Ultrasound measurement - a new way of controlling paper machinesError!

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by
Gunnar Lindblad, Product Manager for AUTOLINE(R) - TSO(R) - ISOTUNER(R),
AB Lorentzen & Wettre, Kista, Sweden.

Summary

Hitherto, paper machines have mainly been controlled using information from on-line
thickness, grammage and moisture measurements. Now ultra-sound measurement is making
its presence felt, despite its only being available as off-line measurement equipment at
present.

Ultrasound measurement or TSO measurement as Lorentzen & Wettre refers to it, has been
available for a number of years. TSO stands for Tensile Stiffness Orientation and is a measure
of the paper's elastic properties, which can be directly related to the runnability in the paper
machine and in the subsequent converting process.

The measurement procedure is simple. A cross profile is cut out directly from the paper
machine's machine roll. A cross profile is run through the TSO meter and the four main
properties are reported.
TSO angle - provides information about how well the head box is adjusted.
TSI-Machine direction - provides information about how well the press section is adjusted.
TSO-Cross direction - provides information about how well the drying section is adjusted and
how the beating is set, and
TSI Machine/Cross direction ratio - provides information about how the sheet strength
conditions are adjusted.

The various properties are shown as profiles and can be compared directly with the On-Line
system's three principal properties. From experience, we have found the boundary values for
the various properties that provide the best running conditions in the paper machine and also
provide the least possible variation in the quality of the paper.

The article describes in detail the way in which the various properties are related and should
be used to achieve the best possible result.

TSO tester

The L&W TSO tester is really a laboratory instrument that can be used for process
optimisation and to simplify quality control.

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Figure Error! Unknown switch argument.. The multi-sensor head makes it possible to measure in all
directions in the plane of the paper sheet

Figure Error! Unknown switch argument.. The transmitter sends an ultrasonic pulse to the receiver, that
propagates through the paper and the velocity is calculated and expressed as TSI.

It is based on the principle of ultra sound, and involves sending out a longitudinal ultrasonic
pulse through the paper, in the plane of the paper, from a transmitter to a receiver. The
measuring instrument is equipped with a measuring head that contains 8 pairs of transmitters
and receivers, uniformly spaced in a circle on the plane. The signals are converted to describe
the elasticity in all directions in the paper. The actual measurement takes 5 seconds per
measurement position, so that a complete measurement on a 9-m wide paper machine takes 9
minutes (90 measurement positions). The results are presented as a machine roll report, with
mean value, standard deviation, maximum value and minimum value and a graphical
presentation of the four main properties' profiles, which are:

• TSO angle - which describes the angle between the machine direction and TSI max.,
which is the direction of greatest elasticity.
• TSI Machine direction - which describes the elasticity in the machine direction.
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• TSI Cross direction - which describes the elasticity in the cross direction.
• TSI Machine/Cross ratio - which describes the relationship between the machine and cross
direction. The ratio is a measure of anisotropy, to be compared with the ratio between the
classical strength properties, like Tensile strength, Stiffness in bending, compressive
strength, etc.

Figure Error! Unknown switch argument.. The measurements are expressed in a polar plot diagram, where
the main properties are reported

Figure Error! Unknown switch argument.. The TSI - Tensile Stiffness Index can be measured with a Tensile
Tester and be expressed as the maximum slope of the Stress-Strain curve, or the Young’s Modules.

Experience from the mills that today regularly use the TSO meter to control their process has
given us certain recommended values to fall back on.

TSO angle

The TSO angle tells us whether the paper in question has a tendency to curl/twist. The actual
curl comes mostly from the two-sidedness in the paper, while the twist component is due to
the Orientation of the elasticity.

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Figure Error! Unknown switch argument.. The TSO angle taken from a sample from a Foudrinier type
paper machine running in Rush mode. The Orientation is expressed as ”toe-out”.

For all grades of paper, except perhaps for sack paper, the recommended value should be
between ± 5 degrees, while the mean value should be about 0 degrees. A mean value other
than 0 degrees (tolerance ± 0.5 degrees) indicates that the head box is not correctly balanced.

Figure Error! Unknown switch argument.. The mean value of the TSO angle should be at 0 degrees, which
means that the head box of the paper machine is well balanced. Variation should be within +/- 5 degrees

This unbalance may be due to many reasons, but it is mostly due to incorrect regulation of the
recirculation valve. Other causes that are important for a perfectly adjusted head box are:

• the Approach system

• the Header pressure distribution
• the Head Box tube pattern (especially edges)
• the Cross flow conditions (such as use of stock bleeders and injection
• the Slice lip profile
• the Stock spread on the wire
• the Forming activity

For copying and laser papers, for instance, our customers have found that the requirements
must be stricter. Values of ± 2.5 to 3 degrees are common criteria for almost all mills
manufacturing this type of paper grade. This permits printers who do reprinting for forms etc.,
for example, to feel calm and avoid expensive disturbances to the process. Nor does it raise
complaints from copying-machine and laser-printer manufacturers or users.

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These criteria cannot be applied across the board to Sack paper. Sack paper is normally run
with an anisotropy value of around 1, that is the strength properties and elasticity are equal in
both the machine and cross directions. On the other hand, we have found that it is valuable
that sack-paper manufacturers also adjust their head boxes on the basis of a somewhat
oriented paper before the paper's anisotropy value is adjusted to close to 1 or that a Clupack
unit is connected in.

It is also important to mention that fibre Orientation and TSO angle are not the same thing.
The TSO angle or Tensile strength Orientation is a composite property in which the fibre
Orientation is one component and the others are built-in stresses and strains in the paper.
These stresses and strains come in part from the press section and in part from the drying
section. A paper that is coated or is in any other way subjected to wetting after the actual
drying subjects the paper to additional built-in stresses and strains. A paper that is moistened
after the manufacturing process and has been allowed to dry freely gives basically the same
value for the fibre Orientation as for the TSO angle.

Tests have also shown that the dimensional stability or, more exactly, the hygro-expansion
and then also the shrinkage, is perpendicular to the TSO angle and not to the fibre
Orientation. This is yet another reason for following the TSO angle on the paper grades
dependent on giving good four-colour printing without register problems or where stack lean
can be a problem.

TSI Machine direction

TSI Machine direction or the Tensile strength index in the machine direction is a property that
can be directly related to many of the runnability problems that today occur in a paper
machine and in subsequent converting.

Figure Error! Unknown switch argument.. A typical TSI-MD profile, showing a tendency to give both
”baggy edges” and ”wrinkles”.

The actual profile must be as plane as possible. This provides us with a uniform elasticity
across the machine. Variations that can be allowed are between 5 and 10%, depending on the
grade of paper

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Figure Error! Unknown switch argument.. Variation of the TSI-MD values should be kept within 5 - 10%.

A strongly oriented paper such as newsprint, should lie with a variation in the lower area, so
as to be able to avoid long edges, web failure in the paper machine and in the printing press,
wrinkles, crease formation, etc.

Figure Error! Unknown switch argument.. The top profile shows a newsprint machine running in Drag
mode, and the below shows a newsprint machine running Rush. The Drag machine shows much lower
variation, and has no problems with ”press room brakes”, nor ”wrinkles”.

In comparison with, for example, liner or fluting, in which the compression properties are
important, we can relate the TSI machine direction to the SCT Machine direction (strip
compression strength) and the CMT (Concora Medium test). Due to the large scatter in
results from the classical methods of measurement and also disturbances in the actual method
of measurement that are more difficult to describe, the comparison between the TSI Machine
direction and the SCT Machine direction and the CMT are often questioned. We wish to
assert that the TSI value gives better and more accurate information about the way in which
the paper will behave in the finished corrugated fibreboard box than what the more
established properties tell us. The future will show the path we will follow to obtain faster,
more credible information and better paper quality.

To be able to improve the TSI Machine-direction profile it is important that the press section
is well adjusted and that the press felts are in good condition. All felt suppliers' service
engineers are today equipped with an L&W Scanpro PressTuner or JetMem for checking the
dewatering in the press section.

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 PressTuner
800
1 HOUR
700
1 DAY
600
g/m2

6 DAYS
500
14 DAYS
400
21 DAYS
300
FS DS

Figure Error! Unknown switch argument.. PressTuner measurements on a machine felt, made at several
occasions.

The information from these Scanpro meters is important for optimising the press section and
the TSI Machine-direction profile. The meter measures the water content of the felt and can
with this information show how well the press section is dewatering, how the suction boxes
are working and whether the press roll is correctly crowned. Another aid that is starting to
become more and more common is the L&W Scanpro FeltPerm.

FeltPerm
1300
1 HOUR
1100
1 DAY
ml/min

900
6 DAYS
700
14 DAYS
500
21 DAYS
300
FS DS

Figure Error! Unknown switch argument.. Typical profiles taken with the L&W SCANPRO FeltPerm,
showing the differences from when the felt was new until it starts to clog and needs to be cleaned.

This meter is based on the principle of water permeance, where water under a known pressure
is sprayed through a nozzle of a determined diameter, through the press felt. By this means
we can calculate the permeability of the felt and also see if it is clogged or in good condition.

Factors that affect the TSI Machine-direction profile are:

• the Refining
• the Draw in between the different Press sections
• the Condition of the suction boxes
• the Dewatering in the Press sections
• the Felt condition
• the Press nip pressure
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• the TSO-angle

TSI Cross direction

The TSI Cross direction or the Tensile strength index in the cross direction can be directly
related to demands on the paper as regards the strength in the cross direction and also
shrinkage/expansion across the machine.

Figure Error! Unknown switch argument.. A typical TSI-CD profile, where the effects from the dryer
section is clearly shown.

A typical TSI Cross-direction profile can be described as an upside down banana with the
highest point in the middle and the edges low. A typical variation is in the region of 20%
when the other three running parameters - thickness, grammage and moisture - are kept
within a range of ± 1 - 2%.

Figure Error! Unknown switch argument.. The variations of the TSI-CD profile should be within 10 - 20%
depending on grade.

But we have observed certain deviations from this, specially for newsprint, whose normal
variation is above 20%. Another example is base paper for labels, which requires a good
support for punching, and is therefore strongly beaten, with low air permeability and, as a
result, a plane TSI Cross-direction profile.

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The TSI Cross-direction profile can be simply related to the SCT Cross-direction (Strip
compression test) and the RCT Cross direction (Ring Crush Test), two very important
properties for determining compression strength of Kraftliner and Testliner.

Figure Error! Unknown switch argument.. The correlation between calculated CCT and measured CCT
(CCT = Concora Crush test, can also be measured as RCT or SCT). The calculated CCT is related to TSI-
CD and Basis weight.

Figure Error! Unknown switch argument.. Long-term variations of CCT values measured and calculated.

The factors that steer the level and appearance of the TSI Cross-direction profile include the
velocity difference between the jet and the wire. In addition, the refining affects the shape of
the profile. This, together with the possibility of affecting the cross draw in the dryer section,
makes it possible to control the shrinkage in the cross direction. This is important as the
shrinkage affects the form of the TSI Cross-direction profile.

Figure Error! Unknown switch argument.. Comparison between SCT-CD measured and calculated from
TSI-CD and Basis weight. SCT can vary up to 20 - 25% within an entire machine reel.
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The factors that directly affect the TSI Cross-direction profile are:

• the Dryer section

• the Refining
• the Draw in the machine direction
• the Draw in the cross machine direction
• the Speed difference between the Jet speed and the Wire speed

TSI Machine/Cross-direction anisotropy

The TSI Machine/Cross-direction ratio or the Tensile-Stiffness index ratio is controlled by the
difference between the jet velocity and the wire velocity.

Figure Error! Unknown switch argument.. A typical TSI-MD/CD ratio profile

The relationship has been known for a long time. It is also known that the best formation and
minimum tendency to curl is obtained in the equilibrium state, that is when the difference
between the velocities is 0. But it is very difficult to run a paper machine in this position and
efforts are made to run with either a negative or positive velocity difference close to the
equilibrium position. It may be mentioned that the jet/wire velocity ratio that the paper
machine's control system usually specifies is not the whole truth. The velocity of the jet is
usually calculated using variations in pressure as the starting point. A very reliable way of
determining the equilibrium position is to measure the web width, which is greatest in the
equilibrium position.

We have found the following recommended values for the TSI Machine/Cross-direction ratio
for various grades of paper:

Copying and Laser paper 1.8 - 2.3

Roll to roll printing paper 2.3 - 2.7
Newsprint 3.0 - 5.5
Liner (strength related) 2.0 - 2.5
Liner (bursting-strength related) 3.0 - 3.5
Paperboard 2.0 - 2.5
Sack paper 1.0 - 1.3

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The variation in these values is related to the magnitude of the variations permitted in the
component profiles. If both the TSI Machine direction and TSI Cross direction are in the
upper area, this immediately gives great variation in the anisotropy.

Figure Error! Unknown switch argument.. The relationship between Jet/Wire ratio (Rush/Drag) and TSI-
MD/CD ratio.

Comparisons have been made in which values have been obtained for the TSI
Machine/Cross-direction ratio, the Tensile strength Machine/Cross-direction ratio and curl in
relation to the velocity difference. This has been done for copying paper, amongst others, on a
Valmet paper machine. The lowest curl was indicated at an equilibrium position, while the
lowest TSI and Tensile strength ratios were found at a negative velocity difference.

Figure Error! Unknown switch argument.. The comparison between TSI-MD/CD ratio, Tensile strength
MD/CD ratio and Curl tendency to Jet/Wire ratio.

Procedure for optimising a paper machine using ultrasonic measurement of the TSO

The first thing to be done is to check that the machine is correctly set as regards parallelism,
level, vacuum flow, velocity variations, concentration of the stock, felt and wire condition,
etc.

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As we intend to start with the head box, we should also note the running parameters used. It
may also be of interest to measure the jet velocity, as this is normally calculated via the
machine control system.

Cross samples are taken from 10 or 20 different positions in the machine roll and tested in the
TSO apparatus. The relatively large number of samples is necessary to be able to observe
whether there is any machine-direction variation that affects the TSO angle. When the
measurements have been made the results are transferred to a calculation sheet (e.g. EXCEL)
to permit calculation of the mean slope of all profiles in the series of measurements
(translation) and the angle at which they are located.

Figure Error! Unknown switch argument.. When the 20 profiles are put together and the mean value
calculated together with the variation within all the profiles, it is possible to establish what kind of actions
to be taken to rectify the problems in the head box.

We can then also observe whether the variation in the machine direction is greater or smaller
than that in the cross direction. To obtain the frequency and appearance of any machine-
direction variation, a test strip is taken in the machine direction. This strip may be of the same
length as or longer than the wire.

Figure Error! Unknown switch argument.. A sample taken in the machine direction, showing variation with
a specific frequency. These variations are related to a shaker built-in to the forming table to get better
formation.

After running in the TSO meter, we can analyse the results and possibly find the origin of the
variation. It is very common that unbalance in the head box gives rise to a machine-direction
variation. Other causes are pulsation’s that occur before the head box or mechanical
vibrations in any of the paper machine's rolls.

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When we have determined the actions to be taken to adjust the head box, this is adjusted and
the test repeated until we have achieved the best possible result.

When the head box has been adjusted satisfactorily it is time to continue forwards in the
paper machine. The forming board and wire part are in fact the next stop, but should have
been remedied before the head box was adjusted, as the wet section affects the final result.

The press section comes next. We should make the measurements using the Scanpro moisture
meter, L&W SCANPRO PressTuner, to find out if everything is as it should be. An L&W
Scanpro FeltPerm should also be used for measuring the permeability by water, as a clogged
felt cannot provide the dewatering required. The press roll nip should be checked as regards
the pressure distribution, load and linear load. In addition, the draw between the press rolls
should be checked as this affects the variation in the TSI machine-direction profile. Check
also the beating and stock concentration, so as to change the appearance of the profiles.

It is important the whole time that we do not change the thickness, grammage and moisture
profiles more than we can permit. These should be checked for each change made.

Figure Error! Unknown switch argument.. Calliper and Basis weight profiles taken on a sample from a
newsprint machine running in Drag mode.

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Figure Error! Unknown switch argument.. Calliper and Basis weight profiles taken on a sample from a
newsprint machine running in Rush mode.

We have seen examples of paper machines that are incorrectly set in the press section as
regards the TSI machine-direction values, in order to compensate for a poor moisture profile.
This showed itself as a hump in the TSI machine-direction profile and the mill felt obliged to
run the machine in this way.

When we have got a grip of the press section, we can try to remedy the drying section. It is
perhaps not the easiest to do but there are certain possibilities, such as changing the draw
between the drying cylinders, temperature regulation between and in respective drying
cylinder. The effect of the beating should not be forgotten and also the velocity difference at
which the machine is being run.

Conclusions

We have tried in this article to show the potential of using modern measurement techniques
like ultrasound for optimising a paper machine.

Paper manufacture is a complex process and long experience and a great deal of knowledge
are required to do it correctly. We are no paper manufacturers but we have great experience of
measurement techniques and also evaluation of the results obtained from the instruments we
manufacture.

Experience from the mills that more or less follow the schedule described in the article as
regards optimisation possibilities has shown itself to be very valuable. The runnability has
been greatly improved, resulting in less scrapping. The quality specifications have become
stricter, which in turn has resulted in cost savings.

Looking at the elasticity instead of the classical strength properties gives us a better picture of
the paper's runnability and gives us unexpected opportunities for further improving the paper.

References

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(1) Polar Diagrams of Elastic Stiffness : Effect of machine variables,
Gary A. Baum, (1987) Paper Physics Conference.
(2) L'Optimisation de la Qualité sur la Machine à Papier,
J. Silvy, V.Morin, A. Allée, ATIP 44 (6)(1990)
(3) The influence of rolls and reels on flutter and windage,
Richard J. Adams, 75 (11) (1992) TAPPI Journal
(4) Automatic measurement of sheet directionality and elastic properties by ultrasound,
H. Ekblad, Pulp and Paper Canada, 94 (9) (1993)
(5) Applications of co-ordinated profile control,
Harri Mustanen, Petri Nyberg, Control Systems (1994) Stockholm.
(6) Module-Jet - erste Betriebserfahrungen mit dem neuen Stoffauflaufkonzept.
Wochenblatt für Papierfabrikation, (12) (1994)
(7) Field experience in prediction of corrugated board strength with ultrasonic testing,
J. Sandström, M. Titus,78 (10) (1995) TAPPI Journal.
(8) A new headbox design featuring consistency profiling decoupled from fibre orientation response.
Scott B. Pantaleo, 78 (11) (1995) TAPPI Journal.
(9) Effects of Wet Straining and Drying on Fibre Orientation and Elastic Stiffness Orientation.
T.R.Hess, P.H.Brodeur, 79 (5)(1996) Journal of Pulp and Paper Science
(10) An On-Line Control System for Simultaneous Optimisation of Basis Weight and Orientation Angle Profiles
John Shakespeare, Juha Kniivilä, Anneli Korpinen, Timo Johansson, (3)(1996) Paper Technology

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