Definition Of instrumentation in process field

Calibration of minor Electronic signal mA & mV with heavy field process

Variables, thousand pascal pressure, hundred barrel/hour flow,
thousand inches level and hundred degree temperature to detect,
sense, Indicate, measure, Auto control,Interlock & record is possible
through Instrumentation.
Paper Drying Systems

A paper drying system provides steam at the right pressure to every dryer in the machine as per
requirement, and ensures an efficient evacuation of condensate from inside the dryers.  A good paper
drying system facilitates this over the varied paper grades that the machine intends to produce.

The objective of a paper drying system is the attainment of the desired dryer surface temperature with
minimum steam consumption and least drive load on the machine.

Classification of paper drying systems

There are two categories into which paper drying systems can be classified –

1)     BLOW THROUGH SYSTEMS

There are two configurations possible for a blow through system –
a)     Thermocompressor based        b) Cascade type
2)     TRAP BASED SYSTEM

1)     BLOW THROUGH SYSTEMS

A blow through system uses the principle of steam assisted condensate evacuation from paper dryers.  
This is known as the ‘blow through’ phenomenon, which is achieved by passing ‘blow through’ steam
through the syphons. The ‘blow through steam drives the condensate out of the dryer as it forms along
with itself.  Machines with speeds greater than 250 mpm (with 1.5m dryer; for higher dryer size the speed
criteria reduces) need a blow through system to facilitate condensate evacuation from dryers.  Slow
speed machines can also be provided with a blow through system to facilitate better condensate
evacuation. 

Thermocompressor based Paper DryingThermocompressor based systems

 Thermocompressor based systems recirculate the flash and blow through steam back into the steam
supply headers for the group.  A well designed Thermcompressor is the heart of this system and therefore
the nomenclature.  The benefits of this system are,

-          This system provides maximum pressure in all dryers with independent pressure control on each
section.  This allows for maximum production rates.

-          While operating finer grades, this system can provide the minimum required pressures in the
individual dryer sections, thereby eliminating / reducing the need for shutting of few dryers and associated
problems.

-          A thermocompressor system recirculates all the flash and blwo through steam and is the most
efficient paper drying system.  The specific steam consumption of a machine with a thermocompressor
based paper drying system (all other things remaining the same) is the lowest.

-          Automatic differential pressure control due to the thermocompressor.

-          Allows for minimum electrical load on the machine due to complete evacuation of condensate and
enhances life of bearing, journals, etc.

 
 Cascade System

In a cascade system, the flash and blow through steam is cascaded into other groups at lower pressures. 
A well designed cascade system allows for a blow through system to be operated where high motive
pressure availability is limited.

A cascade system design requires the utmost attention and a proper study of the machine, the paper
grades and the operating conditions.

Cascade systems operate the machine at the lowest pressures possible thereby enhancing the steam
economy and providing better specific steam consumption.

Essentials of a Good Cascade System

-          Minimum dryers venting to condenser

-          Providing desired differential pressure on each and every dryer

-          Top bottom configuration design, if required

-          Correct calculation of the quantity of flash and blow through steam from each section and
determining its utilization down the cascade chain

Cascade Paper Drying System

Selection of the right control valves, dP control and level control valves, the right control system whether a
DCS or PLC is crucial.

A well engineered ‘blow through’ type of paper drying system has the following sub systems, each of
which is an engineered system in itself.

-          Steam pressure control system complete with moisture separators, strainers

-          Individual pressure control sections

-          Automatic and adequate differential pressure control

-          Thermocompressor

-          Correctly selected syphon and rotary joints

-          Air venting

-          Flash and blow through separator vessels

-          Level controls for separators

-          PLC / DCS SCADA system

-          Paper break logic

Trap based system

This system provides, on each dryer, an individual ball float trap module complete with double window
sight glass, air vent and a bypass arrangement. The traps are fitted with a steam lock release
arrangement.

A trap based system is suitable for machine speeds upto 250mpm (with 1.5 mtr dryer).

To maximize the paper machine efficiency and paper quality, the condensate in the dryer must be
evacuated constantly.

This can be ensured by a well engineered system that takes into account various factors like paper grade,
basis weight, drying rates.

(Fig. Steam Trap Module)

Selection and sizing of each and every component that forms a part of the TRAP BASED system is very
critical.

-          Good quality pressure reducing / de-superheating stations with the requisite turndown and range
 ability are a key requirement.

-          Pressure control valves with required turndown

-          Moisture separators with baffle design are recommended for their higher efficiency

-          Engineered strainers with the correct mesh sizes and suitable free flow areas are required – these
need to be designed correctly

-          Fixed bend stationary syphons are the correct choice along with suitable rotary joints

-          Ball float steam traps with inbuilt steam lock release arrangement – the sizing of the trap is very
important

-          Disc check valves are to be selected, other types of non return valves are sub-optimal

-          Double window sight glass with good quality borosilicate lapped glass for high viewing efficiency

-          Flash vessels to recover flash steam and pressure powered pumps for returning condensate back

-          Wireless trap monitoring systems are recommended for on line diagnosis of leaking or
waterlogged traps

-          Isolation valves and bypass valves on the system need to be piston type – other isolation valves
are not suitable as it is a bi-phase flow.  Piston valves are zero leak valves and thereby save fuel too.

-          Automatic capsule type air vents with air pockets need to be fitted on every dryer as an integral
part of the trap based system.

 
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Control and Automation in Paper Drying

Systems

Paper Drying System comprises of following controls

Steam Pressure/Flow Control

Steam Pressure/Flow Control to individual dryers and drying groups. Maintaining the precise steam
pressure and temperature in every dryer is the basic objective of the paper drying system. A higher than
desired pressure or lesser pressure is just not fine.

The variance in basis weight, moisture levels, minute variations in fibre consistency, the fibre composition
including additives etc make it  important to have a pressure control that is quick in response, accurate,
safe and reliable.

Differential Pressure Control

Differential Pressure Control required to maintain the desired differential pressure which will completely
evacuate the condensate from each dryer without causing excessive blow-through. Higher Dp results in
excess blow-through and lesser Dp results in condensate flooding in the dryer. The Dp control is most
critical considering the dynamic nature of the operation. Dp control also includes control of Vent steam
during paper break conditions.

Separator Vessel Level Control

Separator Vessel Level Control for each separator vessel. This control too is complex as a slack
response can result in wet steam entering into the succeeding cascade groups or in the other scenario
live steam blowing through the separator.

Split Range Control System 

Split Range Control System is required in Thermocompressor based system to ensure that TC acts as the
primary control. This is a critical control as multiple valves need to be operated as per a complex
algorithm with single pressure input.

Heat Exchange Temperature Control 

Heat Exchange Temperature Control is required to maintain the desired vacuum is required to maintain
the desired vacuum in the low pressure group – usually the first group.

Paper break control

An essential operational and safety control whose function is to evacuate condensate from the dryers and
maintain the dryers in a warm condition during paper breaks.

All these controls need rugged, reliable and state of the art process controllers. One could go in for
individual controllers, PLCs or a complete DCS system. Each of these needs to be suitably selected and
engineered into the paper drying system with complete integration taking into account control valve trim
and its Cv / Kv values, the transmitters and also the process.

Quality Control System for Paper

Machines

QCS enables on-line and real monitoring and control of various key parameters related to paper quality.
Typical parameters include basis weight, moisture, caliper, and ash.

QCS can be configured as a stand-alone paper quality monitoring system or as an integrated quality
control system that controls all the desired parameters.

Automatically controlling thee parameters in both CD and MD requires hooking up the QCS and
integrating it fully with the paper drying system, the head box/former section controls, steam box, as
required.