0404000 dryer section

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0404000 dryer section

  1. 1. VKPC – PM#1 Training Dryer Section
  2. 2. Introduction <ul><li>Introduction Trainer </li></ul><ul><li>Training Schedule </li></ul>
  3. 3. Introduction of the Trainer <ul><li>Satoshi Seki </li></ul><ul><li>Paper Machine Engineering Dept. </li></ul>
  4. 4. Training Schedule <ul><li>Training Time </li></ul><ul><li>Breaks </li></ul><ul><li>Lunch </li></ul><ul><li>Question and Answer </li></ul>
  5. 5. Technical Data <ul><li>Basic Design Data </li></ul><ul><li>Technical Specification </li></ul>
  6. 6. Basic Design Data – Layout data 5.300 mm Untrimmed paper width on pope 5.950 mm Wire width Design width 105 - 125 gsm CM 125 - 250 gsm T2 (100% OCC) 125 - 275 gsm T1 (Pulp on Top) Basis weight 125 gsm (Reference liner grade) Basis weight 8% Moisture at reel 100% With efficiency max. 744 to/24h At PM reel Design production Liner Board (Test Liner: T1, T2) Corrugating Medium Paper Grade
  7. 7. Basic Design Data – Layout data 3.000 mm Max. parent reel diameter: Reel spool Drive on right hand side facing the reel:   Standing at the headbox Hand of machine 900 m/min Balancing speed 900 m/min Design speed 900 m/min Drive speed 355 - 800 m/min Production speed range Operating speed
  8. 8. Technology <ul><li>Fundamental - Function of Dryer Section </li></ul><ul><li>Key Technology – Innovation </li></ul>
  9. 9. Function of the Dryer Section 1. Drying of the paper / Evaporation of Water 2. Runnability / Efficiency 3. Paper Quality
  10. 10. Overview of Paper Machine Wire Section Press Section Hard Nip Calender Reel Press Outlet Dry Content 48% Dry Content 92% Dryer Section
  11. 11. Key Technology – Innovation of Dryer Section Duostabilizer Blow Doctor Transfer Foil Silent Drive
  12. 12. Components <ul><li>Dryer Groups </li></ul><ul><li>Dryer Cylinder </li></ul><ul><li>Canvas Roll & Paper Roll </li></ul><ul><li>DuoStabilizer </li></ul><ul><li>Canvas Guide & Run Warning Device </li></ul><ul><li>Canvas Strecher </li></ul><ul><li>Blow Doctor & Hot Air Blow Pipe s </li></ul><ul><li>Tail Cutter </li></ul>
  13. 13. Description - Dryers in the dryer groups 14 dryers, double row (dryers nos. 22 to 35) Dryer group 3 3 15 dryers, double row (dryers nos. 7 to 21) Dryer group 2 2 6 dryers, single row (dryers nos. 1 to 6) Dryer group 1 1 Description Component Item
  14. 14. Description – Dryer Group 1 1 Dryer 6 Single drive via gear casing for drying cylinders 11 Guide roll 2 Take-off doctor 7 Canvas changing device 12 Transfer foil 3 Drilled canvas roll 8 Stretch roll 13 Dryer fabric roll 4 Upper blow doctors 9 Canvas stretcher 14 Rope stretcher 5 Duostabilizer 10 Canvas guide unit Guide Roll Drilled Canvas Roll Blow Doctor Duostabilizer Transfer Foil Canvas Stretcher
  15. 15. Description – Dryer Group 2 1 Dryer 6 Single drive via gear casing for drying cylinders 11 Guide roll 2 Duostabilizer 7 Canvas changing device 12 Canvas roll 3 Drilled canvas roll 8 Stretch roll 13 Canvas roll (With drive shaft) 4 Upper blow doctor 9 Canvas stretcher 14 Canvas roll (inside) 5 Lower blow doctor 10 Canvas guide unit 15 Rope stretcher Blow Doctor Duostabilizer Drilled Canvas Roll
  16. 16. Description – Dryer Group 3 1 Dryer 6 Single drive via gear casing for drying cylinders 11 Guide roll 2 Upper blow doctor 7 Canvas changing device 12 Canvas roll 3 Lower blow doctor 8 Stretch roll 13 Canvas roll (with drive shaft) 4 Take-off doctor 9 Canvas stretcher 14 Paper roll 5 Tail cutter 10 Canvas guide unit 15 Rope stretcher Blow Doctor
  17. 17. Dryer Cylinder Locating bearing Floating bearing Steam Condensate Paper Width
  18. 18. Picture - Dryer Bearing Tender Side
  19. 19. Picture - Dryer Bearing Drive Side
  20. 20. Thermorim inside of Dryer Cylinder Dryer No #4-35 (32 Thermorims) Task Higher Turbilence in the condensate later, and Higher heat Higher production by increasing Drying capacity Quality improvement by increasing uniformity of Moisture profile
  21. 21. Thermorim inside of Dryer Cylinder Dryer No #4-35 (32 Thermorims) Spoiler Bar Spring Ring Spring Ring Spoiler Bar
  22. 22. Steam Joint The Steam Joint supplies Steam into the dryer and discharges the created condensate. Steam Condensate Gap 5mm
  23. 23. Steam Joint Steam Inlet Head Condensate Discharge Head Siphon Cylinder Journal Bearing Housing Carbon Sealring
  24. 24. Enlarged view of Siphon Steam Condensate Condensate Function
  25. 25. Canvas Rolls – Four Types Canvas roll Canvas roll, with drive shaft Canvas roll, shortened Canvas roll, with free sheave used inlet 1st dryer group inside the machine beam For driven canvas rolls
  26. 26. Paper Roll Dryer Section Calender Paper Roll
  27. 27. Transfer Foil Press Section Dryer Section
  28. 28. DuoStabilizer Pick up zone Supporting zone Drilled roll Duo- Stabilizer DynaSeal contactless sealing Operating position Changing position
  29. 29. Web Run Problems 1 web pick-up from dryer adhesion forces, vacuum forces --> web adheres to dryer 1 2 3 4  2 run onto leading roll centrifugal forces --> web lifts off dryer fabric 3 lower apex area of the roll centrifugal forces, dead weight forces --> web lifts off 4 run onto dryer elongated paper --> wrinking (edge)
  30. 30. Picturte - DuoStabilizer
  31. 31. DuoStabilizer (Cross Section A-A) DS Air sealing TS Air sealing Vacuum source A A Supply Air 3
  32. 32. Sealing Blades to the drilled Roll
  33. 33. Description – Canvas Guide 1 Palm unit 2 Pneumatic cylinder 3 Bearing support 4 Dryer−canvas runout alarm 5 Guide roll 1. One palm unit each (1) and one canvas run out alarm (4) are mounted at the canvas edges on front side and on drive side. 2. When the dryer canvas runs centrically to the machine, the canvas run out alarm (4) are not touched by the dryer fabric. 3. When the canvas runs out, the palm unit (1) follows the canvas edge and activates the pneumatic cylinder (2). 4. The pneumatic cylinder (2) moves the bearing support (3) of the guide roll (5) and returns the canvas into the mid−position. 5. If the canvas runs out beyond the tolerance range of the guide assembly, this is signaled by the canvas run out alarm (4). Palm Unit Canvas Run Out Alarm
  34. 34. <ul><li>Pneumatic Cylinder </li></ul><ul><li>Bearing Support </li></ul><ul><li>Base </li></ul><ul><li>Bearing arm </li></ul><ul><li>Base adjustment by hand wheel </li></ul>Consisting of: Canvas Guide Assembly
  35. 35. Palm Unit Palm Rotary Piston Regulator Counter Weight
  36. 36. Description – Canvas Run Warning Device 1 Canvas run warning device 2 Sensor 3 Canvas 1. If the crosswise run of the dryer canvas exceeds the tolerance range, electromechanical sensors (2) on the drive and front side indicate this. 2. If the dryer canvas stays within the tolerance range, the sensors (2) do not touch the edge of the canvas (3). Sensor Canvas
  37. 37. Description – Canvas stretcher 1 Stretcher rail 2 Holder 3 Dryer stretcer roll 4 Canvas 5 Pneumatic cylinder 6 Chain 7 Wire rope 8 Winch 9 Wire drum 1. The drying canvas (4) are tensioned by pneumatic cylinder (5). 2. The canvas tension is controlled by air pressure of pneumatic cylinder (5). 3. Pneumatic cylinder (5) pull the wire rope (7) ,and give the rotation to the wire drum (9). 4. And then give the required canvas tension to the dryer stretch roll (3) mounted in a holder (2) on the stretcher rail (1) by through the chain (6). 5. The winch (8) winds up an extra wire rope . Chain Wire Rope Pneumatic Cylinder Winch
  38. 38. Description – Rope Stretcher 1 Rope 2 Idler pulley 3 Pneumatic cylinder 1. The rope (1) is tensed by a pneumatic cylinder (3), and idler pulleies (2). 2. The retraction force at the pneumatic cylinder (3) can be adjusted via pressure control valves. 3. To change the ropes, the pneumatic cylinders (3) can be run in and out via locally mounted hand valves. Rope Pneumatic Cylinder Idler Pulley
  39. 39. Picture – Rope Stretcher Enlarged View of Idler Pulley
  40. 40. Description – Rope Tension Air Pressure vs Rope Tension
  41. 41. Blow Doctor & Hot Air Blow Pipe s <ul><li>Hot and dry air is supplied by </li></ul><ul><li>Blow Doctor </li></ul><ul><li>Hot air blow pipes </li></ul><ul><li>The hot and dry air supports the drying process, by carrying the moisture, coming out of the drying paper web, away. </li></ul>Blow Doctor Blow Pipe
  42. 42. Hot Air Blow Pipe Task The hot−air blow pipe (1) supplies air to the dryer section which absorbs the water vapor, which collects in the top dryer fabric loop. Dryer Cylinder Hot air blow pipe
  43. 43. Hot Air Blow Pipe – Arrangement Quantity : 10 sets
  44. 44. Tail Cutter Tail Cutter
  45. 45. Tail Cutter – Blade
  46. 46. Description – Device for changing upper canvas 1 Tightening nut 4 Handrail 7 Rail 2 Bearing cover 5 Support 8 Pneumatic motor 3 Unwinding shaft 6 Platform 9 Winding shaft 1. A reeling and unwind device with an accessible platform (6) (to close the canvas seam), are installed for changing the dryer fabrics in the upper canvas run. 2. The rail(7) to draw in the canvas is set up on the platform (6). 3. When closing the canvas seam, the pivoted handrail (4) are used to prevent both end of canvas seam divided from slipping down. 4. The pneumatic motor (8) is attached to wind up the old canvas and to run out the new at the same time. Pneumatic Motor New Canvas Old Canvas
  47. 47. See Video DuoStabilizer See Video Steam and Condensate
  48. 48. Operation 1. Operation & Setting 2. Start 3. Stop
  49. 49. Things to for after before Start Up <ul><ul><li>Are the Dryer Section free from waste paper and dirt? </li></ul></ul><ul><ul><li>Is the Canvas tension on set levels? </li></ul></ul><ul><ul><li>Are the Dryer fabrics in good condition ? </li></ul></ul><ul><ul><li>(no excessive wear or contamination) </li></ul></ul><ul><ul><li>Is there nothing in contact with the Dryer fabrics? </li></ul></ul><ul><ul><li>Is the Central Oil Lubrication activated? </li></ul></ul><ul><ul><li>Are the draw settings in place? </li></ul></ul><ul><ul><li>Are the Doctor blades inserted all and no wear ? </li></ul></ul><ul><ul><li>Are the canvas guide units ready for operation ? </li></ul></ul>
  50. 50. Start Dryer Section Dryer Section to Crawl mode Hood & Air System Heat up (S&C system) Dryer Section to operation speed Pre-production Check list & Central Oil Lubrication on Pneumatic Air system on Dryer Section de- coupled from press section All manual Drive Interlocks Removed Start production
  51. 51. Transferring Paper Web Prerequisite 1. Paper web knock-off completed successfully, Paper web runs sturdily into press Pit. 2. Dryer section cleaned from waste paper 3. All doctors of dryer section pressed on 4. Tail squirt is set to a tail width of 100 to 200 mm 5. Reel Pit at the end of the dryer section is ready condition 6. All drives including rope drives on operation speed 7. Steam system is on break set point value Action 1. Transfer tail transfer into rope nip by means of hand lance. Tail is leaded through the dryer section by the rope carrier system. 2. Observe tails through the dryer section. Tail runs in Reel pit. 3. Set tail squirt to full width. 4. Steam system of Dryer section runs at operation setting value. 5. Paper web runs across the width of the machine into the dryer section. 6. Web runs stably at Reel pit.
  52. 52. Shutting down the Dryer Section (I) <ul><ul><li>Knock off the Paper web </li></ul></ul><ul><ul><li>Close the main steam line. </li></ul></ul><ul><ul><li>Open the hood on front side, drive side and basement </li></ul></ul><ul><ul><li>Turn off the hot air supply </li></ul></ul><ul><ul><li>Switch off the dryer fabric cleaning units </li></ul></ul><ul><ul><li>Set the exhaust-air fans to full speed </li></ul></ul><ul><ul><li>Let the dryers run for 30 min. at machine speed </li></ul></ul><ul><ul><li>Check uniform condensate discharge </li></ul></ul><ul><ul><li>Check the power input (any condensate left?) </li></ul></ul>
  53. 53. Shutting down the Dryer Section (II) <ul><ul><li>Continue rotating the dryers at crawl speed, until they are cooled down to 60˚C </li></ul></ul><ul><ul><li>Turn the dryer drives off </li></ul></ul><ul><ul><li>Allow the central oil lubrication system to continue running for about another 2 hours </li></ul></ul><ul><ul><li>Turn off the hood deaeration </li></ul></ul><ul><ul><li>Turn off all other units </li></ul></ul><ul><ul><li>Slacken the dryer fabric for a long shutdown </li></ul></ul>
  54. 54. Operation – Canvas tension for 1 st group
  55. 55. Operation – Canvas tension for 2 nd , 3 rd group (Top)
  56. 56. Operation – Canvas tension for 2 nd , 3 rd group (Bottom)
  57. 57. 1 st Dryer Operation Panel
  58. 58. 1 st Dryer Operation Panel
  59. 59. 1D Pneumatic Valve Stand
  60. 60. 1D Operation Panel & 1D Pneumatic Valve Stand Piping Diagram (1) Solenoid Valve Pressure Regulator Filter Speed Controller Needle Valve Canvas Guide Canvas Stretcher
  61. 61. 1D Operation Panel & 1D Pneumatic Valve Stand Piping Diagram (2)
  62. 62. 2D Pneumatic Valve Stand
  63. 63. 2D Pneumatic Valve Stand Piping Diagram (1) 2D Pneumatic Valve Stand
  64. 64. 2D Pneumatic Valve Stand Piping Diagram (2) Doctor Lifting
  65. 65. 2 nd – 3 rd Dryer Operation Panel
  66. 66. 2 nd – 3 rd Dryer Operation Panel
  67. 67. 2 nd – 3 rd Dryer Operation Panel
  68. 68. 3D Pneumatic Valve Stand
  69. 69. 2,3D Operation Panel & Pneumatic Valve Stand Piping Diagram (1) Needle Valve Pressure Regulator Filter Speed Controller
  70. 70. 2,3D Operation Panel & Pneumatic Valve Stand Piping Diagram (2) Solenoid Valve Pressure Regulator Filter Speed Controller Canvas Stretch #35 Doctor Nip
  71. 71. 2,3D Operation Panel & Pneumatic Valve Stand Piping Diagram (3) Doctor Lifting
  72. 72. Tail Cutter Pneumatic Valve Stand – Overview
  73. 73. Tail Cutter Pneumatic Valve Stand Piping Diagram (1) Tail Cutter Traverse Tail Cutter Rotate Tail Cutter Lifting Guide Bar Lifting Solenoid Valve Pressure Regulator Filter
  74. 74. 1,2,3D Rope Stretcher Panel - Pneumatic Valve Stand Piping Diagram
  75. 75. Operation – Inserting canvas roll 1 Tightening nuts 4 Run-in and run-out trolley 2 Bearing cover 5 canvas roll 3 Support 1. Open the bearing cover (2) on the front and drive side by slackening the tightening nuts (1). 2. Using the vapour hood travelling crane, place the canvas roll (5) in the support (3). 3. Close bearing cover (2) on front and drive side. 4. Remove both run-in and run-out trolley (4) from the rails. Pneumatic Motor New Canvas Old Canvas
  76. 76. Operation – Preparing the dryer canvas 1 Old canvas 2 Winding shaft 3 Threading aids 4 New canvas roll 5 Ropes 6 Hand rails 1. Perforate old dryer canvas (1). 2. Open the wire seam. New Canvas
  77. 77. Drive <ul><li>Silent Drive </li></ul><ul><li>Properties of Silent Drive </li></ul><ul><li>Drive Arrangement </li></ul>
  78. 78. Silent Drive (for two-tier dryer group) <ul><li>Standard drive concept with gear-train drive: </li></ul><ul><li>Driven dryers are used to pull s everal dryers. </li></ul><ul><ul><li>Drive concept with Silent Drive: </li></ul></ul><ul><li>Driven dryer fabric rolls are </li></ul><ul><li>used to pull 2 dryers each. </li></ul>
  79. 79. Silent Drive <ul><li>The 1 st dryer of the 1 st dryer group is equipped with a single </li></ul><ul><li>drive, due to the higher doctoring work and as the web is still very moist. </li></ul><ul><li>Dryers with small wrap angles are equipped with single drives, due to the risk of slipping . </li></ul><ul><li>Silent Drive is used as complete solution throughout the dryer section, but also in combination with single drives and </li></ul><ul><li>gear-trains. </li></ul>
  80. 80. Silent Drive - System properties (1) <ul><li>Gear-trains with gear wheels are omitted </li></ul><ul><li>-> Improved space conditions at drive-sided framing </li></ul><ul><li>No gears </li></ul><ul><li>-> Low-noise overall system, gear lubrication omitted </li></ul><ul><li>No power loss of gears </li></ul><ul><li>-> Enhanced overall efficiency, reduced power consumption </li></ul><ul><li>No oil leakage </li></ul><ul><li>-> Less soiling, reduced risk of fire </li></ul>
  81. 81. Silent Drive - System properties (2) <ul><li>No influence of dryer diameter tolerances </li></ul><ul><li>-> Reduced loads on web , higher runnability </li></ul><ul><li>The mechanically overdetermined system that connects the dryers through dryer fabric and gears is omitted. </li></ul><ul><li>-> Silent Drive resulting in defined dryer fabric tension between dryers </li></ul><ul><li>Several drive spots </li></ul><ul><li>-> Influencing accessibility to drive side </li></ul>
  82. 82. Silent Drive - System properties (3) <ul><li>More demanding control system, since several drives in each dryer group </li></ul><ul><li>-> State-of-the-art technology by suppliers of electric drives </li></ul><ul><li>Fewer mechanical components </li></ul><ul><li>-> Lower maintenance </li></ul><ul><li>Open framing on tending and drive sides </li></ul><ul><li>-> Symmetric air flow, improved pocket ventilation, </li></ul><ul><li>improved CD moisture profile </li></ul>
  83. 83. Drive Arrangement Legend Double Tier Double Tier Single Tier
  84. 84. Maintenance <ul><li>Roll List </li></ul><ul><li>Lubrication </li></ul><ul><li>Dryer Cylinder </li></ul><ul><li>Roll Changing </li></ul><ul><li>Bearings </li></ul>
  85. 85. Roll List
  86. 86. Roll List
  87. 87. Lubrication List Lubrication No
  88. 88. Lubrication List Lubrication No
  89. 89. Roll Changing (1) Travelling Rail (MD) Cross Rail (CD)
  90. 90. Roll Changing (2) Dryer Cylinder Roll run-out device Dolly
  91. 91. Roll Changing (3) Canvas Roll Car Unit
  92. 92. Bearings for cylinders and rolls Self-aligning roller bearings24122 CC/C3 W33     Cylinder roller bearings NU 2218EC Bearings for drive gear for in drive shaft of separate drive on the drive side 7 Self-aligning roller bearings as locating bearings in the pillow block housing Bearings for paper rolls 6 Self-aligning roller bearings as locating bearings in the pillow block housing Bearings for canvas rolls 5 Self-aligning roller bearings as locating bearings in the pillow block housing Bearings for drilled canvas roll 4 Self-aligning roller bearings as locating bearings in the transmission housing Bearings for drying cylinders with separate drive on the drive side 3 Self-aligning roller bearings as locating bearings in the pillow block housing Bearings for drying cylinders on the drive side 2 CARB roller bearing as floating bearing Bearings for drying cylinders on the front side 1 Description Components Item
  93. 95. Self-Aligning Roller Bearing 参考資料 Oil level Lube hole
  94. 96. Mounting of Anti-Friction Bearing 参考資料
  95. 97. Mounting of Anti-Friction Bearing 参考資料 Installation aid Groove for oil outlet Dryer bearing single drive Dryer bearing drive side Plummer block
  96. 98. Push-on Distance Zero position Start position End position Ss S 参考資料
  97. 99. Mounting of Anti-friction Bearing Dryer bearing single drive Dryer bearing drive side Plummer block 参考資料
  98. 100. Mounting of Anti-Friction Bearing 参考資料 Axial retainer for anti-friction bearing
  99. 101. Dryer Bearing DS With single drive Without drive Oil inlet Oil outlet Oil inlet Oil outlet Oil inlet 参考資料
  100. 102. Dryer Bearing TS Oil inlet Oil outlet 参考資料
  101. 103. Mounting of CARB-Bearing 参考資料 Position of the installed bearing
  102. 104. Alignment of Dryer Z = X - 147 参考資料 5
  103. 105. Dismounting of Anti-Friction Bearing 参考資料
  104. 106. Single Drive - Gearbox for Drying Cylinder Design “A” 参考資料

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