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EMAMI PAPER MILLS LTD. Unit - Balasore

EMAMI PAPER MILLS LTD. Unit - Balasore. “Efforts taken at Emami Paper Mills Ltd. for Better Maintenance Practices”. LOCATION. North. 250 KM. 200 KM. BAY OF BENGAL. EMAMI PRODUCTION MILESTONE. PRODUCTION TPD. YEAR. Emami –Pulp & Paper Production Units at a Glance.

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EMAMI PAPER MILLS LTD. Unit - Balasore

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

  2. LOCATION North 250 KM 200 KM BAY OF BENGAL

  3. EMAMI PRODUCTION MILESTONE PRODUCTION TPD YEAR

  4. Emami –Pulp & Paper Production Units at a Glance

  5. Working Principle & Maintenance Practices • 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.

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

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

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

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

  10. PM # 1 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 Ø 160 Ø45 Chrome plated Dryer Felt Roll Ø50 Rubber cover Dryer Felt Roll Ø 180 10

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

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

  13. PM # 1 CALENDER 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 Before 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 After 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

  14. 2014 95 TPD 1996 60 TPD PAPER MACHINE 2 Hydraulic Headbox, Fourdrinier wire, Close draw, Bi-nip press, Dryer , Swimming Calendar and Pope Reel IPPTA: promoting paper industries growth

  15. PM # 2 Vac Box bearing failures of Suction Pick up roll and Suction Couch roll Problem Frequent failure of locking pins & Bearing failures of box brg. assemble Back head DS Bearing Workdone Bearing assemble arrangement changed from Vac box to Drive head 2. Bearing size change from 23220 to 22322 Stud shaft dia. change from 70 mm to 85 mm ----- Vacuum box Bearing Assemble BEFORE Benefi t AFTER DS Bearing Vacuum box Bearing Assemble Back head

  16. PM # 2 • Roll diameter increase & Maxi flex doctoring system improve press part efficiency BEFORE Problem Face Ink deposition on the centre press surface increase downtime for cleaning and paper breaks Doctor blade life low 5-7 days only Narrow Nip width , Dryness of press 42% Grooved Ø570 Grooved Roll Ø590 SPU Ø650 SPU Ø650 COUCH Roll Couch Centre Press Roll Ø805-Ø825 Workdone Centre press roll and Grooved roll diameter increase. Maxiflex doctoring system installed in place rigid doctoring system. Hole screen replace by 0.15 mm slotted screen Centre Press Roll Ø850 FDR Wash roll WASH FDR Problem Face No Ink deposition on the centre press surface increase uptime and no paper breaks 3-4 days. Doctor blade life low 15-17 days only Wide Nip width , Dryness of press increase 42% to 44.5 % AFTER

  17. PM # 2 FLEXIBLE doctoring system on Top Roll of PM # 2 Calender AFTER BEFORE 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 Maxiflex Doctor Rigid Doctor Work done 1.Replace Rigid doctoring by maxi flex doctoring system. 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.

  18. PM # 2 HEAD BOX STEP DIFFUCER 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 Headbox diffuser BLOCK CRACK

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

  20. M P M 1. Head box electro polish. 2. Pressure screen- may with 015 mm slot 3. Uhle box slot 10 mm to 13 mm Y E A R 4 nos. 200 mm dia. Uhlebox in place of 150 mm with ceramic Head box lip changed 2. Fan pump impeller dia increase from 365 to 380mm 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

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

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

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

  24. PM # 3 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

  25. Modern maintenance practices at Emami 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 Planned Unplanned(downtime) 2011 33 7 2012 17 2 2013 16 0 2014 6 1 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

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

  27. Power Saving in DIP 1 PROBLEM 1. Power consumption too high Work Done Study individual power consumption trend of equipment's in DIP plants. Identified screening section consuming more power Select appropriate equipment and installed 4. Power consumption reduce from 121 KW to 48 kw.

  28. DIP # 1 AFTER MODIFICATION in SCREENING SECTION POWER CONSUMPTIN IS 48 KWH/MT F paper BEFORE MODIFICATION in SCREENING SECTION POWER CONSUMPTIN WAS 121 KWH/MT F paper Mac cell POWER 520 KWH/PAPER Diabolo slot Mac cell Diabolo hole Diabolo slot Diabolo hole POWER 360 KWH/PAPER Coarse Hor. Hole screen 45 kw HD cleaner Fine Hor. Slot screen 90 KW Fine Ver. slot screen 18.5 KW Constant level chest & pump Coarse Ver hole screen 37 KW Constant level chest & pump Fine screen feed chest & pump Fine screen feed chest & pump

  29. 2014 330 TPD Deinking Plant 3 2007 300 TPD ABCDEFGHIJKLMNOPQRSTUVWXYZ

  30. DIP # 3 Reduction of Screw press vibration in of Deinking Plant: Problem Too much vibration at DS screw for polished screw surface . Coupling failure. Basket damaged. Production hampered for frequent stoppage for roughening the polished screw surface. Work Done Tungsten carbide coated body plate welded on polished screw surface Benefit Eliminate excessive vibration at DS screw Coupling & Basket not failed/damage since body plate installed. Frequent roughening not require

  31. Cost Reduction on Reject Plastics Handling in Deinking Plant:  DIP # 3

  32. Conclusion 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. By increasing the lead roll diameter & with VFD arrangement Paper breaks at couch roll in PM#1 reduced. 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. 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. In-house plastic handling system reduces the manpower & nuisance in the Plant. In house overhauling of swimming & nipco roll Eliminated supervision and experts cost Rs. 10 lacs / annum. The deinking plant poire is being rebuild at our workshop which saves around 2.5 Lac/ year

  33. Thank you

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