Tissue Service Catalog

Transcription

Valmet
Tissue Service
for Best Performance
Long live the tissue machine!
Unexpected disturbances, or even stop,
in the production are problems we all
want to avoid as it almost always cause
both headache and cost. No matter if
the machine is new or old it needs a
well-planned service program to obtain
optimum productivity over the years. But
the challenge is to find a good balance
between the service need and actions to
reach cost-efficiency.
Best technology is not enough
Today there is an increasing demand for
sustainable operations, meaning how
to household with resources as energy,
water and fiber but also to increase the
competence and awareness among the
operators in order to take the right actions,
at the right moment. Safety is another
issue which is important in order to
protect the employees from hazardous
situations and unnecessary injuries.
Reducing the environmental impact is a
natural part of our product development
as well as providing safe equipment and
upgrades. Using Best Available Technology
is important but it is not enough. Well
educated and motivated operators utilizing
Best operating practices, is essential to be
capable to operate the machine close to
the limit. Sustainable operation, avoiding
overconsumption of our resources is in the
interest of us all.
Common understanding save time
and money
Having a service program tailored for your
production equipment and requirements
can bring large improvements even with
small actions. With the experience
from more than 200 tissue machine
installations we have the competence,
technology and resources to understand
your maintenance-, upgrade-, or training
needs, suggest solutions and deliver them
according to your targets. We always aim
to reach a common understanding of the
solution best suitable for your requirements
both when it comes to technology and costefficiency.
Close to you
Valmet Service Centers and their dedicated
mill contact persons are present in all
regions and will rapidly respond on your
request. With the technical back-up from
the global technology centers and Valmet’s
gathered expertise you can always get the
support you need to get your production
back on track or take it to the next level.
Today we can also offer process remote
support which has been well received
by many tissue producers. It is instant,
efficient and cost-saving.
In this catalogue you can find examples of
what we provide but this is only a glimpse
of what we can do for you. Let’s meet
and discuss how we can support you to
reach your long term goals and ensure a
sustainable and cost efficient operation now
and in the future.
Yours sincerely
Gunnar Gullbrand
Tissue Global Services Director
TRAINING
Tissue Making Training
Tailor Made Training
01
02
DIAGNOSTICS & AUDITS
Capacity Study
Drying Capacity Service
Energy Saving Study - Tissue Mill
Energy Baseline Study
Energy Saving Service - Drying Section
Yankee Safety Inspection
Dry End Safety Upgrade
Environmental Safety Study
Vibration Study
Tissue Machine Alignment
Headbox Mechanical Condition Study
Forming Section Process and Condition Study
Shower and Cleaning Analysis
Water Consumption Analysis of Shower Pipes
Yankee Internal Inspection
Steam and Condensate System Study
Air System Condition Test
Tail Threading Performance Study
Tissue Reel Process and Condition Study
IQ Scanner Audit
IQ SteamProfiler Audit
Remote Process Support
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
STOCK PREPARATION - REFINER
StockBoost for Refining
25
OptiFiner Pro
26
Fillings and Segments
27
MicroBar28
Exchange System for Shaft Assembly
29
Turbine Housing
30
Closed Mechanical Seal
31
Touch Vibration Detector
32
Filling Gap Measurement
33
Torque Limiter
34
STOCK PREPARATION - SCREEN
StockBoost for Screeing
35
NimLuc36
Nimax DIP
37
Nimax MS
38
NimCat39
Recoating Services
40
ProFoil41
Exchange System for Shaft Assembly
42
WET END
Headbox Surface Reconditioning MX06
43
Headbox Apron Reconditioning
44
Headbox Dilution Control System
45
Headbox Vanes - EasySheet & PolySheet
46
Headbox Vanes - CompoVanes
47
Headbox Vanes - DuraSheet & DuraWedge
48
Headbox Vanes - Data
49
TrimSquirt50
Felt and Wire Stretcher
51
TailCutter52
CleaningNut53
Shower Pipe Family
54
Shower Oscillator
55
Felt Suction Box
56
Felt and Wire Guides
57
Bearing Holders
58
Wet End Exhaust
59
Advantage Returne Service
60
FABRICS
GapMaster Ultra for Tissue
61
SprintMaster and StarMaster Felts
62
BlackBelt Shoe Press Belt
63
BeltScanner64
PRESS SECTION
Advantage Suction Pressure Roll
65
Suction Roll Maintenance
66
Advantage ViscoNip Service
67
Advantage NTT SymBelt Service
69
LocSeal71
FlexSeal72
Oscillating High Pressure Cleaning Shower
73
ROLL COVERS
PressFox TIS & VacuFox TIS
74
PressHusky75
VacuHusky76
PressGator ZL
77
PressGator Z
78
WireGem79
DriveShark Z
80
GuideMustang81
GuideColt82
CalOpal M
83
DRYING SECTION
Yankee Hood and Air System Optimization
84
Advantage Balance Control ABC
85
Yankee Condensate Removal System
86
Yankee Spoiler Bars
87
Yankee Head Insulation
88
Yankee Head Bolt Safety Guard
89
Yankee CARB Bearing Upgrade
90
Yankee Head-to-Shell Joint Upgrade
91
On-site Dynamic Yankee Balancing
92
Infinikote93
Ultrasonic Testing of Yankee Shells
94
On-Site Yankee Profile Grinding
95
Yankee Surface Polishing
96
ScreenCloth - Yankee Polishing
97
Yankee Wear Profiling
98
Yankee Surface Profile Measurement
99
Yankee Crown Optimization
101
THRU-AIR (TAD) Dryer Service
102
Heat Recovery System
103
Waste Heat Steam Generator
104
DOCTORING
Advantage Creping
105
Yankee Doctor Blade Storage
106
LiteFit Composite Blade Holder
107
FiberDoc Composite Blade Holder
108
LiteCompact109
Doctor Loading & Oscillating Unit
110
OsciPro Pneumatic Oscillator
111
Doctor Oscillator Bearings
112
ValDual - Doctor Blade
113
ValEco - Doctor Blade
114
ValEco T - Doctor Blade
115
ValGlass LT - Doctor Blade
116
Doctor Blade Service
117
BladePuller118
DRY END
TailThreader119
Tail TurnUp
120
VacBox121
Edge Trim Chute
122
Active Foils
123
Advantage Run concept - Foils
124
NipDeflector125
Advantage Run Concept - Reel Nip BlowBox
126
WaterJet TurnUp
127
WaterJet Trim
128
Mechanical Slitter
129
WaterJet Slitter
130
Advantage WetDust
131
Calender Gap Control
132
Primary Arm
133
Pivoted Primary Arm
134
Pivoted Secondary Arm
135
Secondary Carriage
136
Advantage Roll Handling
137
Automatic Inflate/Deflate Unit
138
Lifting Table
139
Core Shaft Puller
140
Core Loading Unit
141
Core Robot
142
Advantage Spool Return
143
Advantage DustControl 144
Parent Roll Pusher
145
CONTROLS
Automation Life Cycle Plan
Automation Trainings
IQ Stock
IQ Intelligent Scanning Control
Energy Efficiency Management - ValmetDNA
IQ Fiber Weight Measurement
IQ Basis Weight Measurement
IQ Web Moisture Measurement
IQ Steam Profiler for Tissue
IQ CD Control
Process and Quality Vision - Web Inspection System
Process and Quality Vision - Web Break Analysis
Process and Quality Vision - Upgrades/Replacements
MILL
Advantage Mill Technology
Spare Part Audit
Spare Parts Maintenance Guide
146
147
149
150
151
152
153
154
155
156
157
158
159
160
161
162
ENERGY SAVING PRODUCTS
Energy Saving Study Tissue Mill
05
06
Energy Saving Service Drying Section
07
IQ Steam Profiler Audit
23
OptiFiner Pro
26
MicroBar28
SprintMaster and StarMaster Felts
62
74
PressHusky75
VacuHusky76
Yankee Hood and Air System Optimization
84
Yankee Condensate Removal System
86
Yankee Spoiler Bars
87
88
103
104
Energy Efficiency Management - ValmetDNA
151
155
160
Valmet AB
Valmet Fabrics Inc.
Axel Johnsons väg 6
Box 1014
SE-651 15 Karlstad, Sweden
+ 46 54 17 10 00
Yrittäjänkatu 21
PO Box 427
FI-331 01 Tampere, Finland
+358 (0)10 404 9000
Valmet Italy S.p.A
Valmet Technologies Oy
Via A. Gregorcic 46
IT-341 70 Gorizia, Italy
+39 0481 528 311
Teollisuustie
PO Box 125
FI-376 01, Valkeakoski, Finland
Valmet Paper Ltd.,
Valmet Technologies Inc.
Service Center
Waterside Business Park
Johnson Road, Eccleshill
UK-883 38A, Darwen,
United Kingdom
+44 1254 819 050/070/078
Valmet Inc. USA
516 Alfred Street
US-0040 05, Biddeford, USA
+1 207 282 1521
Rautpohjankatu
PO Box 587
FI-401 01 Jyväskylä, Finland
+358 20 482 150
Valmet Paper Technologies
(China) Co., Ltd.
118 Jian Guo Road, Chaoyang district
10 00 22 Beijing, China
+8610 5666 2568
Specifications in this publication are subject to change without notice
Product names in this publication are all trademarks of Valmet Corporation
Tissue Making Training
Improve your operational skills
Tissue making is a process where many
different parameters must interact perfectly
together to get the maximum output from
the tissue making line. The training will
give you knowledge and understanding to
be able to optimize the performance of the
tissue machine.
Features
During the course you will have the
opportunity to discuss your own tissue
making problems or issues with Tissue
experts and share your experiences with
others.
• Maintenance
The course is designed for everyone who
wants to improve their skills in tissue
making such as production managers and
others with similar backgrounds in the
tissue making field.
• Stock-prep
• The tissue machine
• Runnability
• Environmental issues
After the course you will get a deeper
understanding of how the equipment’s
design impacts the process and how the
properties are affected by the parameter
settings. You will also know how to
supervise and optimize the machine to
fully utilize the production capacity. The
course is held in English and lasts for five
days.
Training
© Valmet 2015
Prerequisites
The course will cover the
essential areas in the tissue
making production including:
1
Tailor Made Training
Training is essential to ensure operational
excellence and performance of the tissue
machine. Based on each mill’s or even
person’s specific needs or knowledge
training can be tailor made both for groups
or individuals. We can also offer skill and
knowledge mapping to define competence
areas to be improved.
Train the Trainer
Training
2
Training related to installation of a
new machine or rebuild performed at
your mill and in Karlstad’s workshop is
complemented with online training. The
attendees will participate in the check-out
as well as the start-up of the machine. After
the training the participants should be able
to perform training for the mill’s machine
crew.
Online Training
The Online training is an individual
program based on each person’s skills
and competence in order to improve the
knowledge level needed for their specific
work position. The training includes self
studies with tests. All tests are checked and
commented. Online training can be used
in areas as:
•
•
•
Rare occasions where detailed
instructions are needed
Generic knowledge
Daily actions, trouble shooting etc.
Skill and knowledge mapping
Skill and knowledge mapping facilitates
training planning, secures sufficient and
improved knowledge level and includes:
•
•
•
Role and knowledge description for each
position
Individual training plans
Report on future improvements
© Valmet 2015
Improve operational competence
and efficiency
Capacity Study
© Valmet 2015
Every production line has bottleneck areas
that limit the total performance. Each one
of the limitations adds up to give a larger
total negative effect both on the efficiency
and speed of the tissue making process.
Features
The study will define:
• Existing capacity
• Bottleneck areas and
propose
de-bottlenecking solutions.
A mechanical and process study of defined
sections or of the complete tissue making
process tells about the current production
capacity. It will also identify and quantify
bottleneck areas which limit the tissue
making capacity.
Report of findings
and recommendations
Based on these findings, Valmet will
recommend priorities for modifications
to reach defined targets. The study of
the machinery and process evaluates
possibilities to increase production to levels
even beyond the original design capacity.
The results from the study will be presented
in a written report together with a graphic
presentation for easy understanding and
for internal presentations. The report will
also include evaluation of the expected
economic return of the proposed solutions.
Diagnostics & Audits
Enhance financial performance and
increase production
3
Drying Capacity Service
Valmet Drying capacity service aims
to improve the drying capacity and
production of a tissue machine. Most tissue
machine drying systems normally undergo
grade and process changes during the years
which may affect the production if they
are not followed by properly related system
adjustments.
The Drying capacity service serves as a
base for drying process adjustments that
can provide an immediate and significant
increase in production with a very short
return on investment.
4
Features
Audit of tissue machine drying
performances in order to:
• Identify drying performance
and production level
• Compare measured data to
those in Valmet database of
similar machines
• Determine and perform
process adjustments
• Advise corrective actions
and modifications to be
implemented both on a
short and medium term
• Estimate drying
capacity and production
improvements
© Valmet 2015
Improve production
and drying capacity
Energy Saving Study
Tissue Mill
Energy Efficiency Analysis
Energy Efficiency Study
Stock Preparation
Vacuum system
dewatering
Air & Ventilation
System
Auxiliary System
Short circulation
Steam and cond.
System
Yankee dryer
section
Water System
Valmet’s Energy efficiency analysis
identifies potential energy savings in the
tissue process, from pulper to reel in order
to help achieve significant cost savings.
Typical potential to improve the energy
efficiency is:
•
With process optimization - 10 to 15%
savings
• With recommended rebuild - 25 to 35 %
savings
With rising energy prices, energy efficiency
measures tend to give a very quick pay off.
© Valmet 2015
Findings and recommendations
The analysis results in a report detailing
energy efficiency measures, present
machine status and recommendations for
actions to reduce energy consumption.
Recommended actions and potential to
reduce energy consumption are prioritized
and facilitate decision making.
Features
Energy efficiency analysis consists
of the following steps:
• Bench marking
• Base line study
Recommendation for
improvements
• Road map for future actions
and decisions
Valmet’s Energy efficiency analysis is
tailored to suit each customer’s specific
requirements and can cover either the
entire production line or a specific sub
process.
Energy consumption and process
parameter information is gathered
from a number of sources such as
process automation system, real time
measurements, possible previous studies,
review of mill systems and interview of
operating personnel. All information is
evaluated and bench marked with other
similar tissue machines as well as Best
Available Technology (BAT).
Improve profitability
and competitive edge
5
Improve Your Energy Efficiency
Continuously increasing energy prices
and regulatory limits force a continuous
improvement of the tissue machine’s
energy efficiency.
Valmet Energy Baseline Study is a stepby-step mapping of the machine’s energy
usage.
The outcome is then benchmarked to find
high consumers, evaluate options and find
the best path forward for an optimum
setup considering both process and energy
consumption.
Features
In the Energy Base Line Study
the energy consumption
is measured on-site in the
machine section by section.
The data is then benchmarked
using Valmet’s extensive
database on comparable
machines as well as in-house
knowledge and experience.
6
The outcome of the study is a prioritized
recommendation list including actions,
energy savings, budget cost and return on
investment analysis.
© Valmet 2015
Energy Saving Service
Drying Section
Valmet Energy saving service focus on
reducing the energy consumption of the
drying system.
© Valmet 2015
About 70% of the energy used in a mill
goes to the drying process (Yankee hood
and Yankee dryer). The energy saving
potential is therefore remarkable, also
considering that most tissue machine
drying systems have been properly set-up
only when originally started-up. Over the
years, machines usually undergo grade and
process changes and the cost of energy is
continuously modifying, too. The energy
saving service is a tool to considerably cut
drying costs.
Features
Service of tissue machine drying
performance to:
• Identify energy consumption
level
• Benchmark measured
data to those in Valmet”s
database of similar
machines
• Determine and perform
process adjustments
• Advise on corrective actions
and modifications to be
implemented both on a
short and medium term
• Estimate energy savings
Remarkable energy saving
potential
7
Yankee Safety Inspection
The Yankee dryer is a pressurized
vessel, exposed to high stress. It is also
regulated by legal demands as well as risk
assessments from insurance companies.
Good functionality is essential for the
steam distribution and condensate
removal, which directly affects the drying
performance and production. Valmet
Yankee safety inspection supports high
safety, optimized production and is
trusted as an approval of functionality by
authorities and insurance companies.
The inspection supports:
•
•
8
•
Enforced high safety level
Improved drying efficiency and
uniformity
Minimum downtime due to quick and
accurate application with tailor-made
tools
Features
The inspection program is a
combined safety and condition
test which includes:
• Inspection and condition
evaluation of the
condensate removal system
and surface of shell, heads
and journals.
• Magnetic particle testing of
critical areas
• Structural bolts integrity by
ultrasonic testing
• Soda straw gap clearance
control
The inspection is a good basis for
correcting measures and potential needs of
maintenance. The programs are developed
according to TAPPI recommendations and
together with insurance companies.
© Valmet 2015
Ensure high safety level
and conform to regulations
Dry End Safety Upgrade
Make your machine a safe place
to work
Features
A successful dry end safety upgrade
in terms of safety and maintaining
production – requires a thoroughly made
plan like;
A dry end safety upgrade could
mean implementation and
setup of:
Step 1: Safety review
»» Safety aspects and machine
operations
•
•
•
»» Possible process improvements
Step 2: Detailed specification
Step 3: Funding & Implementation
Step 4: Activation of safety system
© Valmet 2015
Valmet follows and works according to
existing government directives and we
know how to improve safety in a tissue
machine.
• Safe operator zones
without energy
• Safe and efficient operating
tasks
• Pivotable guards
• Fences
• Process improvements
• Efficiency and production
improvements
Valmet has the solutions to
make all this happen and
to make the work safe and
efficient.
•
9
Environmental
Safety Study
Drying and ventilation systems usually
undergo grade and process changes over
the years. As a consequence, heat, dust
and mist might no longer be properly
controlled and could even interfere with
the normal machine operation. The risk of
fire hazards, unhealthy working conditions
and frequent downtimes will increase
as well as the need of maintenance and
cleaning.
Valmet Environmental safety service will
contribute to
•
10
•
•
•
•
Reduced amount of dust/mist in critical
areas
Reduced downtime caused by dust
Generally improved machine safety
Improved conditions in the machine
hall
Ensured continuous compliance with
environmental regulations
Features
The Environmental safety
service includes gathering of
ventilation data such as:
•
•
•
•
Air flow
Dust
Mist
Other relevant air system
data
Recommendation with required actions
will be reported in order to improve safety
and uptime.
© Valmet 2015
Improve safety and uptime
Vibration Study
Vibration in machine equipment can cause
severe problems and will limit the machine
efficiency. It is also a safety hazard.
A vibration study can determine:
•
•
•
•
The dynamic behavior of machine
sections
The mechanical condition of the
machine
The feasibility of a possible capacity
increase
Future mechanical problems and
reduction of unanticipated shutdowns
© Valmet 2015
Valmet’s vibration studies combine
mathematical analysis and diagnostic
measurements in a distinct aim to make the
machine run smoother, faster and more cost
efficiently.
Features
Valmet vibration studies cover
the entire machine line from
stock preparation to reel, or
specific machine sections.
• Capacity study; mapping the
dynamic behavior of the
machine
towards targeted speeds
yielding
the most cost effective
approach
• Rebuild analysis; evaluate
how
rebuilds will affect dynamic
behavior
of the machine and
consequences
at current or increased
speeds
• Troubleshooting; locate and
eliminate vibration sources
having detrimental effect on
the machinery or process
Check the mechanical condition
and dynamic behavior
11
Tissue Machine Alignment
Proper alignment enhances the runnability
of tissue machines, improves the properties
of paper, and reduces the uneven wear
of roll covers, fabrics, felts and ceramic
blades.
Our alignment methods and tools are
designed to
•
12
Improve basis weight and orientation
profiles
• Improve formation and other quality
characteristics, extend life of fabrics and
ceramics
• Improve moisture profile and
runnability
• Ensure more even wear of roll covers
• Prevent diagonal drive gear contact
We measure all components against the
machine’s center line. When using the
center line as a reference, horizontal and
vertical values can always be reproduced
within 0.1 to 0.15 mm.
Features
A combination of prismatic
mirrors, an electronic total
station and software developed
specifically for tissue machine
alignment needs are used for
measurement including
• Internal alignment of the
headbox and alignment with
forming section
• Alignment of forming
section rolls and dewatering elements
• Alignment for press
section nip rolls relative
to one another and to the
machine’s center line
• Alignment of dryer section
rolls and cylinders
© Valmet 2015
Improve paper properties
and runnability
Headbox Mechanical
Condition Study
Focus on paper quality
and performance
Features
Is your headbox properly aligned?
Formation or streak problems? Headbox
cleanliness or leaking problems?
A headbox condition test
provides information on
condition of the:
© Valmet 2015
A condition test is the most cost effective
approach to evaluate the necessity of
service and to identify problems for
improving the formation performance.
• Slice opening and control
system
• Apron and the top slice
• Micro adjusters
• Alignment
• Surface finish
• Pressure transmitter
• Equalizing chamber and the
tube bank
With long experience and
utilizing custom made tools
we provide a professional and
effective check-out. All critical
areas are thoroughly examined
within one day.
The headbox performance is highly
dependent on the degree of maintenance
interval and quality.
13
Forming Section Process
and Condition Study
Ensure trouble-free production
and uniform paper quality
Based on the findings we recommend
preventive maintenance actions which
ensure trouble-free production and more
uniform paper quality.
•
•
14
•
•
•
Increased forming fabric life
Identification of impending equipment
failures
Reduced safety risks
Maximized de-watering performance
during the life cycle
Increased efficiency
Features
• Doctoring studies
• Alignment of rolls
• Frame alignment and
adjustments
• Fabric stretcher and guide
services
• Runnability studies
• Service of de-watering
elements
• Service of showers and trim
squirts
© Valmet 2015
Optimum de-watering and sheet formation
is critical to tissue production. The
forming section process and condition test
monitors and trends performance of the
former section. It gives information about
the condition of the components and the
potential for improving runnability.
Shower and Cleaning
Analysis
Improve runnability and quality
The shower and cleaning analysis
contributes to:
•
© Valmet 2015
•
•
•
•
Systematic development of working
processes
More efficient cleaning shutdowns
Improved production line efficiency
Improved runnability
Improved quality
Features
The scope of the analysis is
established in consultation with
you and can include analysis of:
• Buildup
• Water consumption of
shower pipes
• Doctoring
• Short circulation review (as an
option)
• Internal and external roll
showers
• Cleaning cycles
Report of findings
and recommendations
The report includes results from all
examinations and recommended measures
by machine section.
A clean machine keeps the efficiency and
runnability of a production line at a high
level. It is also a guarantee of the quality of
the end product.
15
Water Consumption
Analysis of Shower Pipes
There are many things that impact the
water consumption in the shower system.
With an optimized system you will
achieve:
•
•
•
•
•
•
16
Increased system efficiency
Decreased production and maintenance
costs
Excellent quality control of the paper
Less energy consumption as smaller
pumps can be used
Only scheduled maintenance and no
unexpected stops caused by the shower
pipes
Minimized environmental impact
Features
A Water consumption analysis
can help you define problems
which cost time and money
such as:
• Unstable quality control of
the paper
• Unplanned production stops
• High consumption of water
and electricity
Valmet can also check if the shower pipes
are optimized for your process. With the
findings at hand we can recommend minor
adjustments or small investments that
can decrease costs and lower the water
consumption.
© Valmet 2015
Find possible water
consumption savings
Yankee Internal Inspection
The internal components of a Yankee dryer
support the distribution and removal of
steam in the cylinder. This directly affects
the heat transfer performance.
Regular inspections can keep you aware
of the operating condition of the Yankee
cylinder components.
Early detection of potential problems can
yield:
•
•
•
© Valmet 2015
•
Better productivity with limited
investment
Lower cost per ton produced
More systematic way to develop
operations, processes and equipment
Improved drying efficiency and
uniformity
We provide a detailed report and
proposals for all findings’ corrective
measures.
Features
• Visual inspection and
examination of condensate
removal system for
leakages and to evaluate its
performance
• Inspection of balancing
weights
• Inspection of soda straws
• Inspection of shell, heads,
and journals
We provide a detailed report
and proposals for all findings’
corrective measures.
Improve drying efficiency
and productivity
17
Steam and Condensate
System Study
Keep aware of operating condition
Early detection and correction of problems
in the steam and condensate system
ensure better productivity, lower cost
per ton produced and a more systematic
development of operations, processes and
equipment.
Regular audits of the yankee steam and
condensate system keep you aware of
operating condition and secure consistent
supply of steam to the yankee cylinder.
Features
• Inspection of external
steam and condensate
system
• Verification of operation
• Process calculations of the
system
• Troubleshooting of specific
problems
• Temperature measurements
Save time and money
•
18
•
•
•
•
•
Improper controls adjustment and set
points
Excess energy use
Steam erosion and leaks
Corrosion
Drying problems
Safety issues
© Valmet 2015
Early detection of:
Air System Condition
Test
Immediate feedback
on critical issues
Audit of critical equipment and issues that
enables tissue makers to:
•
•
•
© Valmet 2015
•
Carry out preventive maintenance on
hood and air system
Properly set-up or adjust equipment
Get more uptime out of the existing
tissue machine
Involve operators and deepen their
knowledge of the tissue machine
Features
System settings and
performance are analyzed in
relation to original start-up
parameter settings for the:
•
•
•
•
•
•
Hood
Burners/steam coils
Fans
Heat exchangers
Ducts/dampers
Dust collectors/stabilizer
foils
• Separators/filters/silencers
• Exhaust/feed units
• Other air components
Valmet mechanical and functional air
system check-up is a complete audit
of any drying and ventilation system
problem - both from a mechanical and
process perspective - through specialized
diagnostic tools. A complete report is
provided for immediate feedback and
action.
19
Tail Threading
Performance Study
Improve production efficiency
Regular inspections keep you aware of the
operating condition and help to:
•
•
•
•
20
Monitor and trend performance of
threading system components
Identify impending equipment failures
Identify safety hazards
Recommend improvements to
equipment and procedures
Features
• Mechanical condition and
measurement
• Transfer and threading
surveillance
• Control inspection
• Optimization needs
• Vacuum, airflow and
velocity analysis
After the inspection we
provide a detailed report and
recommend corrective actions.
© Valmet 2015
Much time and energy can be spared
if your threading system is performing
properly. Unfortunately, threading
components can lose alignment or
efficiency over time. Each production start
or restart can be an exercise in frustration
for operators if threading fails repeatedly.
Tissue Reel Process
and Condition Study
Maintain high quality paper
The reel study is an analysis of the
condition of the reel in terms of end
product quality, machine runnability and
maintenance which can:
© Valmet 2015
•
•
•
•
Minimize bottom and top waste
Improve runnability
Improve roll quality
Improve daily maintenance and
operation
Features
The objective is to define the
current condition of the reel
and to determine the service
operations needed for the next
scheduled shutdown or the
scope of the reconditioning
needs. The study also
provides the mill maintenance
department with useful
information for their daily
maintenance actions.
Tissue reel process and
condition study includes:
• Reeling and turn up
surveillance
• Control inspections
• Paper roll structure
measurements
A well functioning reeling process is
necessary for good paper roll quality and
the elimination of reel broke. A defective
reel can cause considerable economic loss
due to bottom waste, web breaks, poor roll
structure and unplanned shutdowns.
21
IQ Scanner Audit
Ensure continuous operation
IQ Scanner Audit is a complete mechanical
and electrical inspection of the scanner
which can be performed during 8 - 10
hours downtime.
Well tuned quality control system can be
fully utilized only if performance of the
measurements is maintained in required
level.
22
Results
• IQ Scanner Audit provides
up-to-date information
about the condition of the
measurement system.
• Based on the audit results
and report, required
service actions can be
prioritized and scheduled
for minimizing costs and
maximizing availability of
the measurements
• Regular and preventive
maintenance is the key issue
for following increasing
quality and production
requirements.
© Valmet 2015
Quality control system is in a key role
when production and cost efficiency
are enhanced. System´s capability to
stabilize the process depends essentially
on the availability and accuracy of the
measurements.
IQ Steam Profiler Audit
Quality improvements and savings
© Valmet 2015
Valmet IQ Steam Profiler Audit includes
inspection of the steambox performance,
operating parameters and condition of
the mechanical and electrical equipment.
Report and analysis of the results with
recommendations for further actions is
provided.
Results
• Increased production
capacity
• Energy savings
• Lower production costs
• Better production quality
By ensuring optimal performance
of the steambox, remarkable quality
improvements and annual savings in
production costs can be achieved.
23
Remote Process Support
Remote monitoring and evaluation
•
•
•
•
•
•
•
•
Data collection remotely
Information collection at mill.
Evaluation of data and observations
Annually Performance Review
Recommendations
Actions
Follow-Up
Features
Allow the tissue experts and
the mill team to…
• Jointly optimize production
• Avoid production issues
• Trouble shoot problems
quickly and cost effective
Updated Center Lines/Routines
24
© Valmet 2015
Information security to ensure that data
are confidential information.
Reliable data connection to ensure that the
support can be given whenever it is needed.
StockBoost
for Refining
Improve quality and machinery
Benefits
StockBoost for all refiner types
and all manufactures
• The correct combination of
refiners and fillings
• A tailored service agreement
• Storage services & bearing
exchange services
• Condition management
Stock-Prep Refiner
© Valmet 2015
StockBoost is a process where we work
together with you to define areas for
improvement. These can be related to
improving pulp quality or stock preparation
machinery. Improvements can be made either
to keep the machinery in good condition
by taking care of refiner fillings, organizing
storage service for wear and spare parts, as
well as making mechanical upgrades for
the machinery, such as the exchange refiner
program or by using second-hand machines.
25
OptiFiner Pro
Saving Energy
Stock-Prep Refiner
26
Benefits
• Energy savings
• Improved strength
properties
• Reduced maintenance
• Compact and easy to install
© Valmet 2015
OptiFiner Pro is a revolutionary new
refining concept, in which one refiner can
replace two traditional refiners and even
deliver 40% electrical energy savings.
Suitable for all kinds of LC-refining
applications.
Fillings and Segments
One of the key components in an OptiFiner
RF refiner is its refiner fillings or segments.
These must be exactly suited to the
application and perform perfectly in all
situations.
© Valmet 2015
Valmet’s refiner segments are well-known
tools for improving production efficiency
and for precision control of the pulp quality
produced. Continuous development of our
refiner segment designs ensures that our
customers attain optimal fiber treatment
in OptiFiner RF refining, as in all refining
processes.
Benefits
• A wide range of standard
fillings is available for all
OptiFiner RF refiners: RF-0
(JC-00), RF-1 (JC-01), RF-2 (JC02), RF-3 (JC-03),
RF-4 (JC-04) and RF-5 (JC-05).
• Various standard patterns for
soft and hardwood refining,
for trim refining and for
refining of mechanical pulps,
as well as new patterns for
specific fiber types.
• Maxiflo™ fillings for improved
capacity
Stock-Prep Refiner
Improve production
efficiency and control
27
MicroBar
Valmet’s patented MicroBar design
is the first innovation in decades that
offers clearly higher refiner capacity with
considerably higher loadability in lowconsistency refining than any other refiner
filling design. The more efficient operation
of MicroBar also saves refining energy both
in short-fiber and long-fiber refining.
Stock-Prep Refiner
28
Benefits
• Savings in refining energy
• Higher refiner hydraulic
capacity
• Higher loadability
• Ease of refining
• StockBoost for refining, a
customized service concept
© Valmet 2015
Higher refiner capacity
and reduced refining energy
Exchange System
for Shaft Assembly
Optional solution
for improved usability
The exchange system is an optional solution
for customers seeking improved refiner
usability, shorter shutdowns and minimized
storage levels.
Through the exchange system, customers can
purchase an overhauled shaft unit assembly
at a fixed price from a Valmet warehouse,
and return the old unit to Valmet for
renovation and return to the Valmet storage.
A mechanical guarantee is provided for the
whole drop-in unit.
Benefits
• Shorter shutdowns and
minimized repair time on-site
• Higher turnover in Valmet
stock eliminates storage
damage
• Lower storage costs
• Old and worn parts replaced
with new ones according to
latest design
Exchange units are available for the following
models:
Stock-Prep Refiner
© Valmet 2015
OptiFiner RF-1, RF-2, RF-3, RF-4 and RF-5
29
Turbine Housing
Valmet has developed a new type of
housing for its low-consistency refiners that
can increase the production of the refiner
by 30% and provide longer fillings life.
The new Turbine Housing can be fitted to:
•
•
Stock-Prep Refiner
30
OptiFiner RF-3 or RF-4
Conflo JC-03 or JC-04
Benefits
• Save energy by eliminating
one refiner, lowering
rotation speed or lowering
feed pump speed
• Gain 20 to 40% more
production from your
existing refiner
• Refine more gently with a
denser fillings pattern
• Extend the service life of the
fillings by up to 25%
© Valmet 2015
Boost refiner production
Closed Mechanical Seal
Allows use in difficult water
conditions
The new Valmet-developed closed
mechanical seal allows the use of a
mechanical seal for low-consistency refiners
in difficult seal water conditions.
The closed mechanical seal is available for the
following refiner types:
•
•
OptiFiner RF-1, RF-2, RF-3 and RF-4
Conflo JC-01, JC-02, JC-03, JC-04 and
JC-05
Benefits
• Savings on costs for fresh
water
• No problems with seal water
supply
• Longer service lifetime for
seals
• The latest seal design
Seal water savings sample
calculation from a customer mill:
»» 5 l x 60 min. x 24 h x 300 d
= 2 169 000 l/a/refiner
»» 2 160 000 l/a x 0.01 EUR/l
Stock-Prep Refiner
© Valmet 2015
= 21 600 EUR/a
31
Touch Vibration Detector
Protect from clashing failure
Stock-Prep Refiner
32
Benefits
• Protects fillings from
clashing failures
• The TVD system can be
connected to the mill-wide
automation system
© Valmet 2015
One of the key components in the
OptiFiner RF/Conflo refiner is its refiner
fillings. A touch vibration detector (TVD)
system has been developed to protect
these valuable components from clashing
failures. This extends the refiner fillings’
service lifetime.
Filling Gap Measurements
© Valmet 2015
A refiner’s filling gap has a direct impact on
pulp quality. The filling gap measurement
system ensures that normal refining
conditions are rapidly reached after
shutdowns and interruptions. This reduces
the amount of non-refined pulp.
Benefits
• The refiner starts up with a
pre-set filling gap allowing the
rapid achievement of correct
refining conditions after
shutdowns and interruptions
• The wear level of the filling
can be measured without
opening the refiner
• The filling gap measurement
system can be connected to
mill-wide automation systems
Stock-Prep Refiner
Reduce amount
of non-refined pulp
33
Torque Limiter
This improved safety coupling has been
developed to minimize maintenance
requirements. The torque limiter eliminates
any mechanical changes in the shear pins
after shutdowns and interruptions.
Stock-Prep Refiner
34
Benefits
• Prevents the refiner from
overloading
• Maintenance-free operation,
no shear pin replacements
after shutdowns and
interruptions
• No adjustment is necessary
once installed
• The torque of the friction
plate set is preset based on
the refiner size
© Valmet 2015
Minimize maintenance
requirements
StockBoost
for Screening
StockBoost is a process where we work
together with you to define areas for
improvement. These can be related
to improving pulp quality or stock
preparation machinery.
© Valmet 2015
Availability improvements can be made
either to keep the machinery in good
condition by taking care of screen baskets,
organizing storage service for wear and
spare parts, as well as making mechanical
upgrades for the machinery or by using
second-hand machines.
Features
StockBoost for all screen types
and all manufactures
• The correct combination of
a screen basket, rotor and
rotor speed
• A tailored service agreement
• Storage services & bearing
exchange services
Stock-Prep Screen
Find improvement areas
35
NimLuc
NimLuc is a new screen basket design based
on the Nimax wedge-wire technology.
Advanced laser-cutting capabilities with
new manufacturing techniques bring a new
cost-effective performance for all screening
applications.
The increased accuracy of laser machining
allows the assembly of pre-formed
baskets using a single piece mounting
and stiffening ring to reduce cost while
retaining performance and durability in
operation.
Stock-Prep Screen
36
Benefits
•
•
•
•
•
Targeted pulp quality
High screening capacity
Wide operating window
Minimum fiber loss
Efficient operation
© Valmet 2015
Cost-effective performance
Nimax DIP
Ensure quality and capacity
© Valmet 2015
Nimax DIP ensures targeted pulp quality
and high screening capacity in all operating
consistencies in DIP pre- and fine
screening.
Benefits
• Highly efficient screening
• High screening capacity
• Savings in screening and
maintenance costs
Stock-Prep Screen
Valmet’s new Nimax DIP is the first
screen basket designed specifically for DIP
screening applications and a member of the
new family of application specific Nimax
screen baskets.
37
Nimax MS
Valmet’s new Nimax MS is the first screen
basket designed specifically for machine
screening applications and a member of the
new family of application specific Nimax
screen baskets. Nimax MS ensures targeted
pulp quality and high screening capacity
in all operating consistencies in machine
screening in approach flow systems.
Stock-Prep Screen
38
Benefits
• Highly efficient screening
• High screening capacity
• Savings in screening and
maintenance costs
© Valmet 2015
Designed for screening
applications
NimCat
Save screening costs
NimCat screen basket is an effective way
to save in screening costs. It also adds
flexibility to your screening process by
providing the opportunity to switch to a
different screening panel profile design
during each panel replacement.
Benefits
• Savings in screening costs
• Flexibility in screening
process
• Shorter delivery times
Stock-Prep Screen
© Valmet 2015
NimCat’s advanced design features make
it possible to reuse the support framework
and replace only the screening panel, which
is the wear component. Reuse of the more
expensive component in the basket, the
support framework, reduces screen basket
costs significantly, especially in high-wear
applications.
39
Recoating Services
Maintain capacity at desired level
Recoating services are a cost-effective
solution to maintain capacity at a desired
level. Recoating instead of buying a
completely new basket brings considerable
savings in screening costs.
Stock-Prep Screen
40
Benefits
• Considerable savings in
screening costs
• Minimized unplanned
shutdowns
• Stable screening
performance
© Valmet 2015
Valmet’s proactive recoating service
ensures that the screen basket profile is
maintained in top shape at all times by
replacing the baskets before their profile
starts to wear down and then recoating
them.
ProFoil
Ensure best result
© Valmet 2015
Old foils can be easily replaced with the
ProFoil design without any modification of
the screen itself. Valmet experts can check
the suitability of any screen for ProFoil, and
process optimization in cooperation with
the customer ensures the best result for the
entire screening system.
Benefits
• Streamlined shape reduces
co-rotation of pulp for
10–30% lower energy
consumption
• Low level of thickening –
lower rate of fiber loss and
low reject rate
• Ability to use ultra-narrow
slots – excellent quality
• Higher slot velocities can be
attained without blockage
at higher capacity or
smaller screen size for given
capacity
• No blockage problems even
at low rotation speeds –
excellent runnability in wide
range of applications
Stock-Prep Screen
ProFoil technology delivers a processspecific optimally adjusted relationship
between high capacity, quality and low
energy consumption.
41
Exchange System
for Shaft Assembly
With the exchange system, customers can
purchase an overhauled drop-in unit at a
fixed price from our warehouse and return
the old unit to Valmet, which will refurbish
it for improved performance according
to the latest design. Participation in the
exchange system requires that the old unit
is repairable. A mechanical warranty is
provided for the entire drop-in unit.
Exchange units are available for the
following models:
•
•
Stock-Prep Screen
42
Delta T6, T6i, T9 and T9i screens
OptiScreen FS-90 and FS-250 fine
screens
Benefits
• Shorter shutdowns and
minimized repair time onsite
• Higher turnover in Valmet
stock eliminates storage
damage
• Lower storage costs for
customers
• Old and worn parts replaced
with new ones according to
latest design
© Valmet 2015
Refurbish for improved
performance
Headbox Surface
Reconditioning MX06
Surface reconditioning
to eliminate fiber build up
Headbox surface cleanliness is essential to
prevent build-up of deposits and maintain
formation.
Running recycled fibers or with wet
strength chemicals are processes prone
to increase deposit build-ups. Cleaning
interval may vary case to case, but by
applying a surface coating, the build-up
resistance improves and time in between
cleaning can be increased dramatically.
The MX06 surface treatment leaves a very
thin unnoticeable protective coat that is
a long-lasting and effective dirt repellent
surface.
Features
The coating process includes:
• High pressure water
cleaning (800 bar, 80°C)
• Manual removal of hard
stick dirtied surfaces by
grinding.
• Removal of remaining
oxides using sulphanilic acid.
• Polishing of cleaned
surfaces
• MX06 surface treatment
and hardening.
• Applicable on all metallic
and ceramic surfaces.
• Long-lasting
• Very resistant to
detergents, acids and alkali.
Wet End
© Valmet 2015
Properties of MX06
43
Headbox Apron
Reconditioning
Deformations in the flow surface, front
edge rounding and dents cause problems
and difficulties in CD profile adjustment.
With our grinding method, the front edge
of the apron can be re-conditioned to the
original accuracy of the shape.
In case of major damages local on-site
repairs by other methods such as welding,
straightening and grinding, can usually
restore a failed area.
Wet End
44
Features
• Grinding of apron front edge
and/or flow surface
• Mechanical zeroing of the
slice opening
Benefits
• Reduced need for slice
control
• Reduced CD basis weight
variation
• Improved machine
runnability
© Valmet 2015
Improve variations in the profile
and streaks in the web
Headbox Dilution
Control System
Improved formation
and production quality
In the dilution control process, cross
machine direction basis weight is controlled
by varying stock consistency in narrow
bands across the slice width.
The advantage of dilution control is first
that the cross direction basis weight control
will be on a finer scale and second that
the basis weight response is improved
dramatically.
Benefits
• Improved basis weight
profiles
• Improved end product
quality
• Improved machine
runnability
Changing speed, flow rate,
and/or slice opening, the basis
weight profile will be stable.
Valmet dilution control system
allows better formation and
profile quality which may enable
an increased machine speed but
will also improve the converting
operation.
Wet End
© Valmet 2015
Commercial experience shows
that the 2-sigma value can
be reduced by at least 50%
following the installation of the
dilution profiling system.
45
Valmet HeadBox Vanes
EasySheet & PolySheet
Valmet headbox vanes are manufactured
to exacting straightness, flatness and
smoothness tolerances which benefits a
more uniform CD basis weight, caliper and
edge control properties.
Layering and turbulence vanes are critical
elements for the headbox performance. The
formation improvement is gained by the
vane stability which benefits a stable and
uniform jet.
Wet End
46
Features
• EasySheet is made of PVC
and its chemical resistance
is good but not to solvent.
• PolySheet is made of
Polycarbonate (PC or
“Lexan”) and its chemical
resistance is good but not to
alkali or solvent.
© Valmet 2015
Better formation and reduced
maintenance costs
CompoVanes
Unique properties
CompoVanes are made of hard-wearing
composite glass-fiber material and have
unique and long-lasting properties.
CompoVanes are available for most Valmet
and Beloit headboxes.
Features
Special composite material and
design deliver a stiff but flexible
and thermo-stable vane with
superior surface smoothness
and excellent chemical
resistance.
Wet End
© Valmet 2015
Valmet guarantees 3 years life
time but the expected life time
is up to 10 years.
47
DuraSheet and DuraWedge
Valmet’s improved technology effectively
controls turbulence and layering enhancing fiber utilization, formation,
strength, visual appearance and layer
purity.
DuraSheet and DuraWedge are made of
carbon fiber composite material and have
unique and long-lasting properties.
A full range of products are available for
most Valmet and Beloit headboxes.
Wet End
48
Features
DuraWedge is a tapered carbon
fiber composite and standard
in all new Valmet machine
deliveries.
Excellent chemical resistance
makes it possible to keep them
in the headbox during cleaning
boil-out.
Valmet guarantees one year
lifetime but the expected life
of DuraSheet & DuraWedge
exceeds five years.
© Valmet 2015
Efficient control
of headbox layering
Valmet HeadBox
Vanes Data
HBX sheet type
PolySheet Lexan
EasySheet
DuraSheet
DuraWedge
CompoVanes
Material
Polycarbonate
PVC
Carbon fiber
composite
Carbon fiber
composite
Glass fiber
composite
1200
1520
Water absorbtion [%]
0.15-0.35
0.04-0.45
0.022
0.022
Thermal expansion
[1/°C]
0.000067
0.00008
0.0000055
0.0000055
Specific gravity
[Kg/m3]
1550
0.12
Max. temp [°C]
135
75
140
140
100
Tensile yield
strength [MPa]
62
60
1500
1500
480
Tensile modulus
[GPa]
2.4
2.4
70
70
16
Chemical resistance
Good, but not
alkali and solvent
Good, but
not solvent
Excellent
Expected lifetime
12 months
3 years
5 years
Application
0
PolySheet Lexan
0
EasySheet
x
HTB
ConverFlo
x
Concept III
x
Concept IV
x
5 years
1
DuraSheet
Excellent
10 years
1
3
DuraWedge
CompoVanes
x
x
x
x
x
x
x
x
x
OptiFlo II TIS
SymFlo TIS
Excellent
Wet End
Warranty time [year]
© Valmet 2015
1550
x
x
x
x
x
49
TrimSquirt
Principal sketch
Optimized edge trim control
The TrimSquirt solution ensures the
efficient and reliable sheet edge cutting
at the forming section. Stock build-up is
prevented with proper cleaning during
the process without any loss of production
time.
Wet End
50
Benefits
• Better and more stable
runnability
• Safe operating environment
• Reliable cutting and highquality edges
• Continuous edge trimming
• Good equipment
adjustability
• Easy service
© Valmet 2015
Proper trim control will provide better
runnability and improved production
line efficiency, as well as a safer operation
environment.
Felt and Wire Stretcher
Ensure the right tension
Features
The wire and felt stretcher provides the
right tension with controlled movement of
the stretching roll.
• 3-phase 400 V (optional 500
V) motor with integrated
gear
• Frequency converter for
motor
• Cross shaft, carbon fiber
pipe with flexible connection
• Screw jacks, stainless steel
• Cleaning units instead of
elastic conical covers
It is a reliable device to balance the wire or
felt to the correct tension. The stretcher is
easy to install in older, as well as in new,
tissue machines. The clean design prevents
build-up and the stretcher has a low
maintenance level.
•
© Valmet 2015
50
Max stretch
force
Max stroke
50 kN
2000 mm or 78.75”
100
100 kN
3000 mm or 118”
200
200 kN
3000 mm or 118”
Wet End
Size
51
TailCutter
Features
The TailCutter is a sophisticated, yet simple
device that will simplify the sheet rolling,
reduce fiber waste and costs. It has a reliable
and cost-efficient desig and is easy to
maintain. By cutting the paper sheet with a
water-jet stream you can produce a narrow
paper sheet, a tail, which is easy to lead to
the reel drum. As the tail reaches the reel
drum the sheet is rapidly broadened to full
width.
Wet End
52
It is easy to maintain and
sesigned with product
sustainability in mind.
The device is made of stainless
steel or resistant composite
materials. It is highly flexible
and adapted for all machine
width and concepts.
The Tailcutter fits in various
positions in the wet end, both
in TAD and Crescent former
machines. Both wire and
felt can be cut upwards or
downwards.
© Valmet 2015
Simplify the sheet rolling and
reduce fibre waste
The TailCutter is easy to handle.
It can be remotely controlled
regardning adjustment of
cutting speed and tail width.
CleaningNut
Short life on your elastic
conical covers?
Valmet Cleaning Nut replaces your elastic
conical covers and instead of trying to hide
the screw, it cleans it when rotated.
Valmet Cleaning Nut is easy to install
and having no moving parts, it provides a
design with a long and maintenance free
life.
The Valmet Cleaning Nut is available to all
machines having a felt or fabric stretcher
with trapezoidal threading.
Benefits
• Valmet Cleaning Nut
replaces your elastic conical
covers
• Designed to effectively clean
the felt stretch screws when
rotated
• No moving parts facilitating
long and maintenance free
life
• Easy installed on your
existing equipment
Wet End
© Valmet 2015
Valmet Cleaning Nut is standard
in all new Valmet tissue
machines.
53
Shower Pipe Family
Reduce energy consumption
and extend fabric life
Keeping the fabrics in good condition
ensures low energy consumption and
extended fabric life. Increased machine
speeds, shorter fabrics and the use of
secondary fiber make the role of fabric
cleaning even more important. The shower
pipe family includes different pipe sizes (54158 mm) and pressure classes (3-60 bar).
Automatic brush drive for optimum
cleaning effect
Double tube shower pipes
Designed for top efficiency in specific
applications.
•
•
•
•
Pipe-in-pipe design
Components are protected from buildup and deposit of stock and other mill
debris.
Suitable for both stationary and
oscillating applications
Safe and easy maintenance during
operation, even in narrow spaces
•
Wet End
54
•
Possible to use white water in highpressure showers
Reliable cleaning with minimum
maintenance
© Valmet 2015
The automatic brush drive is developed
especially for applications where manual
cleaning is impossible or difficult to carry
out.
Shower Oscillator
Simple and effective
To optimize profiles and avoid streaks,
cleaning is essential and must be done
evenly over the whole fabric face at all
times.
Valmet shower oscillator has shown
reliability and is encased in stainless steel
which ensures that the oscillator withstands
the most rigorous conditions in a paper
machine.
Features and Benefits
• Stroke length adjustable
0-300 mm.
• Speed adjustable 0-500
mm/min.
• Easily installed and replaced.
• No maintenance required.
Wet End
© Valmet 2015
The oscillator has no internal electronics,
which makes it easy to install and replace,
requiring no maintenance.
55
Felt SuctionBox
For smooth operation
•
•
•
Deflection problems
Vibration problems
Thermal distortion
Computer-aided air-flow simulation avoids
turbulence.
The felt suction box provides:
•
•
•
•
•
•
Wet End
56
Excellent water removal
No vibrations
Low friction
Even cross vacuum levels which gives
even moisture profiles
Improved felt conditioning
Increased felt life
Features
• All parts of stainless steel
• Equipped with a manual
180° turning device
• T bar-mounted polyethylene
strips
• The strips can be tailor made
in various sizes, types and
material.
• Easy to clean with a large
flush port in tend side
• Outlet end is flanged; DN or
ANSI
© Valmet 2015
The felt suction box is designed with Finite
Element analysis to avoid:
Felt and Wire Guides
The automatic guide ensures that the wire
or felt does not travel in a cross-machine
direction. The guide palm indicates the
wire or felt position. The control unit
regulates the air pressure in the controlling
bellows. The air filled bellows swing to one
side of the lead roll to compensate for wire
or felt movements.
© Valmet 2015
It is applicable in all positions, from wet
end to dry end of the machine and is easy
to change from one side to another. It gives
accurate and reliable control of fabric run
and the over pressurized valve chamber
prevents any dirt from entering the valve.
Features
A wire-and-felt guide has
one bellow with constant air
pressure and one bellow with
varying air pressure. The guide
palm indicates if the fabric
moves toward the tend side or
the drive side. The control unit
sends a signal to adjust the
air pressure in the controlling
bellow. This makes the tend
side roll bearing move in the
direction of fabric travel, and
the fabric moves toward the
central position.
Wet End
Improved reliability in both
wet and dry end
57
Bearing Holders
Spherical
bearing holder
Tension
bearing holder
Ensure lead roll position
The bearing holder ensures that the lead roll
stays in its original position. It is designed
to compensate for offset lead roll-bearing
positions in tend side and drive side without inclination in the roll bearing. The
bearing holder is available in two versions;
the tension bearing holder and the spherical
bearing holder.
Features
The load cell in the bearing
holder measures the wire or
felt tension force. Operators
can then adjust the wire or felt
tension by moving the wire or
felt stretcher roll.
Wet End
58
© Valmet 2015
The bearing holder is manufactured of
stainless steel and is easy to dismount
during roll change. The fastening holes are
equal to Valmet lead-roll foot bearings and
tension bearing holders (replaceable)
Wet End Exhaust
Most of the warm and humid air is
generated at the wet end of the tissue
machine.
The system captures such mist through
collectors in different parts of the wet end:
the silo connection, the headbox area, the
save-all, the outer wire and also in the press
area.
© Valmet 2015
The air is then conveyed to a separator and
to an exhaust air fan, which blows it to the
atmosphere through a stack.
Wet End exhaust
•
•
•
Machine is cleaner and has better
runnability with fewer web breaks,
cleaning maintenance is reduced.
Warm and humid air with droplets and
fibers do not spread into machine room,
working conditions are improved and
building and machine structures are
better preserved.
Improved safety. Cleaner machine
and walk ways will improve safety for
operators.
Wet End
Control and eliminate mist
right where it is generated
59
Advantage ReTurne Service
Optimize the performance and
minimize unplanned stops
The Advantage ReTurne is a sophisticated
device that will recover energy and return it
back to the process in form of electicity. It has
a reliable and cost-efficient design and is easy
to maintain.
To ensure a smooth operation we recommend
regular review of the Advantage ReTurn
including:
• Ultrasonic Testing of the turbine
• Overview of the bearings.
• Check the functionality of the deflector plate.
© Valmet 2015
Wet End
60
• Drive optimization
GapMaster Ultra for Tissue
GapMaster Ultra is a fine, thin and stable
SSB forming fabric, especially designed for
Crescent and Suction Breast Roll formers.
Benefits
•
It is designed for high-speed tissue making
to drain quickly, and at the same time gain
high retention and good formation.
Good drainage properties –
High dry content
•
Very high fiber support –
High retention and clean
wire loop
•
High dimensional stability –
No width variation, well
working trim cutting
High fabric stability ensures stable run and
excellent trim cutting.
•
Type: SSB
•
T-count: 129
•
Air permeability,
m³/m²h/cfm ( m/s):
7500 / 475 (2,08)
•
Caliper, mm: 0.68
Fabrics
© Valmet 2015
Features
61
SprintMaster and
StarMaster Felts
SprintMaster
StarMaster
Fabrics
62
Benefits
• Fast start-up and good nip
dewatering
• Good runnability
• Even felt properties during
the lifetime
• Low steam and energy
consumption
© Valmet 2015
SprintMaster and StarMaster felts’ light
weight hybrid structures generate optimum
water handling capacity in tissue machines. Combination of smooth nonwoven and
stable woven base fabrics ensure good felt
properties as well as low steam and energy
consumption during the whole lifetime.
Nonwoven base gives good nip-dewatering
and start-up properties. The void volume of a woven base enables long and trouble free
late life running.
BlackBelt Shoe Press Belt
Designed for high speeds
and loads
BlackBelt is a modern shoe press sleeve that
is made of high performance polyurethane.
It comprises a very stable triple layer
reinforcement structure offering roll type
running and long running time.
It is especially designed for high speeds and
high loads.
High performance urethane has excellent
wear resistance and does not crack easily.
Benefits
• Excellent wear resistance
• Stable structure
• Roll type running
• Long running time
Features
BlackBelt is available in a wide range of
groove designs.
Typical void volume for tissue is 430
ml/m². Dewatering capacity can be
measured during shutdowns by Valmet’s
Fabrics
© Valmet 2015
BeltScanner.
63
BeltScanner
Essential information
on belt condition
With the BeltScanner groove dimensions
such as groove depth, groove width and
land width can be measured during a
shutdown.
Fabrics
64
© Valmet 2015
BeltScanner provides essential information
to estimate the lifetime of the belt. It
calculates the open area and the void
volume of the belt.
Advantage Suction
Pressure Roll
Valmet Advantage Suction Pressure Roll
is designed to be energy efficient and
maintenance friendly. To achieve this, the
very latest, but also the most basic and
proven technology has been used.
A Duplex stainless steel shell provides a
highly durable and strong shell with very
good stress corrosion cracking resistance.
The vacuum box design is optimized for
lowest flow resistance which minimizes the
energy needed to maintain vacuum.
© Valmet 2015
Valmet non-contact LocSeal™ enables a gap
clearance in-between the shell and the seal
strips which benefits minimum friction and
low wear.
Benefits
• Duplex stainless steel shell
• Energy efficient suction
box design facilitating low
energy consumption
• Minimum drive power
requirement due to noncontact LocSeal™ and low
friction spherical roller
bearings
• Low noise level facilitated by
trailing edge sealing
• Vacuum hole cleaning
prevents plugging
Valmet Advantage Suction
Pressure Roll is available either
with vacuum exhaust and
integrated gear box on the drive
side or with vacuum exhaust on
the front side and direct drive
on the opposite side.
Press section
Energy efficient
and maintenance friendly
65
Suction Roll Maintenance
Optimize the roll performance
Reconditioning & Modernization
A suction roll is one of the most important
process rolls and also one of the most costly
to maintain. By optimizing suction roll
maintenance you can reduce costs, enhance
roll reliability, lengthen service intervals
and increase the total lifetime of the suction
roll.
The target is to restore the roll to as close to
the original as possible, and to increase the
roll’s operational reliability. The suction roll
will be completely disassembled, all critical
parts inspected and then necessary repairs
made based on our recommendations.
Scheduled maintenance
Press section
66
Scheduled maintenance, e.g. inspections,
grinding and seal changes ensure the
suction roll operational condition and
the performance of the machine. The
most critical parts are inspected and
consumables changed. Dynamic roll testing
ensures trouble free start-up.
Modernization raises the roll performance
to a higher level. We offer a wide range of
modernization options, regardless of origin
of the roll.
Customized service agreements
With a long-term service agreement you
can ensure that the suction rolls are utilized
to their full potential. With common
targets and shared expertise better results
can be achieved not only in terms of
improved roll performance and extended
service intervals, but also in annual
maintenance cost savings.
© Valmet 2015
The services range from grinding,
scheduled maintenance, repairs,
reconditioning and modernization to a
long term agreement based maintenance
program, according to your needs.
Advantage ViscoNip
Service
Gain the benefits of continuous
technology developement
The long term ViscoNip service program
ensures that all functions are kept fully
operational and include all necessary
actions to maintain the equipment in best
possible condition.
• Safe & reliable
- avoid unplanned shutdowns
• Availability & Quality
- ensure best pressing
conditions for optimum
The ViscoNip service program include
•
•
•
© Valmet 2015
inspections
recommended replacements
operator’s training for most
efficient implementation
The Service program covers essential
service actions during 48 months.
capacity and product
quality
• Cost-efficiency & Sustainability
- maintain lowest possible
energy consumption and
get access to continuous
developments
Press section
Long term service plan
67
Advantage ViscoNip belt and
wear cloth exchange
1/9-12 month
•
•
Pressure element check performed in
addition to belt exchange
The pressure elements needs to be
replaced in two- four years depending
on condition
Complete hydraulic system
condition test 1/24 month
•
•
•
A complete condition test of the
hydraulic system should be done after
one year of operation.
Thereafter every second year.
The test include full inspection of all
components and a condition test.
During the test all proportional valves
are to be maneuvered manually while
pressures recorded and fluctuation or
other possible deviation from expected
performance are collected.
Requires 1 day production stop
ViscoNip complete overhaul 1/48
month
•
•
•
Press section
68
Replacement of all non-metal parts
exposed to wear, but in particular aging,
Exchange of press element, wear cloth,
hoses and gasket rings
Requires a 60 hours machine stop where
the ViscoNip press will be lifted out of
the machine
Recommended service interval
• Belt and wear cloth exchange
9-12 month
• Complete hydraulic system
condition test 24 month
• Pressure element exchange
24-48 month
• Complete overhaul 48 month
© Valmet 2015
•
Advantage NTT SymBelt
Service
Keep the nip load, nip profile and
linear load in shape
The long term NTT SymBelt service
program ensures that all functions are kept
fully operational and include all necessary
actions to maintain the equipment in best
possible condition.
Ensure
• Stable nip load
• Even linear load in machine
cross direction
• Optimal nip profile
The NTT SymBelt service program include
• inspections
• recommended replacements
• operator’s training for most
© Valmet 2015
efficient implementation
The Service program covers essential
service actions during 48 months.
• Best belt tensioning and
full utilization of belt
lifetime
• Sufficient head movements
• Trouble free operation
Press section
Long term service plan
69
Advantage NTT SymBelt condition
test 1/24 month
•
•
•
•
A complete condition test of the
hydraulic system should be done after
one year of operation.
Thereafter every second year.
The test include full inspection of all
components and a condition test.
During the test all proportional valves
are to be maneuvered manually while
pressures recorded and fluctuation or
other possible deviation from expected
performance are collected.
Requires 1 day production stop
Advantage NTT SymBelt Service
1/48 month
•
•
•
Replacement of all non-metal parts
exposed to wear, but in particular aging,
Exchange of press element, wear cloth,
hoses and gasket rings
Requires a 60 hours machine stop where
the ViscoNip press will be lifted out of
the machine.
Recommended service interval
Press section
70
Belt and wear cloth exchange 9-12 month
Complete hydraulic system condition test 24 month
Pressure element exchange 24-48 month
Complete overhaul 48 month
© Valmet 2015
•
•
•
•
LocSeal
Non-Contact Suction Roll Sealing
Suction pressure roll
modernization
LocSeal is a non-contact sealing design
available for modernizing every suction
pressure roll in any Valmet workshop.
LocSeal enables a gap clearance in-between
the shell and the seal strips which produces
less friction and longer life for seals.
The LocSeal non-contact seal generates
savings in the drive power. A trailing
edge gap on the sealing enables a smooth
vacuum drop which reduces noise level by 5
dB compared with a squared sealing.
Benefits
• Reduced drive power
consumption saving energy
• Reduced noise level
improving working
environment
• Reduced wear both on
sealing and shell
• Extended roll service
interval reducing
maintenance cost
LocSeal is controlled by a LocMatic control
unit designed to ensure optimum operation
and connect to a paper mill’s operating
system.
Press section
© Valmet 2015
LocMatic
71
FlexSeal
Improved seal strip performance
It is tough but not breakable and has
improved wet and dry wear resistance.
The improved low-volume swell and low
swelling strain coefficient prevent common
wear patterns.
FlexSeal helps extend the effective life
of suction rolls between reconditioning
by standing up to the difficult operating
conditions suction rolls are subjected to.
Press section
72
Features
• Improved wear-in under
poorly lubricated conditions
• Superior wear resistance
under normal operating
conditions
• Increased seal life
• Less frequent roll changes
• Less maintenance
• Improved handling
characteristics
• Lower power consumption
• Reduced noise generation
• Easy handling during
maintenance
© Valmet 2015
FlexSeal is an innovative suction roll seal
strip which quickly conforms to the inside
diameter of the suction roll shell.
Oscillating High Pressure
Cleaning Shower
The effectiveness of oscillating shower pipes
is based on narrow fan-shaped shower jets,
high pressure and the oscillating motion.
Oscillating high pressure cleaning
effectively cleans suction roll shells in the
tissue machine.
© Valmet 2015
Clean suction roll shells ensure uniform
paper web dewatering, reduced build-up
and calcification. With the oscillating high
pressure shower you get more uniform
paper web moisture profiles, fewer web
breaks, extended roll change intervals and
an extended shell life.
Features
Oscillating high pressure
cleaning showers replace
stationary shower pipes on
the side of suction boxes.
Oscillation is based on reliable
water hydraulics, powered
by pressurized cleaning
water. Therefore leaks will
not disturb the tissue making
process. Shells are typically
washed during web breaks or
shutdowns.
Automation boosts the utility
of the showers and ensures
optimal cleaning results. The
oscillating cleaning showers
can be used for all suctions rolls
regardless of original make.
Press section
Uniform moisture profiles and
extended suction roll service
intervals
73
Polyurethane cover
for pressure rolls
These are highly durable covers providing
prolonged service intervals and latest
adhesion technology facilitating reliable
bonding safety.
Applications
•
•
•
VacuFox TIS is for suction pressure rolls
PressFox TIS is used on pressure rolls
Blind drilling or grooving can be
applied to both covers
Technical data
Roll Covers
74
Color
Dark Red
Hardness
10-25 P&J
Thickness
15-25 mm
(5/8” to 1”)
Maximum temperature
105°C (220°F)
Maximum loading
12 MPa (1700 PSI)
Chemical resistance
Excellent
Benefits
• Superior water removal
provided by the high open
area and big void volume
• Water saving due to less or
no cooling required
• Excellent hardness stability
(±1 P&J)
• Prolonged grinding intervals
provided by the excellent
wear resistance
• Incomparable durable
bonding
• Excellent resilience for
optimum nip performance
• No drying needed due to
hydrolysis
© Valmet 2015
Polyurethane cover for tissue suction
pressure roll and pressure roll application.
PressHusky
Polyurethane cover for tissue machine press rolls
Valmet’s PressHusky is a highly durable cover that maximizes dryness and
runnability, especiallywhen equipped with the iRoll nip pressure measuring
system. It needs only minimal mainte-nance, provides low operating costs
and produces the desired tissue quality. PressHusky is avail-able in several
hardness options and has optimal surface structure, a high open area and
a largevoid volume. Its rolling resistance under dynamic load is low and its
wear resistance is high.
Benefits
• Maximal dewatering and desired tissue
bulkiness/thickness
• Savings in roll drive power
• Less need for grinding, longer running
periods
• No need for internal cooling due to
minimal heat generation
Applications
• Tissue machine press rolls
Chemical resistance
Excellent resistance against all normal
process chemicals. Recommended pH
range: 4-9. Avoid prolonged exposure to
strong alkalis and acids or alcohols
Cover color
Violet
Hardness
12-33 P&J
Cover thickness
15-25 mm
(0.6-1.0”)
Maximum temperature
105oC
(220oF)
Surface roughness
Ra <3.2 µm
(120 µin)
Topography options
Plain, Grooved, Blind Drilled,
Grooved + Blind Drilled
Maximum loading
120 kN/m
(700 pli)
Roll Covers
© Valmet 2015
PressHusky technical data
75
VacuHusky
Polyurethane cover for tissue machine suction press
rolls
VacuHusky is a highly durable cover that maximizes dryness and
runnability. Itneeds only minimal maintenance, provides low operating
costs and produces thedesired tissue quality. VacuHusky is available in
several hardness options andhas optimal surface structure, a high open
area and a large void volume. Its roll-ing resistance under dynamic load is
low and its wear resistance is high.
Benefits
• Maximal dewatering and desired tissue
bulkiness/thickness
• Savings in roll drive power
• Less need for grinding, longer running
periods
• No need for internal cooling
Applications
• Tissue machine suction press rolls
Chemical resistance
Excellent resistance against all normal
process chemicals. Recommended pH
range: 4-9. Avoid prolonged exposure to
strong alkalis and acids or alcohol.
Roll Covers
76
Cover color
Violet
Hardness
12-33 P&J
Cover thickness
15-25 mm
(0.6-1.0”)
Maximum temperature
105oC
(220oF)
Surface roughness
Ra <3.2 µm
(120 µin)
Topography options
Suction Drilled, Suction Drilled + Grooved,
Suction Drilled + Griived + Blind Drilled
Maximum loading
120 kN/m
(700 pli)
© Valmet 2015
PressHusky technical data
PressGator ZL
Premium rubber roll cover for blind drilled or
plain Yankee press rolls and suction pressure
rolls.
Applications
© Valmet 2015
•
•
•
Yankee pressure and press rolls
Suction pressure rolls
Blind drilled pressure rolls, plain
pressure rolls
Benefits
• Excellent lifetime between
grinds
• Excellent hardness stability
• Superior dynamic properties
• Excellent heat resistance
• High impact resistance
Technical data
Color
Black
Hardness
27-50 P&J
Thickness
12-25 mm
(1/2” to 1”)
Maximum temperature
120°C (250°F)
Maximum loading
135 kN/m (750 PLI)
Chemical resistance
Excellent
Roll Covers
Cover for press
and press suction rolls
77
PressGator Z
Rubber roll cover for blind drilled or plain
Yankee press rolls and suction pressure
rolls.
Applications
•
•
•
Roll Covers
78
Yankee pressure and press rolls
Suction pressure rolls
Blind drilled pressure rolls, plain
pressure rolls
Benefits
•
•
•
•
High wear resistance
Maintains hardness stability
Very good heat resistance
High resistance to cracking
Technical data
Color
Black
Hardness
10-50 P&J
Thickness
12-25 mm
(1/2” to 1”)
Maximum temperature
110°C (230°F)
Maximum loading
175 kN/m
(1000 PLI)
Chemical resistance
Excellent
© Valmet 2015
Cover for press
and press suction rolls
WireGem
Long-lasting hard coating for the harsh
operating conditions of forming section
rolls. Ultra-high wear resistance for
maximum fabric lives and runnability.
Applications
•
•
© Valmet 2015
•
Forming section lead, guide, return and
tension rolls
Forming section drive rolls with
sufficient wrap
Rough wear conditions
Benefits
• Superior wear resistance for
maximum cover lifetimes
• Excellent dimensional
stability for better fabric run
• Low blade wear
• Excellent corrosion
resistance
• Easy to keep clean
Technical data
Color
Black
Hardness
900-1100 (Vickers, HV)
Thickness
0.4-0.6 mm (0.016-0.024”)
Surface finish
Ra 0.5-0.8 μm (20-32 μin)
Maximum temperature
No restrictions
Maximum fabric tension
No restrictions
Maximum speed
No restrictions
Friction coefficient
Same as hard rubber
(vs. wet plastic wire)
Roll Covers
Hard coating for forming
section rolls
79
DriveShark Z
Drive rubber roll cover
Applications
•
•
•
•
Roll Covers
80
Wire turning rolls
Wire drive rolls
Breast rolls
Suction couch roll
Benefits
• Superior coefficient of
friction aids wire drive
ability.
• Maximum wear resistance
• Extremely durable against
cracking
• Good doctorability
Technical data
Color
Black
Hardness
12-20 P&J
Thickness
10-16 mm
(3/8’” to 5/8”)
Maximum temperature
110°C (230°F)
Maximum loading
70kN/m (400 PLI)
Chemical resistance
Good
© Valmet 2015
This durable rubber cover is designed for
stable driving of wet end fabrics. Excellent
friction properties and compatibility with
various wire materials guarantee pleasant
performance.
GuideMustang
This very highly wear resistant rubber
cover will deliver years of reliable service
in demanding wire, felt and sheet carrying
positions.
Applications
© Valmet 2015
•
•
•
•
Wire return rolls
Felt rolls
Paper rolls
Also grooved positions
Benefits
• Improved wear resistance
• Better chemical resistance
• Very good surface damage
resistance
• Easy surface cleaning
Technical data
Color
Grey
Hardness
0-2 P&J
Thickness
6-13 mm
(1/4’”to 1/2”)
Maximum temperature
104°C (220°F)
Maximum loading
17.5 kN/m (100 PLI)
Roll Covers
Rubber roll cover for guide and
lead rolls
81
GuideColt
Composite cover for guide rolls
Applications
•
•
•
•
•
Wire rolls
Wet felt rolls
Dryer felt rolls
Felt tension rolls
Paper carrying rolls
Technical data
Roll Covers
82
Color
Mint Green
Hardness
80 ± 2 ShD
Surface roughness
Ra 0.8-1.6 μm
(31-63 μin)
Thickness
6-10 mm
(0.24-0.40”)
Maximum temperature
150°C (300°F)
Maximum fabric
tension
No restrictions
Benefits
• Long service life due to
good wear and chemical
resistance
• Smooth, gentle material for
forming fabrics and felts
• Performs well under normal
dryer section conditions.
• Stays clean due to good
release properties.
• No end lifting, no corrosion
issues
• Lasts much longer than
rubber covers.
© Valmet 2015
Smooth, long-lasting cover for demanding
applications. Also available with grooving.
CalOpal M
Hard coating for machine
calenders
Very hard and very smooth coating for high
quality production and long regrinding
intervals.
Applications
Hard coating for chilled cast iron rolls,
thermo rolls, and deflection compensated
rolls in machine calenders.
Benefits
• Superior wear resistance; no
paper CD variation
• Protects the roll from wear;
prolongs the lifespan of the
roll.
• Surface smoothness is
economical for hard nip
calendering.
• Extended grinding intervals
Coating color
Grey/Chrome
Hardness
1150-1300 HV 0.3
Coating thickness
0.10-0.12 mm
(0.004” - 0.006”)
Maximum temperature
No restrictions
Maximum loading
No restriction
Surface finish
Ra 0.14 - 0.18 μm
(5.5 - 7.1 μin)
Roll Covers
© Valmet 2015
Technical data
83
Yankee Hood and
Air System Optimization
Immediate energy reduction
On-site adjustments are carried out during
the audit and are neatly reported afterward.
As a result, the customer will immediately
benefit from savings of up to 10-15%
and will be able to operate the machine
according to the optimal combination of
the different energy sources.
Drying Section
84
Features
Optimization program includes:
• Yankee hood and air system
set-up for an immediate
pay-back
• Check of operation of the
heat recovery system
• Check of burner settings
• Optimization of distance
between Yankee cylinder
and Yankee hood
© Valmet 2015
This audit targets the optimization of the
hood and air system in order to obtain an
immediate energy consumption reduction.
Advantage Balance Control
ABC
Determine, control and maintain the best possible drying
parameters and settings for the lowest energy consumption levels!
• Continuous monitoring of all
drying process parameters
• Automatic and optimal
control of hood and air
system balance and drying
strategy
• Settings constantly
adjusted, data collection
stored for an easy and
updated benchmarking
activity
• Local and remote access,
possibility to modify
parameters on-line and
to connect directly to
Valmet experts for realtime diagnostics and
troubleshooting on the
drying process
Drying Section
© Valmet 2015
Benefits
85
Yankee Condensate
Removal System
Speeding up your machine means that
everything needs to perform at its
optimum.
Valmet’s long straws condensate evacuation
system provides more uniform drying
of the paper in the machine direction,
resulting in more consistent quality and
thus increased production.
More uniform drying also allows the
organic coating to function as intended and
therefore provides the best condition for
the doctoring and creping process, reducing
both wear and risk of chatter marks.
Drying Section
86
Benefits
By upgrading to the Valmet
long straw condensate removal
system, you may expect:
• Increased production due
to improved product quality
in the machine direction
– fewer sheet breaks and
problems in converting
• Energy saving because
over-drying of the sheet
to compensate for MD
variations is no longer
needed
• Reduced wear rate resulting
in extended grinding
intervals and longer life
of the cylinder due a more
uniform organic coating
• Reduced vibrations and
noise level due to the
rounder Yankee
Valmet’s Condensate Removal
System can be installed in all
grooved shell Yankees.
© Valmet 2015
Increased production
at higher speeds
Yankee Spoiler Bars
Yankee Spoiler Bars are applicable to nonribbed Yankees operating at condensate
rimming speed or faster and the expected
drying rate increase is up to 20% for the
Yankee.
Attaching Yankee Spoiler Bars to the inside
of the dryer shell increases not only the rate
of heat transfer, but also improves the cross
machine moisture profile uniformity.
© Valmet 2015
Valmet Yankee Spoiler Bars are easy to
install without any mechanical intervention
to the cylinder and facilitate a simple way
to improve your drying rate and moisture
profile uniformity.
The improved drying can be used either to
increase the speed of the machine if drying
limited or to save energy by reducing the
hood drying maintaining the same speed.
Benefits
• Increased drying rate of up
to 20% on the Yankee
• Improved moisture profile
uniformity in cross machine
direction
• No mechanical intervention
in the cylinder necessary
• Fast installation
• Short return on investment
Drying Section
Increase drying and improve
moisture profile uniformity
87
Save energy and improve safety
Yankee head insulation:
•
•
•
•
Drying Section
88
Saves energy – Reduces Yankee steam
consumption by approximately 5-10%
Significantly improves working
environment – Reduced heat in work
areas around Yankee heads
Improves safety – Insulation plates
prevent accidental flushing of water onto
the Yankee heads
Fewer fire hazards – the insulation plates
prevent dust from gathering on the
Yankee heads
Features
• The Valmet design consists
of 4-6 segments attached
to each Yankee’s head. Each
segment is split for easy
disassembly and access to
the inner bolt circle and the
manhole segment has a
unique cover plate.
• High quality and fireresistant materials are
selected which facilitates
long-term use. The
containment area is sealed
to prevent dust from
entering.
• Valmet Yankee head
insulation can be applied
to any Yankee or MG
cylinder design, quickly and
accurately and regardless of
the cylinder OEM.
© Valmet 2015
Yankee head insulation reduces the energy
losses though the heads. In addition to
steam consumption savings, it significantly
improves the Yankee surrounding
environment and increases safety.
Yankee Head Bolt
Safety Guard
The Yankee head bolt safety guard prevents
accidental contact with the dangerous
rotating bolts in the head-to-shell bolt
joint which gives an improved safety level.
Additionally, it creates less turbulence in
the surrounding air around the bolt joint
which facilitates a more stable sheet transfer
and fewer sheet breaks.
Benefits
© Valmet 2015
By installing the Yankee Head
Bolt Safety Guard you gain:
• Improved safety around the
Yankee
• No air turbulence from
the rotating head bolts
disturbing the sheet
• Improved cleanliness of the
bolts
• Reduced noise level
Features
Yankee Head Bolt Safety Guard
includes:
• Safety guard segments
which are easy to fit
• Retrofit of new supporting
arrangements for safety
guard segments
Valmet can install Yankee Head
Bolt Safety Guards in partial
or full circumferential cover
installation.
The Yankee Head Bolt Safety
Guard is easy to disassemble for
inspection of head bolts.
Drying Section
Improved safety
and production reliability
89
Yankee CARB
Bearing Upgrade
Choose Valmet for support with our
engineering and installation upgrade from
a bearing housing supported by rockers to a
CARB bearing with a solid bolted-into-theframe bearing housing design.
Scope
A CARB bearing housing installation
includes:
•
•
•
•
Drying Section
90
Engineering
Lifting of the Yankee
Replacement of bearing housing
Replacement of Yankee bearings (both
sides)
Time frame depends on conditions but a
typical installation requires 24 hours.
Benefits
Benefits with a solid bolted
bearing housing including CARB
bearings:
• Free axial internal movement
• Higher radial load
capabilities
• No axial stress on bearing
• Reduced maintenance and
repair costs
• Improved reliability
• Increased lifetime
• Extended re-lubrication
intervals, and improved
grease life
© Valmet 2015
Considering changing your
Yankee bearings?
Yankee Head-to-Shell
Joint Upgrade
Yankee dryers which suffer from persistent
steam leakage from the head to shell joint
are a safety issue for machine operators,
which if not addressed can lead to ultimate
failure of the vessel. By removing damaging
crevice corrosion and permanently sealing
any steam leakage from the head to shell
joints the service life of the vessel can be
considerably extended.
© Valmet 2015
The repair process involves machining
back the head flanges and re-boring the
existing bolt holes to a larger diameter.
These machining operations remove any
existing joint corrosion and allow the
fitting of larger diameter, higher torque,
bolt assemblies.
The joints are re-sealed before final torque
and the combination of the above results in
efficiently clamped, leak free, head to shell
joints.
Features
• Incorporates new design
features in older Yankee
dryers.
• Allows continued safe
operation of the vessel for
prolonged periods of time.
• Joints are fully tight during
the paper making operation
and hence no further
corrosion is able to develop.
• More efficient clamping of
the joint with overlapping
“clamping cones” reduces
the propensity to leak.
• Lower maintenance for cost
savings
Drying Section
Extend the life of “problem”
Yankee dryers
91
On-site Dynamic
Yankee Balancing
Improve operation condition
Vibration problems can be devastating to
machine runnability in general and for the
Yankee bearing lifetime in particular.
Having a Yankee in dynamic balance gives
you the following benefits:
•
•
Drying Section
92
•
Eliminates Yankee as source of vibration
problems at current or targeted speeds.
Facilitates best operating condition for
the Yankee bearings.
Reduces wear on surrounding
components, such as Yankee bearing,
pressure rolls and doctors.
Features
The service is delivered as a
complete package containing:
• Dynamic balance
measurement utilizing stateof-the-art equipment
• Design of balancing weights
• Installation of balancing
weights
Dynamic balancing is performed
by a Valmet service team
on-site during a one day shutdown.
© Valmet 2015
Perhaps you have made a major
intervention on your Yankee, or you wish
to increase the speed to above the design
speed. In either case it is very important
to have your Yankee balanced to avoid
vibration problems.
Infinikote
Standard grinding allowances on a Yankee
dryer are typically 10-12 mm above
“Derate” point. As the root shell thickness
reduces, less allowable steam/roll pressure
is applied to the Yankee thus affecting
drying/production rates. The closer the
shell is to derate point, the more center line
shrinkage is likely to appear which will also
adversely affect the tissue making surface.
The application of Infinikote will provide
an excellent paper making surface, reduce
the frequency of regrinds and greatly
extend the life of the vessel.
© Valmet 2015
Infinikote can also be applied to Yankee
dryers as a solution to other paper making
problems such as chatter marks, porous
areas in the cast iron and loss of profile due
to wear.
Features
Infinikote is a hard, protective
coating that is homogeneous,
has good bond strength and
gives good, even heat transfer. It
is also highly corrosion resistant.
Infinikote:
• Increases doctor blade life
which means increased
production.
• Extends continuous run time
of the machine by giving
operational reliability and
predictability.
• Operates on all furnishes
and types of tissue.
• Gives better product quality
control resulting in more
efficient operation.
Infinikote is the most reliable
Yankee thermal coating
available with unparalleled
reliability.
Drying Section
Optimizing Yankee performance
93
Ultrasonic Testing
of Yankee Shells
Valmet’s tailor made ultrasonic testing
equipment can cover the full Yankee dryer
shell quickly and accurately, and with
minimal downtime.
The ultrasound technique enables
determination of the extent of defects,
where each is determined in both depth
and size.
The complete Yankee dryer shell and its
inclusions are plotted on a single C-scan for
best overview.
A full test is recommended prior to a
full face thermal coating, to secure that
no severe and critical defects are hidden
underneath the coating.
Drying Section
94
Benefits
• Complete Yankee shell test
with minimal down time
• All defects will be detected.
• Every defect is determined
in both depth and size.
• Valmet possesses extensive
experience and know-how
for accurate evaluation.
Expected downtime excluding
cooling down and warm-up:
• 12-foot Yankee: 5-6 hours
© Valmet 2015
Continuous measurement on
rotating Yankee
On-Site Yankee
Profile Grinding
Valmet state-of-the-art grinding machines
are the choice of the Tissue industry for
Yankee cylinder grinding.
The advanced CrownMaster™ grinding
machine is installed on the pressure roll
arms which reduces machine disassembly
and greatly reduces machine downtime.
© Valmet 2015
The Farros Blatter MZA grinding machine
uses technology which provides high
accuracy and grinding quality. The MZA is
installed in the doctor position.
Benefits
Choosing Valmet for grinding
your Yankee yields many
benefits.
• High quality grinding which
extends the interval to the
next grind
• Quick installation either in
the suction pressure roll
position or doctor position
• The CrownMaster has the
shortest sheet-to-sheet time
of any tangential grinding
machine on the market.
• The CrownMaster needs
fewer man hours and less
downtime than competitive
grinding.
• The CrownMaster requires
minimum input from mill
engineering.
• Cost and time efficient
Drying Section
Advanced resurfacing technology –
It’s all about time and quality
95
Yankee Surface Polishing
Grinding profile accuracy and surface
roughness are important as they affect the
sheet adhesion, doctoring and moisture
profile and thereby your production quality
and speed.
By polishing the Yankee surface you restore
the surface finish maintaining production
and extending the time to the next grind.
Valmet focuses on quality, fast response
and quick application. We therefore use
the Farros Blatter RSG – still the unbeaten
equipment used for surface polishing.
Drying Section
96
Features
• Mounts on doctor beam.
• Transports quickly and
easily.
• Superb for emergency
response, normally 12-18
hour total time for grind
Benefits
• Excellent for emergency
response and short grind
times
• Intermediate grind to extend
profile grind intervals
• Improves surface finish, but
not profile.
• Removes localized defects,
grooves, scratches, dents
and chatter.
© Valmet 2015
Optimizing the Yankee surface for
machine performance and quality
ScreenCloth Yankee Polishing
Improve your Yankee performance
Valmet ScreenCloth is an abrasive cloth
specially developed for Yankee cylinders to
be used by papermakers to quickly remove
the uneven spread of organic chemicals or
edge built-up deposits.
Benefits
In case of chatter-marks, ScreenCloth is
used to remove the coating and improve
the drying process, thus maintaining high
quality and production.
• Easy and quick application
• Establishes a uniform
surface finish for the
stability of the organic
Yankee coating.
• Reduces crepe blade
vibrations.
• Reduces sheet holes.
• Reduces edge breaks due to
build-up.
• Reduces early stage chatter
marks.
© Valmet 2015
The ScreenCloth is placedd in-between a
supporting board put into the doctor holder
– with a piece of felt attached – and the
Yankee. Doctor load is then applied while
the Yankee is rotated at Sunday drive speed.
This product can be used on
both cast iron and thermal
coated Yankee shell surfaces.
Drying Section
Procedure
ScreenCloth is to be used by mill
personnel and provides these
benefits:
97
Yankee Wear Profiling
Valmet has a complete program for Yankee
surface refurbishing. Wear generates
more wear, and by controlling wear you
maximize the life of your Yankee.
•
•
•
Drying Section
98
The service gives valuable information
on how to find causes of wear and how
to correct the situation to maintain or
improve high product quality.
The Yankee surface wear pattern
facilitates the decision of whether to
polish or profile grind.
Profiles help determine grinding
schedules for minimized material
removal.
Features
The measurement is made in a
couple of hours of machine stop
with a pressurized Yankee and
includes detection of:
•
•
•
•
Surface wear
Pressing performance
Creping performance
Moisture profile uniformity
A direct comparison with the grinding
curve report will be delivered after
inspection including surface wear profile,
run out and recommendations of actions
needed for the next planned shutdown.
© Valmet 2015
Find cause of wear and maintain
high product quality
Yankee Surface Profile
Measurement
Detect deviations and ensure high quality production
Regular measurements of Yankee surface is crucial to detect
deviationsfrom the original shape at an early stage and thereby allow
correcting actions without disturbing the production. It can also be part
of trouble shooting services. The Yankee Surface Profile Measurement
program ensure that the Yankee cylinder is operating under best condition
and provides high quality tissue production.
Yankee Surface Profile Measurement (SPM)
The SPM program is designed to define current condition of the Yankees surface as well as
detecting deviations from the original shape. During the measurement variations due to
condensate systemtemperature, Yankee crown fluctuations or appearence of local wear is
recorded.
The result from the measurement is analyzed and compared with data from the web
scanner. To provide correct data the measurement is best performerd with grinding
pressure on the Yankee. But if needed it can also be done in cold condition.
Drying Section
© Valmet 2015
The measurement is carried out with high precision tolls by our yankee experts with
operating pressure and sheet off.
99
Wear Profile
Service Intervals based on
condition
To ensure a trouble free operation the
recommended SPM service interval is
one to three years depending on type of
production and condition of the Yankee.
Improving actions
The Result of the service program will
be provided in a report together with
recomendations for needed actions.
Yankee surface profile Measurement (SMP)
Long term service program
Drying Section
100
© Valmet 2015
• Safe and reliable - avoid unplanned shutdowns or extra grinding
• Availability and Quality - ensure best conditions for optimum capacity
and product quality
Yankee Crown
Optimization
Profile problems create reel section and
converting problems which can cause
production losses. The Yankee Crown
Optimization service takes an analytical
approach to the problem - to improve
crown fit and to reduce Yankee wear and
sheet breaks.
© Valmet 2015
Benefits
• Maintain the best crown
profiles for the machine.
• Achieve best cross-machine
product quality.
• Reduce operator’s time
spent maintaining cross
machine profiles.
• Improve drying efficiency.
• Reduce surface wear.
• Prolong overall service life.
Features
To determine the optimum
profile for a given Yankee dryer,
the actual running conditions
must be analyzed. The Yankee
dryer will be tested in the
running state, the correct
profiles calculated and the
profiles will be grinded at the
next scheduled shut-down.
• Operation-condition analysis
• Optimized crown
calculations using FEM
(Finite Element Method)
• Yankee and press roll crown
curve analysis
• Doctor set-up and gapsetting curves
Drying Section
Improve machine efficiency: apply
optimum crowning
101
THRU-AIR (TAD)
Dryer Service
Ensure trouble free operation
Benefits
Drying Section
102
• Identify machine
improvements using the
latest TAD technology
developments.
• Improve up-time through
preventive maintenance.
• Enhance machine safety.
• Benchmark equipment vs.
current industry standards.
Features
• TAD air system inspections
• Review of burner and fan
operations
• Seal adjustments
• Annual audits
• Bearing and lubrication
diagnosis
• Alignment of rolls and
framing
• Monitor condition of the
equipment
© Valmet 2015
THRU-AIR Drying (TAD) is a unique
and superior way to dry tissue and towel
because of its ability to produce a softer
product with higher loft. To ensure trouble
free operation and to extend the life of your
machine, a regular maintenance routine is
recommended.
Valmet heat recovery systems are
specifically designed for paper machine
applications and guarantee a long lifetime
and easy maintenance.
© Valmet 2015
For a remarkable reduction in energy
consumption, we offer an entire family of
products aimed at recovering heat from the
hood exhaust and transferring it so that
it can be used for different purposes: preheating of combustion and make-up air,
room ventilation, fresh, process and white
water.
Different applications,
different products:
•
•
•
•
•
Air to air heat exchanger to reduce hood
gas consumption by pre-heating makeup and combustion air
Indirect air to water heat exchanger
(AHR) for room ventilation and fresh
water
Direct air to water heat exchanger for
process and white water
All the heat recovery systems are
specially designed for the tissue process.
High efficiency and low maintenance
Drying Section
Save energy by taking advantage
of your hood exhaust heat to
the fullest
103
Waste Heat Steam
Generator
As the drying process (Yankee hood
and Yankee dryer) demands a very high
level of energy, the Waste Heat Steam
Generator represents an innovative and
environmentally efficient additional
solution to recover heat from the Yankee
hood exhaust.
Drying Section
104
Condensate is tapped-off from the Yankee
separator and sent by means of a pump to
the Waste Heat Steam Generator.
The steam is usually generated at 16 barG
and used as make-up steam for the steam
produced by the main ´gas fired boiler´, just
before the thermocompressor high pressure
inlet. The amount of steam generated
depends on the waste energy available from
the hood exhaust air.
© Valmet 2015
Reduce steam consumption in the
tissue machine
Advantage Creping
Yankee creping doctor system
Optimum creping angle setting
The Advantage Creping doctor system is a
rigid, easily maintained and well-proven
design, allowing adjustment of the creping
angle during production.
The creping angle adjustment facilitates
fine-tuning your product to high quality
levels and is especially advantageous if
you run many different grades that require
different properties.
• Optimal tool for
papermakers to control bulk
and smoothness at creping
• Blade angle adjustment
means no need of doctor
blades having different bevel
angles.
• Particularly recommended
for operation together
with ceramic coated doctor
blades
Doctoring
© Valmet 2015
Advantage Creping is standard
in all Valmet Advantage™
DCT® machines and due to its
compact design, it’s available
for most tissue machines.
105
Yankee Doctor Blade
Storage
Valmet Yankee Doctor Blade Storage uses
storage boxes located in-line with the
Yankee doctor holders which enables full
support of the blade at all times.
This provides safe and effective doctor
blade handling minimizing both personnel
injuries and production downtime.
Doctoring
106
Features
• Improved safety – storage
always supports the blade in
line with the holder.
• More production – less
down time due to fast and
effective blade change
To refill the storage, the storage
unit is lifted down to floor level
by using the overhead crane.
© Valmet 2015
Improved safety and more
production
LiteFit Composite
Blade Holder
The one-of-a-kind advanced composite
construction of LiteFit holders gives them
exceptional durability and flexibility.
Holders are matched to the specific
requirements of each doctoring position.
The material and width of the top plate can
be tailored for the best possible doctoring
result at each position.
Incredibly lightweight
© Valmet 2015
LiteFit holders are very lightweight at 20%
of the weight of traditional metal holders.
The lightness of LiteFit holders makes them
easy and safe to handle. You’ll really notice
the difference during installation!
Excellent flexibility and impact
resistance
LiteFit holders consist of two distinct parts,
a holder profile and a removable top plate.
LiteFit holders are both sturdy and very
flexible. Their composition provides good
resilience and self profiling characteristics.
LiteFit blade holders are highly impact
resistant and quick to recover even from the
strongest physical shocks.
Easy cleaning
The cleaning of LiteFit is made easier by
a removable top plate, which gives access
to the rivet groove facilitating fast and
effective cleaning.
Doctoring
Unsurpassed LiteFit performance
107
FiberDoc Composite
Blade Holder
Doctor holder for limited spaces
With FiberDoc the lubrication water is fed
inside a pipe and led through holes between
the composite body and the pipe. The water
removes any impurities and ensures a
proper oscillation movement.
Oscillation is done with water lubricated
slide surfaces and an integrated water inlet.
FiberDoc is suitable for all oscillator types.
Doctoring
108
Benefits
The reliable FiberDoc doctoring
solution delivers the following
benefits:
•
•
•
•
Composite body benefits
No thermal distortion
Light and stiff construction
Shaped body precludes
dirt contaminations with
revolutionary foil technology
• Minimum space
requirements
© Valmet 2015
FiberDoc is a unique forming and press
section cleaning doctor suitable for lead
rolls and for cleaning purposes with
minimum space requirements.
LiteCompact
Advanced single-hose composite blade holder
Excellent doctoring performance
Design
•
•
•
© Valmet 2015
•
Very strong and corrosion free
composite
structure with excellent dimensional
stability
Single hose for loading and opening
Biggest opening of all holders currently
on the market
Fast and easy ”plug and play” hose
change
Benefits
• Excellent and uniform
profiling,
low thermal expansion
• Easy maintenance and
cleaning
• Simple and sealed
construction
with large movements
• Light and corrosion-free
• Strong and wear-resistant
• Excellent for the most
demanding doctoring
positions
»» Heavily dirt collecting positions
»» Positions requiring high blade
conforming
»» Difficult cleaning positions
Doctoring
LiteCompact combines a 100% composite
holder and a 100% composite top plate in
an optimal manner. This results in excellent
profiling properties, allowing the doctor
blade to conform to the roll surface being
doctored.
109
Doctor Loading
& Oscillating Unit
Compact and reliable design
The doctor oscillation is made with either
an OsciPro pneumatic oscillator unit or
electric motor with gear and reducer.
OsciPro Oscillator data
•
•
•
Doctoring
110
Thrust force: 11kN/6bar or 22kN/6bar
Stroke length: 10-16 mm ±1 mm (0.40.6”)
Stroke rate: 1-10/min
• Compact and reliable design
• Loading and unloading of
the doctor blade is done
with pneumatic bellows
• Maintenance free doctor
bearings
• Made of acid resistant steel
• Easy to install
• Fitted either with an
OsciPro pneumatic
oscillating cylinder or an
electric motor with a gear
and reducer
© Valmet 2015
Valmet doctor loading unit is a simple and
highly reliable design in which the doctor
load is transmitted from air bellows to the
doctor body by a lever.
OsciPro Pneumatic Oscillator
Pneumatic doctor oscillator
The pneumatic OsciPro oscillators are
designed for tissue machine’s roll doctors and
are characterized by long service intervals,
unsurpassed reliability, limited maintenance
demands and compact construction. The design
makes them appropriate to use both in the wet
end and the dry end of the machine.
Features
The oscillator design is simple and
Benefits
years of uninterrupted and maintenance
• Compact size
• Adjustable stroke length 1016 mm (0.4-0.6”)
• Adjustable stroke frequency
1-10 per min.
• Maximum operating
temperature 180° C (356° F)
• Long service intervals,
minimal maintenance
demand
• Reliable operation
• Easy installation
• Compact size
oscillator housing is warranted against
free service. Used as instructed, the
rust-through for a period of five years.
• Two sizes 11,000 N/6 bar or
22,000 N/6 bar
• Made of acid resistant steel
• Easy to install
• Can replace existing
electromechanical doctor
oscillators when coupled
with adaptor kit
• Compact size
Doctoring
© Valmet 2015
reliable. All units are designed for five
111
Doctor Oscillator Bearings
Valmet’s OEM composite straight-bore
sleeve type bearing is the easy way to
retrofit and modernize Beloit doctor
oscillator bearings. It can easily be adapted
to most doctor applications throughout the
tissue machine.
Benefits
Provides linear motion that:
•
•
•
•
•
Doctoring
112
•
•
•
Improves doctoring
Improves blade wear
Reduces picking/crumbing
Improves web draws/tail
transfer
Extends roll cover/face life,
longer roll change intervals
Wears longer and is self
lubricated
Less costly to replace
Saves maintenance time and
money
Features
It is easy to upgrade / convert
all types of Beloit oscillator
bearings to Valmet’s latest
design.
• Housing and sleeve in
corrosion-resistant 316
stainless steel
• Self lubricating bearing
material that is chemically
inert
• Unaffected by harsh, wet
conditions and typical
machine operating
temperatures
• Housing design limits the
amount of debris that can
enter the bearing surface
area.
• Low replacement cost
• Low coefficient of friction of
the bearing allows existing
doctor oscillator to be
reused.
© Valmet 2015
Modernize Beloit doctor
oscillator bearings
ValDual Doctor Blade
ValDual doctor blades were designed to
provide an effective low-cost solution
for the doctoring of grooved rolls and
suction rolls, particularly those with soft
covers whose doctoring solutions have
traditionally been either ineffective or too
expensive.
ValDual represents the perfect combination
of optimal raw materials technology and
blade geometry. The raw material selected
enables the doctoring of soft covers, while
the blade geometry employed provides
effective water removal and allows loading
against the doctored roll.
© Valmet 2015
ValDual is preferably used in combination
with Valmet FiberDoc or LiteCompact
doctor holders.
Benefits
• Enables effective doctoring
of soft covers.
• Delivers low operating costs
with good dewatering.
• Allows loading against the
doctored surface.
• Lightweight and easy to
handle
• Remains straight in the
machine and provides
uniform doctoring.
Technical data
Material
UHMW-HDPE
Hardness
63-65 ShD
Temperature resistance
90° C (194° F)
Available lengths
100, 110 mm
(4.0, 4.3”)
Doctoring
Effective dewatering of soft
covered suction pressure roll
113
ValEco Doctor Blade
Cost-efficient and wear resistant
overall doctor blade
Features
ValEco blades are high wear– and
temperature-resistant and are especially
efficient in doctoring of ceramic coated
rolls and calendar positions. The wear
mechanism and profile formation of the
doctor blades are slightly different for every
application. Therefore, ValEco is available
in several different carbon fiber contents.
Doctoring
114
Available dimensions
•
•
1.5 x 50 - 100 mm (0.06” x 2” - 4”)
2.0 x 50 - 100 mm (0.079” x 2” - 4”)
© Valmet 2015
The variety of ValEco blades, makes it a
cost-efficient option for most applications
but especially for the most demanding
machine positions.
• Extremely high wear
resistance
• Ideal for all generally used
holders
• Standard bevel 30° (can be
modified)
ValEco T Doctor Blade
Doctor blades for cleaner rolls
Features
Carbon fiber ValEco T doctor blades are
designed for roll surface conditioning
applications.
• Very good cleaning
properties
• For continuous use
• Ideal for all generally used
holders
• Made by unconventional
manufacturing process.
modified)
ValEco T blades can be used as a standard
carbon fiber doctor blade during normal
production.
The high wear resistance of ValEco T is
based on finest carbon fibers and the ecoresin system.
Carefully selected silicon carbides are
added for effective and sensitive cleaning
results.
1.5 x 50 - 100 mm (0.06” x 2” - 4”)
2.0 x 50 - 75 mm (0.079” x 2” - 4”)
Doctoring
© Valmet 2015
•
•
115
ValGlass LT Doctor Blade
Low cost doctor blade with good
wear resistance
Features
ValGlass LT is specially designed for the
press, drying and reel sections in the tissue
machine. It is also suitable for all general
doctoring positions that do not demand
extreme heat or wear resistance.
• Standard epoxy resin
reinforced with finest fiber
glass fibers
• Bend stiffness: 19 GPA/19
GPA
• Maximum heat resistance:
(TG) 160° C (320° F)
modified)
Benefits
Doctoring
116
Good wear resistance
Low cost
Wear resistance material
Ideal for generally used
doctor blade holders
•
•
1.5 x 50 - 75 mm (0.06” x 2”-3”)
2.0 x 50 - 75 mm (0.08” x 2”-3”)
© Valmet 2015
•
•
•
•
Doctor Blade Service
In addition to blade deliveries, BladeStore
and BladeCarry storage containers,
doctor blade service includes solid expert
assistance for solving doctoring problems
in the production line. Operator’s training
as well as work safety procedures and
instruction are also integral parts of doctor
blade service.
Recycling of doctor blades
© Valmet 2015
Doctor blades made of carbon fiber can be
recycled from the press section and used
in the dryer section after re-sharpening.
Used blades are checked, re-sharpened and
returned to the mill in special coil boxes,
using the BladeCoiler.
Features
Valmet doctor blades are highquality, wear resistant blades
made of carbon fiber, glass
fiber, polyethylene, bronze,
phenolic resin or steel.
The blades are designed to
cover all doctor blade demands
in the paper industry.
Doctor blade service provides
a complete selection of beams,
oscillators and other doctor
accessories as well as expert
installation services.
Doctoring
For optimum production line
availability
117
BladePuller
The BladePuller is a handy extractor that
firmly grips the surface of a blade and
quickly removes even the most obstinate
blade from the holder. The grip is safe to
hold as it only releases the blade when
pulled sideways. BladePuller uniformly
compresses the surface of the blade,
without damaging the blade fibers. Its arm
is long enough to reach most locations. It
can also be equipped with an extension if
needed.
Doctoring
118
Features
The BladePuller
• Has a total length of 1.8
meters (5.9 feet)
• Works well with all types of
machines
• Made of stainless steel
• Contains no consumable
parts
• Designed for ease of
operation
• Can be used on blades up to
5 mm (0.2”) thickness
The angle of blade extraction
is always appropriate due to
the design of BladePuller’s
grappling jaw, which can rotate
a full 360 degrees.
© Valmet 2015
Removes blades from blade
holders safely and easily
TailThreader
Valmet tail threading system for tissue and
toweling machines is especially designed to
handle the tail within a wide range of basis
weights up to the highest speeds.
© Valmet 2015
The TailThreader assures safe and efficient
operation.
Features and Facts
• Ability to handle the tail
within a wide range of speed
and basis weight variations
• Simple and logical control
system integrated with
the machine controls and
automation systems
• Continuous chute channels,
standard design with no
open gaps to jump
• Few moving parts
• Minimum need for operator
intervention
• Easy to clean
• Easy to preset for different
machine operations
• Little or no maintenance
required
Dry End
Maximized Safety
and Reliable Operation
119
Tail TurnUp
Increased tail turn-up efficiency
Water soluble glue is sprayed from a selfcleaning spray gun and only on the paper,
not on the reel drum or other equipment.
The system’s modular design enables easy
installation that can be done during a
minor machine stop.
Dry End
120
Benefits
• Increases tail turn-up
efficiency
• Increases operator safety
• Requires very little
maintenance
• No contamination of
surrounding equipment
• No glue related problems in
converting operations
• Automatic operation
facilitating no in-machine
intervention
• Water soluble glue used
• Creates an environmental
friendly product
© Valmet 2015
The Tail TurnUp system facilitates a safe
and reliable glue application at tail turn-up
improving both machine operation and
efficiency.
VacBox
Installing the VacBox from Valmet on your
reel drum increases the dry end efficiency.
This special vacuum box technology holds
the tail firmly to the reel drum, improving
the threading, turn-up operation and
overall machine efficiency.
© Valmet 2015
The special seal arrangement prevents
paper from getting drawn into the box and
catching fire or causing other damage.
Total supply
Valmet offers the complete system. A new
vacuum sleeve and vacuum supply unit can
be provided with the vacuum box.
The cast iron vacuum sleeve has a hole
pattern that is designed to prevent hole
marks in the paper roll.
The Valmet vacuum system is easy to
handle and equipped with a special valve
to adjust the vacuum in the zone to an
optimum level improving threading and
turn-up efficiency.
Dry End
Improved turn-up efficiency
and fewer fires
121
Edge Trim Chute
Get control of your trim
There are various solutions of controlling
the trim and bringing it into the pulper.
Valmet Edge Trim Chute brings down your
trim into the pulper with directed air jets,
a well proven technology which today is
standard in all Valmet Advantage™ DCT®
machines.
Features
• No trim build-up on the
machine frame
»» Edge trims are brought
straight down into the
pulper
• On-the-run adjustable cross
machine position
»» No shut downs required for
adjustments
• Unique design from proven
technology
Dry End
122
© Valmet 2015
»» Pneumatically operated trim
chutes
»» Self feeding from the doctor
blade
Active Foils
Valmet Active Foil is based on a mostly
non-contact airborne sheet transfer
technology that provides complete control
over the tissue web run from doctor to reel.
The web is transferred with no flutter and
ballooning problems, positively affecting
tissue production, the number of web
breaks and converting.
© Valmet 2015
Valmet Active Foil is a complete system
supply with fans and controls
Benefits
Valmet Active Foil provides a
non-contact sheet transfer to
the reel which provides these
benefits:
•
•
•
•
Excellent web transport
Reduces risk of sheet breaks
Reduces web stretch
Increases the dry end
efficiency
• Allows for speed increase
Dry End
Reduced web breaks and increased
speed
123
Advantage Run concept
- Foils
Advantage Foils
•
Valmet Advantage Run is based on a
mostly non-contact airborne sheet transfer
technology that provides complete control
over the tissue web run from doctor to reel.
The web is transferred with reduced flutter
and ballooning problems, positively
affecting tissue production, the number of
web breaks and converting.
The dust on the paper surface is captured
through the web cleaning effect. At the
same time, a low dust environment ensures
reliable and accurate operation of quality
control system scanners and sensors.
Dry End
124
A first Advantage Foil before the scanner
improves runnability and cleaning
for better rewinding, converting and
printing quality.
»» Automatic retraction system
»» No mechanical contact with paper in
•
Foil area
A second Advantage Foil after
the scanner improves runnability
and cleaning for better rewinding,
converting and printing quality.
»» Incorporated adjustable spreader bar
»» No mechanical contact with paper in
•
foil area
Wet exhaust system to reduce
maintenance and eliminate fire risks
© Valmet 2015
Web stabilization and cleaning by
Advantage Foils in the Advantage
Run system
NipDeflector
The Nip Deflector blocks the boundary air
layers coming with the web and with the
reel drum.
This eliminates uneven web edges and
typical ballooning problems in the reel
drum area at high speeds, and will reduce
wrinkles in the sheet and decrease the
number of sheet breaks.
© Valmet 2015
You will achieve a higher efficiency on the
machine and thereby more production.
Benefits
• Eliminates ballooning of the
sheet over the reel drum
• Reduces weaving on your
parent rolls
• Reduces sheet wrinkles
• Reduces breaks specially at
turn-up
• Compatible with all reels
• Excellent return on
investment
Dry End
Do you have problems adhering
the sheet to the reel drum?
125
Advantage Run concept
- Reel Nip BlowBox
The Advantage Reel Nip BlowBox stabilizes
the web on the reel drum surface by
creating underpressure in the closing nip
between the paper web and reel drum. It
includes an automatic retraction system to
allow the tail threading operation.
As a result, the Advantage Reel Nip
BlowBox improves uneven web edges and
typical ballooning problems in the reel
drum area which normally increase when
reeling at high speed.
Dry End
126
Advantage Reel nip blowbox
•
•
•
•
•
•
Stabilizes the sheet over the reel drum
and eliminates ballooning.
Reduces weaving on parent rolls and
sheet wrinkles.
Reduces sheet breaks especially at turnup.
Web-cleaning effect created by the high
velocity air nozzles.
Compatible with all reels
Excellent return on investment
© Valmet 2015
Web stabilization and cleaning for
reel drum operations
WaterJet TurnUp
Valmet WaterJet TurnUp system ensures a
fast and clean parent roll change.
The WaterJet TurnUp system comes as
a complete package including controls,
user support and preventive maintenance
program.
The WaterJet TurnUp system consists of
three main components:
© Valmet 2015
1. WaterJet nozzle beam
2. Adhesive application unit
3. High pressure pump unit
Benefits
• Fast and safe parent roll
change
• Compatible with all reels
• Completely automatic
operation
• Extensive user support
• Designed to accommodate
maintenance during
operation
• Excellent return on
investment
Dry End
No more ballooning and time
consuming turn-up problems
127
WaterJet Trim
Dust-free dry end trim
Valmet dry end Water Jet Trim equipment
trims the sheet edge with high pressure
water which is dust-free and gives a clean
sheet edge without fringe.
Dry End
128
© Valmet 2015
The sheet is well supported, inside of foil
or via a foil extension for excellent cutting
quality. This results in fewer sheet breaks
and the best conditions for rewinding and
converting, thus increasing your overall
production.
Mechanical Slitter
Cut the costs
Valmet Mechanical Slitter utilizes a
specially designed serrated blade which
is applicable for tissue, minimizes sheet
breaks and is simple and foolproof to
change.
© Valmet 2015
A sheet support opposite the slitter is
required including a dust collector.
Features
• Serrated blade specially
designed for tissue
• Automatic speed control
for optimum cutting
performance
• Manually controlled or fully
automatic by the tail squirt
and sheet break indicator.
Dry End
Valmet Mechanical Slitter is a state-of-theart and fully automatic design which fulfills
all safety criteria and requires a minimum
of maintenance.
129
WaterJet Slitter
Clean cut reducing sheet breaks
Valmet Water Jet Slitter facilitates a clean
cut edge of the sheet which minimizes sheet
breaks in the reel section, rewinding and
converting.
The Water Jet Slitter provides a dust-free
cut and cuts the web without reducing the
sheet bulk.
Dry End
130
© Valmet 2015
The clean cut edge and dust-free
environment produce fewer sheet breaks
in the downstream process and therefore
provide an increased production overall.
Advantage WetDust
The innovative patented concept makes use
of a fully wet system, eliminating typical
issues associated with dry systems (fires
and plugging).
Valmet Advantage WetDust system is
designed to capture dust where it is created
by encapsulating it in water, to contain
it near the source and to prevent it from
migrating to the tissue machine hall.
© Valmet 2015
The equipment provides a healthy, safe
and comfortable working environment for
tissue machine operators and minimizes
manual cleaning, thus reducing machine
downtime.
Advantage WetDust Collectors
•
•
•
•
•
Wet vortex collectors with continuous
internal washing (no fire risk)
Dust is captured near the source
Small paper pieces are handled with no
plugging
Advantage Pulper Collector
Pulper is kept in underpressure, with
better runnability
Advantage DustCap
and Elephant Trunk
•
To contain dust within the dry end
Advantage WetDust air system
•
•
One droplet separator for the system
Wet exhaust system
»» less maintenance
»» no fire risks
Dry End
Control and eliminate dust where
it originates and concentrates
131
Calender Gap Control
Calender Gap Control is specifically
designed for tissue applications and enables
a very accurate setting of the gap inbetween the calendering rolls.
Calender Gap Control acts as an adjustable
mechanical stop in-between the rolls.
Full load can be applied which provides
improved stability in the machine direction
while the gap is adjusted with the actuators
to the optimum level for precise and even
nip load in the cross machine direction.
Dry End
132
What is gap calendering?
•
•
•
Acts as an adjustable mechanical stop
in-between the calender roll bearing
housings.
Manual or with electric step motor
which can be running in automatic
mode
Can be adjusted in a range of 8.3 mm
(0.328 inch).
The Calender Gap Control gives you full
control of your calendering down to 15 PLI
(3 kN/m).
© Valmet 2015
Improved caliper control
Primary Arm
Excellent linear load control
Excellent economic return
Higher demands on paper quality and
machine performance put the winding
process in focus. The paper quality has
moved toward a softer and higher caliper
paper produced at higher speeds.
Installation of Primary Arms results in:
Excellent linear load control
Excellent winding process
Excellent turn-up control which allows
you to:
»» Increase the machine speed
»» Produce higher quality products
»» Improve the total machine efficiency
»» Reduce the amount of product waste
Dry End
© Valmet 2015
Valmet Primary Arm is an improved
primary winding system that gives control
of the linear load in-between the spool and
the reel drum and winds high quality paper
products at high machine speeds with
improved efficiency.
•
•
•
133
Pivoted Primary Arm
Valmet Pivoted Primary Arms clamp
the spool, and the nip load and relief are
hydraulic controlled separately in-between
the drive and tending side.
Pivoted Primary Arms can be installed as
a separate unit or combined with Pivoted
Secondary Arms or Secondary Carriage
system for complete control of your parent
roll winding from the turn-up to the
complete roll.
Dry End
134
Features
• Closed loop control with
pressure transmitters
• Individual control TS and DS
• Wind up to 200 mm (8”) of
paper while in primary arms
• One cylinder controlling the
nip load and relief.
Over 30 installations worldwide
since 1998.
© Valmet 2015
Having problems with the nip load
on your Beloit machine?
Pivoted Secondary Arm
Uniform bulk throughout the roll
•
•
Even edges
Uniform bulk through the parent roll.
© Valmet 2015
Pivoted Secondary Arms can be installed
as a separate unit or combined with
Advantage™ or Pivoted Primary Arm
system for complete control of your parent
roll winding from the turn-up to the
complete roll.
• Minimized or elimated
crushing of the sheet
• Minimized bottom waste
• Uniform caliper through the
whole winding process
• Hydraulically operated and
low friction cylinders
• Position control of the arms
• No mechanical parallel shaft
• Closed loop nip control with
pressure transmitters
• High performance pressureflow valves
Dry End
Pivoted Secondary Arm gives high
repeatability and very good load control
which facilitates
135
Secondary Carriage
Secondary Carriages facilitate optimum
control of the nip load which gives better
roll structure and better runnability in both
the tissue machine and converting.
The controlled low nip load allows you to
build bigger rolls which means fewer roll
changes and thereby more production.
The Secondary Carriages can be installed
as a separate unit or combined with Pivoted
or Advantage™ Primary Arm system
for complete control of your parent roll
winding from the turn-up to the complete
roll.
Dry End
136
• Improved runnability
in tissue machine and
converting line – excellent
control of the nip load gives
excellent roll structure
• Reduced amount of
production waste – can wind
larger parent rolls which
improves efficiency and
increases production
• Can use lower linear load to
maintain product quality
• Center wind assist drive as
an option (recommended if
running linear loads lower
than 400 N/m (2.7 PLI))
© Valmet 2015
Improved runnability
and increased production
Advantage Roll Handling
Parent rolls coming from the reel section
are of high diameter and heavy weight and
risk for damage is high. The Advantage
parent roll and core management system
eliminates that risk.
© Valmet 2015
You can easily integrate the Advantage
parent roll and core management system
into Valmet tissue machine reel sections, as
a stand-alone in existing tissue machines or
as part of a dry-end upgrade in a machine
from another vendor.
Reaping the benefits from
countless installations
•
•
•
•
Careful core management, with
automatic core locking
Automatic spool return to overhead
storage
Improved total machine efficiency
Consistent quality throughout the full
roll diameter and width
You can operate the system as an automatic
logical sequence, or control it manually,
step by step.
Dry End
Leveraging our experience
to reduce your risk
137
Automatic Inflate/Deflate
Unit
Valmet Automatic Inflate/Deflate Unit
locks and unlocks the cores onto the core
shafts.
Inflation and deflation are always done in
correct and equal sequence which protects
the core shafts and ensures the cores are
always centered and properly unlocked.
Dry End
138
Benefits
• Fully automatic – less
handling
• Improved reel performance
– cores are always centered
on the core shaft
• Protect the core shafts
– cores are always fully
unlocked at deflation
© Valmet 2015
Fully automatic core
loading system
Lifting Table
Valmet Lifting Table guarantees that your
high product quality is not impaired by
either the shaft pulling procedure or the
delicate core positioning.
© Valmet 2015
Valmet Lifting Table is preferably combined
with a Core Separation unit. The core
loading of the reel spools is made by the
Core Loading System where each core is
loaded separately and then separated on the
Lifting Table by the Core Separation unit.
Benefits
Valmet Lifting Table offers the
following benefits:
• Elimination of safety
hazards for machine – Fewer
personnel injuries
• Exceptionally careful
jumbo roll handling – More
products of the desired
quality
• Minimum waste from roll
handling – Improved overall
machine efficiency
• Consistent quality
throughout the full roll
diameter
• Optimum economic return
Dry End
Reliable parent roll
and core handling
139
Core Shaft Puller
Valmet Core Shaft Puller is a fully
automatic core shaft extraction unit. The
core shafts are deflated by the Automatic
Inflate Deflate unit and pulled out into
position for new cores.
The fully automatic Core Shaft Puller
facilitates efficient and safe core loading
and unloading with minimum damage to
the cores and risk of injuries.
Dry End
140
Benefits
Valmet Core Shaft Puller
ensures optimal return on your
investment.
• Increased production of
desired qualities – Improved
total machine efficiency
• Fewer damaged cores giving
minimum waste
• Elimination of safety
hazards for machine
operators – Fewer staff
injuries
© Valmet 2015
Reliable parent roll
and core handling
Core Loading Unit
Efficient and gentle core handling
© Valmet 2015
Valmet Core Loading Unit is preferably
combined with a Core Robot supplying the
unit with cores and the Lifting Table with
the Core Separation unit installed.
Features
• High precision and
repeatable loading of the
cores
• The system can be run fully
automatic or in manual
mode, step-by-step.
• Gentle handling of the cores,
minimizing waste
Dry End
Valmet Core Loading Unit is fully
automatic. The unit includes core storage
and from storage an electric motor feeds the
cores with high precision and repeatability
onto the lifting table for loading of the next
core shaft.
141
Dry End
142
Core loading and reloading
system for core bins
Improved safety and core lifetime
Reliable core handling is an important
stage between the tissue machine and the
rewinder.
The Core Robot system eliminates heavy
manual lifting and reduces the risk of
damage in lifting situations.
Valmet Core Robot system improves
efficiency, safety and the lifetime of cores
and guarantees a safe and reliable reel
operation.
With safer and more efficient handling of
the cores the lifetime of the cores will be
improved.
© Valmet 2015
Core Robot
Automatic lifting system – from
end of rail to storage above reel
Safer handling with minimum
operator activity
The Advantage Spool Return is a system for
automatic lifting of empty reel spools from
the end of the rails, up to the reel spool
storage on top of the reel. The system closes
the dry end sequence and provides fully
automatic and safe handling of the reel
spools with minimum operator activity.
This system provides several benefits:
Valmet roll handling system including
Advantage Spool Return further minimizes
operator activity. Adding the Advantage
Inflate/Deflate system results in a fully
automatic dry end.
•
•
•
•
•
Minimal requirement of manual effort
in the dry end
No need to use the overhead crane
during normal operation
Minimized risk for damage to reel
spools and cores
Safe handling of reel spools
Fully automatic handling
Dry End
© Valmet 2015
Advantage Spool Return
143
Advantage DustControl
Concept for the rewinder
Dust released from the unwinding and
cutting processes is contained and captured
by this system.
The rewinder area and, if desired, the
unwinding stations and slitter area can
be enclosed in a DustCap, limiting the
spreading of dust.
As a result, the web surface is cleaned and
made stable, the working environment
is improved and the maintenance needs
noticeably reduced.
Dry End
144
Advantage DustControl Concept
•
Vortex collectors nearby jumbo rolls,
slitter, calender and rewinder area to
capture dust at the source, DustCap
above the rewinder to enclose this area
Rewinder Dust Containment Cap
•
To enclose the area between the unwinds
and the slitters
Advantage WebCleaners
•
To clean and stabilize the web on both its
sides
© Valmet 2015
Improve your converting process
by controlling dust in the rewinder
area
Parent Roll Pusher
© Valmet 2015
The parent roll pusher ensure seamless
function of the roll movement in the reel.
The device is available with both pneumatic
and electric functionality
Features
The parent roll pusher enables
trouble free operation of
the paper roll and avoid
disturbances due to paper build
up on the rails. The automatic
pusher eliminate the need of
manual handling and improve
personal safety
Dry End
Ensure the parent roll movement
and increase the reel area safety
145
Automation Life Cycle Plan
Ensure continuous operation and
improved control results
Automation Life Cycle Plan service
provides the customer with a proactive plan
how to upgrade the system hardware and
software in the most beneficial way during
the next coming years.
Modern process automation systems
areunder constant innovative evolution
and there are multiple drivers for continous
updating of the system: hardware
obsolescence, software support, new
software features, spare parts availability,
lacking engineering resources or
improvements in process performance.
Results
• Enable new and better
measurements
• System support and spare
part availability ensured
• Improved production
efficiency through latest
technology and features
• Optimized total cost of
ownership
• Predictable costs and
accurate budgeting
• Secure high life time and
best available performance
Controls
146
© Valmet 2015
Life Cycle Plan service helps the customer
to manage the necessary modernizations
and upgrades so that the costs are foreseen
and easier budgeted. Thus the Life Cycle
Plan service also helps to avoid unexpected
exceeding of the maintenance budget
Automation Trainings
As the automation environment is
constantly evolving, so must emplyee
knowledge and skills. It is essential that
employees stay up-to-date and when
necessary, recieve training to refresh their
existing skill sets. Proper training ensures
that employees remain current with
product features.
© Valmet 2015
Through Valmet’s professional training
programs, either standard courses or
tailored to you specific needs, you will
have optimized competence available in
your organization. Together we make a
development plan for your personnel based
on your business needs, and deliver the
agreed training flexibly and effectively
Results
• Better utilization of features
in the automation and
control solutions
• Proper installation, start-up,
operation and maintenance
of the solutions and
equipment
• Improved knowledge of
product-related safety and
environmental issues
• Better employee motivation
Controls
Skilled staff for getting the most
out of equipment
147
Courses
Content
Valmet IQ
Valmet IQ Basic
Comprehensive survey of operation,
structure and operating concepts of
Valmet IQ Quality Control System.
Valmet IQ Operation
Typical features of Valmet IQ user interface,
as well as, quality monitoring, production data,
quality controls and grade change.
Quality Measurement Maintenance
A detailed review of the functions,
structures and maintenance procedures of
Valmet IQ Measurement system.
Valmet IQ Analysis Tools
Analysis tools integrated in Valmet IQ measurement system, including basic applications and
the advanced analysis package.
Valmet IQ MD and CD Controls
A review of the theory and algorithms of Valmet
IQ machine direction multivariable controls and
profile controls. Controls are detailed through
the use of theory and with the help of Valmet
DNA simulator.
Valmet PQV
Valmet PQV Basic
Basic Knowledge of operating concepts, system
and hardware of Valmet PQV.
Valmet PQV Operation
Operation training during the project start-up
phase. Basic operation functions and features
of Valmet PQV system in production use.
Valmet PQV Maintenance
A detailed review of functions, structures, maintenance and calibration procedures of Valmet
PQV hardware units and peripheral devices.
Practical exercises give insight into troubleshooting, fault rectification, measuring and
maintenance by using self-diagnostics.
Controls
148
Valmet Vibration Measurement and
Analysis
An introduction to vibration measurement and
analysis, vibration characteristic values, time
domain and spectrum analysis, envelope analysis supplemented by STA /Synchronized Time
Average) analysis.
Valmet DNA Machine Monitoring
Details the Valmet DNA Machine Monitoring
features as well as the theory and main concepts of mechanical condition monitoring.
© Valmet 2015
Valmet DNA Machine Monitoring
IQ Stock
Management of the dry stock flow is one
of the most challenging parts of the paper
making process. Flow and consistency
controls in the long stock lines are sensitive
for disturbances causing instability in all the
paper properties.
© Valmet 2015
Metso IQ Stock is an advanced control
package for stabilizing flow, consistency
and level controls in stock preparation
area. Process disturbances can be predicted
and prevented especially in non-steady
state situations which improves the overall
performance of the quality control system.
Results
• Stable dry stock flow
increases performance of
the quality control system
and quality of the end
product
• Quality targets are
achieved faster with less
broke specially in following
situations:
• Grade Change
• Stock recipe change
• Product speed change
• Sheet break and process
disturbance recovery
• Production start-up after
machine shutdown
• Less sheet breaks and
process disturbances
Controls
Predict and prevent disturbances
149
IQ Intelligent Scanning
Control
Improved control
Variable scanning speeds and scan modes
provide optimal machine direction and
cross direction profiling as well as improved
control during transition or upset conditions
like grade changes, start-ups and break
recovery periods.
Controls
150
Features
• Scanning adapts to process
requirements using a faster
scanning mode
• Faster startups with
minimum off-quality waste
• quicker recovery from
upsets
• Online process analysis
helps paper makers to
identify process disturbance
sources and improve paper
quality, process stability and
machine efficiency
• detailed edge measurement
and scanning for prcise edge
area control
© Valmet 2015
Intelligent scanning control with high speed
measurements provides faster grade changes,
improved recovery from web breaks and less
paper waste.
Energy Efficiency
Management - ValmetDNA
Features
• Real-time monitoring of
energy consumption and
costs help the operators to
tune the process´ energy
efficiency
• Commensurate unit for
(kWh/t) specific energy
consumption and costs
(€/t) for all energy classes:
electricity, steam and gas
or oil
• Easily configurable alarms
limits based on reference
production state
• History reports for different
time periods or paper grades
Tissue process has many potential
optimization possibilities energy-wise.
However, typically month-long reporting
periods for energy usage prevent the
machine operators to experiment and
confirm optimization actions.
The real-time information available in EEM
allows the operators to detect the effects of
process parameter changes in short notice.
This helps to find best-practices to run the
process energy efficiently
Controls
© Valmet 2015
Headline
151
IQ Fiber Weight
Measurement
Nonnuclear measurement
technology
The accurate scan averages and
high-resolution CD profiles measured by
Valmet IQ Fiber Weight Measurement
provide a solid foundation for Valmet’s
machine-direction and cross-direction oven
dry weight and moisture controls.
Simultaneous, multi-wavelength signal
detection with a superior sample rate,
combined with the sensor’s high-efficiency
single spot optics provides accurate dry fiber
weight as well as percent moisture readings.
Results
Controls
152
© Valmet 2015
• Only one sensor required for
both oven dry weight and
moisture measurements
• No beta radiation source
needed
• Extremely high
measurement speed which
enables online process
variability analyses
• Precise streak measurement
with a spot size and profile
resolution of 5 mm, available
after the very first traverse
of the web
• Faster on-spec quality and
reduced startup waste
IQ Basis Weight
Measurement
Ensure superior accuracy
The accurate scan averages and
high-resolution CD profiles measured by
Valmet IQ Basis Weight Measurement
provide a solid foundation for Valmet’s
machine-direction and cross-direction basis
weight controls.
Digital signal processing, internal 7-point
calibration verification and sensitive highspeed air density temperature compensation
ensure superior measurement accuracy even
in hot, humid and unclean paper making
environments.
Results
Controls
© Valmet 2015
• Accurate and stable onsheet measurement for
more precise control of
MD and CD properties
under even the harshest
environments
• Precise streak control using
5 mm resolution profiles,
available after the very first
sheet scan
• Produces a reading with
superior signal to noise
and therefore a better
measurement resolution
153
IQ Web Moisture
Measurement
Fast and single spot
The accurate scan averages and highresolution CD profiles measured by Valmet
IQ Web Moisture Measurement provide
a solid foundation for Valmet’s machinedirection and cross-direction moisture
controls.
Simultaneous, multi-wavelength signal
detection with a superior sample rate
combined with the sensor’s high-efficiency
single spot optics provides accurate percent
moisture readings.
Results
Controls
154
© Valmet 2015
• True percent moisture
profiles at the highest
resolution and scanning
speed lead to more accurate
and stable on-sheet
measurements and more
precise control of MD and
CD properties
• Precise streak measurement
with spot size and profile
resolution of less than 5 mm
available after the very first
traverse of the web
• Energy consumption can
be minimized by precise
moisture control
Improve dryness after press
Advanced steam injection technology
maximizes steam absorption efficiency,
providing highest dryness after the press
section.
© Valmet 2015
Flat and curved designs are available for
all wire and press applications with zone
spacing down to 60 mm.
Results
• Increased production
capacity
• Unique profiling accuracy
through electromechanical
actuators
• Lower production costs
• Modular and compact
design can be customized
for all applications for easy
maintenance
• Advanced diagnostic
features of the actuators
Controls
Valmet IQ Steam Profiler is high efficiency
steam profiler to increase production
capacity, improve moisture profile and save
energy.
155
IQ CD Control
Best profile
Controls
156
Valmet IQ CD Controls handles all the
cases from a single loop control to the most
complex multi variable control solutions
providing the best possible profile in
changing process conditions.
Results
• Intelligent optimization
algorithm ensures the best
possible sheet quality, reel
build and runnability
• Fast recovery after sheet
breakes, start-ups and grade
changes
• easy operation and
maintenance
© Valmet 2015
Valmet IQ CD Controls is a high-level
intelligent application which optimizes
the cross machine performance of tissue,
paper and board machines and pulp
dryers including coater and calender
applications. This unique algorithm is based
on the optimization of high-resolution
measurements.
Process and Quality Vision Web Inspection System
The web inspection system records defects,
dirt count, formation and other quality
features throughout the whole web. The web
faults that can be revealed from the web are
typically holes, streaks, stains, dirt drops, felt
hair, indents, or edge cracks. Their precise
location and frequency of occurrence can be
determined.
© Valmet 2015
The result is a superior product which meets
the highest standards for visual quality,
printing performance and high efficiency
converting.
Features
• Fault map throughout the
machine
• Dirt count analysis
• Formation analysis
• Transmission, low angle and
high angle applications for
led light beam and camera
beam accordning to the
needed fault analysis
• Integrated machine vision
system: a full scope web
break analysis system can
easily be added to web
inspection system.
Controls
Improve Product Quality
157
Process and Quality Vision Web Break Analysis
Improve process efficiency
The multiple synchronized cameras
are located at strategic positions in
the production process. Significant
improvement in process efficiency can be
achieved through reduced breaks and better
runnability.
Controls
158
Features
• The patented Valmet
LedCams include an
integrated digital matrix
camera and Led lights with
no heat generation
• Optional vortex cooling,
wiper washer or pinhole
solution
• Remote controlled zoom and
camera controls
• Integrated machine vision
system: a full scope web
inspection system can
easily be added to web
break analysis. The same
computers and electronics
are used in both systems.
© Valmet 2015
Valmet Process and Quality Vision systems
web break analysis utilize the newest
machine vision technology to determine the
origins of web breaks and quality problems
e.g. dirt spots, wrinkles, edge cuts, holes and
other problems leading to web breaks.
Process and Quality Vision Upgrades/Replacements
Improve Runnability
© Valmet 2015
Due to harsh machine conditions, the
integrated camera and LED light solution is
equipped with wiper washing. The system
improves machine runnability and enables
reduction of disturbances that cause breaks.
Features
• Changing analog cameras to
digital: lights and cameras
are replaced with the
patented Valmet LedCams
including a camera housing
designed to keep the camera
lens clean
• Keeping existing cameras
and lights: the existing web
break monitoring cabinet is
changed
• Up-to-date SW and HW
• Possibility to extend the
system with several new
process cameras and to add
new Web Inspection System
later on
Controls
The Valmet Process and Quality Vision
system (Valmet PQV) is an integrated Web
Break Analysis and Web Inspection System.
Upgrades and replacements are suitable
for all existing Web Break Analysis systems
using analog or digital cameras. In addition,
system software updates with the newest
analysis features can be delivered to existing
systems
159
Plant, Process, Electrical, Instrument,
Automation & Process control
Valmet, your solution supplier
Valmet provides optimized scope
definitons regarding production, energy
consumption and maintenance efficiency.
The latest technology and cooperation with
world wide well respected suppliers inspire
us to continuously move our customer´s
performance forward.
•
•
•
•
•
Plant
Process
Electrification
Instrumentation
Mill Automation & Process Control
Pre-studies, optimization, turn-key
deliveries, engineering, site supervision,
3D design.
Valmet, your solution supplier
Curious on how your equipment could
benefit from upgrades? Let us show a couple
of electrical examples. We have looked at
several energy saving options.
The most energy efficient motors, IE3 and
IE4, are installed in a one machine tissue
mill. The upgrades may result in a yearly
saving of 201.600 kWh.
Mill
160
© Valmet 2015
VFD are installed on four selected pumps.
The upgrade enables a saving of 405.000
kWh per year. The return of Investment can
be only six months.
Spare Part Audit
A Spare part audit is Valmet Service way of together, with the customer,
ensure a smoother and trouble free operation of the Tissue machine. Valmet Spare Parts Audit help you ensure
you have the right spare parts available at
the right time and at the right cost. During
a site visit our spare parts experts will
conduct a thorough analysis of the tissue
machine to define the most critical parts
needed to enable a smooth and trouble
free operation. The result is presented in a
report together with a list of recommended
spare parts.
Features
Mill
© Valmet 2015
• On-site visit by Valmet
spare parts expert
• Analysis of the tissue
machine
• Comprehensive report
• Customized Spare Parts list
161
Spare Parts Maintenance
Guide
“Pro-active maintenance”
How can we offer our customers additional
value besides the actual spare part? As we
strongly believe in stabilizing & prolonging
the life of our machine equipment, our
answer to the questions is called Spare
Parts Maintenance Guide.
The guide aims to create a deeper
understanding and educate customers
regarding certain critical spare parts. It
highlights the importance, functionality
& location of the parts on the Tissue
machine. Included is also maintenance
information of each individual part and a
genereal delivery time.
Mill
162
© Valmet 2015
Spare parts maintenance guide will be
made available through a spare part
checkout or a spare part audit
Contact us
Contact us
Valmet Karlstad, Sweden
Tel.: +46 54 17 10 00
Valmet Italy
Tel.: +39 0481 528 311
Valmet Biddeford, USA
Tel.: +1 207 282 1521
Valmet Paper Technologies (China)
Tel.: +86 10 5666 2568
Valmet Norcross, USA
Tel.: +1 770 263 7863
Valmet Fabrics, Finland
Tel.: +358 10 40 9000
e-mail: tissue.info@valmet.com
www.valmet.com
Specifications in this document are subject to change without notice.
Product names in this publication are all trademarks of Valmet
Corporation.
© Valmet Corporation, TIS_S48005V4 EN /2015
For more information about our services,
please contact your local Valmet expert.

Tissue Service Catalog

Transcription

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