > 11 mm, and
GT1-4815 Top lip horizontal position transmitter OK, no measurement
fault
Top lip can be controlled remote Upwards, if

GS2-4812 Top lip Up limit switch OK, no measurement fault, and
fault, and
GT1-4813 Top lip vertical position < 74 mm, and
fault
Top lip controller is activated only by change of set point.

Controller is NOT allowed to activate, when measurement value is changed
but set point is not changed.
Controller is NOT allowed to activate, if control mode is changed from remote
to local, or if there is a fault in position measurement.
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Top lip vertical controller is always in manual mode, and measurement value
is copied to set point value, if
Group controls

GIC-4815 Top lip horizontal position
SC-4802 Rush / drag ratio control and total slice channel flow
 Top lip vertical position setpoint
Alarms
GT1-4813 Top lip vertical position transmitter measurement fault
GT1-4813 Top lip vertical position (calculated real position value)
<LOW (11 mm)
<LOW LOW (10 mm)
>HIGH (74 mm)
>HIGH HIGH (75 mm)
Operator interface
Local control box CB-301 and DCS
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Calculation
Figure 1 Constants in DCS

Constants from headbox physical geometry.
These values are used for calculating lip position from linear sensor values in calculation below.
These constants are never changed.
VARIABLES IN DCS, LOCKED BY PASSWORD, MAINTENANCE USE ONLY

Slice lip stick-
5,5000
U mm out
HORIZONTAL sensor offset value from
-25,7620
HOFFSET mm calibration
VERTICAL sensor offset value from
315,3647
VOFFSET mm calibration
Figure 1 Variables in DCS

Values that can be changed from maintenance-window or software.
Changing these values must requires a password.
If top lip stick-out is changed in the headbox then variable U must be changed to corresponding
lip stick-out value so that the calculation will deliver correct lip position after the change.
EXAMPLE OUTPUT SIGNAL VALUES FROM

SENSORS
HOUTPUT 32,4000 mm Output signal of HORIZONTAL sensor
VOUTPUT 76,9000 mm Output signal of VERTICAL sensor
Figure 2 Example values for linear sensors

These two values are direct measured values from linear sensors.
These values change as the top lip position changes.
These are here just for an example values for checking the calculation below in DCS.
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CALCULATION OF VARIANTS
Calculated values as example
Calculation
Symbol only
H= HOFFSET + HOUTPUT 6,6380
V= VOFFSET + VOUTPUT 392,2647
X1CALC = X1 - H * Cos(σ) 683,9123
Y1CALC = Y1 - H * Sin(σ) 94,3145
T= √((X 1CALC
2 2
-X3) +(Y1CALC-Y3) ) 856,8287

 aCos((S2 + T2 - V2) / (2 * S * T)) 0,34434
 aSin((X1CALC - X3) / T) 0,44770
X4 = X1CALC - Cos(Ω + θ + β - 1,5708) * R 12,4058
Y4 = Y1CALC - Sin(Ω + θ + β - 1,5708) * R 23,4882

X0 = X4 - Sin(-Ω - θ - β + κ) * U 9,53 Calculated slice lip horizontal position
Y0 = Y4 - Cos(-Ω - θ - β + κ) * U 18,80 Calculated slice lip vertical position
Figure 3 Top lip position calculation

This is the actual calculation of top lip position.
Here we combine all the constants, variables and sensor measurements and calculate the actual
top lip position X0, Y0.
This calculated position is then showed in DCS-display and in local digital displays in headbox
control box.
-------------------------------------------------------------------------------------------------------------------
---
Calibration
Headbox lip movement is calibrated by Bellmer-Vaahto.
This calibration is completely separate from DCS.
Normally there is no need to make any calibration.
A new calibration is needed only, if mounting points of sensors or stickout of top lip have been
changed, or if lip position transmitters are changed.
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3.3 HS-4814 TOP LIP HORIZONTAL ADJUSTMENT
Top lip horizontal adjustment change the jet impingement angle and distance
in forming board.
Impingement angle and distance affect to some paper or board quality values,
for example to water removal and retention.
digital display on the control box, or from the mechanical pointer on the
Horizontal position transmitter as well as vertical position tramsmitter are

Position transmitters do not measure directly the top lip position values.
Calculation in loop GIC-4813 Top lip vertical position.
Local control
Local control is selected from control box located at the tending side of
headbox side wall and is used in machine shut down.
In local control operator moves top lip manually by push button with selected
constant slow/fast speed.
Constant speeds are adjusted in DCS software.
vertical direction affects to position of horizontal direction and vice versa.
Operator has to control the horizontal direction if he want to keep it in

previous position after vertical position change and vice versa.
Interlocks
Top lip can be controlled locally Backwards Slow or Fast speed, if
HS3.3-4814 Top lip horizontal Back pushed, and
GS1.1-4814 Top lip horizontal NOT in Back limit switch, NC=1, and
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GS1.2-4814 Top lip horizontal NOT in Back limit switch, NO=0, and
GS1-4814 Top lip horizontal Back limit switch OK, no measurement
fault
fault, and
GT1-4815 Top lip horizontal position < 27 mm
fault
fault, and
Top lip can be controlled locally Forwards Slow or Fast speed, if

HS3.4-4814 Top lip horizontal Forwards pushed, and
GS2.1-4814 Top lip horizontal NOT in Front limit switch, NC=1, and
GS2.2-4814 Top lip horizontal NOT in Front limit switch, NO=0, and
GS2-4814 Top lip horizontal Front limit switch OK, no measurement
fault
fault, and
GT1-4815 Top lip horizontal position > 7 mm
fault, and
GS2-4812 Top lip vertical Up limit switch OK, no measurement fault
Group controls

HS-4812 Top lip vertical adjustment
M-4901 Top lip horizontal motor
Alarms
GS1-4814 Top lip horizontal Back limit switch measurement fault
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(limit on -> off or vice versa).
GS2-4814 Top lip horizontal Front limit switch measurement fault.
(limit on -> off or vice versa).
Operator interface
Remote control
See loop: GIC-4815 Top lip horizontal position
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3.4 GIC-4815 TOP LIP HORIZONTAL POSITION
Top lip horizontal adjustment change the jet impingement angle and distance
in forming board.
Impingement angle and distance affect to some paper or board quality values,
for example to water removal and retention.
digital display on the control box or from the mechanical pointer on the
Horizontal position transmitter as well as vertical position tramsmitter are

Transmitters do not measure directly the top lip position values.
calculation in loop GIC-4813 Top lip vertical position.
Local control
See loop: HS-4814 Top lip horizontal adjustment.
Remote control
In remote mode top lip position is controlled by set point given by operator
from DCS, or by operator from QCS.
Horizontal position controller is activated if deviation absolute value between

set point and measurement value is bigger than dead band (> 0.1 mm).
Movement is stopped, when deviation absolute value decreases under dead
band (0.1 mm).
When deviation is positive (deviation = set point – measurement value), top lip
is moved backwards.
With negative deviation (deviation = set point – measurement value), top lip is
moved forwards.
vertical direction affects to position of horizontal direction and vice versa.
DCS takes care of these position change affects.
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Interlocks
Top lip horizontal controller is force controlled to auto mode, and
measurement value is copied to set point value, if
HS2-4812 Top lip adjustment Remote control is selected
Top lip horizontal controller is force controlled to manual mode, if

Top lip horizontal controller is activated by deviation, if

GT1-4815 Horizontal position measurement OK, and
GT1-4815 Horizontal position transmitter 7…27 mm, and
GT1-4815 Horizontal position controller set point is changed
OR
GT1-4815 Horizontal position measurement OK, and
GT1-4815 Top lip horizontal position transmitter 7…27 mm, and
M-4901 Vertical position motor run info received (set point changed),
and
GT1-4815 Horizontal position measurement changed
Top lip can be controlled remote Backwards, if

GS1.1-4814 Top lip horizontal NOT in Back limit switch, NC=1, and
GS1.2-4814 Top lip horizontal NOT in Back limit switch, NO=0, and
GS1-4814 Top lip horizontal Back limit switch OK, no measurement
fault, and
fault, and
GT1-4815 Top lip horizontal position < 27 mm, and
fault
fault, and
Top lip can be controlled remote Forwards, if

GS2.1-4814 Top lip horizontal NOT in Front limit switch, NC=1, and
GS2.2-4814 Top lip horizontal NOT in Front limit switch, NO=0, and
GS2-4814 Top lip horizontal Front limit switch OK, no measurement
fault, and
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fault, and
GT1-4815 Top lip horizontal position transmitter > 7 mm, and
fault, and
Top lip controller is activated only by change of set point.

Controller is NOT allowed to activate, when measurement value is changed
but set point is not changed.
Controller is NOT allowed to activate, if control mode is changed from remote
to local, or if there is a fault in position measurement.
Top lip horizontal controller is always in manual mode, and measurement

value is copied to set point value, if
Group controls

Top lip horizontal position measurement fault information to the loop:
GIC-4813 Top lip vertical position.
Alarms
GT1-4815 Top lip horizontal position transmitter measurement fault
GT1-4815 Top lip horizontal position (calculated real position value)
<LOW (7 mm)
<LOW LOW (6 mm)
>HIGH (27 mm)
>HIGH HIGH (28 mm)
Operator interface
Local control box CB-301 and DCS
467098830.doc
Bottom headbox
49
3.5 HS-4816 HEADER OPENING
Headbox header can be opened for cleaning and other service work
Header is controlled to open and close locally from control box at the drive
side end of headbox
Control is hardwired so there is not any connections DCS
Header movement is done by hydraulic cylinder

Header movement direction is controlled with a hydraulic directional control
valve
Header movement speed is controlled by throttle-check valve
Load control valve stops movement if hydraulic hose is broken or loosen
Operation instruction
1. Open one end of hydraulic cylinders mechanical installation. So only hydraulic cylinders rods
can be moved without header load
2. Fill the tank with hydraulic oil, ISO VG 46, 8 liters
3. Check the hydraulic pump el motor rotation direction
4. Check the connections tightening. Check the fittings assembly
5. Check the setting of throttle-check valve
6. Check the setting of load control valves
7. Start the hydraulic pump
8. Control header open and close several times to get air out of hydraulic system
9. Check pressure relief valve setting 120 bar
10. Stop the pump
11. Install hydraulic cylinders ends back. So header can be moved with hydraulic cylinders
12. Control header close, up, directional control valve A-coil for little time
13. Open the screws of the headbox header
14. Control header close, up, directional control valve A-coil for little time
15. Control header open down directional control valve B-coil. The pressure pushes the cylinder
rod inside, and the header moves upwards open, down
16. Check load control valves settings
17. Run headbox header movement a few times up and down to get air out from hydraulic
system. Check, that the movement is vibrationless. Check, that there are not any leakages.
Header movement commissioning and hydraulic valves are preadjusted in Bellmer-Vaahto

Hollola Finland workshop
Interlocks
Group controls
467098830.doc
Bottom headbox
50

M-4904 Header opening hydraulic pump electric motor
V-4905 Header opening hydraulic directional control valve electric
supply
Alarms
Operator interface
467098830.doc
Bottom headbox
51
4 ELECTRIC MOTORS
4.1 M-4900 TOP LIP VERTICAL ELECTRIC GEARMOTOR
By adjusting top lip vertical position operator can adjust total stock outflow
and stock consistency.
When operator opens slice total stock outflow increases and consistency
decreases.
By adjusting the consistency of headbox outflow operator can affect to some
paper or board quality values, for example to formation.
Headbox top lip vertical movement is done by the help of frequency converter,
electric motor and gearbox.
Frequency converter gets start and stop commands and speed set point from
the loops HS-4812 Top lip vertical adjustment, and GIC-4813 Top lip vertical
position.
Loop is always forced in auto mode.
It is not possible to operate (start or stop) frequency converter / motor directly
from DCS motor control window.
Interlocks
See:
Group controls

HS-4814 Top lip horizontal adjustment
M-4901 Top lip horizontal motor
Alarms
M-4900:RDY Top lip vertical Frequency converter NOT ready
M-4900:FLT Top lip vertical Frequency converter FAULT
M-4900:RUN_UP
Top lip vertical Motor running UP feedback NOT received
within 5 s from motor start-up
M-4900:RUN_DOWN
Top lip vertical Motor running DOWN feedback NOT
received within 5 s from motor start-up
467098830.doc
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52
HS1-4900 Top lip vertical Safety switch FAULT
Operator interface
DCS
467098830.doc
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53
4.2 M-4901 TOP LIP HORIZONTAL ELECTRIC GEARMOTOR
Top lip horizontal adjustment changes jet impingement angle and jet distance
on forming board.
When operator moves top lip backwards impingement angle decreases and
impingement distance increases.
By adjusting the impingement angle and distance of headbox outflow operator
can affect to some paper or board quality values, for example to water removal
and retention.
Headbox top lip horizontal movement is done by the help of frequency
converter, electric motor and gearbox.
Frequency converter gets start and stop commands and speed set point from
the loops HS-4814 Top lip horizontal adjustment and GIC-4815 Top lip
horizontal position.
Loop is always forced in auto mode.

It is not possible to operate (start or stop) frequency converter / motor directly
from DCS motor control window.
Interlocks
See:
Group controls

Alarms
M-4901:RDY Top lip horizontal Frequency converter NOT ready
M-4901:FLT Top lip horizontal Frequency converter FAULT
M-4901:RUN_UP
Top lip horizontal Motor running UP feedback not received
within 5 s from motor start-up
M-4901:RUN_DOWN
Top lip horizontal Motor running DOWN feedback NOT
467098830.doc
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54
HS1-4901 Top lip horizontal Safety switch FAULT
Operator interface
DCS
467098830.doc
Bottom headbox
55
4.3 M-4902 THERMAL COMPENSATION WATER PUMP ELECTRIC

MOTOR
Thermal compensation water pump is used to pump thermal compensation
water from thermal compensation unit TS to the base frame of headbox.
Thermal compensation water pump can be set in manual or in auto mode by
operator from DCS display.
When pump is in manual mode operator can start and stop pump from pump
operation window on DCS display.
When pump is in auto mode it is started, when thermal compensation is set on
and stopped, when thermal compensation is set off.
See loop TIC-4809 Thermal compensation.
Interlocks
See:
TIC-4809 Thermal compensation
R-4903 Thermal compensation heating resistor
Group controls

R-4903 Thermal compensation water heating resistor
Alarms
M-4902:RDY Thermal compensation pump MCC NOT ready
M-4902:RUN
Thermal compensation pump Motor running feedback NOT
HS1-4902 Thermal compensation pump Safety switch FAULT
Operator interface
DCS
467098830.doc
Bottom headbox
56
4.4 R-4903 THERMAL COMPENSATION WATER HEATING

RESISTOR
Thermal compensation heater is used to warm up thermal compensation
circulation water.
Thermal compensation heater is taken into use, when thermal compensation is
set on.
Control signal, which sets heating elements (resistors) on and off comes from
Thermal compensation heater has overheating switch.

Heater must have hardwired interlocking from MCC electric supply to this
overheating switch.
It is not possible to set heating elements on, if overheating switch is on.
Interlocks
Thermal compensation heater can be set ON only (continuous interlock), if
M-4902 Thermal compensation pump is running
Group controls

M-4902 Thermal compensation pump
Alarms
R-4903:RDY Thermal compensation resistor MCC NOT ready
R-4903:RUN Thermal compensation resistor Resistor ON feedback NOT
HS1-4903 Thermal compensation resistor Safety switch FAULT
Operator interface
DCS
467098830.doc
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57
4.5 M-4904 HEADER OPENING HYDRAULIC PUMP ELECTRIC

MOTOR
See:
HS-4816 Header opening
4.6 V-4905 HEADER OPENING HYDRAULIC DIRECTIONAL

CONTROL VALVE ELECTRIC SUPPLY
See:
HS-4816 Header opening
467098830.doc
Bottom headbox
58
4.7 M-4906 DILUTION WATER SCREEN ELECTRIC MOTOR
The dilution screen is rotated by a belt-driven motor.
When motor control is in manual mode operator can start and stop the motor.
When motor control is in auto mode motor starts and stops according to
dilution water short circulation start and stop sequences (if exists in
Customer’s DCS).
Interlocks
Dilution water screen motor can be started, if
FS1-4800 Dilution water screen sealing water flow OK, and
M-4907 Dilution pump will be started
If dilution screen is installed under the level of wire pit,
when wire pit is filled up
Dilution water screen motor is stopped, if

FS1-4800 Dilution water screen sealing water has been OFF, >5 min
M-4907 Dilution pump is stopped, > 30 s
Group controls

FIS-4800 Dilution water screen sealing water flow switch
PDI-4801 Dilution water screen pressure difference
M-4907 Dilution pump
Alarms
FS1-4800 Dilution water screen sealing water has been OFF >1 min
Alarm valid only when dilution screen electric motor is running
M-4906:RDY Dilution water screen MCC NOT ready
M-4906:RUN
Dilution water screen Motor running feedback NOT received within 5
s from motor start-up
M-4906:CUR Dilution water screen Motor current >HIGH
M-4906:CUR Dilution water screen Motor current >HIGH HIGH
HS1-4906 Dilution water screen Safety switch FAULT
Operator interface
DCS
467098830.doc
Bottom headbox
59
4.8 M-4907 DILUTION PUMP ELECTRIC MOTOR
Dilution pump is used to pump dilution water from wire pit to headbox.
Dilution water is used to control the basis weight CD-profile of board or paper.
In manual mode operator can start and stop dilution pump from DCS display.
In auto mode dilution water pump is started and stopped according to the
group start and stop sequences of dilution water short circulation (if exists, by
Customer).
Dilution pump must be started first.

Pressure difference between dilution water header and stock header must be >
40 kPa, before fan pump can be started.
Fan pump must be stopped, if pressure difference between dilution and stock
header decreases <20 kPa during machine is running.
Dilution pump start
Dilution pump is started, and dilution header pressure controller PDIC-4808 is

set to auto mode, and dilution water feed pump rotating speed is increased with
slow ramp until controller’s measurement value reaches set point.
This start-up ramp (from zero speed to normal running speed) is done by
ramping the maximum value of pressure difference controller output slowly
from zero speed to maximum pump speed (ramp speed is 0…100 % in 120
seconds).
After the ramp dilution header pressure difference controller continues to
control pump speed with normal PI-algorithm.
It is also possible that operator sets dilution header pressure controller back to
manual mode after start-up ramp is finished.
Dilution pump speed and current are measured and measurement values are
shown on DCS monitor.
Dilution pump stop
When dilution pump is stopped, rotating speed is decreased to zero without any
ramp (coarse stop).
Dilution pump speed and current values are measured and shown on DCS
monitor.
467098830.doc
Bottom headbox
60
Interlocks
Dilution pump can be started, if
LIC-907 Wire pit level is >80 % of max measurement range (level
must be over dilution water feed pump suction pipe), and
M-4906 Dilution water screen motor is running (this interlock is valid
only, if dilution screen is installed under the level of wire pit,
when wire pit is filled up)
Dilution pump is stopped, if

LIC-907 Wire pit level decreases <70 % of max measurement range
(level must be over dilution water pump suction pipe), or
M-4906 Dilution water screen motor is stopped, >30 s
Group controls
When dilution pump is in auto mode, it is started and stopped according to the
start and stop sequences of dilution water short circulation (will be updated to
Belisce existing start- and stop-sequences)

FIS-4817 Dilution pump sealing water flow switch
M-4906 Dilution water screen electric motor
Alarms
FS1-4817 Dilution pump sealing water has been OFF >1 min
M-4907:RDY Dilution pump Motor Frequency converter NOT ready
M-4907:FLT Dilution pump Motor Frequency converter FAULT
M-4907:RUN Dilution pump Motor running feedback NOT received within
5 s from motor start-up
M-4907:CUR Dilution pump Motor current >HIGH, >5 s
>90 % of motor’s nominal current
Alarm is masked OFF until 30 s Dilution pump start-up ramp
has finished
Alarm is valid after 30 s from Dilution pump start-up ramp
has finished
Values must be tuned and agreed in start-up with Customer
M-4907:CUR Dilution pump Motor current >HIGH HIGH, >5 s
>95 % of motor’s nominal current
Alarm is masked OFF until 30 s Dilution pump start-up ramp
has finished
Alarm is valid after 30 s from Dilution pump start-up ramp
has finished
HS1-4907 Dilution pump Motor Safety switch FAULT
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61
Operator interface
DCS
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62
4.9 M-901 FAN PUMP ELECTRIC MOTOR
Existing Fan pump, existing function according Customer.
Fan pump is used to pump stock from wire pit through the machine screen to
headbox.
Operator can set fan pump control in manual or auto mode from DCS-display.
When fan pump control is in manual mode, operator can start and stop it from
DCS display.
Operator must increase or decrease fan pump speed from DCS to match the set
point and process value.
In auto mode fan pump is started and stopped according to the short circulation
group start and stop sequences.
All chemical additive pumps must also be interlocked so, that they are stopped,
if fan pump is stopped.
Fan pump start-up
When fan pump is started, total head controller is set in auto mode and fan
pump rotating speed is increased with slow ramp.
This start-up ramp (from zero speed to normal running speed) is done by
ramping the maximum value of controller output slowly from zero speed to
maximum pump speed (ramp speed is 0…100 % in 120 seconds).
After the ramp total head controller continues to control pump speed with
normal PI-algorithm.
It is also possible that operator sets total head controller back to manual mode
after start-up ramp is finished.
Fan pump stop
When fan pump is stopped rotating speed is decreased to zero without any
ramp (coarse stop).
Fan pump speed and current values are measured and shown on DCS monitor.
Interlocks
Fan pump can be started, if all the following conditions are valid (by
Customer):
FS1-XXXX Fan pump sealing water OK, and
467098830.doc
Bottom headbox
63
LIC-907 Wire pit level is >80 % of max measurement range (level

must be over fan pump suction pipe), and
M-XXXX Bottom wire electric drive run info received, and setpoint
reached, and
M-XXXX Machine screen motor is running, and
M-XXXX Cooling fan of fan pump motor is running (if fan pump has
cooling fan), and
M-4907 Dilution pump is running, and
PDIC-4808 Dilution water pressure. Pressure difference between dilution
water header and stock header > 40 kPa, and
Fan pump is stopped, if one of the following conditions is valid (by Customer):
FS1-4817 Fan pump sealing water has been OFF >2? min, or
LIC-907 Wire pit level is <70 % of max measurement range (level
must be over fan pump suction pipe), or
M-XXXX Bottom wire electric drive is not running, or
M-XXXX Machine screen motor is stopped, or
M-4907 Dilution pump is stopped, or
PDIC-4808 Dilution water pressure difference between dilution water
header and stock header decreased <20 kPa, or
M-XXXX Cooling fan of fan pump motor. Cooling fan is stopped,
delay 2? min (if fan pump has cooling fan)
Group controls
When fan pump control is in auto mode, it is started according to the start
sequence of short circulation and stopped according to the stop sequence of
short circulation (if exists, by Customer)

Fan pump running information to the loops:
PIC-4802 Total head
PDIC-4808 Dilution water pressure difference
M-XXXX Machine screen Motor
M-XXXX Fan pump Cooling fan
M-4907 Dilution pump Motor
Alarms
FS1-XXXX Fan pump sealing water has been OFF >1? min
M-901:RDY
Fan pump Motor Frequency converter NOT ready
M-901:FLT
Fan pump Motor Frequency converter FAULT
M-901:RUN
Fan pump Motor running feedback NOT received within 5? s
from motor start
467098830.doc
Bottom headbox
64
M-901:CUR
Fan pump Motor current >HIGH, >5? s
>90? % of motor’s nominal current
Alarm is masked OFF until 30? s Fan pump start-up ramp
has finished
Alarm is valid after 30? s from Fan pump start-up ramp has
finished
M-901:CUR
Fan pump Motor current >HIGH HIGH, >5? s
>95? % of motor’s nominal current
Alarm is masked OFF until 30? s Fan pump start-up ramp
has finished
Alarm is valid after 30? s from Fan pump start-up ramp has
finished
HS1-901 Fan pump Motor Safety switch FAULT
Operator interface
DCS
467098830.doc

Function Description DS Smith Belisce PM2 BTM HB Final After Fat 13112018

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Function Description DS Smith Belisce PM2 BTM HB Final After Fat 13112018

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Function descriptions DS Smith Belisce PM2

1 PROCESS INSTRUMENTATION. DILUTION WATER SHORT CIRCULATION..............1

1.1 FIS-4800 DILUTION WATER SCREEN SEALING WATER FLOW SWITCH.................................................1

1.2 PDI-4801 DILUTION WATER SCREEN PRESSURE DIFFERENCE..................................................................2

2 PROCESS INSTRUMENTATION. BOTTOM HEADBOX.................................................3

2.1 PIC-4802 TOTAL HEAD..............................................................................................................................................3

2.3 LIC-4803 ATTENUTION TANK LEVEL..................................................................................................................9

2.4 PC-4804 AIR FEED TO ATTENUATION TANK...................................................................................................12

2.5 HIC-4805 ATTENUATION TANK OVERFLOW..................................................................................................13

2.6 HC-4806 STOCK HEADER RECIRCULATION....................................................................................................14

2.7 HIC-4807 DILUTION HEADER RECIRCULATION............................................................................................15

2.8 PDIC-4808 DILUTION WATER PRESSURE DIFFERENCE..............................................................................16

2.9 SEQ-4808 DILUTION WATER VALVES WASHING SEQUENCE....................................................................20

2.10 TIC-4809 THERMAL COMPENSATION...........................................................................................................28

2.11 FIC-4810 TS, FIC-4811 DS EDGE FLOW CONTROL.....................................................................................31

3 MACHINE AUTOMATION, HEADBOX BACK PLY........................................................35

3.1 HS-4812 TOP LIP VERTICAL ADJUSTMENT.....................................................................................................35

3.2 GIC-4813 TOP LIP VERTICAL POSITION...........................................................................................................38

3.3 HS-4814 TOP LIP HORIZONTAL ADJUSTMENT...............................................................................................43

3.4 GIC-4815 TOP LIP HORIZONTAL POSITION....................................................................................................46

3.5 HS-4816 HEADER OPENING...................................................................................................................................49

4.1 M-4900 TOP LIP VERTICAL ELECTRIC GEARMOTOR.................................................................................51

4.2 M-4901 TOP LIP HORIZONTAL ELECTRIC GEARMOTOR..........................................................................53

4.3 M-4902 THERMAL COMPENSATION WATER PUMP ELECTRIC MOTOR...............................................55

4.4 R-4903 THERMAL COMPENSATION WATER HEATING RESISTOR..........................................................56

4.5 M-4904 HEADER OPENING HYDRAULIC PUMP ELECTRIC MOTOR.......................................................57

4.7 M-4906 DILUTION WATER SCREEN ELECTRIC MOTOR.............................................................................58

4.8 M-4907 DILUTION PUMP ELECTRIC MOTOR..................................................................................................59

4.9 M-901 FAN PUMP ELECTRIC MOTOR....................................................................................................................62

1 PROCESS INSTRUMENTATION. DILUTION WATER SHORT CIRCULATION

1.1 FIS-4800 DILUTION WATER SCREEN SEALING WATER FLOW

Information to other loops

1.2 PDI-4801 DILUTION WATER SCREEN PRESSURE DIFFERENCE

Pressure difference = Inlet feed pressure PT1-4801- outlet accept pressure

Information to other loops

2 PROCESS INSTRUMENTATION. BOTTOM HEADBOX

2.1 PIC-4802 TOTAL HEAD

Measurement and signal processing

If it becomes a measurement fault in that pressure transmitter which is used in

Direction of controller: controller output is increased, if measured pressure is

Fan pump speed control

When total head controller is in auto/local mode, pressure is controlled

Normal control situation

Normally the total head is controlled according to rush/drag ratio. Rush/drag

system, the rush/drag ratio can be controlled according to grade change

The controller output must be ramped, when

The controller output must be ramped (ramp speed is 0…100 % in 120

Set point change must be done slowly and smoothly, when

Information to other loops

2.2 SC-4802 RUSH / DRAG RATIO CONTROL AND TOTAL SLICE

Total outflow from slice channel is calculated by using the

QTOT = L x (H/100.0) x C x (VJET/6.0), where

QTOT = Total outflow [l/s]

Vjetsp = Jetspeed setpoint [0 … 1000 m/min]

2.3 LIC-4803 ATTENUTION TANK LEVEL

Level is measured by differential pressure transmitter, which includes two

Direction of controller: controller output is increased, if measured level is

Attenuation tank level setpoint 1411 mm (81%)

Information to other loops

2.4 PC-4804 AIR FEED TO ATTENUATION TANK

Information to other loops

2.5 HIC-4805 ATTENUATION TANK OVERFLOW

Overflow valve is opened automatically by a ramp to 100 % opening, when