Professional Documents
Culture Documents
Zonal 2 2018.23 WCPM
Zonal 2 2018.23 WCPM
Zonal 2 2018.23 WCPM
S.K. Mundra
GM (Instrumentation)
About WCPM
West Coast Paper Mills Ltd, today is the largest part of the S.K. Bangur Group from Kolkata, was established in 1955 with
an 18,000 TPA printing and writing paper production line. Since then, the number of machines has been increased to six
and the paper and board capacity to the current 3,20,000 TPA. In August 2009, the company completed an investment in
capacity of 320,000 TPA. The production includes copy papers and other uncoated printing and writing grades (3 PM),
specialty papers (1 PM) and coated duplex board (2 BM). The expansion involves an investment of 13 billion Rupees
1955 18,000 TPA printing and writing paper production line with Paper Machine 1 & 2.
1996 Production increased to 1,20,000 TPA – Renovation of PM 3 and installation of Duplex Board – PM 5.
Capacity raised to 1,58,000 TPA on rebuild of PM-2 and installing Duplex board M/c – 4 & 350 TPD METSO washing and
2002
Screening plant commissioned.
Commissioning of Paper Machine 6 along with state of art Fibreline of capacity 725TPD, modern chemical recovery plant, FBC4
2010
boiler and 34.5 MW Turbo generator set increased production up to 3,20,000 TPA.
Paper Machine 6 rebuild for speed increase from 1000 MPM to 1150 MPM for marginal increase in production and quality
2018
improvement.
Summary Of Present Plants In WCPM
➢ Improvements in steam and condensate system for fine controls enhancing steam conservation
➢ System improvements
Installation Of CD Basis Weight Control System To Improve GSM Spread And 2 Sigma Variation
o New Voith DCS and dilution CD basis weight profile control system installed during rebuild in October 2017.
o Results can be noticed with past data followed by present data of 2 Sigma variation values.
CD dilution actuators o Installation of new ABB QCS along with CD dilution basis weight
control.
o Installation of dilution CD basis weight profile control system for
mould number 5 installed in October 2018.
o Results can be noticed with past data followed by present data of 2
Sigma variation values. 2 Sigma values before controlled run was
4.05 and the present 2 Sigma value is 1.13.
o Steam and Condensate control loops incorporated in DCS for fine controls and ease of operation in January 2017.
o After the modification steam consumption reduced to 2 tons per ton of paper from previous value of 2.3 tons.
o Steam and Condensate control system modified in October 2017 and its control loops incorporated in DCS for fine
controls and ease of operation.
o Steam consumption reduced from 2.80 T/ Ton to 2.40 T/ Ton of paper.
o Condensate recovery improved from 80% to 86%.
o Obsolete Basis Weight control valves replaced in PM#1 and PM#3 resulting in improvement of stock flow control.
o Apart from traditional methods, we have installed 3 microns air filter at each air header.
o This implementation has reduced the malfunctions of the control on/off valves
o There are 6 numbers of through beam type of sheet break detectors in dryer section of paper machine.
o These sheet break detectors malfunctioned frequently, no indication was conveyed during paper break.
o This issue remained unsolved despite of regular cleaning of photo cells and reflectors.
o Thereafter reflectors of high resolution (long distance) were installed and the problem got resolved.
Reflector Sensor
Improvements In Paper Machine 6 - Replacement Of Turbine Type Flowmeter With Magnetic Flowmeter
o To overcome this problem turbine type flowmeter was replaced by magnetic type flowmeter and the problem was resolved.
o It was observed that the relay connected was On and signal obtained from DCS was
o Hence we tried replacing the relay with same contact ratings (6A,230V AC). It
worked well for about 4 months and later the same problem occurred.
o Master reel cables of the encoder were cut frequently close to the connection point, due to the movement of
o Hence replaced the existing with cables of high bending radius. There is no break down from the past 18 months.
o Existing SS palms in dryer's Auto guide caused breakdown (due to abrasion) within 3-4 months of operation.
o So these SS palms were replaced by Ceramic coated palms. These palms did not get any cut, but the screen
Optical Fibre Communication o Since the boiler started normal profibus cable were laid between DCS panels at
different locations.
o We have redundant communication channels so if one channel breaks, others take care.
o However if both communication channels fail, boiler tripped affecting the mills
o We replaced profibus cable with fibre optic cables in between DCS panels and the
operators.
o 2 indicators are provided in the field and other one in the control room.
o New DCS was installed as the PLC based system was obsolete.
DCS with latest version OS Implemented proactive upgrades from Windows XP/ Server 2002 to
Windows7/10/Server 2016 OS based control systems to avoid any long
breakdowns, as listed below:
o Compatible hardware for Windows XP based system is currently unavailable in the market.
o Nowadays DCS/PLC suppliers have upgraded their systems based on windows 7/ 10. So the software support for
o Security updates no longer available for Windows XP; this can make our systems more vulnerable to attacks.
Installation Of Reliable UPS
Reliable UPS with double battery banks WCPM emphasized on reliable UPS in DCS/PLC systems all over the plant.
Parallel redundant UPS of reputed make along with SCVS and double battery
banks were provided at following locations.
1. Enmas Recovery Boiler.
2. BHEL Recovery Boiler.
3. RLK, Caustisizer.
4. PM#3.
5. FBC 4.
6. FBC 2.
7. FBC 3.
8. TG 4.
9. PM#6.
10. Fiber line.
11. PM#6 converting section – Installation of UPS reduced the breakdowns.
Advantages Of Reliable UPS
o When DCS/PLC system is powered by reliable UPS, plant can be restarted within a short period, if the main
o Failure of any electronic card/ power supply in the system is avoided by this implementation.
o The operation of UPS is more reliable due to the presence of redundant UPS and double battery banks.
o Double battery bank ensures power supply with increased backup time.
System Improvements To Save Water
o Installation of reservoir pool level transmitters and level indicators were done in filter house reservoir to prevent
overflows.
o Condensate return line of NFL, FFE-1 and FFE-2 diverted to new tank for double checking of conductivity to avoid
any mixing of foul condensate due to malfunction and slow response of conductivity control loop.