Bellmer
Bellmer
India
Your contact Anssi Muurimäki Phone +358 504 701 937 E-Mail [email protected]
Date 2021-05-20
Project JK CPM PM 4
New TurboJetter headbox
Main Data
paper grade FBB, Grey back
furnish BHKP, Mix waste
basis weight range 185 – 430 g/m²
design basis weight --- g/m²
wire width 2.930 mm
paper width at reeler 2.604 mm
production speed range, min – max 189 – 404 m/min
design speed 500 m/min
drive side seen from headbox to reel left hand
Electrical Data
operating voltage 3 ph 400 V (AC)
frequency 50 Hz
control voltage (plc, control devices, valves) 24 V (DC)
control voltage 230 V (AC)
Ambient Conditions
outside temperature - 10 - 40 °C
ambient temp. for control panels/cabinets 10 - 40 °C
rel. humidity 30 – 55 %
height above sea level 200 m
Utility Data
cooling water temperature, max. 10-15 °C
cooling water differential pressure in/out, min 2,5 bar
instrument air pressure, min 5,5 bar
NOTE:
All pictures and graphs are for illustration only. Execution and scope may vary, technical specification
will prevail.
The project drawing and production file are part of this Technical Specification (see separate
documents)
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CONTENTS OF SPECIFICATION
B Auxiliaries ................................................................................................................. 24
Foundation Plates............................................................................................ 24
D Services .................................................................................................................... 28
Packing and freight .......................................................................................... 28
Erection supervision ........................................................................................ 28
Erection ........................................................................................................... 28
Tests & checking ............................................................................................. 28
Start-up assistance with paper & training ........................................................ 28
Production care ............................................................................................... 29
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Retention range 93 – 94 93 – 94 93 – 94 %
Main parts
The Hydraulic headbox with outside attenuating tank and dilution technology is a
tailor made to the specific flow range of your project.
The headbox is equipped with a set of stainless steel lamella blades to ensure activity
in the stock just before exiting the slice on the wire, thus providing best formation.
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The air cushion loaded attenuator tank is located in the approach pipe before the
headbox to cut away the high pulsation from feed pump and machine screening
before the headbox. Air in the tank is compressible and adsorbs the pulses. Pressure
loss in the tank screen plate (HDPE) also adsorbs the pulses generated by the
screens and pumps.
The dilution control system will produce optimum cross directional basis weight
profiles. Dilution control is supplied only with middle layer headbox
Material
Stock contacting stainless surfaces EN 1.4404
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1 headbox
of stainless steel 1.4404, welded.
consisting of:
headbox bottom part
headbox front wall
headbox top part
headbox cross sections for reinforcement
headbox side walls with cleaning covers.
1 Equalizing chamber
Between the distributor element and the turbulence generators there is a
converging equalizing chamber. The clean-outs on both sides of the equalizing
chamber for inspection and cleaning are provided.
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Adjustment is effected via spindle lifting gears with electro-motor and cross shaft.
The max. final positions are secured with buffers.
Vertical front wall adjustment
Adjustment is effected via spindle lifting gears with electro-motor and cross shaft.
The max. final positions are secured with buffers.
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Spacing
Spindles and actuators Amount of elements
[mm]
Micro-fine adjustors for slice blade 19 150
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Showers
Shower List
Position Qty Type Type of Material Oscillation type
nozzle
Breast roll 1 LP Fan SS Sta
All shower pipes and movers are equipped with holding devices of stainless steel,
welded.
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2 control valves
to control the pressure of the air cushion.
1 control valve
for over-flow control in TurboDamper
1 pipe between TurboDamper and TurboCone header
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Dilution valves 37
dilution injectors
High precision injector blocks made of long-lasting HDPE. The modular design allows
easy cleaning, just in case.
dilution valves
designed with linear movement and accordingly linear flow characteristics in the
range between 15% - 88% valve opening.
Spacing of valves 75 mm
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Following loops, equipment, control boxes and junction boxes are included in the
headbox
Operation of control loops are mentioned by following abbreviations:
L = Local,
R = Remote
CL = Closed loop control
PIC-1 Total head control, R/CL
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1 header opening,
1 hydraulic unit including motor 1,5 kW
1 directional valve
2 flow control valve
1 flow divider
1 control switch
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Prewiring
All electrical equipment on headbox frame are prewired to junction box. Cable
protection tubing is done with straight stainless steel pipes with open curves.
DCS and local controls for headbox
Top lip vertical and horizontal movement can be operated from local control box,
which is located on the tending side of headbox. All these controls can be done also
via DCS monitor.
All other controls are done in the DCS system. DCS hardware and software is not
included in the delivery
Total head is measured with two pressure transmitters. Operator can choose which
one is used as a measurement signal for total head controller. The other one is a
ready installed spare part. Total head is controlled by the help of the fan pump speed.
Pump speed controller is located in pump drive system
Headbox PD tank pond level is measured by a flange model pressure difference
transmitter, pond level is controlled by two valves, air inlet and outlet valves, by
controlling valves in opposite directions. It means that, when air inlet valve is opened
air outlet valve is closes same amount at the same time and vice versa.
Dilution water feed is controlled by controlling the pressure difference between
dilution water header and stock header. Pressure difference is measured by the help
of two pressure transmitters, one installed on dilution water header and the other on
stock header. Pressure difference between two headers is controlled by the help of
dilution water feed pump speed.
Basis weight profile control is done by feeding dilution water into the filler ply
headbox. Dilution water feed is done through dilution control valves. Dilution valves
are of linear movement type
Every dilution valve is driven by own actuator with stepping motor. Delivery of
actuators, stepping motors and control system by Customer. Option for Honeywell
actuators and control system by Bellmer (look 1.10).
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DCS Solution
for DCS Integration and FAT
The customer plans to install a DCS system with a separate system supplier.
The Bellmer scope includes system independent function descriptions and screen
proposals allowing the system supplier to configure the hardware and to do the logics
for the following sections:
Headbox
A Factory Acceptance Test (FAT) test shall be carried out considering the following
preconditions:
All function descriptions shall be completely implemented in the
software of the DCS supplier.
During the FAT the software shall be just reviewed and corrected, not
completed.
The software is pre-tested by the DCS supplier.
A simulation mode is integrated in the program.
The FAT shall be performed by our specialists at the premises of the
DCS supplier or at purchasers’ site.
The FAT shall be performed 4 weeks before the erection
FAT participation for 5 working days with above mentioned
preconditions
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Walkways
Walkways
Specification Qty Material Type Dimensions
l x w [mm]
Cross directional walkway 1 SS fixed 4.000 x 600
Al = Aluminum, anodized
SS = Stainless Steel
Cross walkways
with handrail on both sides. Including supports made of stainless steel.
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2 spare actuators
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B Auxiliaries
Foundation Plates
The headbox is supported in cross machine direction on two points. The supports
allow thermal expansion of the box.
Foundation plates
Position Qty Material Type Dimensions
length x width
SS = Stainless Steel
MS = Steel
CI = Cast Iron
Note:
Headboxes placed on a cantilever beam need adjusting / fastening
pieces of stainless steel material EN 1.4404. This material is supplied
by customer.
Headboxes placed on a concrete foundation will be supplied with base
plates and foundation bolts.
Concrete base and civil works by customer.
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Project management
Coordination with your project management
Project discussions for perfect project processing
Taking measurements on site, if required, to determine interfaces
Project schedule for the Bellmer scope of supply
Erection schedule for the Bellmer scope of supply
For project meetings we have foreseen the following man days:
Project Manager 3 1 1
Specialist erection 1 1 1
Specialist automation 1 1 1
Add. days on site / journey will be invoiced acc. to additional man days on site.
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Layouts
Machine layout = assembly drawing (side view)
Space assignment plan (top view) in which the space requirement and
the arrangement of our scope of supply in relation to the building are
shown, including drive plan (positioning of machine drive)
Foundation and load plan with indication of the static and dynamical
loads caused by the machine parts and affecting the foundation
Process diagrams
Pneumatic diagram
Water diagram
Lists
List with the heaviest components
Motor list for auxiliary drives
Automation engineering
Cable plans and lists
Flow diagrams (hardware-plans)
Lists of instruments
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Documentation
Project language English
1 data stick
Operating and maintenance instructions
Lists with spare and wearing parts
Detailed quotation for spare and wearing parts will be provided in time;
quotation will include recommendation of those parts that should be
available for start-up process
Installation declaration for the Bellmer scope of supply
Format types:
drawings in pdf format
electric planning in pdf format
lists in pdf format
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D Services
Erection supervision
Smooth processing of the individual working phases is assumed.
For the erection supervision we will deploy the following personnel:
Erection supervison Calender days Men day shift Men night shift
Supervisor mechanics 18 1
Specialist automation 9 1
Please note:
The given personnel and time effort are preliminary and will be adjusted after
checking the situation on site.
Erection
Erection service will be provided by customer.
Tests & Checking Calender days Men day shift Men night shift
Specialist start-up 3 1
Specialist automation 3 1
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Training
Training of your personnel will be performed during the tests & checking process as
well as during start-up process on site.
Furthermore, we offer the possibility to carry through some pre-training during the
earlier process of installation / works assembly / functional test phase on our site with
your selected staff.
Production care
Several weeks after start-up, Bellmer will provide experienced specialists to optimize
jointly with your team the production.
Together with your team, we will carry through an invidual optimisation program in
day shift. Within the frame of this program, any arising questions will be discussed
and answered. Further training will be performed.
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Qty Description
HeadBox
1 slice lip
50 m seal 11x11
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Liability exclusion
Liability for consequential loss, in particular loss of profits and/or production is
excluded.
Mechanical warranty
For the parts supplied by Bellmer, our warranty period is 24 months after delivery. If
the delivery is delayed for reasons beyond Bellmer’s responsibility, our period of
warranty will end 27 months after announcement of readiness for shipment, at the
latest.
Excluded from the warranty are:
wearing parts
damages resulting from external effect of force
damages resulting from improper handling or non-observance of
generally known guidelines, maintenance cycles as well as operating
and maintenance instructions
damages caused by inadequate transportation or storage through the
buyer or any third parties
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G Standard components
In order to provide top products and services for the rough production conditions in
paper industry (24/7), Bellmer uses components and products that are designed for
this industrial environment. The selections of components and materials are based
on technical features necessary in the specific use and location. This is combined
with the long-term experience and know how of Bellmer in the area of bio-economy
production lines. All components used meet the safety requirements and are
approved to meet the Bellmer standard for their intended location. This is also
reducing the risk for start-up and operation.
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H Limits of supply
We would be pleased to support you in any respect for the successful performance
of the project. If you would appreciate the inclusion of additional equipment or
services we are prepared to discuss and offer accordingly. For the time being the
following is understood from our side to form the scope of supply / delivery limits:
All items, which are not described in our offer are excluded from supply. For an easy
overview in the following items of exclusion are listed:
TurboJetter
3 Base plate X
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12 Stock screen X
13 Dilution pump X
21 Fan Pump X
26 PD-tank support X
Other Walkways modification on X
Headbox area
Dilution profile control X X
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Exclusions of offer
General
All non-specified items
Taxes, duties and customs
Acquisition of official approvals as well as any filing of official applications
Electrical equipment
Deliveries or works for the low and medium voltage, transformers, feeders up to new cabinets
Basic earthing system
Integration of scope of supply into customer DCS system
Web tension measurement devices
Engineering
Plant engineering
Civil engineering
Piping engineering
Process engineering
Vacuum engineering
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Services
Any non-specified services
Unloading of goods
In-house transportation
Forklifts and mobile cranes
Provision of scaffolds
Storage of goods
Disconnection of supply lines
Dismantling of goods
Unpacking of goods
Erection of goods
Office room or office containers
Changing and sanitary containers
Waste disposal
Cost for electricity, water and welding gases
Cleaning of parts
Any service for options or parts not delivered by Bellmer
Installation of pipelines for steam, condensate, water, compressed air and hydraulics as well as
pipeline adaptation
Field cabling, also adaptation works
Electric installations
Any demolition & building activities, as well as scrabbling of drive foundations
Repair and service works, as far as not specified. We will be pleased to perform such kind of work
and will invoice them according to actual effort.
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