Diffuser Update

Diffuser Update
9th Edition
Andritz continues to provide a high standard of professional service and has extended its best
efforts for this manual; however, the contents of this manual are advisory only. Each company must
decide for itself the best approach to operate and maintain their equipment and to solve any
problem it may have. Andritz will be pleased to work jointly with you.
Diffuser Update
9 Edition
th
© Andritz
March 1998
Introduction Page 1
Introduction
The purpose of this update manual is to familiarize mills which have a diffusion
washer with changes that have been incorporated into the system over the years to
enhance its operation. An explanation of the benefits expected from these changes will
be given. Some of the changes may already have been incorporated into your present
operation. We would recommend that you keep the following in mind when you decide
whether or not to update your system.
• Would any of the changes prevent unnecessary downtime?
• Would any of the changes improve the operation of the diffuser?
• Would the mechanical operation or life of the equipment be benefited?
Also included is information for troubleshooting mechanical and operational

problems, a section on washing efficiency calculationsc, a maintenance procedure
section, and a section on instrumentation and interlocks.
Andritz supplies diffusion washing using two unique designs:
1. ATMOSPHERIC DIFFUSER
2. PRESSURE DIFFUSER
The front section of this manual (blue tabs) discusses the atmospheric diffuser,
the middle section (red tabs) is for the pressure diffuser and the last section is for notes and
seminar information.
It is hoped that if there are any questions or comments on information presented in

this Update Manual, or if there are other topics that you would like to see included, you
will not hesitate to contact Andritz.
Andritz
Ridge Center
Glens Falls, New York 12801 USA
Telephone (518) 793-5111 After Hours (518) 793-2636
Telefax (518) 745-7005 (Customer Services)
Diffuser Update 9th Edition

Introduction Page 2
This manual shall in no way extend the liability of Andritz beyond what is set forth in
the terms and conditions of sale for equipment sold to you. In no event, whether as a result
of contract, tort, strict liability or otherwise shall Andritz be liable for special, incidental,
consequential, or punitive damages including, but not limited to, loss of use, profits or
revenue, loss by reasons of plant shutdown, or increase expense of plant operation.

Introduction Page 3
Safety Guidelines
The following sections provide some safety guidelines relevant to the operation,
inspection and maintenance of diffusion washing systems. These guidelines are not
intended to be all encompassing, but do point out some specific safety practices which
should be followed when operating, inspecting or maintaining any diffuser system. These
practices should be considered as additions to your normal mill safety procedures and
regulations, not as substitutes for existing programs.
General Information
The process materials handled in diffuser systems may include hot pulp, hot filtrate,
hot water, condensate, and hydraulic fluids; and if the diffuser is used in a bleach plant,
various bleaching chemicals (i.e., chlorine dioxide, caustic, etc.). All personnel engaged
in the operation, inspection and maintenance of the system equipment and auxiliaries
should be well acquainted with the associated potential hazards. During normal operation
and maintenance, the procedures stated in the Operating, Maintenance and Hydraulics
manuals should be followed. All personnel working in the area are responsible for being
familiar with the appropriate procedures. If there is any doubt as to the proper
procedures to be used, Andritz should be contacted.
Routine inspection schedules are required to ensure that the diffuser and its
components such as towers, pressure housing, controls and other equipment in the system
are maintained as required. The interlocks and safety devices should be checked on a
routine basis to ensure that they are fully functional and correctly set.
Safety Guidelines
1. Inspect all diffusers, vessels and equipment on a regular basis so that repairs can be
made to maintain structural integrity. Maintain accurate records of all inspections,
repairs and modifications. Revise frequency of inspections if necessary based on
observations.
2. Review the Diffuser Operating, Maintenance and Hydraulics manuals for your
system and equipment prior to any disassembly. Follow specific instructions,

Introduction Page 4
recommendations and caution notes for involved items. Consult spare parts lists
and assembly drawings to ensure correct repair.
3. Be certain that any replacement parts, units or items of equipment meet the original
design specifications. Initially consult the maintenance manual and if required
confirm by contacting Andritz and/or the original manufacturer.
4. Adhere to approved confined entry procedures whenever entering restricted

quarters. Procedures such as those given in OSHA Safety and Health Standard
are recommended.
5. Adhere to mill approved lockout and tag-out procedures before and while working
on any equipment and piping or prior to entering any confined space. Before
working on any piece of equipment or piping, make sure the contents have been
completely drained and all associated equipment and valves locked out. All means
of starting the equipment must be locked and tagged so that it can not be started.
After locking out and tagging a system or item of equipment, double check to be
certain that the correct unit(s) has been locked out by testing the start switch or
other drive mechanism.
6. Do not enter any towers or tanks if pulp is bridged overhead or vapors have not been
cleared. Also, use caution when near open manholes in vessels, as a falling mass of
pulp can force air out of the manhole. If scale is present, exercise due caution if
inspecting in or below scaled areas, as falling scale can be extremely hazardous.
7. Be certain that all gamma sources on the stock chute or towers have been shut off
and locked before entering.
8. Wear the proper safety equipment and clothing for the job you are performing in
your work area. These items may at various times include foot protection, safety
glasses, hard hats, hearing protection, goggles, respirators, special clothing, masks
and rubber gloves, harness, etc. Always wear eye protection when checking seals
and glands. If any liquid gets into the eyes, immediately wash with large quantities
of water and obtain prompt medical attention.

Introduction Page 5
9. Follow mill recommended procedures and wear protective clothing when obtaining
liquor or pulp samples. Do not enter, reach into or try to take a pulp sample from the
top of the atmospheric diffuser unless the scraper power is off and locked out. The
protective grating over the diffuser top inspection manhole should be kept in place
at all times unless the system is down and locked out, and appropriate vessel entry
procedures are being followed.
10. Keep all work areas well ventilated and well lighted, and keep all floors, platforms,
stairways, ramps, guards and permanent ladders well maintained and free of oil and
foreign materials.
11. Use the equipment only as intended. Do not expose equipment, piping, etc. to
corrosive liquids or chemicals which they were not designed to handle.
12. Exercise extreme caution in acid cleaning of heaters, coolers, diffusers, vessels or
other types of equipment. Adhere to recommendations for the particular cleaning
chemicals used. Be aware of the optimum and safe treatment conditions, as
specified by the manufacturers and suppliers of the cleaning solution components
(acids, inhibitors, chelating agents, etc.). Make sure adequate venting arrangements
are in working order prior to starting and avoid exposure to any toxic gases released.
Be certain that cooking liquors or caustic filtrates do not come into contact with the
acid solutions.
13. Be certain that all drains, vent lines, overflows and safety relief valve lines are
properly piped to a safe disposal area (see ASME code section VIII, division 1
pressure vessels, section UG-135 and appendix M).
14. Drain valves should ONLY be opened when the system (i.e. pressure, temperature)
warrant it safe to proceed. Drain valves should be opened slowly, and cautiously.
The drain valve discharge area should be kept clear when draining is in progress.
If a valve is difficult to open or appears to be plugged, DO NOT continue to open;
close at once and consult your supervisor before proceeding.
15. Do not render any safety devices such as pressure control valves, relief valves, or
rupture discs inoperable except as specifically allowed by code (see ASME code as
mentioned above appendix M-5).

Introduction Page 6
16. Do not bypass any interlocks unless a bypass switch has been provided for tempo-
rary use during start-up phases and then only for this purpose.
17. Do not exceed the design pressures and/or temperatures for any of the systems.
Contact Andritz if in doubt about pressure or temperature limitations.
18. Do not place hands around the hydraulic cylinder pistons or diffuser tie rods while
the diffuser is operational. The protective guards enclosing the coupling assembly
should be kept closed and in position while the diffuser is in operation.
19. The hydraulics systems are constructed so that some components such as accumu-
lators, pumps, filters, etc. can be changed on the run. Components which can be
isolated and maintained or changed in this fashion will differ from system to system
depending on the date of manufacture and the particular make of equipment used.
Check your hydraulics manual for your particular system. Before proceeding, be
certain that the component to be worked on has been completely isolated,
depressurized and tagged out. Before working on any components which cannot
be individually isolated, both hydraulic pumps should be tagged out and the entire
system depressurized both at the console and the accumulator rack. If the oil
reservoir is to be drained, the oil heater should be shut off and tagged out first.
NOTE: Consult your hydraulics manual for detailed procedures and safety
precautions before working on your hydraulics system.
20. Use only “oil pumped” nitrogen or “dry” nitrogen for accumulator pre-charge
(never use oxygen or air).
21. Keep a qualified attendant in the control room at all times when the system is in
operation. The equipment should only be operated by trained personnel familiar
with the proper operating procedures.
22. Stock being blown from the digester to an atmospheric brownstock diffuser must
always be kept well below the boiling point to ensure that it does not flash or boil
as it moves up through the diffuser. The automatic high temperature cut off
instrumentation must be well maintained.

Introduction Page 7
The design of the pressure diffuser permits operation at higher blow tempera-
tures.
23. When starting a filtrate pump, make sure the discharge valve is closed and then
open it slowly to avoid hydraulic hammer.

ATMOSPHERIC DIFFUSERS
General Description Page I-1
General Description - Atmospheric Diffuser
The following description assumes a two-stage atmospheric brownstock diffuser

following a continuous digester. (See Fig. 1.1, 1.2 and 1.3) Digester pressure is used to
blow the pulp through the blow line into the two-stage diffusion washer. The conical
section of the diffuser tank is designed to allow the upflowing stock to be evenly distributed
across the diffuser.
TWO STAGE DIFFUSER
Inside the diffuser
ON HIGH DENSITY STORAGE
tank are concentric screen
rings arranged about a com-
mon vertical axis. The
lower row of screen rings
form the first washing
stage, and the upper row,
the second stage. Each
washing stage consists of
screen rings equally
spaced. Each screen ring
is comprised of two screen
plates spaced approxi-
mately two inches apart.
The number of rings per
row and their height are
dependent upon the design
production of the diffuser
and stock drainage charac-
teristics. Three, four or six
arms located between the
first and second stages
serve to support the screen
assembly and transport ex-
tracted filtrate from the
screens.
FIGURE 1.1 2177a-cdr

TWO STAGE DIFFUSER

CROSS SECTION
FIGURE 1.2
0474

WASHING FLOWSHEET
TW O STAGE DIFFUSER
4375
FIGURE 1.3

These arms radiate from the diffuser center to the tank's outside wall where they are
supported by vertical tie rods which are coupled to the hydraulic cylinders. These
cylinders give the screen assembly a vertical stroking cycle. The upstroke speed is adjusted
to be slightly greater than the upflow rate of the pulp mass. The diffuser is held at the top
of its stroke for approximately eight seconds, and is then downstroked rapidly (approxi-
mately one second). The extraction flow is shut off and the wash flow reduced during the
top delay and downstroke. Mechanical or "software" stops are used on the wash valves to
prevent them from closing 100%. A small amount of wash water will still be entering the
diffuser (approximately 200-300 gpm per stage) to prevent the nozzles from plugging.
The function of the rapid downstroking movement of the screen through the pulp mass
is to wipe the screens clean.
To help ensure that the screens will be cleaned, a backflush system is incorporated
into each screen row. During the upstroke, filtrate is pumped to two backflush tanks (one
tank for each stage). The backflush tanks are on both level and pressure control. The
backflush system forces liquor from the inside to the outside of the screens, (momentarily
reversing the extraction flow), thus cleaning them of any stock build-up. The backflush
is interlocked so that it can only occur while the extraction valve is closed, provided the
level in the tank is satisfied.
As the pulp flows upward between the screen rings, clean wash filtrate displaces
the dirtier filtrate which is extracted through the screens and arms to a filtrate tank. First
stage extracted liquor is pumped to the cold blow pump or previous stage washer. Second
stage extracted liquor is returned to the diffuser and is used as first stage wash filtrate.
Heated wash water (decker filtrate, evaporator condensate, etc.) is used to wash in the
second stage. Wash filtrate for each stage enters the diffuser through a slot in the trailing
edge of the wash nozzles. Both first and second stage wash nozzles rotate with the central
shaft in circular paths centered between the screen rings. The wash flow to each of the
pulp segments created by the screen rings is controlled by orifice plates in the wash
nozzles, and is proportional to the volume of pulp between each ring. Wash nozzles for
the first stage are mounted on a common arm located below the screen rings. This arm is
attached to the central shaft. The central shaft serves to transport wash filtrate for both the
first and second stages. Second stage wash nozzles are attached to the top scraper assembly
above the screen rings.

The washed pulp continues to flow upward in the diffuser to the top scraper, which
turns at approximately 7.5 rpm. The function of the scraper assembly is to distribute
wash water to the nozzles, and to remove the pulp evenly from the top of the diffuser tank
into the launder ring and dropleg.
In addition to the two-stage atmospheric brownstock diffuser already described, the

atmospheric diffuser is used for:
Single Stage Brownstock Washing (See Fig. 1.4)

Two Stage Brownstock Diffuser mounted on a Filtrate Tank (See Fig. 1.5)
Single Stage Bleach Tower (See Fig. 1.6)
Two Stage Bleach Tower (See Fig. 1.7)
A typical diffuser bleach plant design using single stage atmospheric diffusers, MC® pumps
and mixers and using the sequence D100 EO D1 D2 can be designed as shown (See Fig. 1.8).

SINGLE STAGE DIFFUSER
FIGURE 1.4 2176 cdr

TWO STAGE DIFFUSER

MOUNTED ON A FILTRATE TANK
FIGURE 1.5 2237cdr

SINGLE STAGE BLEACH TOWER
FIGURE 1.6 2198cdr

TWO STAGE BLEACH TOWER
FIGURE 1.7 2197cdr

DIFFUSER BLEACH PLANT

D 100 E0 D1 D2
FIGURE 1.8

Instrumentation and Interlocks Page II-1
TWO STAGE CONTROL SCHEME

BROWNSTOCK
FIGURE 2.1 3032

II. Instrumentation and Interlocks
The instrumentation is designed to allow the operator to easily control the

process and to alert him whenever abnormal conditions exist. In the event that
corrective action is not taken, interlocks are provided to shut down the system
before mechanical damage occurs. The need to maintain instrumentation is an
important part of any preventative maintenance program. The instruments, if not
properly checked and periodically maintained, will not protect the personnel and
equipment for which they were designed. The attached schematics show the
interlocks and instruments on our latest projects. We would recommend you add
the necessary interlocks so your system will conform to our latest standards.
A. Instrumentation Loops
The following is a brief description of the instrumentation loops and

interlocks currently used on a two stage brownstock diffuser.
F27 FIRST STAGE WASH FLOW

Flow controller FIC27 set to control wash flow through FV27. This valve closes back
to a minimum flow of 200-300 gpm during the diffuser downstroke to prevent
nozzle pluggage. To prevent over thickening the stock there is a differential flow
switch FDSH27 which takes a signal from wash flow transmitter FT27 and extrac-
tion flow transmitter FT22. If the extraction flow is higher than the wash flow by
more than the setpoint on FDSH27 the diffuser scraper will shut down by interlock.
A typical range for FDSH27 is 300-700 gpm depending on the size of the diffuser.
F28 DIFFUSER FLOAT OUT

FV28 is used to float the pulp out of the diffuser. To operate this valve the inlet
pressure under the diffuser must not be high and the scraper must be running.
F37 SECOND STAGE WASH FLOW

Flow controller FIC37 set to control wash flow thru FV37. This valve closes back to
a minimum flow of 200-300 gpm during the diffuser downstroke to prevent surging
the tower and plugging the wash nozzles. To prevent over thickening the stock
there is a differential flow switch FDSH37 which takes a signal from wash flow
transmitter FT37 and extraction flow transmitter FT32. If the extraction flow is
higher than the wash flow by more than the setpoint on FDSH37 the diffuser scraper
will shut down by interlock. A typical setting for FDSH37 is 300-700 gpm depending
on the size of the diffuser.

LEGEND AND BLOCK DIAGRAM
FIGURE 2.2
STROKING DIAGRAM TIMING
FIGURE 2.3
STROKING INTERLOCKS
FIGURE 2.4
MOTOR INTERLOCKS
FIGURE 2.5
MISCELLANEOUS ALARMS
SHUTDOWN INTERLOCKS
FIGURE 2.6
F22 FIRST STAGE EXTRACTION FLOW

Flow controller FIHC22 set to control extraction flow thru HV22.
F32 SECOND STAGE EXTRACTION FLOW

Flow controller FIHC32 set to control extraction flow thru HV32.
F85 LOWER BEARING SEAL WATER FLOW

High pressure water is used to lubricate the bottom bearing. To ensure the bearing
lubricating flow is not interrupted two separate lines are used. Each line has a flow
indicating switch (FIS85A and FIS85B) which should be set for approximately 0.5
GPM. The seal water supply line has a valve, QV85, which opens when the diffuser
scraper starts and closes when the scraper shuts down.
L23 FIRST STAGE BACKFLUSH TANK LEVEL

During the upstroke of the diffuser the backflush tank is being filled with liquor
through LV23. When the tank reaches the correct level LV23 is closed by level
switch LSH23. LV23 will also close by interlock when the diffuser reaches the top.
L33 SECOND STAGE BACKFLUSH TANK LEVEL

Same as L23 for the second stage.
L24 FIRST STAGE FILTRATE TANK LEVEL

The level in the first stage filtrate tank is measured by a level transmitter (LT24)
which sends a signal to two controllers (LIC24A) and (LIC24B). LIC24B controls
LV24B which adds liquor to the tank when the level is low. LIC24A controls LV24A
which bypasses liquor on high level. There is a low level alarm at 25% and a high
level alarm at 80%.
L34 SECOND STAGE FILTRATE TANK LEVEL

The level in the second stage filtrate tank is measured by a level transmitter LT34
which sends a signal to controller LIC34. LIC34 controls LV34 which adds liquor
to the tank if the level is too low. There is a low level alarm at 25% and a high alarm
of 80% tank level.
L31 HYDRAULIC RESERVOIR OIL LEVEL AND LOW HYDRAULIC OIL TEMP.
A two point level switch LSL31 and LSLL31 measures the level in the hydraulic

reservoir. On low level an alarm is sounded. On low, low level the hydraulic oil
pump is interlocked to stop. The hydraulic reservoir has a temperature switch TS31
which controls a heating element that maintains a minimum oil temperature in the
reservoir. When the oil temperature reaches the setpoint on the switch the heating
element is turned off. A typical setting for this switch is 100°F-120°F.
P23 FIRST STAGE BACKFLUSH TANK PRESSURE

The backflush tank is used to clean the diffuser screen by pushing filtrate back thru
the screen thru QV22. After the backflush tank has reached level (LS23) and if the
diffuser has not reached the top, and the pressure in the tank is low (PS23), the air
pad valve PV23 will open and add air to the backflush tank. When the setpoint on
PS23 is reached or the diffuser reaches the top, PV23 will close. A typical setting on
PS23 is 45 to 60 psig.
P33 SECOND STAGE BACKFLUSH TANK PRESSURE

The backflush tank is used to clean the diffuser screen by pushing filtrate back thru
the screen thru QV32. After the backflush tank has reached level (LS33) and if the
diffuser has not reached the top, and the pressure in the tank is low (PS33), the air
pad valve PV33 will open and add air to the backflush tank. When the setpoint on
PS33 is reached or the diffuser reaches the top, PV33 will close. A typical setting on
PS33 is 45 to 60 psig.
P26 INLET STOCK PRESSURE

This is used to measure the stock pressure under the diffuser screen. There is a low
pressure interlock which prevents stroking the screen assembly before the stock
level is up to the top of the screen. There is also a high pressure interlock which
diverts the stock going to the diffuser if the pressure under the diffuser gets too high.
There are also alarms for high and low pressure.
P25 HYDRAULIC OIL PRESSURE

Measures the operating pressure of the hydraulic pump. Typical operating pressure
is approximately 2000 psig. A low pressure alarm is set at approximately 1200 psig.
T12 INLET STOCK TEMPERATURE

This is a temperature transmitter that monitors blow line temperature. If the

temperature rises above approximately 190°F there is an alarm in the control room,
a field warning light and a field warning horn. If it rises above 195°F there is an
interlock to divert the stock to storage thru HV21B. This interlock is to prevent
flashing of the pulp in the diffuser.
T21 INLET STOCK TEMPERATURE

This is a temperature switch mounted in the pulp line. On high temperature (at
approximately 190°F) there is an alarm in the control room, a field warning light and
a field warning horn. On high high temperature at 195°F an interlock diverts the
stock to storage.
T39 HIGH HYDRAULIC OIL TEMPERATURE

This is a temperature switch (TS39) on the hydraulic reservoir which gives an alarm
on high temperature (approximately 140°F) and an interlock on high high tempera-
ture (approximately 160°F) to shut down the hydraulic pump. In addition the
reservoir has a mechanically operated water cooling system. If the temperature
rises above the setting on the water valve it opens and circulates water thru a heat
exchanger to cool the oil. A typical setting maintains the oil at 120°F.
P25 FIRST STAGE EXTRACTION SCREEN DIFFERENTIAL PRESSURE

This instrument is used primarily by the operator to indicate screen pluggage. When
abnormal readings are obtained, the operator can make corrections as required.
PD35 SECOND STAGE EXTRACTION SCREEN DIFFERENTIAL PRESSURE

This instrument is used primarily by the operator to indicate screen pluggage. When
abnormal readings are obtained, the operator can make corrections as required.
PD29 HYDRAULIC OIL FILTERS PRESSURE DIFFERENTIAL

To monitor the filters on the hydraulic reservoir, supply line and the recirculation
loop, each filter has a differential pressure switch across it to indicate plugging.
HS30 SECOND STAGE WASH ISOLATION

This hand switch opens and closes the wash water to the second stage thru HV30.
This should be a slow opening valve to prevent hydraulic hammer. HV30 is
interlocked to close if the scraper goes down.

HS21 BLOW LINE DIVERSION

This hand switch is used to put stock to the diffuser thru HV21A or divert the stock
thru HV21B.
QV20 FIRST STAGE WASH ISOLATION

This valve is interlocked with the No. 2 filtrate pump to open when the pump is
started and close when the pump is stopped. It should be a slow opening valve to
prevent hydraulic hammer.
QV22 FIRST STAGE BACKFLUSH

Valve QV22 is used to backflush the first stage diffuser screen during the fast
downstroke. To be effective this must be a quick opening valve.
QV32 SECOND STAGE BACKFLUSH

Same description as QV22 for the second stage.
C32 SECOND STAGE EXTRACTION CONDUCTIVITY

This conductivity transmitter is located in the second stage extraction line near the
filtrate tank. It transmits a signal to the control room which gives an indication of
the conductivity of the second stage filtrate.
K26 DIFFUSER STROKE TIME

The upstroke and downstroke times are indicated in the control room. An alarm
sounds in the control room when the downstroke time is too high.
H26 DIFFUSER STROKE SPEED

Controller HC26 is used to adjust the diffuser upstroke speed. Speed is normally
adjusted due to a production change. The upstroke will also depend on the wood
species. Normally the diffuser is run faster on hardwood than on softwood.
Z26 DIFFUSER POSITION

The operation of the diffuser is controlled from the control room using hand switch
HS26. This is a three position switch which can put the diffuser in PURGE, STROKE
or RUN. In PURGE the diffuser goes to the top and stops. The wash, extraction and
backflush are not functional. In STROKE the diffuser screen can be stroked with the
extraction valves closed. The wash valves close to the minimum flow at the

mechanical or software stop. The backflush system continues to function. In RUN

the screen will stroke and the wash extraction and backflush will function normally.
Hydraulic cylinder limit switch positions are shown on the diagnostic panel as well
as the position of the diffuser stroking coil EV26.
M200 DIFFUSER SCRAPER

The scraper moves the stock from the top of the diffuser to the launder ring where
it drops to the storage tank. The scraper must be running to allow the wash and
extraction valves to function. Also the scraper must be running to start the No. 2
filtrate pump. HS200 is a bypass to allow starting the scraper without running the
No. 2 filtrate pump. As soon as the system is started up HS200 should be put in
automatic. Once the scraper is started a speed switch on the scraper shaft senses
its rotation. If the speed switch times out the scraper will shut down. The control
panel should have a motor load reading for the scraper and a high motor load alarm.
M201 NO. 1 FILTRATE PUMP

The No. 1 filtrate pump transfers liquor away from the first stage filtrate tank and
provides liquor to the suction of the backflush pump.
M202 NO. 2 FILTRATE PUMP

The No. 2 filtrate pump provides wash water to the first stage diffuser screen and
to the second stage backflush tank.
M203 BACKFLUSH PUMP

The backflush pump provides liquor to the first stage backflush tank. The No. 1
filtrate pump must be running before the backflush pump can be started.
M205 NO. 1 HYDRAULIC OIL PUMP

The hydraulic pump provides the force to move the diffuser screen through the
action of the hydraulic cylinders.
M206 NO. 2 HYDRAULIC OIL PUMP

Spare pump for the No. 1 hydraulic pump.
M207 SCRAPER LUBE OIL PUMPS

The lube oil pumps provide lubrication for the gearbox which drives the scraper.

The No. 1 lube oil pump will automatically start when the scraper is started. Lube
oil flow switch (FSL27) must be satisfied in order for the scraper to stay running. If
the No. 1 lube oil pump stops or FSL27 opens. Then both the No. 1 and No. 2 lube
oil pumps will automatically start. An alarm will sound in the control room if the
lube oil switch senses low flow.
B. Time Delay Relays
The diffuser stroke sequence results in a number of time delay relays that initiate
events or monitor the stroking cycle. The following is a list and description of them.
TDR1 Gives an alarm if the diffuser downstroke is more than 2 seconds.
TDR2 Interlocks the stock to divert to storage if the diffuser downstroke is more
than 6 seconds.
TDR3 Time the diffuser delays at the top of the stroke before downstroking. Typically
5.0 seconds.
TDR4D Gives a diffuser stopped alarm and diverts the stock to storage if the diffuser
is in the up position more than 8-12 seconds.
TDR4U Gives a diffuser stopped alarm and diverts the stock to storage if the diffuser
is between the bottom and top limit switches for more than 120 seconds.
TDR6 Time after the diffuser reaches the top until the backflush starts. Typically
2.5 seconds.
TDR7 This delay prevents flow controllers F27 and F37 from opening up and seeking
the flow setpoint when flow valves sequence. The 10 seconds allow the valves
to reopen and the flow to stabilize before the loop goes back on control.
TDR9 This 6 second delay prevents false shutdown when switching the diffuser from
STROKE to RUN.
TDR10 This half second delay prevents false indication that levels have not been satisfied
in #1 and #2 backflush tanks.

TDR11 This delay allows first stage backflush valve QV22, 3 seconds to close before first
stage backflush tank level valve LV23 opens.
TDR12 This delay allows second stage backflush valve QV32, 3 seconds to close before
second stage backflush tank level valve LV33 opens.
TDR21A This timer allows HV21A 30 seconds to open before giving a "not opened"
alarm.
TDR21B This timer allows HV21A 30 seconds to close before giving a "not closed" alarm.
TDR21C This timer allows HV21B 30 seconds to open before giving a "not opened"
alarm.
TDR21D This timer allows HV21B 30 seconds to close before giving a "not closed" alarm.
TDR26 This 2 second delay prevents diversion of the stock to storage due to the
momentary pressure spike under the diffuser screen during the downstroke.
TDR207 Shuts down the scraper if there is no lube oil flow for 30 seconds.
C. Filtrate Tank Flow and Level Control
The pulp to be washed is blown directly from the digester to the diffuser. Because
there is no air in the pulp to produce foam, the filtrate tanks can be small. The first stage
tank is sized for approximately 6 minutes retention at design tonnage. The second stage
tank is sized for 4 minutes. The small size allows the second stage to be stacked on top of
the first stage tank.
Extraction from the diffuser first stage flows to the first stage filtrate tank, and is then
pumped through a liquor cooler to the cold blow pump to be used as a wash medium in
the digester, or it is pumped to weak black liquor storage. It is also used to backflush the
screens of the first stage. The cooler is provided to control the temperature in the digester
bottom, thus minimizing the possibility of flashing when blowing to the diffuser.

Extraction from the diffuser second stage flows to the second stage filtrate tank. It
is then pumped back to the diffuser to be used as wash medium in the first stage and to
backflush the second stage screens.
2nd Stage: An internal overflow is provided from the second stage tank to the first
stage to keep the second stage level from exceeding the preset maximum. If the second
stage level drops below a preset limit, a makeup valve (LV34) opens and adds 2nd stage wash
water to maintain the minimum level for operation.
1st Stage: A high level in the first stage filtrate tank opens a control valve (LV24A)
in the line going to the weak back liquor storage tank (bypassing the digester). To prevent
the tank from emptying, a makeup valve (LV24B) opens and adds wash water directly to
the first stage tank. This minimizes the upset in the remaining part of the system. Alarms
are provided to alert the operator of both high and low level conditions. Under normal
operating conditions, both the makeup valves and the bypass valve should be closed.
Occasionally pulp may enter the filtrate tank because of mechanical problems in the
diffuser. To prevent this fiber from being pumped into the diffuser and plugging the
internals, a screen is used in the filtrate tank on the pump suction. This screen should be
checked and cleaned during your routine maintenance. There is also a basket screen
located in each wash line at the pack box assembly at the top of the diffuser.
D. Backflush System
Proper operation of the backflush system is essential to maximize the efficiency of

the diffuser. The diffuser screens are backflushed when the diffuser is in the RUN or
STROKE position.
The following is the operating sequence with the diffuser in the RUN position.
1. Diffuser is in the upstroke mode. Extraction valves are open to a predeter-

mined position and the wash valves are on flow control. The backflush tanks
should be filling.
2. Diffuser reaches the top and all top limit switches are made.

3. Extraction valves close completely and the wash valves close to a predeter-
mined setting (minimum wash flow 200 to 300 gpm). The extraction
valves must close and activate the limit switch for the operating
sequence to continue. The closing of the wash valves is not essential for
the continuation of the operation sequence.
4. The extraction valves should be completely closed in 2.5-3.0 seconds, and

the limit switch on the valves (near the closed position) activates two (2)
timers.
5. The first timer times out after 2.5 seconds and signals the backflush valves
to open.
6. The second timer times out after 5.0 seconds and signals the diffuser to
downstroke (<1.0 second) by changing the position of the directional valve.
7. After the bottom limit switches are made, the extraction and wash valves
open and the backflush valves close. The extraction valves must open
before the diffuser hydraulic directional valve will be energized to
shift to its upstroke position. The opening of the wash valves and the
closing of the backflush valves is not essential to activate the upstroke.
8. Diffuser starts its upstroke. After reaching the top, the procedure is repeated.
Interlock protection is provided to protect the diffuser from stroking in an
empty tower. This action will cause high loads on the equipment which
could cause damage. Since interlocks can fail, it is not recommended to
stroke the diffuser if it is known the tower is empty.
9. Three (3) seconds after the diffuser downstrokes, the level valves open and
refill the backflush tanks for the next cycle.
In the STROKE position, the backflush valves are operated by the top and bottom
limit switches. The extraction valves are always closed when the diffuser is in the STROKE
position.

To ensure an effective backflush, the valves must operate quickly, in 2 seconds or

less to either open or close. Proper pressure and level control in the backflush tank must
also be maintained. Extracted liquor is pumped to the backflush tank by the backflush
pump. As the level rises in the tank and contacts the level sensor mounted on the tank, the
relay is energized. The normally open contacts of the relay then close, signaling the level
control valve to close.
Two level probes in each backflush tank are used to detect the liquor level. As the
level rises in the tank, the probe in the lower portion of the tank is satisfied and as the level
continues to rise until the top probe is satisfied. The liquor level, as it rises, compresses
the air pad at the top of the tank to maintain a tank pressure of approximately 45-60 psig.
If the pressure switch is not satisfied a solenoid valve mounted on the air supply valve will
energize and add air to the top of the backflush tank until the pressure switch is satisfied.
A relief valve will bleed off excess air pressure.
Should the liquor level drop below the lower level probe during the backflush, the
backflush valve will close thus preventing the possibility of backflushing air into the
diffuser. Both the upper and the lower level probes must be satisfied before the backflush
will occur.
NOTE: On initial start-up, air may have to be bled off the top of the backflush
tanks until the proper liquor level is obtained. The air relief valve set
pressure should be approximately 10 psi above the desired operating
pressure.
E. Diffuser Pressure Protection (Pressure Transmitter)
A pressure transmitter with a high and low setting has been incorporated into our
safety interlocks (See drawing Fig. 2.8). The pressure transmitter is mounted underneath
the diffuser screen assembly, and is commonly referred to as diffuser stock inlet pressure
transmitter. This transmitter sends a signal to the DCS for indication and trending. There
are also low and high pressure settings for interlocking and alarming. This part of the
interlock assures the operator that there is stock covering the screens, and eliminates the
chance of stroking the diffuser in an “empty tower”. After the diffuser is full of stock, the
second, higher setting pressure switch will cut off the stock flow to the diffuser if the
pressure underneath the diffuser is excessive to the extent of causing damage. The actual

PRESSURE AND LEVEL CONTROL SYSTEM

BACKFLUSH TANK
FIGURE 2.7 0529

set point is based on the force generated by the hydraulics, the tower area, and the static
head above the pressure measurement.
F. Sealing Water
Sealing water is used to lubricate the bottom bearing and for tie rod lantern ring
lubrication. As shown in the schematic (See Fig. 2.9 ), to make sure the bearing
DIFFUSER PRESSURE SWITCH

PI26 (PSL26 & PSH26)
FIGURE 2.8 3564

DIFFUSER
SEAL WATER
FIGURE 2.9 3565

lubricating water is not interrupted, two separate lines are used. Each line should be
adjusted for 0.5 gpm.
The flow to each tie rod should also be adjusted for 0.5 gpm. The rotameter should
be checked during the daily inspection to make sure the purge is on to each tie rod.
The total seal water is interlocked to close when the diffuser scraper stops. A low
flow alarm is also provided to alert the operator to abnormal seal water flow to the lower
bearing.

G. Conductivity Probe
Insertion of a conductivity probe in the second stage extraction filtrate becomes a

valuable tool to the operator. This gives the operator a trend of washing efficiency. If the
blow flow is increased without changing the wash and extraction flows, the probe will let
the operator know his soda loss will be higher. It is extremely helpful for operator
awareness. This probe is normally located between the second stage extraction valve and
filtrate tank.
H. Diffuser Diagnostic Panel
As an aid to troubleshooting, a diffuser diagnostic light panel that is displayed in

the control room or thru the DCS is used. The function of the display is to show the
operator where the diffuser is in the stroking cycle and the position of the cycling
extraction and backflush valves. Starting at the left side of the logic diagram (see figure
2.10) with the diffuser in the top of the stroke, all limit switches are lit. As the diffuser
begins its cycle, the diagnostic display shows the extraction valves being closed as
DIFFUSER DIAGNOSTIC PANEL
FIGURE 2.10 1438

indicated by the limit switch and then the backflush valves opening. Once opened and the
TDR for delay at the top satisfied, the downstroke solenoid is energized as shown by the
graphic display. After the downstroke has occurred, the bottom limit switches are lit. The
display then shows the extraction valves opening and the upstroke solenoid is energized.
The cycle begins again once the top limits are again reached and the extraction valves
closed. Another function of the panel is to tell the operator of the status of the level and
pressure of the backflush tanks. This is very useful for monitoring and troubleshooting the
backflush system.
This diffuser diagnostic display has proved invaluable on diffuser start-ups. It is

useful to tell the operator exactly what the problem is in the event of a diffuser interlock
or mechanical shutdown. By indicating where in the stroke the problem has occurred and
what function was happening at the time, the operator can quickly pinpoint the problem
for fast corrective action.

Hydraulic System Page III-1
Hydraulic System
A. General Description of a Typical Hydraulic System
Function
The function of a typical hydraulic system is to provide the slow upstroke and fast
downstroke movement of the screen assembly through the pulp mass. During the slow
upstroke, the pulp is washed with filtrate. Wash media is extracted from the pulp mass
through the diffuser screens. The fast downstroke action “wipes the screens clean” of the
pulp mass formed against the screens. The screen assembly is “pulled” through the pulp
mass by hydraulic cylinders connected to the screen assembly.
Description
A typical hydraulic system consists of a hydraulic console (power unit), accumulator

rack and hydraulic cylinders. Hydraulic tubing, hoses and piping carry the hydraulic oil
throughout the system. (See Fig. 3.1 and Fig 3.2)
The console consists of an oil reservoir assembled with a main and spare hydraulic
pump mounted on a steel frame. Included in or on the reservoir are oil conditioning
components: supply line filters, an off-line filtration loop, an oil cooler, and air breathers.
Many system monitoring devices are also included on the console. Oil level, temperature
and pressure are indicated by gauges located on the console for local and remote
indication. Oil is drawn from the reservoir by the main or on-line spare hydraulic pump.
The oil is then pumped through the supply line filter, flow meter, and to the accumulator
rack via hydraulic tubing.
The accumulator rack consists of an Olmsted directional valve, high and low
pressure accumulators and flow control valving. The directional valve routes the hydraulic
oil through tubing and hoses to the tops of the cylinders for the downstroke mode and to
the bottom of the cylinders for the upstroke. Oil exiting from the cylinders during
downstroke also passes through the directional valve and is routed to the low pressure
accumulator.

HYDRAULIC SYSTEM FLOWSHEET
FIGURE 3.1

HYDRAULIC SYSTEM LAYOUT
FIGURE 3.2 3567

During the upstroke, oil from the hydraulic pump is routed to the high pressure
accumulator and through the directional valve to the bottom of the cylinders, pushing
the pistons up at a speed regulated by the flow control valve. This valve controls the
upstroke speed of the diffuser by regulating the flow from the cylinders back to the
console. During the upstroke, oil is stored in the high pressure accumulator for the next
fast downstroke. Although the volume of oil required for the fast downstroking of a
typical set of cylinders is small (4-8 gallons), the flow rate required for the fast
downstroke is high (1,000 - 1,700 gpm). The high pressure accumulator can store the
small volume at high pressure and discharge it at a high rate for the fast downstroke.
High oil flow exiting from the bottom of the cylinders during the fast downstroke
is directed into the low pressure accumulator by the main directional valve located on the
accumulator rack. This absorbed downstroke oil is slowly bled back to the reservoir
through an orifice during the next upstroke.
Hydraulic cylinders attached to the diffuser arms provide the force to push the
diffuser up and pull it down through the pulp mass. The cylinders are double acting and
are connected to the diffuser tie-rod assemblies with a claw-coupling. Hydraulic hoses or
piping connect the hydraulic cylinders to header pipes mounted around the tower.
Proximity switches, mounted on drip can assemblies at the cylinders, provide the signals
to start the backflush and downstroke functions in the diffuser stroking logic.
B. Latest Equipment for Typical Hydraulic System
1. Tobul Accumulator
The accumulator rack is supplied with two Tobul piston accumulators (See Fig. 3.3).
The high pressure accumulator provides the high flow of oil under high pressure to
the top of the cylinders to obtain the fast downstroke. Precharge for this
accumulator should be 1/2 to 2/3 of system operating pressure. Nitrogen gas should
always be used to precharge accumulators. This gas should have a high percentage
of purity.
The low pressure accumulator receives the high flow of oil from the bottom of the
cylinder assemblies during the downstroke. This surge volume is slowly bled to the
reservoir during the next upstroke. Precharge pressure for the low pressure
accumulator should be 75-100 psig.

PISTON-TYPE HIGH PRESSURE ACCUMULATOR
FIGURE 3.3 4074

HYDRAULIC ACCUMULATOR
FIGURE 3.4

A drain kit for the Tobul accumulator is available and consists primarily of a hose
assembly, piston adapter, stop tube, and drain fitting. This equipment allows for
quick and easy removal of hydraulic oil that has accumulated on top of the piston.
Oil on top of the piston (carryover) is a common and normal occurrence. The more
often the piston cycles and the more wear on the piston seals, the greater the oil
carryover (see figure 3.4).
It is recommended that the drain kit be used to facilitate the indirect inspection of
the piston seals. By instituting a regular program of draining and measuring the oil
carryover, an assessment of the seals’ integrity can be made. When the oil carryover
rate changes significantly, the piston seals are worn and should be replaced. One of
the best ways to detect this is to plot the oil carryover with respect to time. Contact
Andritz for further details.
2. Automatic Upstroke Speed Control
On older diffusers, the upstroke speed was controlled by a pressure compensated

manual flow control valve. Any upstroke speed change involved an operator
walking out to the accumulator rack and adjusting the valve setting by hand. An
automatic speed control valve is now mounted on the accumulator rack and can be
adjusted from the control room or it can be interfaced with the process to track
changes in stock flow (see Fig. 3.6).
The automatic speed control valve is mounted on the Olmsted valve manifold in
parallel with a manual speed control valve. If the automatic speed control valve fails
it can be isolated from the system by closing a ball valve upstream of it. A check valve
downstream of the automatic speed control valve isolates the valve from down-
stream pressure. With the automatic speed control valve isolated, it can be removed
for maintenance without shutting down the diffuser.
3. Springless Olmsted Valve
A number of years ago, a “springless” version of the Olmsted directional valve was
developed. Previous versions of the valve employed heavy springs that created

potential operational and safety problems. With no pressure in the system, the
springed version of the valve would be in the downstroke mode. The valve would
not shift to the upstroke mode until the pressure reached approximately 400-600
psi, depending on the valve model. The current version of the valve is controlled
strictly by hydraulic pressure, which means that the valve will not move until
directed by the pilot pressure delivered by the solenoid valve. When required to
perform service on the Olmsted valve, maintenance personnel have had to recog-
nize the potential danger that could exist if proper procedures for removal of the
end caps, springs and spool were not adhered to. Since the new version does not
have springs, the potential danger is reduced, thus facilitating easier service of the
valve.
4. Off-line Filtration/Cooling - Change in Filtration Rating
Recent changes have been made in how the hydraulic oil is filtered and to the
micron size of the filter elements.
Previously the standard was to filter the supply line (the line from pump to
accumulator rack) with a by-passable three micron absolute filter followed by a 15
micron non-by-passable filter to collect large debris in the event that the 3 micron
filter became plugged and was bypassed.
The return line (the line returning to the reservoir from the accumulator rack) was
also filtered to a 3 micron absolute rating prior to passing through the oil cover and
back to the reservoir.
The current design utilizes an off-line filtration/cooling system driven 20 gpm

pump and a 3 hp, 1200 rpm motor.
The reservoir is divided into a dirty side and a clean side by a stainless steel 100
mesh screen. The filtration pump draws oil from the dirty side of the reservoir and
discharges it to a filtration can containing 3 Filterdyne, 10 micron absolute
elements. After the filter can the oil passes through the oil cooler and is returned
to the clean side of the reservoir where the main pump suctions are located.

ADJUSTABLE DOWNSTROKE ORIFICE
FIGURE 3.5
3570
A 20 micron non-by-passable filter is also located at the discharge of each main pump
to prevent any large debris from damaging the cylinders, accumulators, and valves
at the accumulator rack.
No filtration is done in the return line.
5. Adjustable Downstroke Orifice
To control the maximum speed of the diffuser during the downstroke, an orifice is
used between the supply/downstroke accumulator and the Olmsted Directional
Valve to limit the oil flow to the tops of the cylinders.

On previous diffusers this orifice consisted of a fixed orifice plate located in the high
pressure accumulator block. The orifice size could only be changed by shutting
down the system and removing a cover plate on the accumulator block to access the
orifice plate. The plate could then be removed and replaced with a different size
orifice plate. This process was a very time consuming task.
Our present design uses an adjustable downstroke orifice which can be adjusted
while the hydraulic system is running. With the adjustable downstroke orifice the
operator can make adjustments to compensate for changing diffuser operating
conditions. The adjustable downstroke orifice can also be used to slow the
diffuser downstroke to prevent "slamming" of the diffuser at the bottom of the
stroke. Some forms of diffuser assembly damage have been attributed to "slam-
ming". (See figure 3.5)
C. Upgrading/Retrofitting of Existing Systems
1. Addition of Automatic Upstroke Speed Control
The automatic upstroke speed control valve can be retrofitted to an existing system
by the addition of a speed control module or an adaptor block. The speed control
module incorporates the automatic speed control valve and a parallel mounted
manual flow control valve. The automatic valve has an upstream isolation valve and
a downstream check valve for removal from the system without shutting down.
Addition of an automatic upstroke speed control valve can also be done by simply
removing the existing manual valve and installing the adaptor block with the
automatic valve. This option does not have the manual bypass valve.

AUTOMATIC (REMOTE) SPEED CONTROL
FIGURE 3.6 3571

2. Addition of Off-line Filtration System
Andritz has designed an off-line filtration console assembly (see Figure 3.7). The
system is similar to the off loop system described earlier in this section with the
exception that the oil cooler is not part of the new filtration loop. The original oil
cooler would still be used as before in the return line from the accumulator rack.
Some modification is required to the reservoir to install this system
3. Addition of Adjustable Downstroke Orifice
The adjustable downstroke orifice can usually be added to an accumulator rack with
some or possibly no modifications required, (see Figure 3.5). Contact Andritz for
details.
4. Conversion to "Hard" perimeter piping.
D. Warnings, Interlocks, Pressure Controls and Back-Up Systems
There are many devices and subsystems to aid in the maintenance and operation
of the hydraulic system.
Before working on any hydraulic component, the appropriate pumps and motors
should be shut off, tagged out and the system pressure bled-down. The bleed-off
valves located on the reservoir and accumulator rack should be opened. Since this
system has gas filled accumulators at high pressure, caution should always be used
when maintaining or opening this system.
1. Oil Level:
A Gems level switch is mounted on the console. The upper limit activates a low
hydraulic oil alarm on the operator’s control panel when the oil level drops to 3/4
full. If the oil drops further to the lower level limit, 3/8 full, all pumps operating out
of the reservoir are shut off.

OFF-LINE FILTRATION SYSTEM
FIGURE 3.7 3573

2. Pressure:
The hydraulic pumps are pressure compensated, but should the pressure for any
reason increase above the preset relief pressure setting (300 psi above operating
pressure), the relief valve will open.
A low hydraulic pressure alarm will activate in the control room should the pressure
drop below 1,200 psi. This alarm is activated by a pressure transmitter connected
to the supply line on the console.
3. Filters:
On older hydraulic units, both the supply and return line filters have a bypass built
into them. As the small pores in the filters plug up with dirt, a pressure drop builds
up across the filters. An indication at the console will show when the pressure
differential across the supply and return line filters reaches 35 psid (pounds per
square inch differential). An internal bypass valve will open to bypass oil around
the filter when the pressure differential is 50 psid. A second filter assembly is
included in the supply line. This is a non-bypass filter with a manual bypass line
around it. The dirty filter indicator light will go on when the pressure differential
is 100 psi.
More recently designed hydraulic oil filtering systems use 22 micron absolute non-
bypass high pressure filter assemblies in the supply line. The console has a
hydraulic oil recirculation pump which draws oil from the dirty side of the baffle.
The discharge is routed through a 7 psi check valve, a Filterdyne oil filter (rated
at 10 micron absolute), an oil cooler, and is returned to the clean side of the baffle
in the reservoir (see Fig. 3.1 and 3.2).
4. Oil Temperature:
The flow of cooling water into the oil cooler is controlled by a water valve with a
temperature probe connected to the reservoir. To protect the heat exchanger and
water valve from dirty water that could cause plugging, a water strainer is installed
upstream of the cooler and water valve.

During cold weather, the oil is heated as needed by a thermostatically controlled

immersion heater in the bottom of the reservoir.
5. Speed Control:
The upstroke speed of the diffuser is controlled by an automatic flow control valve.
The downstroke speed is controlled by pressure compensation built into each
Olmsted valve. This limits the minimum time with which the diffuser can
downstroke, normally 0.4 seconds, and sets off a slow downstroke alarm if the
downstroke is too slow (3-4 seconds). Each complete cycle of the diffuser is also
timed and a diffuser stopped alarm goes off if the cycle is too long (120 seconds)
or if the diffuser stops.
6. Phase Control:
Each hydraulic cylinder has a top proximity switch that has to be activated before
the diffuser can downstroke. This requires that all the hydraulic cylinders will be
brought back into phase, if necessary, every cycle.
7. Backup Equipment:
The console is equipped with two hydraulic pumps - a main pump and a spare.
Running both pumps at once will not harm the system but one pump should be
adequate.
8. Oil Flow:
The console is equipped with flow meters on the discharge lines of each pump.
Once normal running speed has been established, any major deviation would
indicate worn pumps or excessive leakage in the system.

E. Preventative Maintenance
The number one factor in maintaining the hydraulic system is to KEEP THE
HYDRAULIC OIL CLEAN. Contamination by dirt, water, or air causes a high percentage
of all hydraulic equipment failures.
There are many ways the hydraulic oil can become contaminated. To help keep the
oil clean:
1. Keep the hydraulic console clean.
2. Change the filters promptly.
3. Service the air breathers on the top of the reservoir on a regular basis.
4. Keep the packing in good repair on the tie rods above the hydraulic cylinder.
5. Repair hydraulic equipment on a clean bench or area.
6. Cover any connecting ports whenever the hydraulic system is disassembled.
7. Use the console quick disconnect fill port when putting oil in the reservoir.
Periodically (at least once a year), the reservoir should be drained, the sludge
cleaned off the bottom of the reservoir, the suction filters cleaned or replaced, and the
system refilled with new oil. If the oil removed is very dirty, flush out the piping by running
the hydraulic system with the diffuser in PURGE and the hydraulic oil return line diverted
to the oil sewer. Add oil to the reservoir as required.
Oil viscosity is another important factor determining system life. The heater and oil
cooler and the type of oil used are the controllable items in maintaining the proper
viscosity. Refer to Section G of this section for the type of oil recommended.

PREVENTIVE MAINTENANCE SCHEDULE
SEMI-
DAILY WEEKLY ANNUALLY ANNUALLY OPERATION
Check the filter indicator

lights for dirty filter
indication.
Check the oil level in

the reservoir.
Check the oil temperature.
Clean the water strainer.
Check for blown bladders

in the bladder accumulators
(on systems with bladders).
oil bypass on piston accu-
mulator.
Check for pre-charge in the

high pressure accumulator
or as needed. A precharge
pressure indication higher
than original precharge
indicates oil carryover.
Have the oil analyzed.
Remove the hydraulic oil

(replace if the analysis
warrants). Clean the suction
strainers. Clean the bottom
of the reservoir. Replace the
breathers on the reservoir.

F. Maintenance Procedures
1. Changing the Hydraulic Oil:
To completely change the hydraulic oil during a shutdown, the following procedure is
recommended: After shutting down the diffuser (Diffuser in PURGE):
a. Shut off hydraulic pumps (main and recirculation, if installed) and tag out.
b. Open pressure bleed-off valve (on console). (Cylinders will lower to bottom
of stroke.)
c. Shut off and remove power from the oil heater.
d. Drain reservoir.
e. Clean suction filter and reservoir bottom.
f. Temporarily connect the return line (from the return accumulator to an

empty 55 gallon drum or the oil sewer).
g. Fill the reservoir with new, clean oil.
h. Turn on oil heater and reset to previous setting.
i. Close pressure bleed-off valve.
j. Turn on pump with diffuser in PURGE. (Cylinders will go to top of stroke.)

(No change in pressure setting necessary.)
k. Unlock manual flow control valve and open to 100%.
l. Maintain reservoir level by filling with new oil.
m. When the drum on the return line is about full, shut off the main hydraulic
pump. More than one drum may be needed.

n. Open pressure bleed-off valve.
o. Replace original return line piping.
p. Reset flow control valve to original setting.
q. Close pressure bleed-off valve.
r. Check oil level.
s. Start-up main pump.
t. Be prepared to change recirculation filters at least once within the first 24

hours of operation.
2. Replacing any Pressurized Components (Other than Cylinders):
To replace any pressurized component, the following safety procedures should be

used:
a. Switch the diffuser to PURGE.
b. Shut off the hydraulic pumps (all) and tag out.
c. Open the pressure bleed-off (on the console) and wait until the diffuser drops
to the bottom of stroke.
d. Bleed nitrogen pre-charge from the accumulators.
e. Replace the faulty component.
f. Recharge accumulators with pure nitrogen.
g. Close the pressure bleed-off valve.

h. Remove the tags on the hydraulic pumps and start the pumps.
i. Check for leaks.
j. Check reservoir oil level.
k. Purge out all air.
l. Start-up the diffuser.
3. Replacing a Cylinder/Perimeter Piping and Hoses:
Follow this same shutdown and safety procedure when changing an O-ring in the
cylinder piping system. To replace one, two or all of the hydraulic cylinders:
a. Switch diffuser operation to PURGE, verify cylinders at top of stroke.
b. Mount clamps on tie-rod nuts to support diffuser assembly in the up position.
c. Shut off hydraulic pump and tag out.
d. Open pressure bleed off valves.
e. Bleed nitrogen pre-charge from the accumulators.
f. Remove claw coupling.
g. Recharge accumulators with pure nitrogen.
h. Change out cylinder(s), making sure to protect exposed piping from

contamination.
i. Close pressure bleed-off valve.
j. Remove the tags on the hydraulic pumps and start both pumps.

k. Bleed the air off from the tops of each cylinder (be sure to bleed off all the air).
l. Install claw couplings.
m. REMOVE CLAMPS and start the diffuser back up.

WARNING: Be sure clamps have been removed. Stroking without
removing clamps will cause damage to the diffuser.
n. If diffuser will not stroke properly, check limit switch on replaced cylinder.
The setting may have been altered with the change out of the cylinders.
4. Hydraulic System Start-Up
NOTE: Do not try to start-up the hydraulic system with the diffuser in the
down position unless the cylinders and piping are full of oil. If the
cylinders are not full of oil, jack the diffuser to the up position.
Be sure to keep the diffuser level (within one inch during jacking). With the diffuser
operation switch in PURGE position and the diffuser in the up (or within one inch
of the top of the stroke), proceed with start-up as follows:
a. Check the hydraulic oil level and close the pressure bleed-off valve.
b. Remove the locks and tags on the hydraulic pumps and start the pump.
c. Check the operating pressure.
d. Bleed-off all air from the top of the cylinder and the top of the Olmsted
valve.
e. Remove clamps or blocking supporting the diffuser.
f. Start-up the diffuser.

G. Hydraulic Oil Specifications
200-250 SSU
Operating Temperature - Normal 110°F, Range 80° - 150°F (26° - 66°C)
Petroleum Base
Additives for wear, rust, corrosion, oxidation and foam
Kendal R & O Texaco Phillips 66

AW-46 Rando Oil HD46 Magnus-A-Oil
150 VG 46
Exxon Amoco Grade 215
Nuto H 46 AW Oil #46 8134
Standard Oil Co. Arco Mobil

SOHIO Duro AW 46 D.T.E. 25
Energol HLP 46
Shell Oil Chevron Conoco

Tellus 46 HW Hydraulic Oil 46 Super Hydraulic 46

Maintenance Procedures Page IV-1
Mechanical Maintenance Procedures
Introduction
This section of the manual was written to provide information regarding repair and
maintenance of your atmospheric diffusion washer.
Maintenance of the support machinery such as hydraulics, instrumentation, etc.,

has been covered in separate sections. Special consideration should be given to the
mechanical parts of the diffuser, since many of these are unique and require special
maintenance.
Each area of the diffuser will be discussed as follows:
1. The name of the part.
2. A description of the part and its importance to the successful operation of the
diffuser
3. Procedures of inspection, fixing, or replacing the part with a minimum of

downtime
4. Any related drawings.
A. Wash Flow Packboxes
Sub-Assemblies
The wash flow packboxes, which are located above the tower cover, distribute the
wash filtrate to the internal piping in the central shaft. From the shaft, the filtrate passes
through the distribution arms and is distributed between the screen rings by the
distribution nozzles.
The packboxes are either for a single stage style (see Fig. 4.1) or for a two stage style
(see Fig. 4.3).

The latest standard incorporates shaft mounted reducers enabling the introduc-
tion of wash flows from above the gearbox. Figures 4.1 and 4.3 show the packing
arrangements to be used on new single stage and double stage diffusion washers.
Any packbox is a maintenance item. Excessive leakage from these packboxes can
cause problems such as:
1. Electrical failures due to shorts, particularly limit switch failures.
2. Poor system efficiency. A badly leaking packbox can cause the true dilution
factor to be less than the required amount, and will cause the washing
efficiency to drop.
3. Gear reducer oil contamination.
SINGLE STAGE PACK BOX ASSEMBLY

OLD STYLE
FIGURE 4.0 2579

SINGLE STAGE PACK BOX ASSEMBLY

NEW STYLE
FIGURE 4.1 0438

TWO STAGE PACK BOX ASSEMBLY

OLD STYLE
FIGURE 4.2 1349

TWO STAGE PACK BOX ASSEMBLY

NEW STYLE
FIGURE 4.3 3574

Maintenance:
For any packing, a small amount of leakage is normal and necessary for lubrication, but
if the leakage becomes excessive,the packing gland can be tightened. If this does not
reduce the leakage, the packing itself should be replaced.
On older two stage diffusers, excessive leakage from the first stage packbox may
contaminate the cleaner pulp in the top of the tower if the drip pan is plugged or damaged.
If there is no drip pan, one can easily be made. These should be kept clear of stock and
the leakage drained away from the top of the tower.
When tightening the packing gland nuts, be sure to use an alternating sequence to
assure that the packing is compressed evenly and that the packing gland maintains proper
alignment. The gland should be tightened only enough to reduce the leakage. Do not over-
tighten.
Replacing the Packing
1. Remove the gland, packing, lantern ring and wear ring, and thoroughly clean
the packing area. If the lantern ring or wear ring is worn excessively, it should
be replaced.
2. Check the packbox for alignment with the shaft. If the misalignment is1/8"
or greater, proper alignment should be made by either adjusting the packbox
supports or repositioning the wash flow line that enters the packbox.
3. Prepare the proper number of packing rings to be installed. (See the main-
tenance drawing for your specific diffuser.) Cut the ends of the packing
sections on a bias, 45° to the horizontal. If the packing is flattened for ease
of installing, it should be rolled with a clean pipe used like a rolling pin and
not pounded flat with a hammer. Packing that has been flattened by rolling
has a more uniform thickness and will wear and seal better.
NOTE: Square packing is now recommended for all wash flow

packboxes.

4. Insert the wear and lantern rings as required along with the packing rings.
Seat each individual ring of packing into place before seating the next ring
of packing. See the maintenance drawing for specific configuration. Be sure
the ends of the packing do not overlap more than the biased sections and
stagger the joints in the successive packing rings 90° apart.
5. Install the packing gland and tighten the nuts finger tight, making sure that
the gland is not misaligned. The gland should be tightened when the shaft
is turning and the seal water is on. Be sure to maintain the alignment of the
gland and do not over-tighten. A small amount of leakage is normal. The gland
should have double nuts to prevent the nuts from backing off during
operation.
NOTE: The alignment should be checked at operating temperatures

to make sure that the expansion of the wash piping does not misalign
the packbox.
B. Wash Line Vacuum Breaker/Screen Basket
Vacuum Breaker Description:
The wash line vacuum breakers are located on the piping going into the packboxes
on the central shaft (See Fig. 4.4). The purpose of these vacuum breakers is to prevent the
nozzles which distribute the wash water from becoming plugged with pulp when the
filtrate pumps are shutdown for any reason. It always takes a certain amount of time for
the check valves on the discharge of these pumps to close. Until they are closed, flow can
go backwards through the pump. With a vacuum breaker, any siphon effect will be broken
and the backward flow will not pull pulp into the wash nozzles but will instead pull air into
the piping.
The vacuum breaker and wash control valve should both be located in the
horizontal piping run at the diffuser top cover with the vacuum breaker located upstream
of the control valve.
The vacuum breakers should be cleaned during each scheduled outage to keep dirt
and fiber from causing the internal check to stick.

VACUUM BREAKER WITH PRESSURE GAUGE
FIGURE 4.4 0421
Screen Basket Description:
In addition to the vacuum breaker, there is a screen basket inserted into the
incoming wash line. The screen basket will collect any fiber that may cause plugging of
the central shaft and wash nozzles.
The baskets should be cleaned during each schedule outage to remove fiber that
may have built up on the basket. For details on the baskets, contact Andritz.

C. Central Shaft Thrust Bearing
Description:
The thrust bearing supports the weight of the central shaft and scraper assemblies
and provides radial support for the top of the shaft. Our latest design has the thrust bearing
incorporated into the Hansen hollow shaft gear reducer, and it should be serviced
according to the manufacturer's recommendations.
For the older systems the two stage diffusers use a spherical roller bearing and the
single stage diffusers use an "X" type bearing. (See Figure 4.8)
For older spherical roller bearings, Andritz has an upgrade that we can offer.
Contact Andritz for furter details. (See Figure 4.9)
Maintenance:
The importance of maintaining this bearing is obvious. Without it, the diffuser
cannot be operated. Lubrication needs vary for any bearing depending on speed,
temperature, soundness of seals, etc. Normally, the bearing should be greased every 800
working hours, or roughly once per month. We recommend running the bearing full of
grease. When full, the grease should start coming out around the seals.
Recommended greases are as follows:
Rolexa 3 ................................. Antar

Energrease LS EP 2 ................................. BP
Dura-Lith Grease EP 2 ................................. Chevron
Beacon EP 2 ................................. Esso
Gulfcrown Grease No. 3 ................................. Gulf
Mobilplex 47 ................................. Mobil Oil
Alvania Grease R2 ................................. Shell

If the bearing does fail, it will probably start making loud, rumbling noises. It may
also cause the central shaft drive to start drawing high amps. If it is determined that the
bearing must be replaced, the preferred procedure for changing the bearing is as follows:
Bearing Removal (Spherical Roller)
1. Float out the pulp in the diffuser with filtrate available to the stock line.
2. With the diffuser tank empty, all equipment tagged out, and the diffuser in
the down position with the hydraulic pressure bleed-off valve open, wrap
5 ton chain falls around the diffuser arms between the No. 1 and No. 2 rings
and down around the central shaft just under the wash distribution arm
hub. If the diffuser has three or four arms, you will have a chain fall on
each arm. If it has six arms, put one on every other arm.
SCRAPER DRIVE THRUST BEARING

SPHERICAL ROLLER TYPE
FIGURE 4.5 3575

3. Apply sufficient tension on each one to take up the weight of the shaft. Now
drive at least three hardwood wedges between the No. 1 ring and the central
shaft. This will keep the shaft centered while the bearing is being replaced.
4. Unbolt the drive coupling on the central shaft
5. Unbolt the gear reducer from the support steel and slide it far enough so that
the bearing may be removed.
NOTE: The gear reducer does not need to be lifted with a crane but can
be slid on the support steel using come-alongs or chain falls.
6. Heat the coupling on the central shaft and remove it.
7. Remove the bearing cover (See Fig. 4.5).
8. Remove the lockplate that secures the locknut from rotating loose.
9. Remove the locknut.
10. Thread the removal nut onto the withdrawal sleeve until contact is made with
the bearing. After contact has been made, apply the necessary pressure to the
removal nut to retract the withdrawal sleeve and release the loading on the
bearing.
11. The bearing will now lift out of the bearing housing.

Bearing Installation
1. Measure the internal bearing clearance in the new bearing before installing.
The internal clearance in a spherical roller bearing is the total distance one
bearing ring may move in relation to the other under no load in a radial di-
rection. In a bearing with its axis horizontal, supported on its outer ring and
loaded on its inner ring, the clearance may be measured with a feeler gauge
between the uppermost roller and the outer race. However, in a vertically
mounted bearing, the clearance must be measured by pressing the outer and
inner rings together on one side and measuring 180° opposite this load point.
The clearance should be measured by inserting progressively larger feeler
blades the full length of the roller, between the roller and the spherical race
of the outer ring. Do not roll the feeler blade through the clearance, slide it
through. Record the measurement of the largest size blade that will slide
through. This is the internal clearance. The attached tables describe
acceptable clearances (see Fig. 4.6).
2. Hand pack the bearing with grease and check the location of the grease fitting
in the housing to assure that when greased during operation, grease
will reach the bearing.
3. Slide the bearing over the shaft and into the bearing housing, starting with
the small bore diameter first to permit installation of the withdrawal sleeve.
4. Slide the withdrawal sleeve onto the shaft and into the bearing bore. Mi-
cronized or powdered (not flaked) graphite applied to the sleeve's outside
diameter surface results in easier bearing mounting and removal.
5. Install the lockwasher onto the journal with the inner prong of the lockwasher
toward the face of the bearing and riding in the keyslot located in the threads
on the journal. Thread the locknut on the journal with the chamfered face
toward the bearing. Large size bearings will require a heavy duty spanner
wrench and a sledge hammer to obtain the required reduction in the internal
clearance. Do not attempt to tighten the locknut with a hammer and a drift.
The locknut will be damaged, and metal chips can enter the bearing. Tighten
the locknut and measure the internal clearance as described in the next

FIGURE 4.6 4382

section. Find the lockwasher tang that is nearest the locknut slot. If the slot
is slightly past the tang, don’t loosen the nut, but tighten it to meet a washer
tang.
Installing the withdrawl nut onto the assembly when installing will secure
the sleeve and bearing from sliding downward and increasing the internal
clearance in the roller bearing.
6. Internal Clearance Check - Through the life of the bearing, the internal
clearance will increase. It has been calculated that the total axial clearance
is approximately 10 times the diameter clearance. The way to monitor the
internal clearance of the main thrust bearings is to check the vertical
positions of the two races. As an example, if the bearing has 0.007"
diametrical clearance in the vertical position, the loaded inner race will be
lower than the supported outer race by 10 x 0.007" or 0.070" (see Fig. 4.6).
Measure the vertical difference between the bearing races and divide by 10.
This is the internal diametrical clearance. If the diametrical clearance is
greater than the original unmounted clearance listed on the chart, it is
recommended that the bearing be replaced.
Bearing Replacement (X Roller)

SPHERICAL ROLLER BEARING 1. Float out the pulp in the diffuser
with filtrate available to the stock line.
2. With the diffuser tank empty, all

equipment tagged out, support the wash
distribution arms with blocking in the
launder ring. Be sure the shaft is sup-
ported and will stay centered while the
FIGURE 4.7 3576 bearing is being replaced.
3. The bearing can be replaced with

the bearing support housing still on thetower, but it is suggested that the
entire unit be removed from the tower and rebuilt in the shop. Remove the
bolts which bolt the bearing hub to the shaft. These bolts are located on the
bottom side of the bearing. Remove the bolts which mount the bearing
support housing to the support structure and remove the bearing assembly
(see Fig. 4.8).

SPHERICAL ROLLER THRUST BEARING ASSEMBLY
FIGURE 4.8 4374
4. The bearing can be removed by removing the two bearing covers.
5. Clean the parts and reassemble with the new bearing. When installing the
bearing covers, install
shims so that there is
"X" ROLLER BEARING ASSEMBLY
zero clearance be-
tween the bearing
and the covers.
6. Install new grease

seals and pack full of
grease.
7. Install the bearing as-

sembly on the cen-
tral shaft.
8. Remove blocking,
and unlock all equip-
ment.
FIGURE 4.9 3577

D. Lower Bearing
Description:
The lower bearing (See Figs. 4.10 and 4.11) provides radial support for the bottom
end of the central shaft. The bearing is a simple journal type with a split bearing insert made
of cast iron or reinforced teflon. Lubrication is provided by two fresh water purge lines
mounted on the support arms. If these lines plug, allowing no fresh water to purge the pulp
fibers away from the bearing, it will wear prematurely.
Maintenance:
The lower bearing is a journal bearing. It will wear with operation. The original
nominal radial clearance should be measured at installation. This clearance should be
checked once a year by removing the upper cover and using feeler gauges. If the total
clearance is greater than 3/8" on one side with the shaft touching the bearing on the other
side, the bearing should be replaced. On new style diffusers using a hollow shaft reducer,
a worn bearing increases the chances of bending the shaft.
LOWER BEARING ASSEMBLY
FIGURE 4.10 2186

Replacing the Bearing:
1. To remove the bearing, the conical lower cover must be removed (See Fig.
4.9). Before removing all the bolts, insert three pieces of threaded rod ap-
proximately 30" long to lower and support the conical lower cover. Use
double nuts at the top of each rod to securely support the rods.
2. Lower the cover about an inch and confirm that the bearing pieces are sliding
out of the housing. If not, they can be pushed down from the top.
BEARING HOUSING DETAIL
FIGURE 4.11 2183

3. Drop the cone and bearings enough to remove the split bearing pieces.
4. Clean out the housing and stack the bearings in position on the lower cover.
The lantern ring should not have to be replaced since its only purpose is to
distribute the purge water.
5. Line up the keyways with the keys in the housing and jack the assembly
into position.
6. Reinstall the purge water lines, the top cover, and seal.
7. Tack weld all hardware.
On newer diffusers additional reinforcement has been added to the lower

bearing assembly. The support arms have been strengthened in several ways (See Fig.
4.12). Support angles have been added to both sides of the arms to reduce horizontal
flexing. Also, gussets have been added where the support arms attach to the lower
bearing housing. On diffuser towers greater than 23' in diameter, vertical support
pipes have been added to reduce vertical flexing of the arms (See Fig. 4.13). These
changes can be made to older diffusers if the need arises. Please contact Andritz for
further details.
E. Central Shaft
On newer diffusers the packing sleeve and the lower bearing surface on the shaft
have been made replaceable. The packing sleeve slides down from the top and is
bolted in place. The lower bearing surface is now bolted on to the bottom of the shaft
(See Fig. 4.14).
These changes can be retrofit to most existing diffusers. Please contact Andritz for
further details.
Shaft Mounted Gear Reducer Assembly Procedure
Install the gear reducer onto the shaft. The tolerances between the gear reducer and the
shaft are tight. It may help to warm the reducer sleeve with a light bulb and cool the shaft.

BOTTOM BEARING
SEAL WATER LOCATION
FIGURE 4.12 2184
Install the gear reducer shrink disc and remember to tighten the bolts around in a circle
not on opposite sides. Level and center the reducer with the shaft hanging free. Once
the shaft is installed on the reducer, the lower bearing can be assembled onto the shaft.
Note: The reducer has two bearings on the shaft, so the lower bearing has to be installed
without moving the shaft from its free position. Once the bearing housing is installed
concentric to the shaft, the bearing should slide into the housing without moving the shaft
more than a 1/16" to the side.

LOWER BEARING SUPPORT
FIGURE 4.13 2185
F. Nozzles
Occasionally nozzle pluggage or damage can occur, requiring maintenance work.

After the repair work has been completed, check the distribution of the wash flow. If the
flow is not in proportion to the screen ring area, either the arm is still plugged or the orifices
have been installed incorrectly. Each orifice has a number stamped on it. The number one
orifice should be adjacent to the diffuser center, with the numbers increasing towards the
outside tank wall. The orifice plate should be installed with the chamfer on the orifice hole
facing the nozzle. Tack weld the hardware to prevent loosening during operation.

DIFFUSER CENTRAL SHAFT
FIGURE 4.14 2182
The scraper mounted nozzles have a 1/4" hole drilled in the top of them. This
vacuum breaker hole helps the nozzle drain during shutdowns to prevent plugging. This
hole can be added to nozzles that do not already have one.
G. Pocket Assembly
The diffuser screen assembly is moved up and down by hydraulic cylinders which
are coupled to the diffuser by a series of parts consisting of the tie rod, the split nut and

the claw coupling. The

screen extraction cham-
ber in the arm is con-
SINGLE STAGE POCKET ASSEMBLY
OLD STYLE
nected to the external
piping in the pocket by
the extraction tube.
Both new and old style
single stage and double
stage pocket assemblies
are described in Figures
4.15 thru 4.18.
H. Claw Coupling
Description:
The claw cou-

pling connects the split
nut on the tie rod and
the hydraulic cylinder
rod.
Maintenance:
It is very impor-
tant to be certain that
the socket head cap
screws holding the two
half couplings together
are tight. If these cap
screws are not properly
torqued, the fit will be-
come sloppy and dam- FIGURE 4.15 0436
age to the split nut or
cylinder rod could occur. The cap screws should be re-torqued after initial operation
following shutdown. The claw coupling should also be checked for wear, especially if it

SINGLE STAGE POCKET ASSEMBLY

NEW STYLE
FIGURE 4.16
0426

TWO STAGE POCKET ASSEMBLY

OLD STYLE
FIGURE 4.17 0433


NEW STYLE
FIGURE 4.18 0427

has been loose. After tightening the bolts, the claw coupling must grip both the cylinder
rod and tie rod without movement. The shoulders on the coupling should not bottom out
in the grooves in the tie rod and split nut, but wedge in tightly to prevent movement. If
it does slip, it must be replaced. The specified torque is 330 ft.-lbs. using SAE grade 8 or
17-4PH (F593 GR7). Be sure that whenever the coupling is taken apart, the starwashers
are replaced. To increase the gripping force on the tie rod, the splits in the split nut and
claw coupling should line up.
This coupling should be routinely checked for any visible sign of loosening.
If the claw coupling is damaged at any time, it should be replaced. It would be

recommended to keep a spare on hand.
If a coupling needs to be replaced, refer to the procedures used to change a

hydraulic cylinder, (explained in your hydraulics manual and on page III-20 of this manual),
and replace the coupling only.
I. Split Nut
Description:
The split nut is threaded onto the lower end of the tie rod and provides a gripping
surface for the claw coupling. The threads provide a means of adjusting the level of
the diffuser (See Leveling the Diffuser). The split in the nut permits the claw coupling
to clamp the threads tight onto the tie rod and prevent it from working up and down
on the tie rod threads. A locking clip which tack welds to the split nut prevents the
split nut from unscrewing. Do not weld to the tie-rod. Welding to the tie-rod or
arcing across it will cause premature failure of the tie-rod. (Also see Item m in
Section S, Centering, Leveling, and Balancing the Diffuser.)
Maintenance:
Whenever the coupling is removed, the split nut should be checked for damage.
When the claw coupling is installed on the split nut, the splits in the individual parts must
line up to make sure the split nut clamps tightly to the rod. Check for extra loose threads
and wear on the outer surfaces. If there is damage, the split nut and possibly the tie rod
should be replaced.

To remove the split nut, grind off the tack weld and remove the locking clip on top
of the split nut. Spread the nut with a steel wedge and screw off the tie rod.
When reinstalling, screw the split nut back to the original position on the tie rod.
If it was loose, it may have moved up or down on the tie rod if so, the diffuser should be
re-leveled and balanced. The split nut should not be off the end of the tie rod by more than
5/16", this will compromise the strength of this connection.
J. Tie Rod
Description:
The tie rod connects the claw coupling to the diffuser. This rod transmits the force
necessary to raise and lower the diffuser. The top of the tie rod is a ball joint, to allow some
misalignment or tilt of the diffuser. This ball joint consists of the ball, and two retainer rings
commonly called ball seats. At the bottom of the rod, there is a threaded connection to a
nut. The tie rod nut is split so that when the claw coupling is installed properly, this nut,
commonly referred to as the split nut, will clamp tight on the threads. With the weld tab
in place, the split nut will not turn on the rod during operation. This threaded joint serves
as the adjustment for balancing.
There is a clearance designed into the ball joint connection at the top of the tie rod.
This clearance is necessary so that the ball seats can slide horizontally. This allows some
misalignment, which can occur when the anti-rotation bars wear. This clearance is initially
between .005 to .015 inches.
Maintenance:
Over a period of time, the clearance in the ball seats will increase due to wear on
the ball cap, seats and tie rod. Once a year, or anytime a clinking noise is heard during the
downstroke, this clearance should be checked.
Listed below is one procedure for checking the clearance in the tie rod ball joint.
The pocket described is a two-stage exterior pocket. Since there are differently designed
pockets in operation, each mill should use this as a typical guideline and modify the
procedure to suit their diffuser.

TIE ROD BALL SEAT CLEARANCE
Figure 4.19 0358
K. Ball Joint Clearance Measurement
1. Empty the diffuser tower, shut off the hydraulics and bleed off hydraulic
pressure, flush out the pockets and open pocket doors.
2. Install a hydraulic jack under each arm end.

3. Jack each arm end up enough to take the load and block the diffuser up.
4. Remove the claw coupling in each pocket.
5. Set up a dial indicator assembly as shown on the sketch (See Fig. 4.19).
6. Using a prybar, lift the tie rod until it bottoms out. Read the vertical
movement on the dial indicator.
NOTE: Care must be taken to pry only on the tie rod and not on the split nut. The
threads of the split nut have some clearance, if you pry on the split nut, the dial
indicator will show the clearance of these threads plus the ball cap clearance.
7. When the clearance is greater than 0.030", determine the wear rate by
referring to the clearance measurements from the previous tie rod clearance
check. Project what the clearances will be at the next shutdown. If the
clearance is predicted to be more than 0.060", then proceed with the
following steps.
8. Grind off the tack welds on the tie rod cover bolts and remove the bolts.
9. Remove the rod cover.
10. Machine the tie rod cover to reduce the clearance to 0.005" - 0.015" range.
NOTE: Make sure you have a clearance in the tie rod. Zero clearance would
mean that the cover is not seated. This will result in premature failure of
the bolt, and tie rod damage.
11. Clean all the parts of the ball joint. Any dirt between mating surfaces will
cause an improper clearance. Check for damaged surfaces. Many units have
a replaceable insert under the lower ball seat. If the tie rod has to be removed,
this insert should be checked for wear and the upper surface should be
machined flat if it is dished more than 0.005".
12. Reinstall the ball cover.

13. Torque the ball cover bolts to the recommended value, as indicated on the
diffuser pocket assembly spare part drawing and tack weld.
14. Re-check the clearance.
15. Lower each arm end, balance the diffuser, and reconnect the claw coupling.
It is important to balance the diffuser before re-connecting the claw cou-
plings. Refer to the section on "Balancing the Diffuser".
L. Tie Rod Replacement
After a period of operation, the ball joint may become excessively worn, or the tie
rod may become badly scored and have to be replaced.
Note: It is not Andritz's recommendation to refurbish the diffuser tie rods.

Through past experience, the tie rods which have been refurbished fail, causing
unplanned downtime.
Removal
1. With the diffuser tower empty, the hydraulics shut off and bled down (dif-
fuser in down position), the pockets flushed out and the pocket doors open,
install a hydraulic jack under each arm end.
2. Jack each arm end up enough to take the load and block the diffuser up.
3. Remove the claw coupling in each pocket.
4. Remove the arm end cover or the upper extraction tube if necessary.
5. Remove the ball cover bolts and the ball cover. A lifting lug is provided on
top of the cover.
6. Remove the split nut.
7. Screw an eyebolt in the threaded hole in the upper end of the tie rod.

8. Using a come-along, lift the tie rod up out of the packbox and remove it from
the pocket. Remove the packing set and the tie rod bearing. These can be
removed using standard packing pullers. On pockets with 12" diameter
hydraulic cylinders, the packbox items and flinger must be removed before
the tie rod. On other units, the tie rod can be pulled through the packing
without removing it from the packbox.
9. At this point, you may check the centering of the diffuser. Refer
to Centering the Diffuser (IV, Section S).
Reinstallation
1. Install a new ball seat and if needed, a new tie rod insert on the new tie rod
and lower the new tie rod and lower ball seat into position. Make sure all parts
in the ball joint area are clean.
2. Thread the split nut onto the tie rod.
3. Install the new upper ball seat and the ball cover.
4. Install the ball cover bolts and check the ball joint clearance. See section K
covering this.
5. Slide a new tie rod bushing into the packbox.
6. Install a new set of packing (see Section N. Tie Rod Packing).
7. Install the packing gland. Do not tighten over one turn more than hand tight
until the tower has pulp in it and the diffuser is stroking. Then tighten to stop
any leaks.
8. Before the claw coupling can be installed and the split nut locked in
place, the diffuser must be leveled and balanced. See Section S, Centering,
Leveling, and Balancing the Diffuser.

TIE ROD BUSHING
FIGURE 4.20
2000
M. Tie Rod Bushing
Description:
The tie rod bushing is located above the packing in the tie rod packing box. This
is shown on the attached sketch (see Fig. 4.20). Its purpose is to guide the tie rod in the
packbox and prevent side loads on the packing. The assembly consists of two plastic
bushing separated by a lantern ring. On the latest design pocket, there is a wear ring above
the top bushing, which eliminates the wiper.
Maintenance:
If the following observations are made, it is a good indication that the tie rod
bushing assembly should be replaced:
1. Score marks on the tie rod where it slides through the pack box.
2. Packing wearing out in less than three months.

3. Tie rod appears to be very close to the packing gland on one side during
upstroke.
The procedure for replacing the tie rod bushing assembly is as follows:
1. Remove the packing gland.
2. Remove the old packing set with standard packing puller.
3. Using the packing puller in one of the holes in the lower bushing, slide this
bushing down out of the packbox. This bushing is split so that it can be taken
off the tie rod without removing the claw coupling and tie rod nut.
4. Remove the metal lantern ring in the same manner.
5. Remove the upper bushing.
6. The wear ring is shown in Figure 4.20. It does not have any holes for a puller,
but can be removed by bending some stiff wire and hooking it over the top
of the wear ring.
7. The wiper should have come out as the wear ring was removed. If not, use
the wire to hook it and pull it out.
8. Wash the pack box out to remove dirt and fiber.
9. Take a new rod wiper and split it in the same way as a ring of packing, then
fit it in the wear ring.
10. Under the wear ring, assemble two halves of a new tie rod bushing and slide
this whole assembly into the pack box. A silicone grease can be used as a
lubricant to make the parts easier to install.
11. Using the old lantern ring (if it is still in good shape), mount these on top of
two new half bushings and slide them up into the pack box.
12. Install a new set of packing as described in section N on tie rod packing.
13. Install the packing gland.

N. Tie Rod Packing
Description:
The tie rod packing used on all atmospheric diffusers is a C-ring type packing
(Merkel Style 1040 or Allegeny York). Our experience with this type of packing has been
excellent. When installed properly and adjusted correctly, it will seal with nearly dry
results. The packing set is made up of a starter ring, multiple rings of C-ring packing, and
a following ring. It is important that the starter ring, which looks like an O-ring, is installed
on the pressure side toward the pulp (See Fig. 4.21).
Maintenance:
As with any packing, eventually the rings wear out. If a tie rod is leaking and
adjustment of the packing gland does not stop it, make a note to change it on the next
scheduled outage. If the spare packing set is not split, it may be split on a bias or 45 degree
angle. When this set is installed, the rings are spread apart to get over the tie rod, and then
slid up into the packbox. Stagger the splits 90 degrees apart with each successive ring.
This type of packing need not be tight to seal. Overtightening this packing will only
cause the packing to wear out more quickly.
When the packing is replaced, it is recommended that the tie rod bushing be
replaced at the same time.
O. Extraction Tubes
Description:
The extraction tubes are designed as a double ball joint which telescopes while
maintaining a seal between the pulp and the extracted filtrate. These tubes connect the
diffuser screen assembly, which strokes up and down, with the fixed extraction piping.
This enables the filtrate to flow out of the diffuser screen assembly to the filtrate tank, and
the backflush filtrate to flow back to the diffuser.

DIFFUSION WASHER
TIE ROD PACKING DETAIL
FIGURE 4.21 1994

Maintenance:
The telescoping action of the extraction tubes causes some wear on the sliding
surfaces of the tube and the ball bushing as it slides through. Although a tube will last many
years, eventually the wear will cause a need for replacement. Andritz currently uses metal
extraction tubes, an upgrade from the original plastic tubes. Clearances should be
checked, on a regular basis, between the extraction tube and its retainers as well as
between the ball bushing and its retainers. If the fiber levels in the ex-tracted filtrate are
high, the tubes may need to be replaced on the next scheduled outage.
P. Extraction Tube Replacement
The procedure for extraction tube replacement on our latest style diffuser is as
follows (See Fig. 4.22):
1. After the diffuser tank has been floated out and drained according to your
operating manual, open all the pocket doors.
2. With the diffuser at the top position, resting on the tie rod clamps with the
hydraulic system shut down, remove all the bolts in the extraction tube
retainers.
3. For the older style diffusers, it will be necessary to remove the upper
extraction tube with the diffuser in the down position. The tie rod must also
be removed before the lower extraction tube is removed. See Section L, Tie
Rod Replacement: Removal.
4. The tubes can be removed by sliding the ball end of the tube over until the
tube will pull out of the extraction pipe. Pull out the tube, the ball bushing,
and all four retainers.
5. Install a new tube and a new ball bushing. Usually the retainers can be reused,
but this depends on the amount of wear on the spherical surfaces.

FIGURE 4.22 0427

6. Install the whole assembly and bolt in the retainers. Be sure to use lockplates
on all the retainer bolts. If you have experienced problems with the tubes
pulling out of the retainers, add solid metal retainer plates over the top of the
retainer and bolt down with the retainer. This will add some extra strength.
Bend the corners on the lockplates up over a flat on the hex heads to prevent
loosening.
7. Before installing the upper extraction tube, re-install the tie rod using the pro-
cedure outlined in Section L, Tie Rod Replacement: Re-Installation.
8. Re-install upper extraction tubes using the same procedure as with the lower.
Make sure the pocket insert is installed over the upper tube.
9. After checking that all hardware is secure, close the pocket doors. If the
extraction tube failure allowed large quantities of fiber to enter the screen
assembly, the diffuser should be run on water at a high extraction rate to flush
out the fiber.
Q. Tie Rod Ball Cap Bolts
On brownstock diffusers the preferred material is 17-4PH (F593Gr7). An alternative

would be SAE Grade 8. On most bleach diffusers the material should be Titanium Grade 5
(B348GR5). Projects designed since 1980 use military thread specs and a specially designed
tensile bolt as shown in the sketch (See Fig. 4.23).
TENSILE BOLT
MILITARY SPEC. THREADS
FIGURE 4.23

R. Arm End Bolts
Alloy bolt identification can be confusing. Below are some tips to assist you.
However, consult your vendor for positive identification:
17-4PH (F593 Gr 7) - Magnetic, may be black in color.
SAE Grade 8 - Magnetic, must have 5 marks on the head.
Ti 6-4 Grade 5 - Lightweight, silver, non-magnetic; Rockwell C Hardness approx. 30.
S. Centering, Leveling and Balancing the Diffuser
To ensure the smooth operation of the atmospheric diffuser it is necessary to

center, level and balance the diffuser screen assembly periodically.
Centering the diffuser is the procedure by which the diffuser assembly, once
leveled, is located directly over the hydraulic cylinders.
Leveling the diffuser is the procedure by which the split nut is adjusted on the tie
rod at each pocket, enabling the diffuser arms to remain level during the full range of
hydraulic stroke as well as keeping the individual screens parallel to the motion of the
pulp mat.
Balancing the diffuser is the procedure by which the split nut on the tie rod is
further adjusted after leveling, so that each hydraulic cylinder experiences the same
forces during operation.
Although each procedure is critical to smooth operation, the most critical of all is
the balancing procedure.
NOTE: The diffuser can be centered, leveled or balanced in either the full up or
full down position. If the procedure is done in the up position, the tie rod clamps
should be installed to hold the diffuser up before the hydraulics are shut down.

1. Leveling the Diffuser
a. Obtain a 50-60 ft. length of clear tygon tubing, either 3/8" or 1/2" diameter.
b. Fill the tube with water. Make sure there are no air bubbles.
c. Determine which of the pockets is the highest in elevation: Open the

pocket doors and use the bottom of each pocket for reference (refer to Figs.
4.24 and 4.25). With one person at pocket A and another man at pocket B,
string the water level between the two pockets. The person at pocket A will
let the other man know when his mark is true. The person at pocket B will
be able to determine whether that pocket is higher or lower than pocket
A. The same procedure should be used between all the pockets to
determine the highest pocket.
d. Open the pocket doors and install hydraulic jacks under each arm end and
lift only enough to take the weight. Disconnect the claw couplings.
e. Working on the high pocket, adjust the level of the arm so that the distance
from the bottom of the arm end to the bottom of the pocket is 19 3/4" or
whatever the reference dimension is for the specific diffuser. (See Andritz for
this reference dimension.) Be sure to subtract the correct stroke length (6"
or 9" or 12") if the leveling is to be done in the down position.
f. Adjust the split nut on the tie rod so that the claw coupling fits exactly over
the split nut and the hydraulic cylinder. Be sure the hydraulic cylinder is in
the full up or full down position.
g. Check the position of the split nut on the tie rod. In the highest pocket, the
tie rod should be flush with the bottom of the split nut or sticking beyond the
split nut up to 5/16". Adjust the split nut if necessary and raise or lower the
arm end to compensate. Using the claw coupling, check the fit between the
split nut and the cylinder rod.
h. String the water level from the arm end in the high pocket to the next pocket.
Using either the top or bottom of the arm end as a reference, adjust the level
of the other arm end so that it is equal to the level of the high pocket arm end.

LEVELING THE DIFFUSER IN TOWER
FIGURE 4.24 0424
i. Repeat the above for the remaining pockets and recheck so that all the arm
ends are level within 1/4".
j. If the diffuser is a 4 or 6 arm diffuser, it must be balanced at this time.
k. After the diffuser is leveled, and balanced, adjust the remaining split nuts so
that the claw couplings fit exactly. Check the position of split nuts on the tie

rods. They should be flush with the end of the tie rod plus or minus
5/16". It may be necessary to move the entire diffuser up or down again and
re-level.
l. Install the claw couplings with the split in the coupling aligned with the
split in the split nut. Torque the 3/4" (A193 B7 Cad plated) bolts to 200 ft.-
lb. SAE grade 8 or 17-4 PH (F593 Gr 7) bolts should be torqued to 330 ft.-lb.
Do not use standard 304 SS bolts.
CHECKING FOR HIGH POCKET
FIGURE 4.25 1996

m. Install the locking tabs against the flat on the tie rod and tack weld the tab to
the split nuts. Do not weld the locking tab to the tie rod. Make sure that
during welding the tie rod is protected from all arcs, grounding or weld
spatter.
n. If the diffuser was leveled in the down position and any work was done on
the hydraulics after the claw couplings were installed, the diffuser should be
jacked up to the fully up position and the tie rod clamps installed. There is
the possibility that air may have entered the hydraulic system during the
shutdown period. If the hydraulic system is started up in the down position
with air in the system, it may raise unevenly and cause damage to the pocket
hardware or the screen assembly. Raising the diffuser manually allows the
air to be purged out in the up position.
o. The jacks can be removed and the doors closed any time after the tie rod
clamps are installed.
p. Be sure to remove the tie rod clamps before start-up.
2. Centering the Diffuser
During yearly inspection of the pockets, the gap between the side of the diffuser
pocket and the wear plates on the arm end should be measured.
NOTE: Our latest design diffuser does not require re-centering. As shown on the
enclosed sketch, when the wear pads are replaced, the diffuser will be centered.
Older style wear pads can be converted to our present design. However, if you still
have the old style wear pads, proceed as follows:
a. Level the diffuser following steps a-p in the section of Leveling the Diffuser.
b. After the diffuser is level, remove the tie rod following the procedure
described under Section L, Tie Rod Replacement, steps 1-9.
c. Bolt a 1" x 1/8" flat bar across the tie rod ball cover hole or lower retainer ring
flange hole.

DIFFUSER LEVELING & CENTERING PROCEDURE

SINGLE STAGE DESIGN
FIGURE 4.26 0429


OLD TWO STAGE DESIGN
FIGURE 4.27 0434


NEW TWO STAGE DESIGN
FIGURE 4.28 0430

d. Using the bolt holes as a guide, mark the exact center of the bolt circle and drill
a small (1/16") hole.
e. Install a string for a plumb bob through this hole and suspend the plumb bob
above the cylinder rod. Refer to the attached sketch.
f. With a plumb bob in the pocket, jack the diffuser arms sideways until the
plumb bobs are centered as close as possible on the hydraulic cylinder rods.
The plumb bobs should be within 1/4" of the center of the cylinder rods.
g. After the above procedure has been completed on each arm, the diffuser is
level and centered.
h. Follow the procedure under Section L, Tie Rod Replacement: Installation.
3. Balancing the Diffuser
Balancing the Diffuser adjusts the loading on each hydraulic cylinder so that all the
hydraulic cylinders experience the same forces during operation. Only four or six arm
diffusers need to be balanced (see Fig. 4.29). Three arm diffusers do not need to be
balanced.
Equipment
Four or six identical (correct size) jacks with pressure gauges, 10,000 psi Porta-
Powers are recommended.
Procedure
a. Level the diffuser per steps a-p of Leveling the Diffuser.
b. Adjust the jacks so that all the jacks read within 200 psi of each other. Since
the diffuser has been leveled, try not to move the arms up or down more than
1/8" when adjusting the jacks.
c. Proceed with Step k of Leveling the Diffuser.

BALANCE LOAD ON DIFFUSER ARM
FIGURE 4.29 0423
T. Anti-Rotation Wear Plates
Description:
The anti-rotation wear plates are located in the pocket. These plates serve to keep
the diffuser centered in the tower during operation, and to keep it from rotating due to the
torque transmitted through the stock while the scraper is running. See Figure 4.31 for a
drawing of the new style.

NOTE: On the new style anti-rotation wear plates, it is not necessary to use the
procedures in this manual for centering the diffuser. All that is necessary is to
replace the wear plates on the anti-rotation bars and the diffuser will center
itself.
DIFFUSER ARM END

ANTI-ROTATION WEAR PLATES
OLD STYLE BLEACH AND BROWNSTOCK
FIGURE 4.30 0437

DIFFUSER ARM END

ANTI-ROTATION WEAR PLATES
NEW STYLE BLEACHING AND BROWNSTOCK
FIGURE 4.31 2818
Maintenance:
As the wear plates become worn, the diffuser will no longer be held exactly centered.
The tie rod ball joints allow for some misalignment; but as the wear becomes excessive, the
tie rods and extraction tubes may become damaged. The tie rod packing will also wear out
prematurely and leak.

On the newer diffusers, replacement of the wear plates is very easy. Remove the
mounting hardware and install the new wear plates. Install and tack weld the hardware.
No centering check is required.
On the older units, Andritz recommends that the modification be made to convert
to the replacement style wear plate. When this modification is made, the diffuser must
be centered before installing the new wear plates and supports.
Two additional upgrades for the wear pads include a material change that has been
tried at a few mills, and the "T" bar support that also can be retrofitted. Contact Andritz for
details.
U. Preventative Maintenance
As equipment downtime becomes more and more costly, a good preventative

maintenance program becomes increasingly necessary.
This section is a recommended preventative maintenance program based on our

operating and service experience with your Andritz supplied system.
Every shift:
A walk through visual inspection of the diffuser should be made at least once a day,
preferably during the day shift when there is more manpower available in the mill. The
inspection should include the following:
1. Check the filtrate and backflush pumps for:

a. Cooling water
b. Excessive leakage by the packing
c. Excessive vibration
d. Leaks
2. Check the filtrate tanks for:
a. Leaks
b. Damage

3. Check the wash, extraction, backflush and backflush tank level control valves
for:
a. Proper operation
b. Leaks - air and liquor
c. Limit switch wear
d. Solenoids
4. Inspect expansion joints in the wash and extraction lines.
5. Inspect the stock diverter valve and operator tubing, limit switches and
solenoid.
6. Inspect the blowline temperature transmitter.
At the Hydraulic Console:
1. Check the oil filters for:
a. Dirty oil filter indication

b. Leaks
2. Check for proper oil level.
3. Check for proper oil temperature.
4. Look for loose fittings and leaks.
At the Diffuser Cylinder Platform Area:
1. Visually check the claw coupling bolts for looseness.
2. Check the cylinder mounting bolts for looseness.

3. Listen for noises during the diffuser "RUN" cycle.
4. Inspect the tie rod packing. Check for excessive leakage.
5. Inspect the limit proximity switches on the hydraulic cylinders.
6. Check the hydraulic pipe clamps for looseness.
7. Make a general check for hydraulic leaks or seeps.
8. Inspect the cylinder support and drip can drainage system.
9. Check for loose or broken pipe hangers.
10. Check rotameters for purge flow on the following:
a. Bottom bearing (both lines)

b. Diffuser pressure transmitter
c. Extraction dp transmitters
d. Pocket purge (older units)
11. Check that all lights on the troubleshooting panel are functional
(if provided).
At the top of the Diffuser:
1. Check the packbox packing.
2. Listen for unusual noise in the scraper drive system.
3. Look at the stock in the top of the tower.
4. Check the backflush tank(s) for proper:
a. Pressure
b. Level
c. Operation

Upon returning to the control room, problem areas should be noted. The problems
that can be fixed on the run should be repaired as soon as the people are available, and the
others should be taken care of at the next outage.
Preferably once a day, someone from the various maintenance trades should also do
a walk through visual inspection.
A clean installation will invariably aid the visual daily inspections.
About once a week, the hydraulic accumulators should be checked. On older units
check for blown bladders. On newer units with piston accumulators, check to make sure
the piston has not sunk. If the bladder is not blown or the piston not sunk the top of the
accumulator will be cooler than the bottom. If the top of the accumulator is hot or the
accumulator is the same temperature throughout, there is a problem.
Once a year, the diffuser should be emptied and inspected.
Check for:
1. Broken, bent, cracked or plugged nozzles.
2. Cracked or bent screen plate.
3. Cracked structural welds.
4. Broken, bent or cracked bottom bearing arms.
5. Broken bottom bearing purge water lines.
6. Broken bolts, cracked welds, or bent paddles on the scraper.
During the shutdown, the pocket doors should also be opened.
In the pockets check for:

1. Damaged extraction tubes or tie rods.

2. Damaged extraction tube retainers or missing bolts.
3. Loose or missing arm end bolts or taper pins.
4. Damaged or badly worn anti-rotation and guide bars.
5. Excessive tie rod ball clearance.
After the internal work is done and the pocket doors have been reinstalled, check for
plugged wash nozzles.
On the Hydraulic System:
1. Drain the reservoir.
2. Replace the oil filters.
3. Replace air breather(s).
4. Clean cooling water strainer.
5. Clean reservoir tank (inside and out).
6. Change or add new oil, if needed.
7. Check the pre-charge in the accumulators.
8. Have the hydraulic oil analyzed.
On Scraper Assembly:
1. Open inspection covers on scraper gear reducer and inspect.
2. Re-pack packboxes.

On Filtrate System:
1. Clean out filtrate tanks and suction screens.
2. Re-pack filtrate pumps.
3. Check for leakage around extraction valve(s) and backflush valves.
4. Check for erosion or corrosion to the tanks.
The following major repairs should be done if wear or leakage is apparent:
1. Replace tie rods if worn.
2. Replace bottom bearing if gap between bearing is 3/8" (total).
3. Replace extraction tube assembly parts as needed.
4. Rebuild hydraulic cylinders.
5. Inspect claw couplings and split nuts. Replace if worn.
6. Replace wear plates if excessive wear is seen.
7. Replace tie rod packing.
Prior to re-starting, the diffuser interlock system should be reviewed.
Check that:
1. The scraper will not start without its lube oil flow.
2. The diverter valve will divert on hot stock in the blow line.

3. The diffuser will not stroke without stock in the diffuser tank.
4. The diverter valve will switch to bypass if the pressure under the diffuser
gets too high.
5. The diverter valve will switch to bypass if the downstroke takes too long.

Troubleshooting Page V-1
Troubleshooting
Interlocks and alarms are supplied with the diffuser system to help prevent
mechanical damage and to alert the operator to abnormal conditions. The following is a
brief description of typical problems, along with items the operator should check.
A. Diffuser Stopped
1. Check pressure recorder PI26, which measures the pressure under the
screen assembly, to see if you have a high reading. A high reading may
indicate screen pluggage, high consistency stock, or an upstroke speed that
is too slow for the production rate. If the pressure recorder indicates the
diffuser is plugging, leave the diffuser in the STROKE position with the
backflush system operating until clear.
2. Check the differential pressure across the screen to see if the screens are
plugging. If the differential pressure is increasing, the first step would be to
reduce the extraction flow. Then check that the feed consistency is normal
and the flows are correct according to the flow balance (also check the flow
valve opening to make sure the flow meter gives a reliable indication). The
recorded pressure drop is also affected by wood species, diffuser upstroke
and downstroke speed, wash and extraction flows, stock consistency,
backflush system operation and plugged wash nozzles.
3. Check that the hydraulic oil pump is running.
4. Check for low hydraulic system pressure. If so, check the hydraulic system
for a leak in the piping or equipment. If starting up after a shutdown where
work was done on the hydraulic system, make sure the pressure bleed off
valve at the console has been closed.
5. Check the extraction valve position lights on the troubleshooting graphic (or
panel). Lights should be on when the extraction valves are open. Switch the
diffuser to the STROKE position. If the diffuser operates, check that there is
an output to the extraction valve and that the extraction valve limit switch
is working.

NOTE: When the diffuser is switched to the STROKE position, the extraction
valves should close automatically. However, double checking that these
valves are closed will prevent over thickening the stock and help to prevent
damage to the internals on restart.
6. Check that the low level interlock PSL26 is not set too high.
7. Check that all limit switches are working. There is an indicator light on each
switch that shows if the switch is made.
8. If the up solenoid is energized and the diffuser will not move up, or if the
down solenoid is energized and the diffuser will not move down (providing
it is not plugged), use a welding rod or similar object to activate the pilot valve
which operates the Olmsted valve. If the diffuser then operates, check the
coil on the pilot valve. (This is a recommended spare part.)
B. Slow Downstroke
1. Check the flow balance and feed consistency.
2. Check the differential pressure across the extraction screens and the tower
static head recorder, PI26. If pressure indications appear to be normal, the
diffuser is not plugged.
3. If the extraction differential pressure recorder shows increasing pressure

drop, check to see if the backflush system is operating correctly. If the
problem is not mechanical or hydraulic, reduce the extraction flow from the
appropriate stage. If the differential pressure remains high, switch the
diffuser to the STROKE position until the downstroke time is satisfactory. Put
the diffuser back in the RUN position, and check the flow balance around
the diffuser.
4. Check the hydraulic pressure indicator. If the pressure has dropped, check
for hydraulic leaks. Check the oil pressure drop on downstroke. The oil
pressure should drop about 300 to 400 psi when the diffuser downstrokes.

If it is more, or if the pressure goes to zero, the high pressure accumulators

may have lost their precharge. Make sure the accumulators are valved in. Pre-
charge of the high pressure accumulator should be approximately two-thirds
of operating pressure. The high pressure hydraulic pump has a low capacity,
but should recover from downstroke in about 30 seconds. If not, check for
leaks back to the reservoir.
5. If you are unable to obtain hydraulic operating pressure, the pump may be
worn. Switch to spare pump. On start up after a maintenance shutdown of
diffuser hydraulic system, recheck the pressure relief valve and the bleed off
valve at console to be sure they are closed.
NOTE: Slow downstroke (slightly longer than usual) will give an alarm to
alert the operator. Very slow downstroke will shut down the diffuser.
C. Loss Of Extraction Flow
1. Observe the extraction differential pressure. If the extraction flow has

dropped off, the differential pressure will fall also. Look for changes in the
flow from the corresponding filtrate tank. If the flow has not changed, and
the filtrate tank level recorder indicates no change, check the position of the
level control makeup valve to the filtrate tank. If the valve is closed, continue
to operate and have the flow instrumentation checked.
2. If the flow is correct, cut the wash flow back, check the air supply, and the
signal to the extraction valve.
D. Loss Of Wash Flows
1. First Stage: (lower screens)
a. Make sure the 2nd stage filtrate pump is operating. Check the level
in the second stage filtrate tank and level makeup valve (LV34).
Check wash flow instrumentation. If loss of flow is correct, immedi-

ately cut back on first stage (FIHC22) extraction to avoid overthick-

ening. Check wash flow control valve FV27, valve air supply, signal
air, and I/P.
b. Check flow indication instrumentation.
c. Check if the basket screen on the inlet to the packbox at the top of
the diffuser is plugged. Pipefitters are needed to remove the screen
from the line for inspection.
2. Second Stage: (upper screens)
a. Make sure the mill’s wash water pump is operating. Cut back second
stage extraction (FIHC32) immediately to avoid over thickening and
check that wash water makeup valve LV24B opens to maintain filtrate
tank level to supply adequate wash medium for the digester. Check
wash flow control valve FV37, signal air and solenoid. If solenoid has
failed, bypass with tubing, continue to run, and repair at first oppor-
tunity.
b. Check flow indication instrumentation.
c. Check the corresponding filtrate pump.
d. Check for fiber in the extraction flow.
NOTE: The scraper will shut down if the flow difference (be-
tween wash and extraction flows) exceed a preset amount,
normally 500 to 700 gpm depending on design.

E. Erratic Upstroke
A sticky flow control valve will cause the upstroke speed to vary. This is the result
of contaminated hydraulic oil. The flow control valve should be replaced to correct the
immediate problem. To prevent further problems, the hydraulic filters should be checked
and changed as required.
F. High Scraper Load
High discharge consistency or high stock level caused by a seal water leak during
a shutdown will cause the scraper to overload. The operator should check that the proper
flow balance is being maintained. Normally, a high scraper load will occur at the same time
as a slow downstroke.
G. Diffuser Not Level
1. Air in the system (cylinders) may cause the unbalance of the diffuser. Bleed
off the air at the top of each cylinder.
2. Check for broken tie rod or cylinder rod and replace.
H. Incomplete Stroking Cycle
General
1. Check if the accumulators are working correctly. Check that the precharge
is sufficient, high pressure accumulator should be about 2/3 of operating
pressure. If a low pressure accumulator is installed, the precharge should be
approximately 100 psig. If the system has bladder type accumulators, check
to see if more than one bladder is blown. If the system has piston type
accumulators check to see if the piston has sunk.

2. Check if the diffuser is plugged (downstroke will appear bouncy). Dilute

stock if necessary.
3. Check that the backflush system is working properly.
4. Check that the bottom limit switch or switches are working correctly. If the
limit switch is not made at the bottom of the stroke, readjust the switch. If
the switch is being actuated prematurely, check for a foreign metal object
actuating the switch.
5. Check that PI26, the pressure under the screen assembly is not too high.If
high, lower the consistency with the wash flow.
PROBLEM Diffuser stopped in down position.
Possible Cause: Bottom limit switch or switches not “Made”.
Source & Corrective Action:
1. With cylinder at bottom of stroke, adjust the switches to actuate.
2. Check electrical status of the switches and replace if necessary.
Possible Cause: Olmsted valve not shifting.
1. Flow control valve opened too far - adjust valve to approximately 60-70%.
2. Solenoid valve not operating - check coils and replace if necessary.
3. Olmsted valve stuck - install spare and rebuild replaced unit.
Possible Cause: Upstroke speed control valve failed.

1. Amplifier card failed - replace.
2. Solenoid on valve failed - replace.
3. Valve stuck closed - valve in manual upstroke valve and replace automatic
valve.
Possible Cause: Loss of hydraulic pressure.
1. Pump not running - check oil level.
2. Pressure bleed-off valve open - close valve.
3. Relief valve open - check setting and adjust if needed (300 PSI higher than
operating pressure). Valve stuck - install spare; rebuild and clean replaced
unit.
Possible Cause: Extraction valve not opening.
1. Limit switch on valve not making - switch to STROKE to check, replace if bad.
2. Check electrical status of switch and replace if necessary.
PROBLEM Diffuser stopped in up position.
Possible Cause: Extraction valve not closing.

1. Limit switch on valve not making - switch to STROKE to check; replace if bad.
2. Faulty time delay relay.
Possible Cause: Diffuser or pocket plugged with stock
1. Dilute stock.
PROBLEM Low oil pressure.
Possible Cause: Open connection or leak.
1. Blown O-ring - replace with new one.
2. Ruptured hose - change hose.
3. Relief valve open - check setting and adjust (300 psi above operating
pressure). Valve stuck - install spare - rebuild replaced unit.
4. Pressure bleed-off valve was left open - close valve.
5. Dirt in pressure compensator on hydraulic pump - replace with spare.
Possible Cause: Pump functioning improperly.
1. Pump is worn - install spare and rebuild replaced unit.
2. Pump suction is obstructed - check suction line.

3. Pressure compensator on hydraulic pump is sticking - install spare and

rebuild replaced unit.
PROBLEM Low hydraulic oil level.
Possible Cause: Open connection or leak.
1. Blown O-ring - replace with new.
2. Ruptured hose - replace hose.
3. Reservoir drain partially opened - close valve.
4. Clean-out cover gasket leaking - tighten bolts on cover.
5. Bleed-off valve left open on cylinder or Olmsted valve - close valves.
PROBLEM Diffuser downstrokes part way.
Possible Cause: Accumulators not functioning correctly.
1. Accumulators not valved in - open isolation valves. (on older design)
2. Precharge insufficient: high pressure accumulator precharge equals 2/3 of

operating pressure.
3. More than one accumulator bladder blown - change bladder (on older
design).
4. Low pressure accumulator bad (check precharge 100 psi approximately).

Possible Cause: Diffuser plugged (downstrokes will appear bouncy).
1. Backflush system inoperative - check system.
2. Thick stock - Dilute stock.
Possible Cause: Bottom limit switches not functioning correctly.

1. Switch is not set at bottom of stroke - readjust the switch.
2. Switch is being actuated prematurely - check for a foreign metal object

actuating switch.
PROBLEM Erratic upstroke speed.
Possible Cause: Flow control valve.
1. Valve is sticking - install spare and rebuild replaced unit.
Possible Cause: Air in hydraulic oil.
1. System was not purged sufficiently - with diffuser in PURGE, bleed-off each
cylinder and Olmsted valve.

Process Data Page VI-1
General Diffuser Information
The following is the general operating theory regarding diffusers. Specific information is
contained in the Process Calculations section starting on page VI-7.
A. Inlet Consistency
One of the key elements to an efficient operation is the consistency to the diffuser.
The consistency range for best operating efficiency is in the 10-12% range, with the
higher consistency preferred. The effect of consistency is more pronounced with
hardwoods or poorly draining pulps. The web strength of the pulp bed has a
tendency to collapse when the consistency is in the 7-8% range. The fiber structure
is not strong enough (intertwined) to allow a plug flow through the diffuser.
Instead, the stock in the center moves faster (channeling) than the stock at the
screen. Typical symptoms would be a higher dp on the extraction screens, as well

as slow downstrokes. When this happens, the washing efficiency falls off dramati-
cally. One possible solution is for the operator to increase the extraction flow. By
increasing or keeping the consistency entering the diffuser on the high side, the
extraction required per square foot of screen area to obtain the same dilution factor
is reduced.

B. Atmospheric Diffuser Wash Nozzles
A minimum wash flow through the nozzles should be maintained whenever the
scraper is running. This is to prevent nozzle pluggage. As soon as the scraper has
been started, the filtrate and wash pumps should be started. Since there are no
check valves in the nozzles, running the scraper without a flow can create a
pumping action which can pull stock into the nozzles. A vacuum breaker system
in the wash line using a ball check valve helps prevent this. The check valve is
installed near the packbox and seats against the flow. Each nozzle is orificed based
on the volume of pulp in the ring segment. If these are not in the right location
or not the correct size, several problems result:
• Channeling
• Poor washing efficiency shown by high saltcake loss
• Stroking problems
• Uneven discharge consistency
C. Stock Temperature
There are several benefits to keeping the stock temperature to the diffuser as high
as possible. First of all, the drainage is improved. Secondly, the friction in the
stock line is reduced. When the stock line temperature is fairly cool (less than 150°
F), the friction in the stock line increases dramatically. The final wash temperature
is also important. Ideally, it should be at least 160-180° F. If you exceed a 30°F
difference between the stock and wash temperatures, a "fingering" or "channeling"

effect occurs where the wash forms thin areas in the pulp mat, causing other areas
to be bypassed, which reduces the efficiency of the diffuser.
When upsets in the digester occur, the blow temperature may approach the flash
point. In order to protect a blow line atmospheric diffuser, there is a safety interlock
on all blowline diffuser systems. Normally, the high temperature alarm is set at
approximately 190°F. This alarm signals the operators in advance and gives them
a chance to bring the temperature under control. The stock will divert from the
diffuser to the storage tank at 195°F. It is important that this interlock is not
bypassed or changed, and it should be checked on a routine basis.
D. Wash Flow, Dilution Factor, and Washing Efficiency
The amount of wash water that is being added to the diffuser is calculated by
one of two methods. The first way is with the use of the wash ratio (WR). The
wash ratio is expressed as pounds of incoming wash flow (V2) divided by
the pounds of liquor or filtrate flow (L1) that is leaving with the pulp. A diagram
of a single washing stage is shown on the next page. This would also apply to
each stage of a two stage diffuser. Definitions of the wash ratio and dilution
factor are also shown. Calculations are given starting on page VI-7.
In ideal conditions, with a wash ratio of 1.0, the filtrate entering the stage with the
pulp is completely displaced by the same amount of wash flow. Since conditions
are never ideal, it is necessary to use a higher wash ratio to obtain the required
washing. A wash ratio of 1.2-1.3 is typically used.

The other way to calculate the amount of wash water being added is with the
dilution factor (DF). The dilution factor is a measure of the excess tons of wash
water used relative to the tons of liquor (L1) leaving with the pulp, all expressed
per ADST of pulp. The diagram below also shows the definition of dilution factor.
A higher dilution factor means that more wash water is being used, which gives
better washing. However, there is a point where the cost of using more wash
water outweighs the benefits of better washing.
Since the wash ratio and dilution factor are really measures of the amount of
wash water being used, a different calculation is needed to determine the actual
DISPLACEMENT RATIO CALCULATION
2194-1

efficiency of the diffuser. One way of measuring the washing efficiency of a washer
at a given dilution factor is the displacement ratio or DR number.
The DR number is defined as:
X0 - X1
DR = (Refer to the diagram on page VI-4)
X0 - Y2
where X0 is the concentration in the liquor with the inlet pulp, X1 is the concentra-
tion in the liquor with the outlet pulp and Y2 is the concentration in the wash liquor.
Sodium, dissolved solids, or C.O.D. can be used when calculating the DR number
and the concentrations can be expressed in any convenient units, as long as they are
consistent.
The DR number shows the ratio of performance between the actual washer and an
ideal washer. The DR number is very dependent on the type of washer
(drum, diffuser, etc.) and the amount of wash liquor added.
To check the washing efficiency of the diffuser as well as the liquor and sodium, dry
solids and/or C.O.D. material balance, the following are needed:
- Sodium, dry solids and/or C.O.D. concentrations of the pulp inlet, pulp outlet,
wash, and extraction liquors.
- Consistencies of inlet and outlet pulp.
- All inlet and outlet flow rates.

There should be no filtrate tank make-up or overflows during the testing. If the
DR number is not satisfactory, check:
- Liquor balance. Check that the sum of the inlet flows is the same as the sum
of the outlet flows. A false flow meter reading may give a higher or lower
dilution factor than is correct.
- Check that the pulp samples are not being diluted or dewatered.
- Sodium, dissolved solids and/or C.O.D. balance. The inlet mass flow should
equal the outlet. If not, have the lab recheck the samples, and check the sample
points and sampling procedure.
If the mass balances are satisfactory and the DR number is unsatisfactory, check
the operation for the following:
- Any bypass or dilution valves left open.
- Low consistency. Diffuser discharge consistency should be higher than

9.5% BD.
- Plugged wash nozzles causing poor wash liquor distribution. Check packbox
pressure.
- Low wash temperature. The wash liquor should ideally be 160°- 180°F.
- Abnormal cycle time. The diffuser should not run too slow or too fast.

E. Process Calculations - Atmospheric Diffuser
The following process calculations are based on a production rate of 1000 ADST/D through
a two stage atmospheric brownstock diffuser operating at 10% consistency.
Calculations
Pulp Flow to Diffuser gpm Q1
Pulp Flow from Diffuser gpm Q2
Pulp Consistency to Diffuser % BD C1
Pulp Consistency from Diffuser % BD C2
Average Wash Flow to First Stage gpm W1
Average Wash Flow to Second Stage gpm W2
Average Extraction Flow from First Stage gpm E1
Average Extraction Flow from Second Stage gpm E2
Blow Flow from Digester gpm BF
Blow Line Dilution Flow gpm D

Production Rate ADST/D P
Wash Ratio T/T WR
Dilution Factor T/ADST DF
Instantaneous Wash Flow to Each Stage gpm IW
Minimum Wash Flow to Each Stage gpm MW
Instantaneous Extraction Flow from Each Stage gpm IE
Diffuser Total Cycle Time sec TCT

Diffuser Upstroke Time sec UT
Diffuser Delay and Downstroke Time sec DT
Average Backflush Flow gpm BFF
DIFFUSER FLOW BALANCE
1900

1. Consistency, Flow & Production Rate
The consistency in the blow line or in the washed stock line is calculated below:
15 x P 15 x P
C1 = C2 =
Q1 + (0.05 x P) Q2 + (0.05 x P)
Where Q1 = BF + D for a blow line atmospheric diffuser
The derivations for the conversion factors and an example appear in the Pressure
Diffuser section VI on page VI-7.
The above formulas can also be solved for production or flow as follows.
Q1 x C1 Q2 x C2
P = P =
15 - (0.05 x C1) 15 - (0.05 x C2)
P x (15 - (0.05 x C1)) P x (15 - (0.05 x C2))

Q1 = Q2 =
C1 C2
Example:
BF = 1,450 gpm
D = 50 gpm
Q2 = 1,450 gpm
C1 = 9.7% BD
C2 = 10.0% BD
P = 1,000 ADST/D

Q1 = 1,450 + 50 = 1,500 gpm
15 x 1,000
C1 = = 9.7% BD
1,500 + (0.05 x 1,000)
1,500 x 9.7
P = = 1,000 ADST/D
15 - (0.05 x 9.7)
1,000 x (15 - (0.05 x 9.7))

Q1 = = 1,500 gpm
9.7
1,450 x 10.0
P= = 1,000 ADST/D
15 - (0.05 x 10.0)
1,000 x (15 - (0.05 x 10.0))

Q2 = = 1,450 gpm
10.0
A quicker, but less accurate, estimate of consistency can also be made using the following
formula, which does not correct for the specific gravity difference between water and
stock.
15 x (Production, ADST/D)
Consistency, % BD =
(Stock flow, gpm)
15 x P 15 x P
C1 = or C2 =
Q1 Q2

2. Dilution Factor
Calculation of dilution factor (DF) from the average second stage wash flow
(W2), production rate (P) and stock flow (Q2).
Dilution Factor = 0.6 + [ 6 x (Wash flow - Stock flow out)
Production rate
]
DF = 0.6 + [ 6 x (W2 - Q2)
P
]
The conversion factor "6" used above, is derived in the Pressure Diffuser section
VI on page VI-7.
Example:
Q2 = 1,450 gpm
P = 1,000 ADST/D
W2 = 1,767 gpm
DF = 0.6 +
[ 6 x (1,767 - 1,450)
1,000
]
DF = 2.5 T/ADST
2.5 T/ADST
DF = = 2.78 T/BDST
0.9 BDST/ADST

3. Wash Flow from the Dilution Factor
The required second stage wash flow (W) for a given dilution factor (DF) can be
calculated given the washed stock flow (Q2) and the production rate (P).
Wash flow = Stock flow + [ Production x (DF - 0.6)
6
]
[
W 2 = Q2 +
P x (DF - 0.6)
6
]
Example:
Q2 = 1,450 gpm
P = 1,000 ADST/D
DF = 2.5 T/ADST
W2 = 1,450 +
[ 1,000 x (2.5 - 0.6)
6
] = 1,767 gpm
NOTE: If the average wash flow is adjusted to obtain a given dilution factor,
the average extraction flow must be adjusted by the same amount to
maintain a constant washed stock flow.
4. Wash Ratio
The wash ratio (WR) can be calculated with the following equation, given the
second stage wash flow (W2), the stock flow from the diffuser (Q2), and the stock
outlet consistency (C2).

Wash flow gpm

WR =
Stock flow gpm x
[ 1-
Consistency % BD
150 ]
W2
WR =
Q2 x (1 - C2 / 150)
The denominator is the flow of liquor or filtrate that leaves with the pulp. It is
determined by subtracting the portion of the stock flow (Q) that is actual, bone dry
pulp which has a specific gravity of 1.5.
Example:
W2 = 1,767 gpm
Q2 = 1,450 gpm
C2 = 10% BD
1,767
WR = = 1.31
1,450 x (1 - 10.0/150)

5. Average Wash Flow from the Wash Ratio
The required second stage average wash flow (W2) for a given wash ratio (WR) can
be calculated given the washed stock flow (Q2) and the washed stock consistency
(C2).
Wash flow gpm = (Wash ratio) x (Stock flow gpm) x

[ (
1 −
Consistency % OD
150 )]
W2 = (WR) x (Q2) x ( 1 - (C2 /150))
Example:
WR = 1.31
Q2 = 1,450 gpm
C2 = 10.0% BD
W = (1.31) x (1,450) x (1 - (10.0/150)) = 1,772 gpm
The difference between the wash flow given here and the wash flow calculated
with the dilution factor is in the rounding of the wash ratio.
6. Stock Velocity
The upstroke speed of the diffuser is determined by the velocity of the pulp mass
through the tower. Experience has shown that running a diffuser slower than the
pulp speed will promote pluggage and/or channeling. In the past, we have

recommended that the diffuser be run approximately 20-30% faster. Depending

on the stock drainage characteristics, the speed of the diffuser will vary from
mill to mill. The stock velocity can be estimated given the stock flow rates.
Stock flow to the diffuser (gpm)

Stock Velocity (in/min) =
196*
Q1
SV =
196
* The "196" is a conversion factor to go from gpm to in/min. The number will
change for different diameter towers. It is derived as follows:
Example:
I.D. of the diffuser = 20 ft
Area of the diffuser = ∏r2 = ∏(102) = 3/4 ft2
7.48 gal 314 ft2 ft gpm

x x = 196
1 ft3 1 12 in in/min
Example:
Q1 = 1,500 gpm
1,500 gpm
SV = = 7.7 in/min
gpm
196 in/min

7. Diffuser Cycle Times
The appropriate upstroke time can be estimated given the stock velocity and the
relative speed between the stock and the screen.
Example:
Stock velocity = 7.7 in/min
Relative speed = 1.2 (softwood); 1.3 (hardwood)
Screen velocity = Stock velocity x relative speed
= 7.7 x 1.2 = 9.2 in/min
Stroke length = 6 inches (some diffusers have a 9 inch stroke length)
60 sec
6 in x min
Upstroke time = = 39.1 sec
9.2 in/min
Downstroke
and Delay = 8 sec
Total cycle time = 39.1 sec + 8 sec = 47.1 sec
8. Instantaneous Wash Flow
The wash flows calculated in parts 3 and 5 are the average wash flows. However,
since the wash valves are closed to a minimum position during the downstroke, the
instantaneous wash flow (during the upstroke) will be higher than the average
wash flow. When the wash valve is at its minimum position, the wash flow is

approximately 250 gpm. The instantaneous wash flow is also called the apparent
wash flow. The instantaneous wash flow is calculated using the following equation:
Instantaneous wash flow, gpm =
Total cycle time, sec

average wash flow, gpm x
Upstroke time, sec
Delay & downstroke, sec

 minimum wash flow, gpm x
Upstroke time, sec
[ [
[
IW = W x
TCT
UT
−
[
MW x
DT
UT
The previous equation expresses the fact that the instantaneous flow during the
upstroke will be higher than the average flow, to compensate for the period of time
that the wash flow is cut back to approximately 250 gpm.
Example:
W2 = 1,767 gpm
MW = 250 gpm
[ [
TCT =
UT =
47.1 sec
39.1 sec
[
IW2 = 1,767 x
47.1
39.1 [
 250 x
8
39.1
= 2,077 gpm
DT = 8.0 sec

9. Backflush and Backfill
Average backflush flow can be calculated from the total cycle time and the backflush
volume per cycle.
Example:
Total cycle time = 47.1 sec
Backflush = 200 gal/cycle (This will vary for different diffusers)
60 sec
(Backflush, gal/cycle) x min
Average backflush flow =
Total cycle time, sec
200 x 60
BFF = = 255 gpm
47.1
The backflush tank fill (backfill) flow rate can be estimated given the backflush
volume, and assuming the backflush tank will fill in 30 seconds.
200 x 60
Backfill = = 400 gpm
30

10. Average Extraction Flow
If the inlet and outlet consistencies are the same, the average extraction flow is the
average wash flow plus the backflush volume. This is shown in the following
equation:
Average extraction flow = Average wash flow + Average backflush flow
E = W + BFF
Example:
W2 = 1,767 gpm
BFF = 255 gpm
E2 = 1,767 + 255 = 2,022 gpm
11. Thickening
If the inlet consistency is less than the desired outlet consistency, thickening
will be required. In a double stage atmospheric diffuser, the thickening should
happen in the first stage. The average extraction flow on this stage will be as
follows:

Average extraction flow = Average wash flow + Average backflush flow +
)
Production
15 − (0.05 x Consistency to the diffuser)
Consistency to the diffuser

−
15 − (0.05 x Consistency leaving the diffuser)
Consistency leaving the diffuser )

E1 = W1 + BFF + P
( 15 − (0.05 x C1)
C1
−
15 − (0.05 x C2)
C2 )
Example:
W1 = 1,767 gpm
BFF = 254 gpm
P = 1,000 ADST/D
C1 = 9.7% BD
C2 = 10% BD
E1 = 1,767 + 255 +
1,000 x
( 15 - (0.05 x 9.7)
9.7
−
15 - (0.05 x 10)
10 )
= 2,068 gpm

12. Instantaneous Extraction Flow
The extraction flows calculated in parts 10 and 11 are the average extraction flows.
However, since the extraction valves are closed for approximately 8 seconds every
cycle, the instantaneous extraction flow during the upstroke will be higher than the
average. As with the wash flow, the instantaneous extraction flow is also called the
apparent extraction flow. The instantaneous extraction flow is calculated using
the average extraction flow, the upstroke time and the total cycle time.
Total cycle time

Instantaneous extraction flow = average extraction flow x
Upstroke time
TCT
IE = E x
UT
The above equation accounts for the fact that in taking an average flow over the
entire cycle the flow during the upstroke will be proportionately higher. This
compensates for the delay and downstroke, when there will be no flow.
Example:
E1 = 2,068 gpm
TCT = 47.1 sec
UT = 39.1 sec
47.1
IE1 = 2,068 x = 2,491 gpm
39.1

F. Metric Calculations - Atmospheric diffuser
Pulp flow to the diffuser L/sec Q1
Pulp flow from the diffuser L/sec Q2
Pulp consistency to the diffuser % BD C1
Pulp consistency from diffuser % BD C2
Average wash flow to first stage L/sec W1
Average wash flow to second stage L/sec W2
Average extraction flow to first stage L/sec E1
Average extraction flow to second stage L/sec E2
Blow line dilution flow L/sec D
Production rate ADt/D P
Wash Ratio t/t WR
Dilution Factor t/ADt DF
Instantaneous wash flow to each stage gpm IW
Minimum wash flow to each stage gpm MW
Instantaneous extraction flow from each stage gpm IE
Diffuser total cycle time sec TCT
Diffuser Upstroke time sec UT
Diffuser delay time sec DT
Average backflush flow gpm BFF

1. Consistency
The consistency in the blow line or the washed stock line can be checked:
1.042 x (production, ADt/D)

Consistency %BD =
(stock flow, L/sec)+(0.0035 x production, ADt/D)
1.042 x P 1.042 x P
C1 = or C2 =
Q1 + (0.0035 x P) Q2 + (0.0035 x P)
Where Q1=BF + D
The "1.042" is a conversion factor. It is the ADt to BDt factor in the numerator multiplied
by 100 to express consistency in percent divided by a conversion factor to go from
L/sec to t/D in the denominator.
To convert from L/sec to t/D of liquor:
liters 3600 sec 24 hr 1 kg 1t

x x x x
sec h D 1 liter 1,000 kg
86.4 x liters t
=
min D
0.9 x 100
= 1.042
86.4

stock.
1.04 x Production ADt/D

Consistency % BD =
(Stock flow L/sec)
1.04 x P 1.04 x P
C1 = or C2 =
Q1 Q2
2. Dilution Factor
Calculation of diffuser dilution factor (DF) from average wash flow (W2), production
(P) and outlet stock flow (Q2).
86.4 x (Wash flow - Stock flow out)

Dilution Factor = 0.6 +
Production
86.4 x ( W2 - Q2 )
DF = 0.6 + = t/ADt
P
NOTE: Q2 = Q1 + W - E
* The “86.4” is a conversion to go from L/sec to t/D. It is derived in part 1. Consistency.

3. Average Wash Flow from the Dilution Factor
The required average wash flow (W2) for a given dilution factor (DF) can be
calculated given the washed stock flow (Q2) and the production (P).
Production x (DF - 0.6)

Wash flow = Stock flow +
86.4
P x (DF - 0.6)
W = Q2 +
[ ] 86.4
4. Wash Ratio
(Same as English unit formula, but with flow rates in L/sec.)
5. Wash Flow from the Wash Ratio

(Same as English unit formula, but with flow rates in L/sec.)
6. Stock Velocity
The upstroke speed of the diffuser is determined by the velocity of the pulp mass
through the tower. Experience has shown that running a diffuser slower than the
pulp speed will promote pluggage and/or channeling. In the past, we have
recommended that the diffuser be run approximately 20-30% faster. Depending
on the stock drainage characteristics, the speed of the diffuser will vary from mill
to mill.

The stock velocity can be estimated given the stock flow rates.
Stock Velocity (in/min) = Stock flow to the diffuser (L/sec) x CF
SV = Q1 x CF
* The denominator is a conversion factor to go from L/sec to in/min. The number will
change for different diameter towers. It derives as follows:
liters 1 gal 1 ft3 1 12 in 60 sec

CF = x x x x x
sec 3.785 L 7.48 gal CSA ft2 1 ft 1 min
with CSA = cross sectional area of the diffuser tower, in ft2
25.4
CF =
CSA
All other calculations are similar to the English unit calculations, with flows in L/sec.
Conversions:
1 ADST = 0.9 BDST

1 BDST = 0.9 BDt
1 ADST = 0.81 BDt
1 gallon = 3.785 L

PRESSURE DIFFUSERS
General Description - Pressure Diffuser
The pressure diffuser is used to wash pulp blown directly from a continuous digester or
it may be used in other washing applications (such as post O2) when fed by an MC® Pump.
Pulp at medium consistency (10-12%) enters the bottom of the pressure diffuser and passes
up through the 6" annulus between the tapered extraction screen and the wash baffle
plates (see figure 1.0). Wash water enters a number of vertical headers with evenly spaced
PRESSURE DIFFUSER SECTION
FIGURE 1.0
1170

nozzles surrounding the diffuser. Washing is accomplished by the lateral displacement of
wash filtrate across the pulp bed (See Fig. 1.1). The wash filtrate is introduced into a series
PRESSURE DIFFUSER SCREEN MOVEMENT
FIGURE 1.1 1167
of wash baffles on the inside of the shell. Liquor is displaced through the pulp bed, through
the extraction screen and into the central collection chamber. The extracted filtrate is
discharged through the bottom head. Each nozzle has a check valve and a manual valve
to protect it from plugging with pulp, in case the wash pump goes down. The wash baffles
provide for even distribution of wash into the pulp bed and also helps protect the wash
nozzles from plugging with stock. The washed pulp discharges at the top of the vessel.
Uniform discharge is provided by a discharge device.

The pressure diffuser contains a slightly tapered extraction screen which surrounds an
extraction chamber. The extraction screen and the extraction chamber occupy the major
part of the vessel. The screen is supported by four or six arms that are attached to a vertical
tie rod which is coupled to a hydraulic cylinder. This cylinder gives the screen assembly
a vertical stroking cycle. The upstroke speed is adjusted to be about 1.15 times the velocity
of the pulp flow. The rapid downstroke serves to clean the extraction screen by a
combination of wiping and backflush action.
The vertical movement of the screen assembly serves two purposes. It assures that pulp
flows evenly in all parts of the pressure diffuser. It also provides backflush for the screen
during each rapid downstroke. Due to the tapered shape of the screen, which is larger at
the bottom of the diffuser, the downstroke will decrease the volume in the extraction
chamber. This causes a reverse flow back through the screen perforations, which will
loosen any fiber that may have entered into the holes. The wash and extraction flows are
continuous and are controlled by flow control valves. Various interlocks protect the
pressure diffuser from plugging and over-pressurization.
Applications
The Pressure Diffuser can be installed in a Continuous digester blow line or fed by
an MC® Pump. For multiple stage washing, two pressure diffusers can be installed in series.
See Figure 1.4.

PRESSURE DIFFUSER
FIGURE 1.2 2178

PRESSURE DIFFUSER FLOWSHEET
FIGURE 1.3 3552

PRESSURE DIFFUSER APPLICATIONS
FIGURE 1.4 3550

Instruments and Interlocks
1. General
The instrumentation (See Fig. 2.1) is designed to allow the operators to easily
control the process and to alert them whenever abnormal conditions exist. In the event
that corrective action is not taken, interlocks are provided to shut down the system before
mechanical damage occurs.
The enclosed logic diagrams (See Fig. 2.2 and 2.3) show interlocks and instruments
provided with the pressure diffuser. The following is a brief description of these interlocks
and instruments.
The logic diagrams show the order of equipment start-up. Start from the left hand
side and proceed to the right. If any unit of equipment for any reason should shut down,
all of the equipment to the right of this equipment in the interlock diagrams will
automatically shutdown. The interlock diagrams show all the limit switches in a
nonactivated position and the process switches in the normal operating position.
2. Process
The interlock system is provided to help the operator run the diffuser safely and
effectively. In addition to basic self-explanatory interlocks and alarms for stopped motors
and filtrate tank levels, the pressure diffuser has some interlock features which are
somewhat unique and will therefore be described more thoroughly. These interlocks help
to prevent diffuser from plugging, control the hydraulic system and simplify start-up.
A. Vertical Differential Pressure (PDIC29)
Vertical dp (Vdp) is a measure of the difference in pressure between the top and
bottom of the extraction screen. It is measured on the pulp side of the screen and has a
range of (-50 to +150) inches of water column. The vertical dp controls the upstroke speed
of the extraction screen. Pulp does not flow past the screen, but is moved upward with
it. The vertical dp controller (PDIC29) controls the upstroke screen velocity by regulating
the oil flow to the bottom of the hydraulic cylinder, which is attached to the screen by a
tie rod.

PRESSURE DIFFUSER
FIGURE 2.1 3553

Normally, the screen velocity is controlled by the vertical dp controller which

maintains the vertical dp to a setpoint. Therefore, the upstroke velocity of the screen will
slow down (to increase vertical dp's) or speed up (to decrease vertical dp's) in order to
maintain the controller’s setpoint value. The typical setpoint range for vertical dp’s is
between -10 and +10 inches. This is the optimum range for good washing. Running at
much higher vertical dp setpoint (slower screen velocity) could result in pluggage of the
diffuser and possible physical damage to the screen. To prevent this from happening, an
interlock is incorporated which will shutdown the diffuser and close the stock valve
controlling the flow to the diffuser on high vertical dp's.
B. Vertical dp Controller (PDIC29)
The vertical dp is maintained by a PID controller. In addition two unique

operational functions are associated with it.
a. Override Function
On high vertical dp (PDSH29), the controller PDIC29 will switch to manual

and the output will be set to a preset value (approximately 80%) until the
dp goes below PDSH29. Controller PDIC29 will then return to auto and the
dp will control the previous set point.
The operator can put the loop in manual at any time, but cannot put the loop
in automatic unless the dp is below PDSH29. If the operator has the loop in
manual at the time of a high dp, no action will be taken.
b. Vertical dp Follow and Hold Function
The fast downstroke of the extraction screen causes the vertical dp signal to
spike. To keep the controller from reacting to this spike, the dp signal is held
for the duration of the downstroke. The signal is released after the screen
leaves the bottom limit switch.

C. Horizontal Differential Pressure (PDI25)
The horizontal dp is a measure of the difference in pressure across the extraction

screen. It has a range of 0 to +200 inches water column. Unlike the vertical dp, the
horizontal dp has no control function. It is primarily used to monitor pluggage of the
extraction screen. High horizontal dp’s give an alarm and very high dp’s shut the
extraction valve (FV22), stops the screen motion and prevents stock from entering the
diffuser. High horizontal dp’s can be lowered by reducing the extraction flow rate.
D. Stock Inlet Pressure (PI23 and PS3H23)
The pressure at the bottom of the diffuser is indicated by PI23. This pressure
indicator has no control function, but is linked to interlocks. Primarily the stock inlet
pressure is used to ensure that the diffuser is hydraulically full, not over pressurized and
will prevent stock flow to the diffuser if the inlet pressure is too high. PS3H23 is a field
mounted pressure switch which is hardwired back to the digesters cold blow pump and
make-up liquor pump (spare) to prevent over pressurization of the diffuser.
E. Stock Outlet Pressure (PV26)
The pressure in the diffuser is controlled by the discharge valve PV26. By

controlling the diffuser pressure, the stock flow, wash flow, and the extraction flow are
stabilized and easily maintained by their controllers. Typically, the setpoint for PV26
should be such that the valve opening is between 55 and 75% open.
F. Screen Velocity
Slow screen movement will shut off the stock flow and shut down the diffuser. This
is done to prevent physical damage to the diffuser in the event of pluggage.
The operator should not control the vertical dp’s to maintain a given upstroke
velocity. The screen velocity will vary with changes in operating parameters. The screen
velocity is useful for troubleshooting but not for control.

G. Low Wash Flow
To avoid inadvertent over-thickening, the interlock system requires a minimum

wash flow to be established prior to opening the extraction valve (FV22) and accepting
stock into the diffuser. The wash flow switch (FSLL27) and the limit switch on the wash
valve (ZSC27) must be satisfied before the extraction valve will open.
H. Hydraulic
To prevent unnecessary stresses on the hydraulic system and screen assembly, the
high pressure hydraulic oil pump will not run unless the diffuser is full of liquor or stock
as indicated by stock inlet pressure switch PSL23. The hydraulic oil pump is also protected
by interlocks for low oil reservoir level (LSLL11) and high oil temperature (TSHH30).
I. Start-up
Bypassing some of the interlocks is required to start the system; where required
bypass switches have been provided. To fill the vessel and for other reasons, hand switch
HS27 has been installed. When HS27 is in bypass, the wash valve FV27 may be opened any
time the wash pump is on. This bypass is used only for start-up and shutdown procedures.
During normal operation of the pressure diffuser, all bypass switches must be in the
“normal” position.
Besides starting the diffuser motion, switching HS30 to “start” energizes two time
delay relays (TDR1, TDR2) which provide two timed bypasses. TDR1 bypasses the screen
slow motion interlock for 15 seconds. If a minimum diffuser speed cannot be maintained
after 15 seconds, the start-up procedure will need to be repeated. TDR2 bypasses the
vertical dp, horizontal dp, low wash flow, and high stock inlet pressure interlocks for 30
seconds.
Time delay relays TDR3 and TDR4 are used to detect a "stopped" pressure diffuser
in either the upstroke or downstroke travel direction during normal operation.

J. Interlock Troubleshooting
Problem Cause
1. Hydraulic pump will not run. a. Low hydraulic oil level (LSLL11)
b. High hydraulic oil temperature
(TSHH30)
c. Diffuser not full (PSL23)
2. Diffuser discharge device will a. Speed switch not made (SSL200)

not stay running.
3. Wash valve will not open. a. Wash pump not running

(HS27 In Normal Position) b. Diffuser not running
c. Inlet stock pressure high (PSHH23)
d. Vertical dp high (PDSHH29)
e. Horizontal dp high (PDSHH25)
f. Wash flow low (FSLL27)
4. Diffuser will not downstroke. a. Hydraulic pump not running

b. Discharge device not running
c. Wash pump not running
d. Top hydraulic cylinder limit switch
not made
e. Bottom hydraulic cylinder limit switch
is made
f. Hydraulic stroke directional valve not
energized (ZEV30)
5. Diffuser stops stroking. a. Top and/or bottom hydraulic cylinder

limit switches not made in 15 sec.
b. High stock inlet pressure (PSHH23)
c. High vertical dp (PDSHH29)
d. High horizontal dp (PDS3H25)
e. High horizontal dp(PDSHH25)

Problem Cause
f. Low wash flow (FSLL27)

g. See Item 4, “Diffuser Will Not
Down Stroke”
6. Extraction valve will not open. a. Diffuser not stroking

b. Wash pump not running
c. Wash valve limit switch made
(ZSC27 is normally open)
7. Stock to diffuser valve will a. Inlet stock pressure high (PSHH23)

not open. b. Vertical dp high (PDSHH29)
c. Diffuser not stroking
d. Horizontal dp high (PDSHH25)
e. Wash flow low (FSLL27)

Hydraulic System
A. General Description of a Typical Hydraulic System
Function
The hydraulic system provides the force required to move the diffuser screen. The
screen is attached to a vertical tie-rod that is coupled to a single hydraulic cylinder. The
cylinder gives the screen assembly a vertical stroking cycle comprising a fast downstroke
and a slower upstroke. The fast downstroke cleans the extraction screen by a combination
of wiping and backflushing.
Description
The hydraulic system consists of a console with a pump station, and a valve station
(See Fig. 3.1 and Fig. 3.2). The console is a large reservoir for storage, filtering and cooling
of the hydraulic oil. The pump station provides the oil under pressure to the system. The
valve station consists of a hydraulic cylinder, high and low pressure accumulators and
valving for providing the slow upstroke and fast downstroke of the pressure diffuser.
Fast Downstroke
When the piston reaches the top of its stroke, the target plate located above the tie-
rod coupling actuates a top proximity switch. This signal switches the solenoid pilot valve
(EV30) to the energized position. Pilot pressure shifts the main directional valve to the
downstroke mode (See Fig. 3.3).
High pressure oil from the high pressure accumulator flows rapidly to the top of the
cylinder at a high rate of flow. Since the bottom of the cylinder is now connected through
the main directional valve to the return line, the cylinder will downstroke fast. This high
flow oil from the bottom of the cylinder will be directed to flow into the return or “low
pressure” accumulator. An orifice in the return line after the low pressure accumulator
prevents the high flow of oil from going through the return line directly to the reservoir.
(This oil that is pushed into the low pressure accumulator from the fast downstroke will
be bled back to the reservoir on the next slow upstroke).

HYDRAULIC SYSTEM FLOWSHEET
FIGURE 3.1

HYDRAULIC SYSTEM LAYOUT
FIGURE 3.2 1803

FAST DOWNSTROKE
FIGURE 3.3 0782

As the piston reaches the bottom of its stroke, it is slowed down by a built-in cushion.
After the cylinder passes through the cushion at the bottom of its stroke, the bottom
proximity switch will be actuated. This will switch the pilot valve to start the slow upstroke
cycle again.
Slow Upstroke
During the upstroke mode (See Figure 3.4), the main hydraulic pump draws oil from
the reservoir and pumps it through a check valve, flowmeter, and a coarse (22 micron
absolute) supply line filter. This filter is non-bypassable and its element is rated for full
system pressure to prevent collapse.
From the supply line filter the oil passes by the taps in the line for the pressure relief
and bleed off valves located on the left side of the reservoir.
The oil is then pumped to the valve station located directly under the pressure
diffuser.

For the upstroke cycle, the solenoid pilot valve (ZEV30) is de-energized. In this
position it causes the main directional valve to shift into the upstroke mode and stay
there as long as the pilot valve is de-energized.
At the valve station, the oil flow is divided into two flow paths. One flow path is to
the flow control valve or “upstroke speed control” valve. This regulated oil flow then
travels through the directional valve to the bottom of the hydraulic cylinder. Since the
bottom of the piston in the cylinder has a greater effective area than the top of the piston,
the piston will go up. Oil forced out of the top of the cylinder is recycled back through the
flow control valve, into the directional valve and then to the bottom of the cylinder.
The upstroke speed control valve is interfaced with the vertical dp of the pressure
diffuser. Since the vertical dp may be changing during the upstroke, the “upstroke speed
control” valve will track this function and change its flow output automatically during the
stroke. The upstroke time may vary from 5 to 10 seconds, depending on the process
requirements.
SLOW UPSTROKE
FIGURE 3.4 0781

The oil that was pushed into the low pressure accumulator during the previous fast
downstroke will be bled back to the reservoir during the slow upstroke. This oil flows
through the return line where it is returned to the dirty side of the reservoir. Also during
the slow upstroke, oil is being routed to the high pressure accumulator compressing the
nitrogen pre-charge in the accumulator. This oil stored in the high pressure accumulator
provides the volume of oil at the high pressure required to give a fast downstroke once the
cylinder reaches the top of its stroke.
Additional filtration is done at the console by the off-line filtration loop. The pump
takes its suction from the dirty (or return) side of the reservoir and discharges it to a filter
canister containing 5 to 10 micron absolute, filters. From the filter canister the oil is routed
back through the cooler to the clean side of the reservoir where the main pump(s) suction
line is located.
B. Hydraulic Valve Station
The valve station is made up of three main blocks or assemblies: the hydraulic
cylinder, the high pressure block and the low pressure block (See Fig. 3.3 and 3.4). Integral
to the valve station is the directional valve and the speed control valve. Following is a
description of the major components of the valve station.
C. Hydraulic Cylinder
The hydraulic cylinder is part of the valve station. It consists of a single piston rod
mounted in a cylinder barrel (See Fig. 3.5). The barrel top is bolted to the upper cylinder
head. Two external pipes connect the top head to the bottom head.
The piston is equipped with a seal and four guide rings. A Chevron packing set
mounted in the upper head provide the sealing on the piston rod. A bearing also located
in the top head provides proper alignment for the piston rod. Also included in the piston
rod is a built-in cushion. This cushion provides the proper deceleration at the bottom of
the piston stroke.

HYDRAULIC CYLINDER
FIGURE 3.5
3556

CYLINDER/PISTON ROD REMOVAL
FIGURE 3.6 3557
If it becomes necessary to replace and to rebuild the hydraulic cylinder, the

following procedure can be used (See Fig. 3.6).
a. The weight of the diffuser screen must be supported by a tie rod clamp
(See Fig. 4.0); then remove coupling.
b. Lift and support the diffuser screen.
c. Unbolt barrel from the cylinder block.

d. Clamp the tie-rod using the tie-rod coupling and block up on cylinder top
head to prevent the piston from sliding out of the barrel.
e. Lift the barrel and piston as a single unit up approximately 11" and then out
from the cylinder block (NOTE: this dimension may vary. Contact Andritz for
additional details).
D. Accumulator
There is both a high presssure and a low pressure

hydraulic accumulator (See Fig. 3.8).
The high pressure accumulator provides the high flow of

oil under pressure required for the fast downstroke cycle
of the cylinder. Pure nitrogen gas pre-charging for the
accumulator should be 1/2 to 2/3 of the operating pres-
sure of the hydraulic system.
The low pressure accumulator receives the surge of oil

from the bottom of the cylinder during the downstroke.
This accumulator should be charged with pure nitrogen
at 75 to 100 psig.
A drain kit for the Tobul Accumulator is available and

FIGURE 3.7 3595 consists primarily of a hose assembly, piston adapter,
stop tube, and drain fitting (see figure 3.7). This equip-
ment allows for quick and easy removal of hydraulic oil that has accumulated on top of the
piston. Oil on top of the piston (carryover) is a common and normal occurrence. The more
often the piston cycles and the more wear on the piston seals, the greater the oil carryover.
It is recommended that the drain kit be used to facilitate the indirect inspection of
the piston seals. By instituting a regular program of draining and measuring the oil
carryover, an assessment of the seals' integrity can be made. When the oil carryover rate
changes significantly, the piston seals are worn and should be replaced. One of the best
ways to detect this is to plot the oil carryover with respect to time. Contact Andritz for
further details.

PISTON-TYPE SUPPLY ACCUMULATOR
FIGURE 3.8 4074

E. Directional Valve
Changing the direction of the stroke from either the upstroke or the downstroke is
the function of the directional valve. This is a spool type, 3-way, two position valve (See
Fig. 3.9). In the upstroke mode, the valve is shifted so that oil from the speed control valve
goes to the bottom of the cylinder forcing it up. Oil from the top of the cylinder is also
routed back through the speed control valve to the directional valve making a regenerate
system for the upstroke (See Fig. 3.4).
When the directional valve is shifted to the downstroke mode, the oil under the
piston is pushed out at a high rate of flow by the action of the high pressure oil stored in
the high pressure accumulator during the previous upstroke (See Fig. 3.3).
A smaller solenoid operated directional valve directs oil to and from the pilot ports
of the main directional valve described above. The solenoid is activated by the top and
bottom limit switches on the hydraulic cylinder. With no electrical signal to the valve, the
valve is spring centered and the hydraulic system is in the slow upstroke mode. When
energized the system is in the fast downstroke mode.
Newer installations use a double solenoid with the second solenoid energized when
the diffuser screen has stopped and the hydraulic pump is still running. This function
allows some oil to pass through the valve station and back to the reservoir, thus lubricating
and cooling the pump.

DIRECTIONAL VALVE
FIGURE 3.9 3559
F. Speed Control Valve
The speed control valve regulates the upstroke speed of the diffuser automatically,
based on the diffuser screen vertical differential pressure. This is an electrohydraulic
proportional throttle valve which has a spool activating coil and transducer for feedback
(See fig. 3.10).
The position transducer monitors the main-stage position while the proportional
solenoid operates the pilot valve stage.
If this valve malfunctions, a manual adjustment screw permits manual operation

until the next shutdown. A clockwise adjustment of this screw speeds up the diffuser
stroke by increasing oil flow. For automatic operation, this manual screw should be backed
all the way out

SPEED CONTROL VALVE
FIGURE 3.10 3560
G. Latest Equipment for Typical Hydraulic System
1. Off-line Filtration
Previous hydraulic systems had filter units in the supply and return lines on the
console assembly which had elements rated at 3 micron absolute.
The current hydraulic system design uses an off-line filtration loop which circulates
oil from the dirty side of the reservoir to the clean side at a flow of approximately 40 gpm.
This is described in more detail earlier in this section (See page III-6).
This off-line filtration system can be added to an existing console assembly with
some modifications required to the reservoir. Contact Andritz for details. (See Figure 3.11)

OFF-LINE FILTRATION SYSTEM
FIGURE 3.11 3573

2. Adjustable Downstroke Orifice
The adjustable downstroke orifice makes it possible to adjust the maximum

downstroke speed of the diffuser screen without shutting down the hydraulic system. (See
Figure 3.12)
Without this adjustable orifice the hydraulic system must be shut down in order to
remove the fixed orifice plate inside the high pressure accumulator block and replace it
with a different orifice diameter.
Contact Andritz for details on replacing a fixed orifice with an adjustable orifice
assembly.
ADJUSTABLE DOWNSTROKE ORIFICE
FIGURE 3.12
3570

Maintenance Procedures
Introduction
Every effort has been made in the design of the pressure diffuser to minimize
maintenance problems. This section on preventive maintenance lists the steps necessary
to keep the machine running smoothly and to provide the maintenance personnel with
pertinent information so that if a problem does arise, it can be addressed.
Mechanical Operation
A coupling connects the hydraulic piston rod of the valve station cylinder to the
bottom of the tie rod. The top of the tie rod is attached to the screen support, which has
four or six arms radiating from it. These arms are connected to the bottom of the screen
assembly. This assembly, which is powered by the hydraulic system, moves down quickly
and up slowly. This action (also described in the “General Description”) cleans the screen
and transports the pulp.
The discharge device in the top rotates (clockwise looking down) to remove the
pulp from the top of the diffuser. The discharge device is driven by an electric motor
through a gear reducer.
The above are the only moving parts internal to the pressure diffuser.
A. Coupling, Tie Rod to Piston Rod
A coupling connects the hydraulic cylinder piston rod to the tie rod. The piston rod
and the tie rod have straight machined grooves. For proper orientation, the larger, inside
diameter is the mating end for the tie rod, and is die stamped “TOP” on each half.
Note that the tie rod clamp is used to hold and adjust the height of the screen
assembly so that the coupling may be installed easily (see Fig. 4.0). The tie rod should be
touching the top of the hydraulic cylinder rod or slightly higher so that the grooves in the
tie rod and cylinder rod align with the grooves of the coupling (See Fig. 4.1).

COUPLING REMOVAL ARRANGEMENT
FIGURE 4.0 2380

B. Coupling Removal
To remove the coupling, raise the screen to the top of the stroke using the hydraulic
cylinder. Make sure that the hydraulic system is not in the RUN position.
Remove the guard and the flinger. Install the tie rod clamp and snug up slightly to
take the weight off of the screen (see Fig. 4.1). Shut off the hydraulic system (see Section
III, Hydraulic System) and bleed off the hydraulic pressure. Loosen all coupling bolts.
Make sure coupling halves are not stuck to either the piston rod or the tie rod. Use a
hammer if it is stuck. Remove the coupling bolts and coupling halves.
TIE ROD CLAMP ASSEMBLY
FIGURE 4.1 2379

SCREEN SUPPORT ARRANGEMENT
FIGURE 4.2 2440
C. Coupling Installation
Lower the screen by adjusting the threaded rods so that the top end of the piston
rod is touching the bottom of the tie rod.
NOTE: In any situation where the hydraulic cylinder has been moved, the tie rod
and the piston rod must be realigned. Use a holder and two (2) dial indicators, and
clamp the holder to the piston rod and check the run out on the tie rod in two
places approximately one stroke length apart (18" to 30" depending on design).
The lower indicator should show no more than .030" total run out, and the upper
indicator should show the same or not more than ± .030" from that of the lower
one. During the alignment procedure the screen must be supported using a
support pipe (See Fig. 4.2), and not the tie rod clamp.

Using a thread lubricant such as moly-disulfide on the high strength 1-1/2"-8UN

socket head capscrews, mount the coupling halves loosely on the tie rod and cylinder rod
(See Fig. 4.1). Be sure the coupling halves match (both halves have “TOP” stamped on same
end). The coupling will only fit in one orientation, with the larger inside diameter mating
to the tie rod. Be sure the horizontal center of the coupling is over the joint between the
tie rod and the cylinder rod. The screen may have to be raised slightly so that the groove
sets engage properly.
Step tighten the coupling bolts using a crisscross pattern and maintain an equal gap
on both sides of the split coupling until proper torque is obtained.
The coupling bolt material specification has recently been changed. The recom-
mended material specification for the bolts is now a SA193 B7 Cadmium plated bolt. The
recommended torque with bolts of this material is 200 ft.-lb.. This material will be less
likely to gall with the stainless steel coupling.
After one week of operation, retorque the coupling bolts to specification.
D. Tie Rod
The tie rod connects the hydraulic cylinder piston to the screen assembly. It pushes
the screen up and pulls it back down. The tie rod is connected from inside the pressure
diffuser to the outside. A packbox provides the seal in this connection.
Although the tie rod should last a very long time, there is the potential for damage:
If the tie rod coupling on the bottom of the tie rod is loose during operation, the
grooves on the end of the tie rod will be damaged. The damage appears as severe enough
to require replacement of the tie rod and coupling.
If the diffuser is operated long enough without proper alignment the tie rod could
also be damaged. The damage appears as bending or scoring of the tie rod surface in the
packbox or bushing regions or as a tie rod fracture.
If the tensile bolts holding the tie rod to the top of the screen support hub are not
properly torqued and the pressure diffuser operates this way for a period of time, the tie
rod could become worn and require replacement.

E. Tie Rod Replacement
To replace the tie rod, shut off the hydraulic system (See “Hydraulic System” in
Section III) and bleed off the hydraulic pressure. Remove the guard and the tie rod flinger.
Remove the tie rod coupling (Refer to Section B, Coupling Removal). Remove the
outer and inner manways in the top head.
TIE ROD TO SCREEN CONNECTION
FIGURE 4.3 2381

TIE ROD REMOVAL
FIGURE 4.4 2863

Block the screen assembly securely. Remove the tie rod clamp. Unbolt the tensile bolts (See
Fig. 4.3) which hold the tie rod cap to the screen support assembly and remove the tie rod
cap, using an eyebolt in the threaded hole on the end of the rod.
The tensile bolts are tack welded so grinding will be necessary.
Rig the tie rod by installing a threaded eyebolt into the top end of the tie rod. Remove
the tie rod split ring from the tie rod when the tie rod is being lifted. Lift the tie rod through
the manways (See Fig. 4.4). Cover the tie rod grooves on the coupling end to protect the
grooves from damage during tie rod replacement.
During assembly, use an anti-seize compound on top of the new tie rod and on the
tensile bolt threads and torque the tie rod cap tensile bolts (See Fig. 4.5).
NOTE: Depending on size, the unit may have four, six, or eight tensile bolts.
TIE ROD CAP TENSILE BOLTS

TORQUE PROCEDURE
First Step Second Step
Torque all the bolts to Torque all the bolts to
1/4 ft-lbs of full torque 1/2 ft-lbs of full torque
1
6 3
4 5
Third Step Fourth Step
Torque all the bolts to 2 Torque all the bolts
3/4 ft-lbs of full torque to full torque
NOTE: Full torque specification can be obtained from Andritz for a particular
installation.
FIGURE 4.5 3597

INLET PACKBOX ASSEMBLY
FIGURE 4.6 2018
F. Packbox, Tie Rod
The tie rod packbox is a seal that allows the tie rod to move in and out of the pressure
diffuser with minor seal water leakage. The bushings above the packbox acts as a guide that
helps keep the screen assembly aligned with the packbox and the hydraulic cylinder.
The assembly has fresh water piped into the cavity between the lower bushing and
the packbox to purge the stock fibers out of the bushing, cool the assembly, and to
lubricate the lower bushing and the packing. The packing should be changed when the
leakage becomes excessive; possibly as often as every six months. The diffuser must be

INLET PACKBOX ASSEMBLY
FIGURE 4.7 2382

depressurized, drained and locked-out before the packing is removed. Remove the gland,
the packing can then be removed with a packing hook. It may be necessary to remove the
packbox and push the packing out.
A special LIP packing is used. It is composed of a top adapter ring, intermediate rings
of packing, and a bottom adapter ring. The top adapter ring is used on the pressure side,
toward the pulp. Be sure that the rings are installed properly as shown in Fig. 4.6 and Fig.
4.7.
Before installing the ring packing, be sure to lubricate it with a waterproof grease
for ease of assembly and to help the packing seat. Alternate adjacent ring splits 90 degrees
during the installation. Install the bottom adapter ring and the packing gland.
Do not overtighten the gland nuts. The initial gap between the packbox and the
gland should be approximately 5/8 inch.
The packing needs to be lubricated with water during operation. Therefore, the
gland bolts should be tightened until just a trickle of water comes out of the packbox. If
the gland is overtightened, the packing will run dry and wear out quickly.
G. Bushing, Tie Rod
The bushings are replaceable Rulon (plastic) cylinders which center the tie rod in
the packbox. In diffusers designed to accept high inlet temperatures, these bushings are
made using a wear-resistant metal.
There are two tie rod bushings; one just above the packbox and the other just below
the screen support hub. (See Figs. 4.6, 4.7 and 4.8).
They are split for ease of replacement and should be replaced when they show
excessive wear (more than 1/16" total). To replace the bushings, shut off the hydraulic
system (See Safety Procedures) and bleed off the hydraulic pressure. Open the bypass
valve. Drain, and lock-out the diffuser. Remove the inner and outer manways.
To replace the upper bushing: Remove the rod guard and the tie rod flinger and in-
stall the tie rod clamp after lifting the screen using the hydraulics. See Section IV, part B.

UPPER BUSHING
FIGURE 4.8 2866
Remove the split cover and use the tapped holes to remove the split bushing. Put
new split bushing in place, reattach split cover with bolts and tack weld bolts.
To replace the lower bushing: Lower the screen assembly to the down position and
remove the tie rod clamp. Lower the packbox until it rests on the tie rod coupling. (See
procedure in Section F, Packbox, Tie Rod). Remove split cover and split bushing. Install
new split bushing and reassemble.
H. Screen Assembly
The screen assembly is a large welded structure which consists of a conical screen
supported by an inner cylinder assembly. At the bottom, the inner cylinder is connected
to the screen support hub by the radial arms. At the top and bottom are heavy rings to
which the screen bearings are mounted (See Fig. 4.9).

I. Bearings, Screen
There are two bearing rings, one on each end of the screen assembly, that guide the
movement of the screen. These bearings also act as seals which separate the pulp from the
extracted liquor (See Fig. 4.10 and 4.11). At the outlet bearing, the Rulon outlet bearings
are cut into segments and are held in place by the bearing retainers, each with one flat head
SCREEN ASSEMBLY
FIGURE 4.9 2385

machine screw securing the bearing assem-

bly. At the lower bearing, the inlet bearings STOCK OUTLET BEARING
are cut into segments and are held by the
bearing retainers, each with one flat head
machine screw.
There are two situations which will

indicate that the screen bearings need to be
replaced. One is an abnormally high pulp
content (>300ppm) in the extraction liquor.
The second is an unusually short life of the
tie rod bushings and packing. If either one
of these conditions exist, the screen bearing
segments should be inspected and replaced
if more than approximately 1/8" worn.
To adequately inspect the bearings FIGURE 4.10 2388

for wear, several bearing segments should
be removed, measured with a micrometer,
and visually inspected.
STOCK INLET BEARING
Spare bearing segments should be kept in
the box they came in when stored. Remov-
ing them and laying them flat will cause the
bend in the bearing to flatten out.
J. Bearing Replacement Procedure
If it has been determined that the screen

bearings are worn excessively, the follow-
ing procedures should be used to replace
them. It is assumed that both sets of bear-
ings will be replaced during the same shut-
down.
FIGURE 4.11 2858

Shut off the hydraulic system and bleed off the hydraulic pressure. Open the bypass
valve. Remove the guard and the tie rod flinger. Open the inner and outer manways.
Remove the segments of the upper screen bearing. The bearing segments are
replaced one at a time by removing only the bearing retainers that hold that one bearing
segment. Use the (2) 1/4"-UNC tapped holes in the bearing segment to pull it out. Install
the bearing segment and the bearing retainer so that the next bearing segment can be
replaced. Install with 1/16" to 1/8" gap between segments. For each bearing retainer, tack
weld the machine screw that secures the bearing segments in place.
To replace the bottom screen bearing segments, adequately support the tie rod
champ and, using either chain falls with older units or threaded rods on newer units (see
Fig. 4.0 and 4.1), lift the screen assembly to the up position. The screen can also be raised
using the hydraulics as described in Section IV, part B. Remove the bearing retainers.
Install new bearing segments by following the same procedure as for the upper
bearings, replace the bearing retainer pieces over joints where possible with machine
screws, and tack weld machine screws to retainer. Lower the screen assembly and install
the manways.
K. Cylinder, Screen Bearing
The two screen bearing cylinders are flanged stainless steel cylindrical shells which
bolt to the inner head of the top and bottom heads. The Rulon screen bearings slide over
them as the screen assembly strokes up and down. The screen bearing cylinders normally
experience very little wear but the surface should be periodically checked for scoring. The
integrity of the fasteners should be checked by removing a few capscrews and inspecting.
L. Bearing Cylinder Replacement Procedure
Using standard mill safety procedures, with the hydraulics system down, break all
connections to the valve station. Disconnect the stock inlet head piping and the stock
outlet head piping, as well as all electrical connections to the scraper drive motor. Remove
the packing gland and the LIP ring packing set.

STOCK OUTLET HEAD ASSEMBLY

LIFTING ARRANGEMENT
FIGURE 4.12 2400

Rig the stock outlet head as shown in Fig. 4.12. Remove the studs and nuts from the
flange connection which joins the stock outlet head to the top of the vessel shell. Lift the
outlet head out of the way.
Rig the top of the screen assembly using the internal lifting lugs and take up the slack
until the weight of the screen assembly is carried by the rigging (See Fig. 4.13).
Leave the top head with the bearing cylinder and attached platform hanging. Make
sure that the bottom of the platform is about three feet off the ground, and put supports
under the large flange of the top head.
Disassemble the platform from the bearing cylinder. Put supports under the bearing
cylinder. Remove the top bearing cylinder mounting bolts. Lift the top head without the
bearing cylinder.
Set the new bearing cylinder up on

blocks as described above. Reattach plat- SCREEN LIFTING
form and tack weld hardware. Lower the ARRANGEMENT
top head into place over the new bearing
cylinder. Align the bolt holes, and lower
the top head into place. Put blocks under
the top head as before. Install the hex head
bolts and nuts to secure the bearing cylin-
der to the top head. Torque the bolts to 75
ft. lbs, and tack weld the bolt head and nut
to the bearing cylinder flange. Now, the
bottom bearing cylinder may be replaced.
Remove the tie rod coupling following the
procedure outlined in the section labelled
“Coupling, Tie Rod”. Move the entire hy-
draulic valve station out of the way by using
the lifting lugs provided on the top of the
hydraulic cylinder after removing the accu-
mulators. Rig the bottom head as shown in
Fig. 4.14 using the lifting lugs provided on
the bottom of the vessel shell and the top of FIGURE 4.13 2397

the bottom head.

Remove the nuts from the STOCK INLET HEAD
flange connection which couples
the bottom head to the vessel
shell.
Lower the bottom head to
the valve station sole plate, pro-
tecting the bottom face with
wooden blocks. Raise the screen
assembly with the tie rod still
attached until the bottom end of
the tie rod clears the top of the
bottom bearing cylinder by three
feet.
The bottom bearing cylin-

der is now exposed and is bolted
to the flange on the inner head.
The bearing cylinder has a pilot
fit and is held in place with hex
head bolts and nuts. All the bolts
and nuts are tack welded to hold
them in place, so grinding will be
necessary to remove them. After
removing all the bolts and nuts,
the bottom bearing cylinder may
be lifted from the bottom head. FIGURE 4.14 2399
Lower the new bottom bearing cylinder into place. Install the bolts and nuts to
secure the new bearing cylinder to the bottom head. Torque the bolts to 75 ft. lbs., and tack
weld all nuts and bolts. Reinstall the bottom head and the hydraulic valve station using the
reverse order of the disassembly procedure listed above. Similarly, lower the screen
assembly and install the tie rod coupling. Refer to the pages on “Coupling, Tie Rod to Piston
Rod” in Section A. Install the top head and reconnect all piping to the pressure diffuser.

DISCHARGE DEVICE ASSEMBLY
FIGURE 4.15 2392

M. Discharge Device
The discharge device located in the top head of the pressure diffuser, rotates
clockwise, looking from the top, to assure even pulp discharge from the pressure diffuser.
The discharge device is expected to last indefinitely, but if some tramp material should hit
it, the arms could be damaged seriously enough to require replacement. Even though
diffuser sizes vary, the discharge device tip speed will remain the same. Because of this,
the discharge device rpm will vary as the diffuser diameter changes. The speed of the
discharge device will be 32, 38, 47, or 64 rpm.
N. Discharge Device Replacement
To replace the discharge device (See Fig. 4.15), following standard lock-out
procedures, drain the vessel and lock out the discharge device. If the discharge device is
damaged beyond use, it may be necessary to use flushing water in the outlet of the tower.
Remove the outer manway.
All the fasteners which attach the support bar to the discharge device arms and the
arms to the shaft are tack welded. Grinding will be necessary to remove them. First,
remove the support bar and then the capscrews in the end of the discharge device shaft.
Remove the socket head capscrews which hold the halves together and remove the key.
Each half and the support bar may then be removed out the manway of the head.
Reassemble the new discharge device in reverse order of the disassembly. Don’t
forget to install the key. Be sure to tack weld all the capscrews and nuts.
O. Discharge Device, Packbox
The packbox (See Fig. 4.16) is the seal that allows the discharger shaft to rotate with
little leakage. The packbox has one inlet and one outlet piped into it, one for fresh water
to purge the stock fibers out of the packing and the wear ring, to cool the assembly, and
to lubricate the wear ring and packing; and one for installation of a rotameter that meters
water flow.

DISCHARGE DEVICE PACKBOX
FIGURE 4.16 2383

The square packing can be changed by isolating and depressurizing, but without
emptying the pressure diffuser. It is possible that this packing may need to be changed
twice a year. The square packing must be installed the following way: The first ring of
white packing (Teflon) goes on top of the wear ring, then a black one (Graphite) followed
by a white packing. Then the lantern ring must be installed followed by two rings of black
packing and last, a white packing ring. The number of packing rings varies with diffuser
size, refer to the pressure diffuser spare parts drawing for the proper packing arrangement.
The split wear ring acts as a guide for the discharger and should also be replaced
whenever the packing is changed.
The lantern ring distributes the purge water around the shaft. It is split for ease of
maintenance.
Note that the packing needs to be lubricated with water during operation.
Therefore, the gland bolts should be tightened until just a trickle of water comes out of the
packbox. If the gland is overtightened, the packing will run dry and wear out quickly.
P. Discharge Device Shaft
The discharge device shaft is the connection between the speed reducer and the
discharge device at the top of the pressure diffuser. This shaft is also a connection between
the inside and the outside of the pressure diffuser. A pack box is provided to prevent this
connection from leaking. The discharge device shaft should not require replacement, but
if the contents of the packing box are neglected, severe scoring could occur on the shaft.
If this happens, the discharge device shaft should be replaced.
Q. Discharge Device Shaft Replacement
Section N. describes the removal of the discharge device. After the halves of the
discharge device arms have been removed, remove the discharge device shaft paddle
assembly and its key.

Remove the outlet flinger assembly from the discharge device shaft. It is located just
above the packbox. Loosen the packing gland from the shaft packbox. The bushing on
top of the gland is split to aid replacement. Next, remove the contents of the discharge
device shaft packbox. The lantern ring is also split and has four 1/4-20 UNC holes tapped
through to aid its extraction. The wear ring in the bottom of the packbox is split in half
for removal purposes.
Lift out the gear reducer with the discharge device shaft. Remove the two 1/2"-
13UNC hex bolts and thrust washer. Remove the shaft from the gear reducer.
Follow the reverse of the disassembly procedure listed above to reinstall the
discharge device assembly.

Troubleshooting
The interlocks and alarms discussed in Section II are designed to help prevent
mechanical damage and to alert the operator to abnormal conditions; however, problems
which may arise and possible solutions:
PROBLEM Slow downstroke.
Possible Cause: High consistency
1. Dilute the stock entering the diffuser.
2. Decrease diffuser extraction.
3. Increase the wash flow.
Possible Cause: Hydraulics
1. Low hydraulic operating pressure.
2. Check for low pre-charge in high pressure accumulator.
3. Check that low pressure accumulator is functioning properly and has the
correct pre-charge.
PROBLEM Diffuser stopped in down position.
Possible Cause: Loss of hydraulic pressure
1. Pump not running - check oil level.
2. Pressure bleed-off valve open.
3. Relief valve open - check setting and adjust if needed (300 psi higher than
operating pressure).

Possible Cause: Electrical
1. Limit switch is not making at bottom of stroke. Adjust or replace if bad.
2. Solenoid pilot valve must de-energize to cause the main directional valve to
shift into the upstroke mode.
3. Check wiring.
4. Upstroke speed control valve amplifier card bad or solenoid bad, not
allowing upstroke oil through. Use manual speed control adjustment to get
an upstroke.
Possible Cause: Main directional valve
1. Check solenoid.
2. Check main directional valve. Check that it moves using manual stroke
adjustment screw.
Possible Cause: Interlock has not been satisfied
1. (See Section II: Instruments and Interlocks - Interlock Troubleshooting).
Possible Cause: Thick stock
1. Check wash and extraction flows.
2. Check incoming consistency.
PROBLEM Slow or erratic upstroke
Possible Cause: Low hydraulic pressure
1. Check for oil leak.

2. Check hydraulic pump for wear.
3. Check pressure setting of the system.
4. Check to make sure all bleed off valves are closed.
5. Check to see that oil filters are not plugged.
6. Check that oil pressure returns to normal after downstroke.
Possible Cause: Speed control valve
1. Debris stuck in hydraulic speed control valve. Stroking valve may clear.
Possible Cause: Diffuser plugged with stock
1. With interlocks bypassed or with inoperative dp transmitters, it may be

possible to plug the diffuser causing slow upstrokes. If this occurs, divert
stock around diffuser, close extraction valve and purge diffuser with wash
liquor until the screen moves freely.
Possible Cause: Screen to hydraulic cylinder misalignment
1. Check that the screen tie rod is aligned with the hydraulic cylinder rod.
PROBLEM Diffuser stopped in up position
Possible Cause: Electrical
1. Limit switch is not making at top of stroke. Adjust or replace if bad.
2. Solenoid pilot valve must energize to cause main directional valve to shift to
downstroke mode.

Possible Cause: Main directional valve
1. Check solenoid. Did it shift?
2. Check main directional valve.
Possible Cause: Thick stock
1. Decrease diffuser extraction.
2. Increase wash flow.
Possible Cause: Discharge device failure
1. Check that the discharge device is rotating and that the ammeter reads
normally.
Possible Cause: Interlock has not been satisfied
1. (See Section II: Instruments and Interlocks - Interlock Troubleshooting)
PROBLEM Screen stops part way down
Possible Cause: Hydraulic accumulator
1. High pressure accumulator precharge too high not allowing sufficient

volume of oil to reach the cylinder.
2. Low pressure accumulator has lost the precharge and is full of oil.
Possible Cause: Mechanical failure
1. Refer to maintenance manual for corrective action.

PROBLEM Hydraulic oil temperature too hot
Possible Cause: Hydraulics
1. Check hydraulic relief valve - should be closed.
2. Check oil heater - temperature setting too high.
3. Check bleed valves - should be closed.
Possible Cause: Cooling system
1. Check cooling water flow.
PROBLEM High or low vertical dp.

The optimum differential is -10 to +10 inches of water column.
1. High dp indicates the upstroke speed is too slow. Running with greater than
30 inches dp can cause channeling through the diffuser.
2. Low, negative dp indicates the upstroke speed is too fast. Running with
negative dp’s will decrease washing efficiency.
3. Periodically, the dp instrument calibration and purging should be checked.
PROBLEM High or low horizontal dp.

The maximum normal extraction dp is 100 inches of water. At
dp’s much greater than this, screen plugging and fiber losses
may become a problem. Depending on wood species (hard-
wood or softwood) the optimum differential may run 20 to 40
inches of water. Several problems can cause high extraction
dp.

1. Slow downstroke will cause insufficient backflush and poor screen cleaning.
2. High or low consistencies can cause problems with extraction dp. The
optimum consistency is 10-11%. Consistencies between 9 and 12% are
acceptable.
3. Rapid increases in extraction flow often cause plugging of the screen and
thus high dp’s.
4. Overcooked stock (low Kappas) tends to plug the screens, causing high dp.
5. Cold wash temperatures and/or digester blow temperatures, can cause

higher extraction dp’s.

General Diffuser Information
The following is the general operating theory regarding diffusers. Specific information is
contained in the Process Calculations section starting on page VI-6.
A. Inlet Consistency
One of the key elements to an efficient operation is the consistency to the diffuser.
The consistency range for best operating efficiency is in the 10-12% range. The
effect of consistency is more pronounced with hardwoods or poorly draining pulps.
The web strength of the pulp bed has a tendency to collapse when the consistency
is in the 7-8% range. The fiber structure is not strong enough (intertwined) to allow
a plug flow through the diffuser. Typical symptoms would be a higher dp on the
extraction screens, as well as slow downstrokes. In this case, the washing efficiency
falls off dramatically. One possible solution is for the operator to increase the
extraction flow. By increasing or keeping the consistency entering the diffuser on
the high side, the extraction required per square foot of screen area to obtain the
same dilution factor is reduced.
B. Stock Temperature
There are several benefits in keeping the stock temperature to the diffuser as high
as possible. First of all, the drainage is improved. Secondly, the friction in the stock

line is reduced. When the stock line temperature is kept fairly cool (less than 150°F),
the friction increases dramatically in the stock line. The wash temperature is also
important. Ideally, it should be at least 160-180°F.
C. Wash Flow, Dilution Factor, and Washing Efficiency
The amount of wash water that is being added to the diffuser is often calculated
by one of two methods. The first way is with the use of the wash ratio (WR). The
wash ratio is expressed as pounds of incoming wash flow (V2) divided by the
pounds of liquor or filtrate flow (L1) that is leaving with the pulp. A diagram of a
single washing stage is shown on the next page. Definitions of the wash ratio and
dilution factor are also shown. Calculations are given starting on page VI-6.
In ideal conditions, with a wash ratio of 1.0, the filtrate entering the stage with
the pulp is completely displaced by the same amount of wash flow. Since conditions
are never ideal, it is necessary to use a higher wash ratio to obtain the required
washing. A wash ratio of 1.2-1.3 is typically used.
The other way to calculate the amount of wash water being added is with the
dilution factor (DF). The dilution factor is a measure of the excess tons of wash
water used relative to the tons of liquor (L1) leaving with the pulp, all expressed
per ADST of pulp. The diagram on the next page shows the definition of dilution
factor. A higher dilution factor means that more wash water is being used, which

gives better washing. However, there is a point where the cost of using more
wash water outweighs the benefits of better washing.
Since the wash ratio and dilution factor are measures of the amount of wash water
being used, a different calculation is needed to determine the actual efficiency of
the diffuser. One way of measuring the washing efficiency of a washer at a given
dilution factor is the displacement ratio or DR number.
DISPLACEMENT RATIO CALCULATION
2194-4

The DR number is defined as:
X0 - X1 (Refer to the diagram on page VI-3)

DR =
X0 - Y2
where X0 is the concentration in the liquor with the inlet pulp, X1 is the
concentration in the liquor with the outlet pulp and Y2 is the concentration in
the wash liquor. Sodium, dissolved solids, or C.O.D. can be used when calculating
the DR number and the concentrations can be expressed in any convenient units,
as long as they are consistent.
The DR number shows the ratio of performance between the actual washer and an
ideal washer. The DR number is very dependent on the type of washer (drum,
diffuser, etc.) and the amount of wash liquor added.
To check the washing efficiency of the diffuser as well as the liquor and sodium, dry
solids and/or C.O.D. material balance, the following are needed:
- Sodium, dry solids and/or C.O.D. concentrations of the pulp inlet, pulp outlet
wash, and extraction liquors.
- Consistencies of inlet and outlet pulp.
- All inlet and outlet flow rates.

There should be no filtrate tank makeup or overflows during the testing. If the DR
number is not satisfactory, check:
- Liquor balance. Check that the sum of the inlet flows is the same as the sum of
the outlet flows. A false flowmeter reading may give a higher or lower dilution
factor than is correct.
- Check that the pulp samples are not being diluted or dewatered.
- Sodium, dissolved solids and/or C.O.D. balance. The inlet mass flow should
equal the outlet. If not, have the lab recheck the samples, and check the sample
points and sampling procedure.
If the mass balances are satisfactory and the DR number is unsatisfactory, check the
operation for the following:
- Any bypass or dilution valves left open.
- Low consistency. Diffuser discharge consistency should be higher than

9.0% BD.
- Plugged wash nozzles causing poor wash liquor distribution.
- Low wash temperature. The wash liquor should ideally be at least 160°- 180°F.
- Abnormal cycle time. The diffuser should not run too slow or too fast.

D. Process Calculations - Pressure Diffuser
The following process calculations are based on a production rate of 1000 ADST/D through
a single stage brownstock pressure diffuser operating at 10% consistency.
Calculations
Pulp Flow to Diffuser gpm Q1
Pulp Flow from Diffuser gpm Q2
Pulp Consistency to Diffuser % BD C1
Pulp Consistency from Diffuser % BD C2
Wash Flow gpm W
Extraction Flow gpm E
Blow Flow from Digester gpm BF
Blow Line Dilution Flow gpm D
Production Rate ADST/D P
Wash Ratio T/T WR

Dilution Factor T/ADST DF
1. Consistency
The consistency in the blow line or in the washed stock line is calculated as
follows:
15 x (production, ADST/D)
Consistency, %BD =
(stock flow, gpm) + (0.05 x (production, ADST/D))

15 x P 15 x P
C1 = C2 =
Q1 + (0.05 x P) Q2 + (0.05 x P)
Where Q1 = BF + D for a blow line pressure diffuser
The "15" is a conversion factor. It is the ADST/D to BDST/D factor in the numerator,
multiplied by 100 to express consistency in percent, divided by a conversion factor to go
from gpm to T/D in the denominator.
ADST 90 BDST
x = 0.9 x ADST/D = BDST/D
D 100 ADST
AD means air dry, which is pulp with 10% water.

BD means bone dry, which is pulp that is completely dry (0% water).
To convert from gpm to T/D of liquor:
gal 60 min 24 hr 62.43 lb 1 ft3 1T

x x x x x
min hr D ft3 7.48 gal 2000 lb
6 x gal T
=
min D
0.9 x 100
= 15
6

Example:
P = 1,000 ADST/D
BF= 1,450 gpm
D = 50 gpm
W = 1,767 gpm
E = 1,817 gpm
Q1 = BF + D
Q1 = 1,450 + 50 = 1,500 gpm
Q2 = Q1 + W - E
Q2 = 1,500 + 1,767 - 1,817 = 1,450 gpm
15 x 1,000
C2 = = 10.0% BD
1,450 + (0.05 x 1,000)
15 x 1,000
C1= = 9.7% BD
1,500 + (0.05 x 1,000)
A quicker, but less accurate, estimate of consistency can also be made using the
following formula, which does not correct for the specific gravity difference between
water and stock.
15 x (Production, ADST/D)
Consistency, % BD =
(Stock flow, gpm)
C1 = 15 x P or C2 =
15 x P
Q1 Q2

2. Dilution Factor
Calculation of diffuser dilution factor (DF) from wash flow (W), production (P) and
stock flow (Q2).
Dilution factor = 0.6 + [ ]

6 x (Wash flow - Stock flow out)
Production rate
DF = 0.6 + [6 x (W - Q2)
P ]
NOTE: Q2 = Q1 + W - E
The “6” is a conversion to go from gpm to T/D. It is derived on page VI-7.
Example:
W = 1,767 gpm
Q2 = 1,450 gpm
P = 1,000 ADST/D

DF = 0.6 + [ 6 x (1,767 - 1,450)

1,000
]
DF = 2.5 T/ADST
2.5 T/ADST
DF = = 2.78 T/BDST
0.9 BDST/ADST
The required wash flow (W) for a given dilution factor (DF) can be calculated given
the washed stock flow (Q2) and the production rate (P).

6 ]
W = Q2+
[ P x (DF - 0.6)
6 ]
Example:
Q2 = 1,450 gpm
P = 1,000 ADST/D
DF= 2.5 T/ADST
W = 1,450 + [ 1,000 x (2.5 - 0.6)
6 ] = 1,767 gpm

NOTE: If the wash flow is adjusted to obtain a given dilution factor, the
extraction flow must be adjusted by the same amount to maintain a
constant washed stock flow.
4. Wash Ratio
wash flow (W), the stock flow from the diffuser (Q2), and the stock outlet
consistency (C2).
Wash flow
WR =
Stock flow x (1 - (Consistency/150))
W
WR =
Q2 x (1 - (C2 / 150))
determined by subtracting the portion of the stock flow (Q2) that is actual, bone dry
pulp which has a specific gravity of 1.5.
Example:
Note: Q2 = Q1 + W - E
W = 1,767 gpm
Q2 = 1,450 gpm
C2 = 10.0 % BD
1,767
WR = = 1.31
1,450 x (1 - (10.0 / 150))

The required wash flow (W) for a given wash ratio (WR) can be calculated given the
washed stock flow (Q2) and the washed stock consistency (C2).
[ (
Wash flow gpm = (Wash ratio)(Stock flow gpm) x 1 - Consistency % BD
150
)]
W = (WR) x (Q2) x ( 1 - (C2 /150) )
Example:
WR = 1.31
Q2 = 1,450 gpm
C2 = 10.0% BD
W = (1.31) x (1,450) x (1 - (10.0/150) ) = 1,772 gpm
The difference between the wash flow given here and the wash flow calculated
with the dilution factor is in the rounding of the wash ratio.
6. Stock Velocity
The stock velocity in the pressure diffuser can be estimated given the stock
flow rates.
Pulp flow to the diffuser Q1

Stock velocity (in/sec) = =
613 613*
* This factor will vary depending on the size of your diffuser (see Table 6.1)

The “613” is a conversion factor to go from gpm to in/sec. It is derived as follows:
I.D. of vessel shell = 102"
O.D. of bearing cylinder = 86"
(102)2 - (86)2 Õ
Area = x = 16.4 ft.2
144 in2/ft2 4
where Õ = 3.14
gal 1 ft3 1 12 in 1 min gal/min in

x x x x = =
min 7.48 gal 16.4 ft2 ft 60 sec 613 sec
Example:
BF = 1,450 gpm
D = 50 gpm
Q1 = 1,450 + 50 = 1,500 gpm
1,500
Stock Velocity = = 2.45 in/sec
613
Screen Conversion
Diameter Factor
50" 352
70" 483
90" 613
110" 744
TABLE 6.1

7. Upstroke Time
Stock Velocity = 2.45 in/sec
Relative Speed = 1.15 (hardwood and softwood)
Screen Velocity = 1.15 x 2.45 = 2.82 in/sec
Stroke Length = 24 in (this will vary for different diffusers)
24 in
Upstroke Time = = 8.51 sec
2.82 in/sec

E. Metric Calculations - Pressure Diffuser
Pulp flow to the diffuser L/sec Q1
Pulp flow from the diffuser L/sec Q2
Pulp consistency to the diffuser % BD C1
Pulp consistency from diffuser % BD C2
Wash flow FIC27 L/sec W
Extraction flow FIC22 L/sec E
Blow flow from digester FIC12A L/sec BF
Blow line dilution flow FIC28 L/sec D
Production ADt/D P
Wash Ratio t/t WR
Dilution Factor t/ADt DF
1. Consistency
The consistency in the blow line or the washed stock line can be checked:
1.042 x (production, ADt/D)

Consistency %BD =
(stock flow, L/sec)+(0.0035 x production, ADt/D)
1.042 x P 1.042 x P
C1 = or C2 =
Q1 + (0.0035 x P) Q2 + (0.0035 x P)
Where Q1=BF + D

The "1.042" is a conversion factor. It is the ADt to BDt factor in the numerator multiplied
by 100 to express consistency in percent divided by a conversion factor to go from l/sec
to t/D in the denominator.
To convert from L/sec to t/D of liquor:
liters 60 min 24 hr 1 kg 1t
x x x x
sec h D 1 liter 1,000 kg
86.4 x liters t
=
sec D
0.9 x100
= 1.042
86.4
stock.
1.04 x Production ADt/D

Consistency % BD =
(Stock flow L/sec)
1.04 x P 1.04 x P
C1 = or C2 =
Q1 Q2

2. Dilution Factor
Calculation of diffuser dilution factor (DF) from wash flow (W), production (P) and
outlet stock flow (Q2).
86.4 x (Wash flow - Stock flow out)

Dilution Factor = 0.6 +
Production
86.4 x ( W - Q2 )
DF = 0.6 + = t/ADt
P
NOTE: Q2 = Q1 + W - E
* The “86.4” is a conversion to go from L/sec to T/D.
It is derived in part 1. Consistency.
The required wash flow (W) for a given dilution factor (DF) can be calculated given
the washed stock flow (Q2) and the production (P).


86.4
]
W = Q2 + [ P x (DF - 0.6)
86.4 ]
4. Wash Ratio
wash flow (W), the stock flow from the diffuser (Q2), and the stock outlet
consistency (C2).
Wash flow L/sec
[ ]
WR =
Consistency %BD
Stock flow L/sec x 1 -
150
W
WR =
Q2 x (1 - (C2 / 150))
determined by subtracting the portion of the stock flow (Q2) that is actual, bone
dry pulp which has a specific gravity of 1.5.
The required wash flow (W) for a given wash ratio (WR) can be calculated given
the washed stock flow (Q2) and the washed stock consistency (C2).

[ ]
Wash flow L/sec =
Consistency % BD
(Wash ratio) (Stock flow L/sec) 1 -
150
W = (WR) x (Q2) x ( 1 - (C2 /150) )
6. Stock Velocity
The stock velocity can be estimated given the stock flow rates.
Pulp flow to the diffuser (l/sec) Q1

Stock velocity (in/sec) = =
33.7 33.7
*** The “33.7” is a conversion factor to go from L/sec to in/sec. This factor will vary with
diffuser size. One example is derived as follows:
I.D. of vessel shell = 83.5"
O.D. of bearing cylinder = 66"
(83.5)2 - (66)2 Õ
Area = x = 14.3 ft.2
2 2
144 in /ft 4
liters 1 gal 1 ft3 1 12 in liters/sec in

x x x
2
x = =
sec 3.785 L 7.48 gal 14.3ft ft 33.7 sec
Screen Diameter Conversion Factor

50" 19.4
70" 25.6
90" 33.7
110" 40.9 Table 6.2

7. Upstroke Time
Stroke length
Upstroke Time =
Screen Velocity

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Diffuser Update

• Would any of the changes prevent unnecessary downtime?

• Would any of the changes improve the operation of the diffuser?

• Would the mechanical operation or life of the equipment be benefited?

Also included is information for troubleshooting mechanical and operational

Andritz supplies diffusion washing using two unique designs:

It is hoped that if there are any questions or comments on information presented in

Diffuser Update 9th Edition

Diffuser Update 9th Edition

Diffuser Update 9th Edition

4. Adhere to approved confined entry procedures whenever entering restricted

Diffuser Update 9th Edition

Diffuser Update 9th Edition

Diffuser Update 9th Edition

Diffuser Update 9th Edition

General Description - Atmospheric Diffuser

The following description assumes a two-stage atmospheric brownstock diffuser

FIGURE 1.1 2177a-cdr

Diffuser Update 9th Edition

TWO STAGE DIFFUSER

Diffuser Update 9th Edition

Diffuser Update 9th Edition

Diffuser Update 9th Edition

In addition to the two-stage atmospheric brownstock diffuser already described, the

Single Stage Brownstock Washing (See Fig. 1.4)

Diffuser Update 9th Edition

SINGLE STAGE DIFFUSER

FIGURE 1.4 2176 cdr

Diffuser Update 9th Edition

TWO STAGE DIFFUSER

FIGURE 1.5 2237cdr

Diffuser Update 9th Edition

SINGLE STAGE BLEACH TOWER

FIGURE 1.6 2198cdr

Diffuser Update 9th Edition

TWO STAGE BLEACH TOWER

FIGURE 1.7 2197cdr

Diffuser Update 9th Edition

DIFFUSER BLEACH PLANT

Diffuser Update 9th Edition

TWO STAGE CONTROL SCHEME

FIGURE 2.1 3032

Diffuser Update 9th Edition

II. Instrumentation and Interlocks

The instrumentation is designed to allow the operator to easily control the

The following is a brief description of the instrumentation loops and

F27 FIRST STAGE WASH FLOW

F28 DIFFUSER FLOAT OUT

F37 SECOND STAGE WASH FLOW

Diffuser Update 9th Edition

LEGEND AND BLOCK DIAGRAM

STROKING DIAGRAM TIMING

F22 FIRST STAGE EXTRACTION FLOW

F32 SECOND STAGE EXTRACTION FLOW

F85 LOWER BEARING SEAL WATER FLOW

L23 FIRST STAGE BACKFLUSH TANK LEVEL

L33 SECOND STAGE BACKFLUSH TANK LEVEL

L24 FIRST STAGE FILTRATE TANK LEVEL

L34 SECOND STAGE FILTRATE TANK LEVEL

Diffuser Update 9th Edition

P23 FIRST STAGE BACKFLUSH TANK PRESSURE

P33 SECOND STAGE BACKFLUSH TANK PRESSURE

P26 INLET STOCK PRESSURE

P25 HYDRAULIC OIL PRESSURE