Verso Paper - Can

Verso Paper
Ni
Niagara
Wet
W t lap
l Machine
M hi
•Rebuild
•Refurbishment
Agenda
• Introduction
- Project goals
goals, current status to date
- Intended work scope
• Mill Project Schedule
- Needs
N d ffor P
Project
j t iimplementation
l
t ti
- Project time line expectations
• Wet Lap Machine upgrades
- Existing equipment capacity
- Options to increase capacity
- Options to upgrade controls and components
- Recommended
R
d dS
Spares, wires
i
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Date/Title/Author
Carl Andersen
John McAuliffe
Peter Jones
Agenda (Cont.)
• Wet Lap Relocation
Tony Genisot
- Disassembly,
Disassembly support and supervision
- Machine refurbishment and handling of unplanned costs
- Installation and supervision
• Baling Line
Peter Jones
- Typical baling line with cost estimate
- mill has available flash dryer with 3 presses - discussion of possible options for
reusing any of this equipment
-
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what would it take to put on a strapping to the bale line
Date/Title/Author
Wet Lap production
Machine Layout
Bleached pulp machine screening
Cutter
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Wire section
Baling
Press section
Cutter
Wet Lap Machine in Niagara, WI
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Date/Title/Author
Original Metso Wet Lap Machine
P&G Mehoopany 1993
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Date/Title/Author
Original Machine Specifications
• Manufactured
• Metso (Hymac) 1993
• Production
• 200 BDSTPD
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Date/Title/Author
INTERNAL
Upgrades to Original Wet Lap Machine
• Vacuum System
- Vacuum system installed on
the Cutter layboy and used to
convey the pulp sheet from the
transfer belt to the lowering
conveyor.
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Date Author Title
Upgrades to Original Wet Lap Machine
• Floating Wedge with Side
Deckle
D
kl Assembly
A
bl
- The whole upper wedge
-
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section floats on the pulp
located in the wedge section
The wedge section continually
adjust to changes in the pulp
characteristics
Process disturbances are
easily accommodated.
Date Author Title
• Wire Tensioning Device
- Assembly consists of a pair of
-
pneumatic cylinders that are
attached to a SST Rod
The tension rolls are attached
at the end of the rod
A gear mechanism with cross
shaft ensure that the tension
roll is pushed/pulled evenly
from one side to the other.
INTERNAL
Upgrades to Original Wet Lap Machine
• Sheet Transfer Device
and
d Edge
Ed Trim
Ti
- Sheet Transfer Device used to
-
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transfer the pulp sheet from
TWP to Cutter Layboy
Adjustable edge Trim nozzles
attached to the transfer doctor
Date Author Title
• Wire Cleaning Shower
- High pressure oscillating
-
showers on both the top and
bottom wire to keep the wire
clean
clean.
The shower pipes are located
inside SST boxes equipped
with seals to prevent leakage.
Machine Capacity
Discussion
• Production
• Grade
G d
• Freeness
• Feed consistency
• Ph
• Ash content
• Stock Temperature
• Dryness target
• Bale SIze
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Date/Title/Author
TBD
SW HW
SW,
HW, Blend
Bl d
Minimum of 620 CSF
Minimum of 4.2%
4.2%+// .2%
7.0 +/- 0.2 units
Maximum of 3%
Minimum of 140 deg F
Minimum 45%
52" large x 50"
52
50 high x 46"
46 deep
Wet Lap Machine Rebuild
Production Upgrade engineered solutions
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Date/Title/Author
INTERNAL
Wet Lap Machine Rebuild
Engineered machine modifications
• TWP frame extended by 78
inches.
• New frame support legs added.
• Existing S roll section relocated
and 4 S rolls added
added.
• New independent foil section (2
segments) added.
• New saveall c/w drain (under S
roll section) added.
• Top wire guide roll relocated.
• New
N
ttension
i rollll d
doctors
t
c/w
/ llube
b
showers added.
• New dewatering barrier added
between last foil and first S roll.
roll
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Date Author Title
• New grooved roll showers (3)
added
added.
• New grooved roll wipers (3)
added.
• HP wire clean showers (2) c/w
savealls and pulp doctor.
• New outside bottom wire roll
shown to increase wrap on bottom
drive roll.
• New bottom wire outside roll
cleaning
g shower
• New headbox dilution shower
added.
Wet Lap machine rebuild
Headbox
• Adding a dilution shower
-
Even out the sheet profile and
improve sheet formation on the
wire
• Change slice lip of headbox to
stainless steel.
-
Increase the delivery area to the
forming section allowing more pulp
being fed to the forming area thus
increasing the throughput.
• Add to inspection doors to the
headbox.
-
1
4
Improve maintenance of the
headbox and ease removal of
foregn contaminants
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Date/Title/Author
Wet Lap Machine Rebuild
Top Wire Loop
• New Machine Wire
• New
N
R ll D
Roll
Doctor
t w/shower
/ h
-
to remove stock accumulation on the
fabric transferred to the tension roll
securing a proper fabric run to the lead
in roll and improving runnability of twin
wire press thus maintaining proper seal
between headbox and lead in roll.
• HP Shower
-
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Relocate high pressure shower to spray
from inside the fabric toward outside.
This will result in a properly cleaned
f b i thus
fabric
h iimproving
i runnibility
ibili and
d
capacity of the twin wire press. A badly
cleaned fabric will result is loss of
throughput.
Date/Title/Author
Wet Lap Machine Rebuild
Bottom Wire Loop
• New Machine Wire
• New
N
R ll D
Roll
Doctor
t w/shower
/ h
-
to remove stock accumulation on the
fabric transferred to the tension roll
securing a proper fabric run to the lead
in roll and improving runnibility of twin
wire press thus maintaining proper seal
between headbox and lead in roll.
• Wire Roll
-
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Add one new deflector roll on outside of
fabric in order to improve wrap on the
bottom drive roll to eliminate fabric
slippage
li
Date/Title/Author
Wet Lap machine rebuild
Table & Wedge
• Gravity Table
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-
Replace plastic static foil on both
the top and bottom gravity table
with stainless steel static foils.
This will improve dewatering the
entire forming section thus
increasing throughput. It will also
eliminate plugging of the holes
thus reducing downtime required
to unplug the draining holes of the
static foils.
-
Install one new foil blade
complete with cross machine
b
beam.
Thi
This will
ill preventt water
t
carry over into “S” Rolls
preventing re-wetting of the sheet.
Date/Title/Author
Wet Lap Machine Rebuild
Table & Wedge
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Date Author Title
Wet Lap Machine Rebuild
“S”
S Roll section
• “S” Rolls
-
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Add new frame between last “S”
S
roll and high pressing section to
add additional “S” rolls increasing
the draining surface of the twin
wire press
press. This modification
increases the retention time of
the pulp in the twin wire press
thus removing more water from
the pulp.
pulp A more solid sheet will
be fed to the high pressing
section allowing applying more
nips and increasing the
dewatering in order to achieve
the final discharge consistency.
Date/Title/Author
Wet Lap Machine Rebuild
Press Section
•
Press Rolls
-
•
Transfer Doctor
-
20
Add grooves to the bottom three press
rolls. Because you have better drainage
at the nip. A flat roll surface is a
restriction to proper dewatering. Also it
will minimize damage of the fabrics
when the twin wire press is loaded
beyond the drainage capacity. For each
roll add new shower to keep grooves
clean and rubber wiper to minimize
water re-entry into the nip and rewetting
th sheet.
the
h t
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Relocate the doctor doctoring the mat
(stock) onto the transfer conveyor to the
cutter
Date/Title/Author
Wet Lap Machine Rebuild
Transfer Conveyor
• Transfer conveyor
-
Change the angle of the
transfer conveyor from the twin
wire press to the cutterlayboy
so that the sheet coming out of
the drive rolls remains as
straight as possible.
• Edge Trim
-
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Add new edge
g Trim Squirts
q
w/
supply system good for 2500 psi
Date/Title/Author
Wet Lap Machine Rebuild
Cutter Layboy Section
• Cutter Knife
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-
Replace the knife assembly &
Anvil
-
Replace the bearings and seals
on knife assembly, flip roll,
d i rollll and
drive
d tracking
t ki roll.
ll
Date/Title/Author
Wet Lap machine rebuild
Transfer belt,
belt Lifting Table & Conveyors
• Vacuum Transfer Belt
-
New supply system
• Lifting Table with Conveyors
-
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Peg table Lifting Table
4 Strand Chain conveyor
Pick up station
Controls, Pneumatics, Hydraulics
Date/Title/Author
Roll Upgrades
• Existing Rolls
QTY
ROLL
MATERIAL
12
Table Roll
Guide Mustang
0-1P&J
2
Tension Roll
Guide Mustang
0-1P&J
2
Guide Roll
Guide Mustang
0-1P&J
1
Deflection Roll
Guide Mustang
0-1P&J
6
Press Roll
Ray Roc
0-1P&J
2
Drive Roll
Ray Roc
0-1P&J
• Scope
-
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New covers for all rolls as noted above
Bearings and Seals
S
for
f all rolls except “S” rolls
New Pillow block bearings for existing “S” rolls as needed
Blast and paint rolls ends
Date/Title/Author
(with grooving of 3 bottom rolls)
Machine Relocation
Machine Refurbishment
• Disassembly Drawings with details
• Details
D t il off shipment
hi
t
• Details of shipment sections
• Wet Lap Refurbishment
• Disassembly and Assembly Supervision
• Asset Tracking and Tagging
• Metso Capabilities
• Controls
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Disassembly Drawings with details
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Date/Title/Author
Details of shipment
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Date/Title/Author
Details of shipment sections
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Date/Title/Author
Wet Lap Refurbishment Scope
Proposal
• Clean wire section frame and repaint complete.
• Clean
Cl
press section
ti fframe and
d paint
i t as needed.
d d
• Cutter/Layboy section clean only.
• Inspect and test all cylinders and air bags for leaks.
• Inspect wire guide roll slides.
• Inspect cutter and conveyor roll bearings.
• Install new components and upgrades in table
table, press section
section, trim
system and cutter layboy per quote
• Install reconditioned rolls.
• Install new lift table in cutter/layboy section.
section
• Replace all pneumatic lines with new stainless steel lines, fittings and
plastic lines.
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Date/Title/Author
Wet Lap Refurbishment Scope
(cont )
(cont..)
• Mount all prox switches, photo eyes and replace all conduit and wiring with
new as existing. (Note: mill to supply hardware).
• Machine will be shipped in assembled sections
• Transportation from Appleton to Jay ME.
• NOT INCLUDED
-
Defective items found during disassembly (A cost estimate will be priced for each
it )
item).
-
Any item found to be damaged or defective upon inspection at disassembly and
upon cleaning at Appleton (A cost estimate will be priced for each item).
• TIME FRAME
-
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Three (3) months in Appleton - Time dependent on length of time to re-cover rolls
Date/Title/Author
Disassembly and Assembly Supervision
• Supervision of the machine disassembly at Niagara mill
-
Six (6) - 24 hour shifts - Days and Nights
• Supervision of the machine assembly at the Jay mill
-
Nine (9) - 24 hour shifts - Days and Nights
• Supervision is calculated with a FLAT rate of $ 170/ hour with no overtime
premium (Rate does not account for Sunday and Holiday work)
premium.
• Expenses are charged at actual cost - No mark-up
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Date/Title/Author
Asset Tracking and Tagging
• Option Price given for computerized tracking of all equipment
• The disassembly and assembly cost estimates include:
-
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Supervising match marking of removed equipment
Filling out hand tags to identify equipment as removed
Date/Title/Author
Metso Capabilities
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Date/Title/Author
Controls
In House and millsite meetings
• Convert existing AB 540 PLC Logic to AB Control Logix Metso will follow new tag name list which the mill will provide prior to the start of the conversion.
p
p
• Reconfigure the analog I/O to work with Control Logix
• Provide Bit map between PLC and DCS using Ethernet communication protocol
• Convert existing isolated (inputs / outputs) motor starter logic to work with Devicenet
Convert existing isolated (inputs / outputs) motor starter logic to work with Devicenet
communications
• Provide Bit map between PLC and 700 Series Drive using Controlnet PLC software for new supplied equipment will be integrated into the converted Control Logix
pp
q p
g
g
• All software will be submitted for review during P & I review (mill trip)
• Provide specification sheets for any new devices, which will follow New Page equipment specifications
p
• Field trip to millsite to simulate drive to PLC communications (FAT test – Factory acceptance test)
• Field trip to millsite
p
to simulate DCS to PLC communications (FAT test)
(
)
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Date/Title/Author
Controls (cont.)
• Not Included:
– All Hardware (PLC, cards, valves, P/I’s,
P/I s, I/P’s,
I/P s, Solenoid valves, photo
photoeyes, proximity switches)
– P & I drawings
• Controls Support
– Checkout and commissioning of equipment at millsite
» 2 -E & I engineers for five (5) – 10 hour days
» 1 -Fluids
Fluids engineer for two (2) - 10 hour days
– Start-up with Paper support
» 2 -E & I engineers for two (2) – 10 hour days
» 1 -E & I engineers
g
for two ((2)) – 10 hour days
y
– Training
» 1 -E & I engineers for two (2) – 10 hour days
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Date/Title/Author
Baling Lines
INTERNAL
Wet Lap
Shipping Discussion
• For loading into Railcars (108" wide) or Trucks (100" wide)
• Maximum
M i
b
bale
l width
idth iis 52" - times
ti
ttwo ffor a ttotal
t l sheet
h t width
idth after
ft
edge trim of 104".
• Slitting (3) times across would result in (4) 26" wide and cut to 32/33"
length with the layboy.
• Fit (4) wide at 26" each in a railcar
• (3) wide at 32/33" each in a trailer
• Bale size is Max 500 kg and LxWxH = 800 (31.5”)x800 (31.5”)x900
(35.5”)) for bale press
(35.5
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Date Author Title
Robopress™
PR 2 W
PR-2
WetLap
L
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The PR-2 WL compresses each
Wet Lap sheet stack with a force of
up to 2 MN. It consists of a press
unit with built in belt conveyor and
a separate hydraulic unit. The
press unit is equipped with a
fenced top platform for service
work. Capacity of 200 bales/hr
Robopress™
PR 2 W
PR-2
WetLap
L
• Press force: 2 MN
• Press
P
stroke:
t k 700 mm
• Press plate with indentation
plate and spacer
40
•
Maximum intake bale height:
1200 mm
•
•
•
Conveyor length: 1620 mm
Conveyor belt width: 1000 mm
Conveyor height: 900 mm
© Metso
Date Author Title
INTERNAL
Robopress™
PR 2 WL
PR-2
Press unit
• Press force: 2 MN
• Press stroke: 700 mm
• Press plate with indentation plate and spacer
• Maximum intake bale height: 1200 mm
• Conveyor length: 1620 mm
• Conveyor belt width: 1000 mm
• Conveyor height: 900 mm
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Robopress™
PR 2 WL – MAIN PARTS
PR-2
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INTERNAL
Baling Line Layout
Cutter Discharge
Pivot Conveyor
Storage Conveyor
Strapping Machine
Robo Press
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Date Author Title
Scale Conveyor
Swing Conveyor
INTERNAL
Baling Line Layout
Discharge Conveyor
Robo Stacker
Strapping Machine
Ink Jet Marker
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Date Author Title
Pivot Conveyor
INTERNAL
Baling Line Layout
Palletizer Option
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Date Author Title
INTERNAL
Wrap up
• Quotation review
• Layout
L
t Drawings
D
i
review
i
• Time frame
• Machine building drawing
• Services needs
• Spare Parts package
• Machine wires
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Date Author Title