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EMAMI PAPER MILLS LTD. Unit - Balasore “Efforts taken at Emami Paper Mills Ltd. for Better Maintenance Practices”

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Presentation on theme: "EMAMI PAPER MILLS LTD. Unit - Balasore “Efforts taken at Emami Paper Mills Ltd. for Better Maintenance Practices”"— Presentation transcript:

1 EMAMI PAPER MILLS LTD. Unit - Balasore “Efforts taken at Emami Paper Mills Ltd. for Better Maintenance Practices”

2 LOCATION 250 KM 200 KM North BAY OF BENGAL

3 PRODUCTION TPD YEAR EMAMI PRODUCTION MILESTONE

4 MACHINEPM # 1PM # 2PM # 3DIP # 1DIP # 3 PRODUCTWRITING PRINTING NEWSPRINT Pulp- Writing printing Pulp - Newsprint RAW MATERIAL WASTE PAPERS DECKLE2.15 MTRS2.85 MTRS3.55 MTRS SPEED320 MPM515 MPM1120 MPM Production50-150 gsm45 gsm CAPACITY50 TPD95 TPD250 TPD50 TPD330 TPD Emami –Pulp & Paper Production Units at a Glance

5  Maximize the machine Uptime at optimum efficiency.  Achieved target & follow up for update.  Spare parts management.  Critical checks & recording during any available shut.  To improve the awareness of the people in the area of Best Practices in maintenance.  To build a positively challenging relationship across the maintenance departments.  Create a learning opportunity for the development and education of maintenance people.  To create an atmosphere where people will readily share experiences and information.  Use modern systems for health check of machineries. Working Principle & Maintenance Practices

6 ABCDEFGHIJK LMNOPQRSTU VWXYZ 2014 50 TPD PAPER MACHINE 1 1983 15 TPD PAPER MACHINE 1 o Hydraulic Headbox, o Fourdrinier, open draw, o 2 straight Press, Pre-dryers, o Size Press, Post dryer, o Swimming Calender o and Pope Reel

7 Approach Flow & Head box PROBLEMS 1.Uneven parent roll built up for GSM variation 2. Failure of Micro Jack fingers due to forced Operation Pr.. Scrn PA Tan k air vent Standard Bend and pipe 15 nos. @ 150 mm BEFORE HEADBOX Top Lip Pr Scrn From PCCFrom PCC To PA tankTo PA tank PA Tan k air vent Accept to PA tank HEADBOX Taper pipe Accelerating Bend Accelerating Bend 18 Nos. @ 120 mm Top Lip Benefit 1.Parent Roll built up improve by minimise GSM variation 2.Eliminate Micro jack failures AFTER JOB DONE 1. Approach piping change to taper piping with Accelerating bend from std. piping 2.Head box Front Panel change. No. of Micro jack increase from 15 to 18 3.Head box top lip redesign for more flexible PM # 1 Slot & drill for flexibility Plain

8 Ø750, 90 ° Shore A Rubber pr Ø740,100° Shore A Dynarock Ø740, 100° Shore A Dynarock Ø750, 90 ° Shore A Rubber Ø110 mm dia. & Stiff Angle Rigid doctoring system Ø600 mm, 125 mm wide box 6/10 counter SS Couch Roll TOP FELT BOTTOM FELT 2 nd pr. BOTTOM FE LT Wire & Press 630 Problem : 1.Too high Draw between wire and press (23 MPM). 2.Delayed the paper passing for Stiff angle. 3.Paper breaks at couch lead roll for low dia. And paper drive. 4.2 nd press Doctor passing. 5.Steam consumption high (3.30 Mt/Ton paper for low dryness after press. PM # 1 Plain press Roll

9 Ø750 BD mm, 90 ° Shore A l Ø750 BD mm, 90 ° Shore Ø750, Dynaro ck Ø750 mm, 90 ° Shore A l Ø600 mm, 125 mm wide box 6/10 counter Bronze Couch Roll TOP FELT BOTTOM FELT 2 nd press BOTTOM FELT Maxiflex doctoring System & 2 nd doctor 150 mm dia. lead roll VFD drive reduce stiff angle by lift up couch roll 930 Wire & Press 1.Couch roll UP by 300 mm and reduce stiff angle 2.150 dia. Couch lead roll installed with VFD dive in place 110 mm dia. roll 3.Installed maxi flex doctor with a 2 nd doctor at 2 nd press top roll 4.Both 1 st press top & bottom Roll changed to Blind drill Roll Work done 1.Reduce Draw between wire and press from 23 MPM to 12 MPM. 2.Paper passing time reduce. 3.Reduce paper breaks at lead roll. 4.Doctor passing eliminate at 2 nd press roll 5.Dryness increase d to 42% from 40%. 6.Steam consumption reduce to 2.8 MT/Ton paper from 3.3 MT. 7.Deckle increase at Pope by 2 cm. 8.Speed increased to 320mpm from 300 MPM. 9.Production increase. Benefit PM # 1 Blind drill press Rolls

10 Eliminate the Dryer felt roll breakdown There used to be frequent breakdown of Dryer felt rolls due to journal shearing after changing from dryer felt to screen & speeding up the machine. The journal size of 45mm was replaced with 50 mm for all felt rolls with rubber cover to avoid this breakdown Chrome plated Dryer Felt Roll Ø45 Ø 160 Rubber cover Dryer Felt Roll Ø 180 Ø50 10 YearPre dryerPost dryerTotal 2008527 2010325 2012112 2013000 2014000 PM # 1

11 Problem 1.Roll life 1 month 2.Single line shaft drive 3.Paper passing delay 4.Size solution GPL 30 5.Size gain less 6.Paper wrapping 7.Pneumatic loading 8.Nip load too low 15 kg/cm Loading Unloading Loading Unloading 30° Paper Size Press Workdone 1.Made inclined size press from horizontal 2.Made drive arrangement to lead out roll 3.Made loading 4.Size solution increase to 50 GPL 5.Nip load increase to 20 kg/cm Benefit 1.Roll Life increase from 1 month to 2 month 2.Paper passing easy PM # 1

12 Loading Unloading 45° Proposed Size Press Proposed modification 1.For Further Roll Life increase and size gain we plan to installed AC VFD drive both top & bottom roll and hydraulic loading arrangement PM # 1

13 Problem 1. Roll wear out was fast about 500 µm 2. Roll changing (Grinding) Frequency- 4 month 3. Parent roll not built up uniform. 4. Weight loss more 5. Paper smoothness not appropriate 6. Roll changing time takes more - 12 hours 7. Roll Edge wear out more for rigid doctoring system result Deckle short CALENDER Work Done 1. Installed new 2 roll swimming calendar system in place 4 roll stack 2. Installed swimming roll at bottom with hyd. loading system and heating arrangement 3. Both top and bottom roll provided maxi flex doctoring system Benefit 1. Roll wear out minimum 100 µm. 2. Roll changing (Grinding) Frequency increase - 12 month 3. Control Crown, Parent roll built uniform 4. Weight loss minimum. 5. Paper smoothness improve 6. Roll changing takes 4 hours 7. No Deckle shortage as no wear at edge for maxi flex doctoring system Before After PM # 1

14 2014 95 TPD PAPER MACHINE 2 Hydraulic Headbox, Fourdrinier wire, Close draw, Bi-nip press, Dryer, Swimming Calendar and Pope Reel 1996 60 TPD IPPTA: promoting paper industries growth PRODUCTNEWSPRINT RAW MATERIAL RECYCLE DECKLE2.85 MTRS SPEED515 MPM GSM45 PRODUCTION95 TPD

15 Vac Box bearing failures of Suction Pick up roll and Suction Couch roll Back head Vacuum box Bearing Assemble DS Bearing ----- Back head Vacuum box Bearing Assemble DS Bearing BEFORE AFTER Problem 1.Frequent failure of locking pins & Bearing failures of box brg. assemble Workdone 1.Bearing assemble arrangement changed from Vac box to Drive head 2. Bearing size change from 23220 to 22322 3.Stud shaft dia. change from 70 mm to 85 mm YearPick up roll Couch roll Speed, MPM Producti on loss MT 2008-09 9:2534:50 470.1 160 2009-10 14:5016:00 494 118 2010-11 10:0000:00 505 39.00 2012-13 00:00 506 00.00 2013-14 00.00 51500.00 Benefi t PM # 2

16 Roll diameter increase & Maxi flex doctoring system improve press part efficiency SP U Ø6 50 Groo ved Ø570 CO UC H Roll FDRFDR W as h ro ll Centre Press Roll Ø805- Ø825 Problem Face 1.Ink deposition on the centre press surface increase downtime for cleaning and paper breaks 2.Doctor blade life low 5-7 days only 3.Narrow Nip width, Dryness of press 42% Workdone 1.Centre press roll and Grooved roll diameter increase. 2.Maxiflex doctoring system installed in place rigid doctoring system. 3.Hole screen replace by 0.15 mm slotted screen SPU Ø650 Centre Press Roll Ø850 Groo ved Roll Ø590 Couch FDR WA S H Problem Face 1.No Ink deposition on the centre press surface increase uptime and no paper breaks 3-4 days. 2.Doctor blade life low 15-17 days only 3.Wide Nip width, Dryness of press increase 42% to 44.5 % PM # 2 BEFORE AFTER

17 Problem 1.Doctor Loading not uniform, at Edge more. 2. Wear out at edge up to 500 µm. 3. Grinding frequency 4-5 month. 4.Roll life less Benefit 1. No edge wear out doctor Load uniformly distributed 2. Wear out only up to 50-75 µm. 3. Grinding frequency 8-9 month 4. Roll life increase. AFTER BEFORE FLEXIBLE doctoring system on Top Roll of PM # 2 Calender Work done 1.Replace Rigid doctoring by maxi flex doctoring system. PM # 2 Rigid Doctor Maxiflex Doctor

18 CRACK Headbox diffuser BLOCK PROBLEM : 1. Heavy leakage due to HDPE step diffuser block crack and no spare in hand 2. Repaired temporary by isolating Horizontal Movement of Top Slice lip. 3. Flow not uniform and Channelling. Heavy leakage HEAD BOX STEP DIFFUCER BLOCK PM # 2

19 Manufacturing Head Box Diffuser block at Home HDPE DIFFUSER 182 nos. BOX SS 304 Work done 1.Diffuser Block’s Drawing, Design Developed &Manufacture at home. 2. Arranged 182 nos. HDPE diffuser Nozzle by injection moulding at Kolkata. Benefit 1.Run the machine at full speed and produced good quality paper. 2. Paper rejection and finishing loss go down. PM # 2

20 Y E A R 1. Head box electro polish. 2. Pressure screen- may with 015 mm slot 3. Uhle box slot 10 mm to 13 mm 1. 850 mm Centre press roll in place 805 mm dia 2. Centre press Maxi flex doctor ing system 3. 570 mm to 590 mm Groove 4. 0.5° Hydrofoil 1. Orthoflow 1.Head box lip changed 2. Fan pump impeller dia increase from 365 to 380mm M P M 1.4 nos. 200 mm dia. Uhlebox in place of 150 mm with ceramic

21 2014 250 TPD PAPER MACHINE 3 Hyd.headbox, Twinwire Gap former belbie IV Trinip Ceramic Nipco Press, Dryers, Double stack Soft Calender & Pope Reel 2007 205 TPD IPPTA: promoting paper industries growth

22 Before HB After HB Abnormal vibrations in the forming section at wire part. Forming roll Bow roll Problem 1. Too much Vibration at Forming roll. 2. Restricted speed up above 1000 mpm Work done 1.FE analysis carried out By IIT, Kharagpur. 2. Bow roll reposition with new bracket Benefit 1.Vibration reduce. 2. Speed up the machine to 1120 MPM DRIVE END BEARINGMPMNON DRIVE END 13.10.13.329858.718.493.21 BEFORE VIBRATION AFTER VIBRATION 7.54.31.810583.52.31.53 PM # 3

23 Higher vibrations of Dryer Frames and paper breaks for sticky coming along with recycle pulp Problem : 1.Vibration in dryer frame 2.No doctoring system on dryer for sticky cleaning Work done 1.Arch type Tie connected in between dryer frame 2.Installed doctoring system on every dryer. Benefit 1.Vibration Reduce 2.Keep the dryer surface clean. BEFORE: Original Dryer Frame configuration AFTER: Dryer Frame configuration with addition of Arch Beams PM # 3

24 In house overhauling of swimming & nipco roll reduces foreign experts cost. BEFORE Previously the Swimming roll and Nipco roll servicing was carried out by sending the rolls to Europe. PRESENT We have developed in house facilities for overhauling & maintenance of same PM # 3

25 Condition monitoring system(SPM) On-line condition monitoring system installed at Emami PM # 3. This on line system is very effective for unplanned stoppage, fire safety. The bearing changed as per online condition symptom on planned and unplanned as follows Year PlannedUnplanned(downtime) 2011337 2012172 2013160 201461 Condition monitoring on off line: Offline bearing conditions are also monitored regularly and 20% bearing consumption cost reduces since last 5 years Proactive maintenance Regularly monitoring the lubricant quality prevent downtime in Nipco roll Swimming roll and COL system rolls and cylinders bearings SCREW PRESS MOTORDRIVE END DATETORQUELR/HR HORVERTAXIAL M INMAXMINMAXMINMAX 06-11- 2014 44/35 2.19 2.21 2.3 06-04- 2014 31/25 1.92 1.3 2.21 06-03- 2014 31/25 1.25 1.31 1.16 Modern maintenance practices at Emami

26 WE SHALL OVERCOME 2014 54TPD Deinking Plant 1 2005 48 TPD

27 Power Saving in DIP 1 PARTICULARS Horizontal slot screen Horizontal Hole screen Vertical slot screen Vertical hole screen Slot/Hole size0.15 mm slot dia 1.8/2.20.15mm slotdia 1.4mm Basket sizeØ740 x 600Ø500 x 430Ø495 x 500Ø495 x 495 % of Open area4.295.712.7 Rotating element weight Kg580275270 Rotor dia733496490 Rotor rpm571763440715 Tip velocity m/sec22201118 Inlet Consistency (% )1.6 -1.8 %2.5-2.6%0.8-2.0%3-3.5% BKW75391531 Motor KW904518.537 Motor rpm1500 14551450 Motor FLC157813566 Motor RLC128742555 Running KW 77441533 Work Done 1.Study individual power consumption trend of equipment's in DIP plants. 2.Identified screening section consuming more power 3.Select appropriate equipment and installed 4. Power consumption reduce from 121 KW to 48 kw. PROBLEM 1. Power consumption too high

28 BEFORE MODIFICATION in SCREENING SECTION POWER CONSUMPTIN WAS 121 KWH/MT F paper Fine screen feed chest & pump Constant level chest & pump Coarse Hor. Hole screen 45 kw Fine Hor. Slot screen 90 KW Diabolo slot Diabolo hole Mac cell DIP # 1 POWER 520 KWH/PAPER POWER 360 KWH/PAPER

29 ABCDEFGHIJKLM NOPQRSTUVWX YZ 2014 330 TPD Deinking Plant 3 2007 300 TPD

30 Reduction of Screw press vibration in of Deinking Plant: Problem 1.Too much vibration at DS screw for polished screw surface. 2.Coupling failure. 3.Basket damaged. 4.Production hampered for frequent stoppage for roughening the polished screw surface. Work Done 1.Tungsten carbide coated body plate welded on polished screw surface Benefit 1.Eliminate excessive vibration at DS screw 2.Coupling & Basket not failed/damage since body plate installed. 3.Frequent roughening not require SCREW PRESSDRIVE ENDNON DRIVE END AFTERTORQUE HORVERAXIAHORVERAXIA 06-04-201456% 1.020.510.591.170.790.97 06-03-201456% 0.780.380.290.840.40.35 BEFORE 01-09-201454% 5.52.61.33.74.73.5 26/12/201355% 6.54.22.64.35.55.1 DIP # 3

31 SAVINGS IN PLASTICS HANDLING BY INSTALLATION OF BALE PRESS & NEW CONVEYING SYSTEM Sl.No.PARTICULARS PREVI OUS PRESE NT SAVINGS of Manpower UNIT PRIC E (Rs.) Total Savings (Rs.)/Day Total Savings Lacs/Mo nth 1 Manpower engaged in Power plant for Baling & feeding Plastics 3410 4 Manpower engaged in DIP#3 & DIP 1 plant for shifting Plastics to Power plant/Day 60 6Total Manpower40103020060001.8 7 Transportation charge 10440.24 9 Total Savings per month 70442.04 10Total Savings per Annum in Lacs24.48 Cost Reduction on Reject Plastics Handling in Deinking Plant: DIP # 3 ProblemWork doneBenefit Dirty House keepingA heavy duty Bale press installedClean House keeping More Man power (40 nos.) Two conveyor installed which carry the reject plastic to bale press directly from source Less Manpower (10 nos.) Higher moisture ( 60%) in plastics. Less moisture (20%) in plastics

32 1.Frequent breakdown of Dryer felt rolls on PM#1 was eliminated by changing the journal size from 45mm to 50 mm for all felt rolls. 2.By increasing the lead roll diameter & with VFD arrangement Paper breaks at couch roll in PM#1 reduced. 3.PM#2 machine speed increased from 470 mpm to 515 mpm by in house modifications in suction couch & suction pickup roll, adding wire table dewatering element & installing maxi flex doctoring system at centre press roll resulting increase in Production by 2000 MT/Annum. 4.Reduce power consumption at Deinking plant#1 by 165 KW/ton of finish paper after changing Horizontal screen by Vertical screen in both Hole & fine screening stage. 5.In-house plastic handling system reduces the manpower & nuisance in the Plant. 6.In house overhauling of swimming & nipco roll Eliminated supervision and experts cost Rs. 10 lacs / annum. 7.The deinking plant poire is being rebuild at our workshop which saves around 2.5 Lac/ year Conclusion

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