0401000 headbox

VKPC – PM#1

Training

Headbox

Introduction

1. Introduction Trainer

2. Training Schedule

Introduction of the Trainer

Toru Maruyama

Paper Machine Engineering Dept.

Training Schedule

Training Time

Breaks

Lunch

Question and Answer

Technical Data

1. Basic Design Data

2. Technical Specification

Basic Design Data – Layout data

Design widthWire width 5.950 mmUntrimmed paper width on pope 5.300 mm

Basis weightT1 (Pulp on Top) 125 - 275 gsmT2 (100% OCC) 125 - 250 gsmCM 105 - 125 gsm

Design production At PM reel max. 744 to/24hWith efficiency 100%Moisture at reel 8%Basis weight 125 gsm (Reference liner grade)

Paper Grade Liner Board (Test Liner: T1, T2)Corrugating Medium

Basic Design Data – Layout data

Reel spoolMax. parent reel diameter: 3.000 mm

Hand of machineStanding at the headbox 　facing the reel: Drive on right hand side

Operating speedProduction speed range 355 - 800 m/minDrive speed 900 m/minDesign speed 900 m/minBalancing speed 900 m/min

Technical Specification of HEADBOX

Top LayerUnder Top

LayerBack Layer

Headbox TypeMaster Jet II F/B

25/3-H-2LMaster Jet II F/B

33/3-B-HMaster Jet II F/B 33/3-MJ-H-SC

Flow to wire(m3/min)Flow to HC Header(m3/min)Flow to LC Header(m3/min)

20.9 – 51.822.2 – 55.1

NONE

28.6 – 44.730.8 – 48.0

NONE

28.9 – 45.225.0 – 42.5

6.5 – 6.5

Slice Width(mm)Design Speed(m/min)Production Speed(m/min)

5739900

323 - 747

Basis Weight(g/m2) 30 - 60 47 - 112 48 - 113

Description

1. Technology

2. Component

TOP Layer HEADBOX

UNDER TOP Layer HEADBOX

BACK Layer HEADBOX

Stabile Jet

Influence of jet direction

Cross profile Control- Stock consistency

Turbulence generation

Cross profile Control- Slice blade adjustment

Function of the Headbox

MasterJet F/B with directly flanged-on header

TOP Layer

MasterJet II F/B 25/3-H-2L

- PD tank (for stable pressure)- Swing Header (for easy cleaning)- Turbulence generator (for good sheet formation)- Edge Master (for stable stock on wire)- Lamella (for good sheet formation)


UNDER TOP Layer

MasterJet II F/B 33/3-H

- PD tank (for stable pressure)- Swing Header (for easy cleaning)- Turbulence generator (for good sheet formation)- Edge Master (for stable stock on wire)

MasterJet F/B with ModuleJet

BACK Layer

MasterJet II F/B 33/3-MJ-H-SC

- PD tank (for stable pressure)- Stilling chamber (for even profile)- Swing Back wall (for easy cleaning)- Turbulence generator (for good sheet formation)- Edge Master (for stable stock on wire)- Module Jet (for good profile)


Turbulence generator Slice nozzle

Slice lip

Bottom lip

HC header

(Top Layer & Under Top Layer)

Good Distribution

The parabolic header and pressure drop in turbulence generator make uniform distribution.

Ball valve

Solenoidvalve

Water line Compressed-air line

PneumaticControlcabinet

Pressurecontrolvalve

Throttlingvalve

Pressurereliefvalve

Slice-bladevalve

Overflowvessel

Supply

Lightsource

Sequence

Pulsation Damper

Reduction of pulsation in stock line

Pulsation Damper

Overflowbore

Compressed-air cushion

Suspension

Supply

Perforated-hole plate

Compressedair connection

Outlet

A evacuating compressed airB evacuating suspension

Pressure drop in perforated plate and cushion of compressed air reduce pulsation.

Compressed air and overflow keep the level automatically.

Turbulence Generatorwith exchangeable Inserts

View AView A

Insert at inletfor spec. pressure dropand micro turbulence

Micro turbulence make good sheet formation

Pictures of a Turbulence Tube Block

Turbulence generator with lamella fixing device

(Top Layer Only)

Turbulence generator Lamella

Slice lip

Bottom lip

Top-lip beam

This picture is sample.Top layer HB has only 2 Lamella.

Lamellas in the Headbox Nozzle (Top Layer Only)

short lamella with smooth tip

long lamella with structured tip


Lamella make stabile jet for good sheet formation

Bottom lip

Fixing bolt spacer

Bottom-lip fixing bolt

Supportingplate

Bottom lip

Installation lever

Spacer/guide plate

Rod headScrew jack

element

Bottom lip can move to adjust the Jet landing

wrong

The Problem of Jet Impingement

Jet landing point is adjusted with bottom lip extension

MasterJet F/B with ModuleJet

Slice lip

ModuleJet

LC header

HC header

Bottom lip

Slice nozzle

Turbulencegenerator

Stilling chamber

(Back Layer)

ModuleJet Unit (Back Layer only)

ModuleJet Unit mix the stock and white water to control the consistency in Headbox

ModuleJet Unit and Header

ModuleJet Valve

BW with slice

BW with dilution Control

The Problem of CD-Profile Control

BW control with Slicedisturb the jet direction

BW control with Dilutionkeep the jet direction

Misalignement of Fibers through Slilce BladeFiber orientation

TS Jet direction DS

Slice geometry

v wir

e

v wir

e

vjet

vjet

BW control with Slicedisturb the jet direction.

TelephonePowerData LinkQCS (Profiles, ...)

Power

24 VDCActuator-

Bus

CD Control

Headbox

Dilution Water

Stock

C O L-A C T-S TA -

1 2 3 4 5 6 7 8 9 101112

H S 1 H S 2 O K 1 O K 2 P SC O N S O LE

Zip Modem

SD

VOITH PAPERAUTOMATION

800 x 2000 x 800

Power Supply

Cable VPAH Supply

Cable Customer Supply

DCS

SetpointDifferential Pressure

Recirculation

PDIC

PTPT

SIC

Profilmatic M – Hardware Overview

ModuleJet valves are controled with Profilmatic M

ModuleJet – Headbox Installation

Connecting boxes( stainless steel )

PowerDistribution Boxes

Profilmatic M Profilmatic M control ModuleJet valves withProfile data from QCS

Operation

1. Start up

2. Shut down

3. Adjusting

Operational Data

Top LayerUnder Top

LayerBack Layer

Slice Opening (mm)Max. Slice Opening to service

Approx.3 - 17125

Approx.3 – 20.8125

Approx.3 - 21125

Bottom lip extension(mm) 4 – 44 4 – 44 4 – 44

ModuleJet Unit(PC) NONE NONE 89

Slice dajustment device (PC) 30 30 30

Operational Data

Top LayerUnder Top

LayerBack Layer

Total Retention (%) 0.50 – 0.87 0.63 – 0.78 0.63 – 0.78

Consistency in Headbox (%) 0.30 – 0.80 0.70 – 0.90 0.63 – 0.78

Static Head in the Nozzle(kPa) 14 - 78

Pressure drop in HB HC(kPa)Pressure drop in PD HC(kPa)Pressure drop in HB LC(kPa)

11.8 -65.94.0 – 24.7

NONE

23.4 – 57.47.7 – 18.7

NONE

48.2 – 127.16.9 – 20.1

166.5 – 232.8

Start Headbox

PrerequisitesEnsure, that all cleaning covers are closed.after longer downtime, activate the headbox heating (6 preheating hours)Ensure, that header (or back wall), and deckle plates are closed and all screws are tighten.Ensure, that manhole of PD tank are closed and hanble is tighten.Check operational reliability of limit switch of top lip beam adjustment.

Start Headbox

Adjust lip openingOpen slide valve of stock feeding pipeOpen valve of headbox recirculation pipeOpen valve of compressed air to PD tankStart LC screen (Back layer only)Start HC screenEnsure, that the former is ready-to-operateOpen shower valves Enter machine speed, jet-wire-difference, lip opening, ... into the PLS.Activate LC fan pump (Back layer only)Activate HC fan pump, when the LC-line is running stable.

Start Headbox

Check after StartCheck pressure difference at the header.Correct it, if necessary.Check stock level of PD tank. Correct it, if necessary.Check stability of the jetCheck required static head with indicated static head.If necessary, correct it.Check that the edge of jet is straight. If necessary, correct it.

Shut Down Headbox

Close slide valve of stock feeding pipeThe headbox will be flushed with white water.Stop HC fan pump after 5 minutesStop LC fan pump after 1 minute (Back layer only)Close shower valves, when the wire stopsClose slide valve of headbox feeding pipeHose down the nozzle area and the nozzleClose valve of compressed air to PD tankPreparing for longer downtime:- Empty and clean the headbox

Headbox Operation panel

Vertical adjustment

Horizontal adjustment

Slice opening is displayed on HB operation panel

Top-lip beam vertical adjustment

Hinged joint

Top-lip beam vertical adjustment

Worm shaft Slice opening is adjusted with worm jack on HB

Swiveling away the deckle plate

Measuring pin

Measuring unit for slice-opening size

determination

Deckle plateHex. boltsHinge

Sidesection

Slice opening is measured with measuring unit on deckle plate

Bottom lip extension

Top-lip beamSlice lip

Apron board

Bottom lip

l = Bottom lip extensionr = Stick downs = Slice opening

Bottom lip extension

Fixing bolt spacer

Bottom-lip fixing bolt

Supportingplate

Bottom lip

Installation lever

Spacer/guide plate

Rod headScrew jack

element

Bottom lip extension is adjusted with worm jack in HB

Display unit for the bottom lip position

Side Section

Scale

Deckle Plate

Bottom lip position is shown with scale on side section(not displayed on operation panel)

Breast roll shower

Nozzle platelets

Breast roll

Breast roll shower

Pressure-difference in Nozzle (Top and Under Top Layer)

Flushingline

Headbox Recirculation valve Recirculation line

Flushingline

Ball valveFlushing line

Pressure-differencetransmitter

Flow rotameter

Check Differential pressure with transmitter.Adjust Differential pressure with Recirculation valve.

Differential pressure in Header (Back layer Only)

ValveMeasuring

line

Three-way cock

Three-way cock

Pressure difference Sight glass

Recirculation valve

Sample-taking opening

Header

Position A: Pressure equilibrium check of pressure difference display

Position B: FlushingPosition C: Sample takingPosition D: Resting position

Check Differential pressurewith sight glass.Adjust Differential pressure with Recirculation valve.

Edge deckle “EdgeMaster”

Edge master improve the straightness of jet in edge area

Fastening and locking of nuts

Fastening bolt

Adjusting bolt(vertical lifting/lowering)

Adjusting screw(swiveling vertically)

EdgeMaster - elevation on front sideAdjusting bolt(vertical lifting

/lowering)

Adjusting screw(swiveling vertically)

Fastening bolt

ShowerEdgeMasterbottom edge

Edge protectionAdjusting screw(swiveling horizontally)

EdgeMaster

Breast roll

Adjusting bolt(vertical lifting

/lowering)Deckle plate

Sealing water distributorHose coupling

Adjustment of EdgeMaster

Basically, 3 directions of adjustment A, B and C of the EdgeMaster are possible:

Vertical lifting / lowering (A approx. ± 5 mm (approx. 0.2 inch))

Vertical swiveling (B approx. ± 4 mm (approx. 0.1575 inch) at the EdgeMaster end)Caution: Do not exceed.

Variation of the outlet width (C approx. ± 5 mm (approx. ± 0.2 inch) at the EdgeMaster end)

Slice-lip adjustment

Cup spring stuck with washer

Collar screw

Hex. nutConnector

Slice lip

Long spindle

Adjusting machine

Slice lip is adjusted with handles.

Slice lip can’t control the BW profile during ModuleJet is running.

Slice lip adjustment and Fiber orientationFiber orientation

TS Jet direction DS

Slice geometry

v wir

e

v wir

e

vjet

vjet

Slice lip is adjusted to arrange Jet direction for fiber orientation.

Ball valve

Solenoidvalve

Water line Compressed-air line

PneumaticControlcabinet

Pressurecontrolvalve

Throttlingvalve

Pressurereliefvalve

Bladevalve

Overflowvessel

Supply

Lightsource

Sequence

Pulsation Damper

Pulsation Damper

Overflowbore

Compressed-air cushion

Suspension

Supply

Perforated-hole plate

Compressedair connection

Outlet

A evacuating compressed airB evacuating suspension

Level is kept in too high→ Increase Air pressure

Level is kept in too low→ Decrease Air pressure

Up down is too big→ Close Blade valve Close Throttling valve

Maintenance

1. Change Seal

2. Change ModuleJet Valve

3. Remove Lamellas

4. Install Lamellas

Maintenance

1. Change Seal


3. Remove Lamellas

4. Install Lamellas

Hydraulic Unit (3 Headboxes share this one)

Long hose -Connect to the port

in tender side of each Headbox Control lever

Header (Top and Under Top layer)

Header(closed)

Flange bolt for header(flange closed: A)

Flange screw for header inserted on flange 　 back side

(flange open: B)

Hex. nut M24 / Md = 400 Nm

Flange bolt for the turbulence generator

Sealing surfaces



Hydraulic cylinder

Header(opened)

Flange for Header (Top and Under Top Layer)

Sealing surface


Flange screw for headerinserted on flange

back side(flange open: B)

Open the header

1. Connect the hoses of hydraulic unit to port of headbox.

2. Turn hydraulic pump and set lever to close.

3. Turn out all flange bolts for the header.

4. Turn out and remove nuts.

5. Set lever of hydraulic unit to open.

Close the header


2. Clean sealing surfaces before closing.

3. Set ever of hydraulic unit to close.

4. Pull header with nuts.

5. Insert and tighten all flange bolts for the header.

Back wall (Back layer only)

Bolts(1)

Bolts(2)

Back wall (closed)

Back wall (open)

Back-wall hinge

Distributor bar

Hydraulic cylinder

Bolts(3)

Open the back wall


2. Turn hydraulic pump and set lever to close.

3. Turn out all bolts(1) and (2) of back wall.

4. Unscrew all bolts(3) and turn them back into distributor bar.

5. Set lever of hydraulic unit to open.

Close the back wall



3. Set ever of hydraulic unit to close.

4. Pull the back wall against the stop by bolts(1) and (2).

5. Insert bolt(3) and fasten them with torque 120Nm.

6. Tighten bolt(1) and (3) with torque 120Nm.

Swiveling away the deckle plate

Measuring pin


determination


Sidesection

Open the deckle plate

1. Remove all red hex. Bolts fir deckle plate fastening.

2. Swivel the deckle plate horizontally open. Carefully put the measuring device out from the measuring pin at top lip beam.

Close the deckle plate


2. Close the deckle plate. Carefully insert the measuring device into the measuring pin at top lip beam.

Open the deckle plate Measuring pin


determination


Sidesection

Change of seals in top-lip beam, slice lip and deckle plate


Turbulence generator

Seal for the top-lip beam

Top lip beamSlice lip

Bottom lip

Apron Board

Bottom-lip seal

Seal for the turbulence generator

Open the deckle plate


1. Dismount deckle plates.

2. Pull old seals out of the grooves.

3. Clean groove bottom.

4. Bond new seals into groove bottom.

5. Install the deckle plate.

Open Header (Top and Under Top layer)

Header(closed)


Flange screw for header inserted on flange 　 back side

(flange open: B)



Sealing surfaces



Hydraulic cylinder

Header(opened)

Change of seals in header

Open Back wall (Back layer only)

Bolts(1)

Bolts(2)

Back wall (closed)

Back wall (open)

Back-wall hinge

Distributor bar

Hydraulic cylinder

Bolts(3)

Change of seals in back wall

Change of seals in header or back wall

1. Open the header or back wall.

2. Pull old seals out of the grooves.

3. Clean groove bottom.

4. Bond new seals into groove bottom.

5. Close the header or back wall.

Maintenance

1. Change Seal


3. Remove Lamellas

4. Install Lamellas

Open cover sheet

Support

Cover sheet

Supporting frame

Change of valve insert

Valve insert

Seal/Mounting plugConnecting bushing

Mixing chamber Screw Throttle

Distributorblock

Motor

Screw

Fork and sealing ring

(valve housing)

Sealing ring(valve rod)

Screw

Holding plate

Valve insert

Valve body

ScrewSealing ring

ModuleJet Valve Change

remove electrical plug-in connectionsloosen screws inside the fork approx. 1 turn with a hexagon socket wrench (pic. 1)

Pull out the fork to the side (pic. 2)

ModuleJet Valve Change

Remove valve insert complete with motor (pic. 3 + 4)

Insert new valve insert (the last 2-3 mm are somewhat difficult).re-insert forkTighten the screws with hexagon socket wrenchReinstall electrical plug-in connections.

Mech. Position Display

Gear Linear force: ± 500 NLinear travel: ±15 mmRev. Backlash: 0.1 mm

ProfilTronicIntelligent Motor Control

Status Display

Stepper MotorLin. travel: 0.5 mm/rev.Power: 24-28 V, 1ASteps: 200/ revolutionSpeed: 1rev./sec (200Hz)

Module Jet – Actuator LVM-3

Maintenance

1. Change Seal


3. Remove Lamellas

4. Install Lamellas

Open Deckle PlateMeasuring pin


determination


Sidesection

Remove Lamellas

Deckle Plate opened.

Turbulence generator Lamella

Slice lip

Bottom lip

Top-lip beam

Remove Lamellas


Bring the Transport Box Lid to the Headbox

Remove Lamellas

Pull the lamellas out of the Headboxand place them on the Transport Box Lid,continuously fitting the Edge Protector.

Remove Lamellas

Lift the Lamellas out of the Transport Box Lid and place in the Shipping Case.Lift simultaneously - Avoid Deformations.

Remove Lamellas

Cleaning of Lamellas

Lamella holding unit

Lamella

Remove the suction Lifters. During the Transport remains the Edge Protector on the Lamella Tip.

Remove Lamellas

Removal/mounting of the edge protection

Lamella Edge protection

Wrap the Lamellas in their original Wrapping and store them so that they are protected.

Remove Lamellas

Maintenance

1. Change Seal


3. Remove Lamellas

4. Install Lamellas

Install Lamellas

Unpack the Lamella

Note: In the presentation lamellas in blue and transparent were used. Color depends on the ordered material.

Edge Protector Remains on the Lamella Tip

Install Lamellas

Installation SequenceObserve:The „first“ lamella in the nozzle is the „last“ lamella on the transport box lid.

Last lamella

First lamella

First lamella

Last lamella

Fit Suction Lifters to the Lamella

Install Lamellas

Lift the Lamella Out of the Shipping CaseLift Simultaneously - Avoid Deformations

Install Lamellas

Place Lamella on the Transport Box Lid.(Place all the lamellas in the same way on the transport box lid.)

1 Lamella

2 Transport box lid

3 Lamella

Install Lamellas

Check Direction of InstallationThe chamfer of the lamella tip points in the direction of the top-lip beam.

Install Lamellas


Bring the Transport Box Lid to the Headbox

Install Lamellas

Pull the Lamellas out of the Transport Box Lid and push them into the Grooves.

Install Lamellas


Install Lamellas

Continuously remove the Edge Protector while pushing in the Lamellas.

Push the Lamellas in completely to the Drive Side.

Install Lamellas


Center Lamellas:Measure the distance from the outlet width and align them.

Install Lamellas


Troubleshooting

Contact Voith for support.

Headbox operated below minimum layout limit

§ Flushing before each shut-down

§ Cleaning procedures according to operation manual

§ Boil-out

Insufficient cleaning

Optimization of the retention-aid system with chemical supplier

Poor retention of trash/binders etc. creating agglomerates

Adapt biocide-dosage or -type

Excessive micro-biological activity

Co

nta

min

atio

n/ b

uild

-up

s/ h

ole

s o

r sp

ots

in th

e p

ap

erTroubleshooting

Problem Illustration Possible Cases Solution

Sp

inn

ing

s


Screen-basket defect

Wrong type of screen-basket

Insufficient cleaning

§ Check screen for damages or clogging

§ Cleaning

Contact Voith for Support

§ Flushing before each shut-down

§ Cleaning-procedures according to operation manual

§ Boil-out

Troubleshooting

Contact Voith for support.

Insufficient pressure difference between LC- and HC-Header

§ Check position of slice-adjustment spindles

§ Measure slice opening profile with dial indicator

Slice lip not correctly aligned (parallel with bottom lip)

Cleaning according to operation manual

Slice lip contaminated

Change Slice-LipSlice lip damaged or deformed by excessive adjustment

Bas

is w

eigh

t-pr

ofile

def

ects

(s

ee a

lso

next

pag

e)Troubleshooting


Scanner-measurement error

Scanner-measurement error Check Scanner-noise with a single sheet or preferably a Mylar-sample

§Check stability of retention-aid dosage§Check stability of ash dosage§Check level-stability in PM-chest§Check differential speed

at thick-stock injection§Contact Voith for engineering assistance

Consistency deviations in MD leading to problems in controlling the profile

Check inserts for cracks and gaps - possibly increasing the pressure-loss in the tubes locally

Turbulence generator insert defects

See “contaminations” aboveContamination

§Measure consistency in HC- and LC-Header§Increase retention§Check White water tank for sediments§Check engineering for back-flows

(excessive consistency in LC-Line)§Contact Voith

Insufficient consistency difference between HC and LC

Ba

sis

we

igh

t-p

rofil

e d

efe

cts

(see

als

o p

revi

ous

pa

ge)

Troubleshooting


Constalip-hose Leakage or low pressure (For headboxes with Constalip-hose only)

§Check couplings§Check compressed-air supply§Change Hose

Operation only using short lamellas

Excessive clearance between lamella and deckle-plate due to low operation temperature

§Change wire§Check function of cleaning showers

Wire clogged or defect

Change foilsDewatering-elements (forming-board) damaged

Change Slice-LipSlice lip damaged or deformed by excessive adjustment

Jet-

dist

urba

nces

(g

ener

al)

Troubleshooting


Slice sealing defect (side-sealing between slice-lip and deckle-plate)

§Change sealing§Remove (cut) parts of the sealing outside of the groove

Jet-

dist

urba

nces

(e

dge)

See “Jet-disturbances (general)” above

EdgeMaster clogged or poorly adjusted

§Clean EdgeMaster§Optimize EdgeMaster

See “Contamination” aboveClogging of turbulence-generator tubes

§Forming-roll vacuum low§Forming-roll clogged§(both in combination with formation defects)

Forming-roll defects (Gap-former)

Poor slice-opening alignment

§Optimize Profile through EdgeModule-adjustments§Optimize Profile through slice-lip adjustments §Contact Voith

Profile not optimized

Troubleshooting


Speed-difference between jet and wire too low

§Perform rush/drag-trial to define the actual 0§Optimize settings§Contact Voith

Fib

er-

orie

nta

tion

pro

file

-def

ect

s

Poor forming-board alignment

Wrong flow from EdgeModule- valves

Check calibration (change) of flow-meters

Check distance between forming-board and bottom-lip (horizontally and vertically)

§Check for deviations in slice opening profile§Check straightness of the bottom-lip§Contact Voith

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-8,00

-6,00

-4,00

-2,00

0,00

2,00

4,00

6,00

8,00

10,00

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Position von FS / Messpunkt No.

TSO

-Win

kel [

°]

2006-11-27 2006-11-20 2006-12-04

Example of an operating curve

Business

0401000 headbox