ABB Oy, KPM

Sakeusmittaukset paperikoneen massanvalmistuksessa

KPM – Kajaani Process Measurements Ltd.

 KPM was established 2001

 KPM was acquired by ABB on

2011, now
 Worldwide Sales and Service Network
Researh & Development and
Manufacturing in
Kajaani, FINLAND

Canada Baltic Countries

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USA Denmark
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Comparison of Consistency
Measurement Technologies
Technologies

 Shear force consistency transmitters

 Rotary type
 Blade type
 Static
 Active • all technologies are indirect
 Optical measurements
 Reflection, scattering
• not measuring dry weight of
 Attenuation
material in g/l or Cs% as
 Direct light
done in laboratory
 Polarized light
 Microwave
 Velocity of microwaves

 CCD-camera image,Ultrasonic, Nuclear...very rarely used

 Operating range of consistency transmitters

Transmitter
Type: Limitations:
Rotating -sensitive for grade
1,5-16 (SW > 0,8%, HW > 1,2%) changes

Blade
2-8 -needs laminar flow,
sensitive for grade
6-16 changes
Optical
0-2
-sensitive for grade
changes
0-5 (TMP, GW) -air
Microwave
-conductivity
0 - 50 -air

Consistency-%
0 2 4 6 8 10 12 14 16
 Cost of consistency transmitters

Transmitter
Type:
Rotating

Blade

Optical

Microwave

1000 Euro
0 2 4 6 8 10 12 14 16
Shear Force transmitters
Existing pipe line

 Rotary type
 Blade type
DN 150 mm

 90% of all transmitters in

use are shear force type
 Measure fiber consistency,
does not measure fillers
 Different grades require
different calibration receipt
 Modern design of Rotary Consistency Transmitter

 Smaller size – Low weight

 Direct Drive Servo Motor
 Less Maintenance / repair
 No drive belt
 No wearing parts in motor
 Only 1-phase power supply
No 3-phase power to sensor
 Removability from process available with
Gate Valve Installation
 No waiting for shutdown
 No draining of process pipe
Selection Criteria for Rotary Transmitter

 Large pipe (>DN400, 16” )

 Low flow rate ( blade type transmitter requires min 0,5m/s)
 Consistency 2-3% (blade measures but signal is noisy, rotary
still gives accurate measurement )
 Production measurement ( = Flow rate * Consistency)
 High sensitivity and accuracy applications, such as after the
mixing chest and machine chest
 Not enough straight pipe section after the pump to install blade
transmitter
 High amount of air in the process with low pressure, microwave
technology cannot be used
Blade consistency transmitter

 Basic design of measurement blade 50 years old

 2 wire technology and smart electronics
 KC/3
 Static Blade
Blade Consistency Transmitter

 Shear force principle

 Requires laminar flow Gap measurement probe
conditions, turbulence
disturbs measurement Probe protection
 Operates well on specified
flow range 0,5-5m/s Measuring arm

 Sensitive to grade variations Diaphragm (2mm thick)

Flow Sensor blade

 One piece sensor body and
diaphragm
 Diaphragm works as a spring
 No maintenance (no O-ring, no
seals no leaks)
Gap measurement probe

Probe protection

Measuring arm

Diaphragm (2mm thick)

Flow Sensor blade

Selection Criteria for Blade Transmitter

 Cheapest solution wanted

 Not required high precision, early in process
 After MC-pump where Cs>10%, as good as rotary
 Flow rate relatively steady
 Consistency more than 3% up to 16%% and same fiber mix
Comparison of shear force transmitters
 Blade type
+ Price
+ Reliable measurement if
conditions are suitable (process,
installation)
+ No wearing parts, no preventive
maintenance
+ 2-wire transmitter
- Require laminar plug flow
- Long straight pipes before and
after installation point
- Limited acceptable flow range
 Rotary type
+ Performance
+ Turbulent flow acceptable
+ Freedom of installation location
+ Wide flow range
+ Wide measurement range 1,5-16%
- Price
- Wearing parts; seals, bearings, needs
preventive maintenance
Optical Consistency transmitters

 Inline type
 Mainly for clean not refined mechanical pulps
 Installed to process pipeline with saddle and
clamps

 By-pass type
 Low consistencies below 2%,
– Head box and white water
– Save-all
 Sensor is installed in by pass-line normally over
pump
Optical consistency transmitters

 Best choice for very low consistency

applications, below 2%Cs
 Works best with clean pure pulps, like
TMP, GW, Kraft pulp.
 Lignin, black liquor disturb measurement
 Grade sensitive (fiber lenght, fines
content, freeness)
 Air content in pulp affects the
measurement
Selection Criteria for Optical Transmitter

 Low consistency 0-2%Cs (0-20g/l)

 Paper machine Retention Measurement ( Head box, White
water)
 Save-all filters, filtrate and superfiltrate
 Very low consistencies: 0-0,02%Cs ( 0-200mg/l )
 Effluent plant
Microwave consistency transmitters

 KC/7
 Latest Microwave technology
Microwave technology

 Total consistency measurement

 Measures fibers and fillers
 Unaffected of wood species change
like pulp grade, fiber length, freeness,
brightness, colour, shives
 Unaffected of process conditions change like
flow rate, pressure, temperature, turbulence
 One calibration line for all kind of pulps

 No moving parts
 No preventive maintenance needed
 Measurement principle
 Microwave is transmitted to pulp through
ceramic antenna
 Microwave speed depends on material between antennas
 Measures any organic or inorganic material
mixed with liquid
 Response is naturally linear

Transmitter Receiver

Microwaves travel faster

in pulp than in water.
Selection Criteria for Microwave Transmitter
 Superior accuracy compared to shear force transmitters
- Needed minimum 150 kPa pressure ( 22 psi, 15mH2O)
- High conductivity >20mS/cm prevents measurement
(pulp mill bleaching applications)
 Measures total consistency, fibers & fillers
 Variation in fiber mix, short fiber/long fiber, freeness etc.
 Mixing Chest and Machine Chest applications
 Recycled pulps, excellent for unscreened applications like after
pulper
 Before de-inking
 Effluent plant before thickener
Transmitter selection
Contact your supplier, fill questionnaire

We help you to
select correct
measurement
technology
General Recommendations for good consistency
measurement and control

 Select Cs transmitter by application, not by price

 Design Cs loop to work well - tune loop
 Proper tank agitation is critical
 Constant dilution water pressure
 Dilution water injection point and correct dilution water
velocity
 Dilution valve dimensioning
 Retention Measurement and Control

 KRA Retention
Measuremenent
First Pass Retention calculation in DCS
KRA Retention Measurement

Retention is the Yield of Paper Machine wire section

Headbox
Pulp Paper
Wire

White Water

Tot Cs HB – Tot cs WW
Total Retention % = *100 %
Tot Cs HB

Ash Cs HB – Ash cs WW
Ash Retention % = *100 %
Ash Cs HB

September 20, 2018 Slide 27

KRA Retention system and control

Headbox Cs % and Ash Cs %

4-20mA

Head Box

DCS Calculation: Fan Pump White Water

DCS

CS HB – CS WW
Retention% = X 100% SP White Water Total Cs
CS HB

4-20mA

4-20mA

White Water Retention White Water

Consistency Chemical Cs % and Ash Cs %
Control Flow Control

Retention
chemical

September 20, 2018 Slide 28

Typical Advantages of Retention monitoring and Control

• Understanding what happens in the Wet

End
• Improved wet-end stability
• Variability reduction of paper quality
• Reduced downtime due to sheet breaks
• Smoother transitions and faster grade
changes
• No maintenance required so far with first
installations.

September 20, 2018 Slide 29

Questions?
Thank You