The document describes the instrumentation and process control systems used at a pulp and paper mill. It discusses the various measurement devices such as level transmitters, pressure transmitters, and flow transmitters. It also describes the control systems that regulate processes like stock preparation, quality control, boiler operations, and turbine generation. The calibration and maintenance of instruments is conducted according to ISO standards to ensure accuracy of measurements.

2. Yard + Stock Finishing +
Paper
Chipper Pulp Mill Preparation Shipping
machine
House Area Area

3. • Head box level and pressure control.
• Level Control of Seal Pit Tank.
• Differential Pressure of Kuster in Calendar Section.
• Steam Pressure control in Pre- Dryer.
• Steam Pressure Control in Post-Dryer through QCS system.
• Measurement of GSM, Moisture and ash in the paper through
Smart Gauge 3000.
• Hydraulic Presses and Drum Reel Hydraulic System.
• Measurement & control of Speed through Inductive Proximity
Sensor.
• Photocell detector to detect Paper breakage.

4. Air from Air Receiver
LP
Head box
HP
LT PT
Inlet Pulp
PV
PCV 4-20 mA
LIC IP
Air Drain PIC
SP
Air Supply 1.4
0.2 To 1 kg/cm2
kg/cm2
VFD
Fan Pump
4-20 mA
IP- Current to Pressure Converter LIC- Level Indicating Controller
SP- Set Point VFD- Variable Frequency Drive
PV- Process Value LT- Level Transmitter
PCV- Pneumatic Control Valve PT- Pressure Transmitter

5. White Water
Inlet
PCV- Pneumatic Control Valve LIC- Level Indicating Controller
IP- Current to Pressure Converter LT- Level transmitter
Tank
LT • Inlet White water to Seal Pit is
coming from the filtered pulp through
4-20 m A wire. It is installed at the bottom of wire
PV
part. At the output a pump is used to
LIC SP
Pump sent white water to Silo via Pneumatic
4-20 m A Control Valve
0.2 To 1
kg/cm2
IP
PCV Air
Supply
1.4 kg/cm2
OUTLET to Back
Water Silo

6. Components:
 GSM Radioactive material
 Ash X rays
 Moisture measurement IR sensor
 Edge Sensor
 Phase Encoder
 Limit Switch

7. -
+ Electrometer
Ground High
Voltage Ion Chamber
Process Signal
Isotope Source

8. Process
X-Ray Sensor Electrometer Intelligent
(current is amplified & ADC
Source Source (Example converted to voltage)
Micro Controller
ION Chamber) (IMC)
Smart PC RS-422 to RS Raw Counts RS-232 to RS-
232 422
Converter Converter
Turbo PC/
Super PC

9. Inlet
Close Tank LP
HP
Air Supply (1.4
LT
kg/cm2)
4-20 mA
PCV
4-20 m A
IP LIC
Outlet SP
LT- Level Transmitter LIC- Level Indicating
Controller
PCV- Pneumatic control
Valve IP- current to pressure
converter

10. SP PV 4-20 mA
FIC
1.4 kg/cm2
FT 0.2 to 1
kg/cm2
FT
IP
Wild Flow Controlled
PCV PCV Flow
SP = Wild Flow X (Controlled
Flow / Wild Flow)

11. 4-20 mA
220 V 50 Remote
Hz Transmission
Outlet to Refined Magnetic Flow indicator
Stock +Transmitter
Interlock
A PG
Excitatio
4 n
voltage
O/p Voltage
PS1
Flow Tube
Inlet from Buffer
PG PG Chest
3
1
Interlock A: if the Pressure of
Water Triple Disc Three Phase Motor Inlet flow will goes below 0.5
Refiner (469 Hp)
kg/cm2 then Pressure switch
PS1 unload the TDR
PS2 Interlock B: if the pressure of
Water (which is acting as
Interlock
PG
coolant to TDR )fall below 0.5
2 B
kg/cm2 then PS2 unload the
TDR

12.  Number of Boilers - 7
 Coal Fired - 4
 HP Boiler 1,2,3 & 7
 Black Liquor Fired 2
 ABL and JMW

13. Boiler # 7 (Coal JMW (Black ABL (Black
Fired) (OPP) Liquor) (OPP) Liquor) (NPP)
MP MP
MP
46 kg/cm2
Header From HP steam
MW) Header (from PRV)
(6.2
BTH
PRV- Pressure Reduce Valve
MP- Medium Pressure

14. Boiler # 1 (Coal Boiler # 2 (Coal Boiler # 3 (Coal
Fired) Fired) Fired)
HP HP HP
85 kg/cm2
Header PRV 46 Kg/cm2 to MP
steam header
MW)
(18
TG
PRV- Pressure Reducing Valve

15. Boiler
PDM Deareator Feed Economiser Steam
Tank Pump Drum
Tank
DM Stop Super Heater MUD
Section
Plant Valve Drum
Turbine
Conden
sate

16. Inlet from PDM Air Supply
tank thru Pump 20 psi
4-20 mA
Steam IP LIC
Inlet PG PCV
PCV
SP
LP
IP
Deareator Tank
20 psi
PT H
P
LT
TG- Temperature Gauge
LIC LIC- level Indicating Controller
TG
Drain PT- Pressure transmitter
SP Outlet to feed
pump PG- Pressure Gauge
PCV- Pneumatic Control Valve
LT- Level Transmitter
IP- Current to Pressure Converter

17. Three Element Control...Drum Level
Steam Flow Drum Level Water Flow
P+I
A T
P+I
A T
4-20 mA
1.4 IP
kg/cm2
To feed Water Control Valve

18. Transmitter is a device which is used to measure physical variable i.e.
transducer and to transmit signal into electrical signal in form of 4-20 mA
or 1-5 V DC signal.
Types of transmitter:
 Conventional
 Smart/Intelligent

19.  In this Calibration can be done after
disconnecting the Transmitter from the field. In
this calibration cannot be done using HART
communicator. A Conventional Transmitter
consists of Zero and Span Adjustment for the
calibration

20.  Disconnect Transmitter from the field.
 Apply 24 V dc supply and a multi meter in series to the
transmitter
 Apply a known Pressure through Pressure gauge or dead
weight tester.
 Check zero of the transmitter. For zero pressure a
transmitter gives 4 mA. If transmitter shows some zero
error then calibrate it through zero adjustment.
 Apply 100% Span Pressure & then adjust 20 mA from the
Span adjustment.
 Check mA output for mid range pressure.

21. • In this Calibration can be done by using HART
(Highway Addressable remote transducer)
Communicator. Online calibration can be
performed using HART communicator. In this
Sine wave frequency signal over right the
Previous Calibration.
• HART is based on Frequency Shift Keying. In
this 1200 Hz is equal to Binary logic 0 and
2200 Hz is equal to logic 1.

22. Flapper Spring
Gap 4-20 mA
Supply
Pressure Nozzle
20 psi Restriction
Pressure signal 3-15 psi
 Its working principle is based on the flapper nozzle
arrangement. Its input range of pressure is 20 psi or 1.4
kg/cm2. Depending upon the control signal i.e. 4-20 mA a
flapper moves up and gives output in the range of 3 to 15
psi or 0.2 to 1 kg/cm2.

23. 1. Apply input pressure of 20 psi and also apply current signal from
mA source (Loop Analyzer).
2. Attach a manometer or calibrated gauge at the output of IP.
3. Apply 4 mA and check output pressure to be 3 psi or 0.2
kg/cm2. If this pressure will not come then adjust using zero
adjustment.
4. Apply 20 mA signal and check o/p pressure to be 15 psi or 1
kg/cm2. If this pressure will not come then adjust using span
adjustment.
5. Check for mid ranges by changing control signal to 8, 12 & 16
mA.
6. If step 5 is not showing exact reading then repeat step number
4, 5 & 6.

24.  Flow in any pipe is defined as velocity of liquid at
certain point.
 Various flow measuring techniques are available
and some are enlist which are used here
1. Orifice Plate
2. Venturi Meter
3. Flow Nozzle
4. Vortex Flow meter
5. Magnetic Flow meters
1,2 & 3 are Differential Pressure type flow meters.

25. QCS PROCESSING FLOW DIAGRAM
Feed
Forward
PID
BW S.P. Consistency Tx
Stock Flow
DTC Control
Feed
Forward
Feed
Forward
Steam
PID Pr.
Moisture Control
S.P.
Feed Forward
Feed Forward
PID Ash Flow
Control
Ash S.P
QCS
CPU

26. V=2 ∏ R N
V= D ∏ N
∏D=V/N
V= Line Speed of the Drum from the Encoder (Taken from the Drive 01-10
VDC)
N= Unwind Speed from the proximity (14 ppr)
R= Radius of the Unwind Roll
D= Diameter of the Unwind Roll

27.  Instrumentation is the branch of science which
deals with the measurement, record and
control of process variable.

28.  ABB MP-200 Series Distributed Control System
in Pulp Mill
 Supervisory Control And Data Acquisition
System used in Stock Preparation Area at PM4
and at ABL Boiler.
 Quality Control System at PM1, 4 and 5.
 PLC Control System at PM7 and Color Kitchen.
 Various Types of Field Instruments like Level
Transmitter, Pressure Transmitter, Flow
Transmitter, Conductivity Transmitter and
Consistency Transmitter, Temp.Transmitter.

29.  Various Types of Control Valve for Pressure,
temperature and flow Control application like
Butterfly, Globe Valve, Plug valve
 Others measuring devices like RTD,
Thermocouple, pH measurement, Khajani
for brightness Measurement.
 Hydraulic System of Press part.
 Vibration Monitoring.

30. These Instruments are Calibrated Against the ISO
from ETDC.
 Loop Analyzer
 Dead Weight Tester
 Vacuum Gauge Tester
 RTD Simulator
 Conductivity Jig

31.  Governer Control System for the Turbine
Generator.
 Temperature and Vibration Monitoring for
Safety and Tripping.
 Dereator Tank Level and Pressure Control at
HP Boilers.
 Feed Water Flow and Steam Flow
Measurement and Control at all Boilers
 Three Element Drum Level Control for HP
Boilers

32.  761 controller based SCADA control system at
ABL Boiler.
 Various Temperature Indication, ID indication.
 Various Pressure and Flow measurements and
Control like Soot Blowing Pressure and Flow.
 Various types of Control Valve for different
application like Flow Control of Feed water,
Steam flow etc.
 Conductivity measurement at DM plant and
Evaporator.

33. Thank You !