| On this page we have provided summaries for recent pulp and paper projects that we have provided engineering services for. Detailed summaries in .pdf file format are available for selected projects by clicking on the project .pdf link. Our profiles include:
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Profiles
Load Shedding | |
 | Mills continue to optimize all aspects of their operations with the goal to minimize the costs of production. A significant component of these costs is electrical power. At times, Mills may need to curtail power usage to avoid stiff penalties for over usage or to avoid high market prices for power. Power usage is typically determined by the Utility from within 10 to 15 minute periods. |
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CC Roll Controls | |
 | The failure of a Paper Machine 2nd press CC roll pressure controller prompted a quick solution for eliminating the outdated Fischer & Porter 53MC2112 multifunction controllers supplied with the Beloit press section installed in 1988. |
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Threading Systems/Threading Conveyors | |
| KMH has provided the electrical and control design for installation of a number of paper machine wet end and dry end threading systems. We have completed installations of 4th press threading rolls on Metso SYM-Press II machines as well as numerous threading pans for press, dryer and calendar threading. One innovative installation design recently completed by KMH was a new Metso Foil Force threading conveyor system, consisting of 5 conveyors, for the Calender and Reel of a fine paper machine. Calender and Reel threading, sheet widening and sheet turn-up was completely automated so that minimal operator intervention was required. The project was an overwhelming success as the tail was threaded and the sheet was automatically widened and turned up onto the reel spool successfully the very first time the system was tested. | |
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Paper Machine Interlocking Audits | |
| KMH has a substantial amount of experience with paper machine interlocking strategies through involvement with large capital projects, recent paper machine PLC conversions and field experience. Typically an interlocking audit includes thorough analysis of all applicable machine components including the stock approach system, former, press, dryers, size press calender and reel. Once the thorough interlocking audit is completed improvement recommendations are provided to bring interlocking on the machines to "today's" standards. Our experience shows that a number of critical interlocking deficiencies are normally found during the audits. | |
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Tail Cutters | |
| KMH has provided the electrical control design for installation of a number of paper machine wet end and dry end tail cutters. | |
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Nipco Calender | |
| KMH completed the E&I design for the installation of a replacement two roll Calender complete with an Escher Wyss NIPCO roll and Aquatherm hot water roll. Auxiliary equipment included top and bottom ABB steam smoothness profilers complete with steam skid for individual steam pressure and desuperheating controls, a Mount Hope roll, a hydraulic pump skid and hot water skid. Control was integrated into a new GE 90-30 PLC and Cimplicity HMI, all programming, configuration and graphics were provided, which included all FIFO/permissive displays. | |
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Refiners | |
| KMH has provided electrical, instrumentation and process control design for a number of new and retrofit post refiner applications. Control of stock freeness, specific energy, flow and consistency, as well as refiner motor and plate motor positioning have been integrated into the customer control platforms, replacing OEM controllers in some cases. VFD control of plate motor position replaced 2-speed motor control in some applications. PLC/DCS/HMI configuration was provided. | |
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Cationic Starch Cooking | |
| KMH has completed the electrical/Instrumentation design and make-down/batch/continuous control integration of OEM starch cooking systems into the customer's Foxboro/Allen-Bradley control platforms. Batching includes make-down from solids and pre-conditioning and cleaning cycles of the cooker. Continuous cooking was achieved through ratio control of solids within a cooked starch storage level scheme. PLC/DCS/HMI configuration was provided. | |
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Sodium Hydrosulphite Bleach Handling | |
| KMH provided electrical, instrumentation and mechanical design modifications for the conversion of a newsmill stock bleach generation system into a bulk bleach handling system. Tanker truck unloading of 15% sodium hydrosulphite, and mass flow ratio control to 3% solution was included. | |
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Paper Machine Broke Pulpers | |
| KMH completed an electrical and instrumentation controls audit of paper and pulp machine broke pulpers. Controls upgrades/modifications to couch, press, dryer, dry end and/or winder pulper operations were recommended for the optimization of white water use, energy savings, machine protection and level and broke consistency control. | |
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Near Neutral Deinking | |
| KMH provided the complete E&I design for the conversion of an existing soap storage system into a Sodium Sulphite make-down system. PLC/DCS/HMI configuration was provided, including group start/stop control. Specific gravity control of the chemical was achieved using a mass flowmeter and ratio control of dilution. | |
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Stock Preparation DCS Upgrade | |
| KMH completed a capital cost estimate (+- 10%) for the replacement of 1980's vintage electronic control system (Moore Mycro) with ABB/Bailey DCS system for stock preparation, colour system and broke and white water systems for two newsprint machines. Three vintages of operator consoles within the ABB/Bailey product line were evaluated, as well as all required E&I and DCS equipment upgrades/replacements, including cable, tray and marshalling equipment. | |
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Multi-Stage Screen (MUST) Controls | |
| KMH completed the DCS control and graphics configuration for the operation of a Metso MUST screen. Controls include regulatory controls for level and accepts/rejects flow ratioing as well as sequencing controls for group start/stop and backflush controls. | |
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SCMP Impregnator Feed Controls | |
| KMH provided the DCS control and graphics configuration for feed control of an Andritz impregnator on SCMP stock. Coordinated torque and speed VFD controls on a side-screw and plug-screw feeder were implemented to provide an operator entered production target. | |
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Noss Knotter Controls | |
| KMH implemented the complete electrical and instrumentation installation and controls design for a digester Noss secondary Knotter. PLC and DCS configuration were included for regulatory controls and backflush sequencing. | |
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Kraft Mill Bleach pH Controls | |
| KMH provided detailed electrical and instrumentation design for the installation of pH, residual CLO2 and brightness monitoring and control for four bleach towers. Included the installation design for Valmet Kajaani Polarox-fi, Cormec-I, Cormec-C, Polarox-C, Filtrate Pistons and TBI Bailey pH instrumentation. The controls were integrated into the existing Simatic-TI PLC and Foxboro DCS systems. | |
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Recycled Newsprint Polymer Supply System | |
| KMH developed the detailed design for the installation of a Polymer based chemical addition system. Scope included all electrical and instrumentation equipment specifications, detailed installation drawings, GE Series 6+ PLC and Foxboro IA DCS control algorithm development. | |
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Paper Mill Dye System | |
| KMH developed the detailed mechanical, electrical and instrumentation design/specifications for vendor fabrication of a red dye pump skid. Developed the detailed installation design to integrate red dye flow control into the mill's existing GE PLC/Foxboro DCS control system. | |
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ASA Chemical Additive System | |
| KMH completed the DCS graphic development and control configuration for the control of 4 vendor supplied ASA pump skids c/w emulsifier pumps, ASA and starch flow controls. Each pump skid had a local Allen-Bradley SLC 5/04, these were networked on DH+ to an Allen Bradley 5/40E. A communications gateway from the Foxboro DCS to the 5/40E was configured to allow for information transfer via the 5/40E to the local skid SLC 5/04's from the DCS for control. All message transfer programming for the 5/40E and applicable revisions to the local SLC 5/04's was completed. | |
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Bleach Plant Medium Consistency Pumps | |
| KMH provided the electrical and instrumentation design for the installation of four new medium consistency stock pumps. The design included level control for the suction drop legs and speed control of one pump utilizing a 4160V Allen Bradley 1557 VFD. The pump motor horsepower's ranged from 450 to 600. The design also included integrating control into the existing Foxboro DCS and Allen Bradley 5/40E PLC. | |
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Digester VFD Upgrades | |
| KMH provided the electrical and instrumentation design for the replacement of three existing Relcon Dynamatic variable speed eddy current clutches. New ABB ACS600 variable frequency drives replaced the Dynamatics; horsepower's ranged from 40 to 200. The design included integrating control into the existing Foxboro DCS and Allen Bradley 5/40E PLC. | |
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Paper Machine Retention Monitoring | |
| KMH completed the installation design for a BTG RET-5300 Retention Monitoring System. The RET-5300 samples both Headbox and White Water consistency and determines % retention of fines in the sheet as it is formed. All analytical signals were brought into the Valmet DCS for display and trending. | |
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Paper Machine Broke Shredders | |
| In order to allow for broke recovery in the basements of two newsprint machines, shredder blowers were added for collection and transfer of broke to a pulper. KMH integrated the shredder blower motors and dilution water flow controllers into an existing GE Series 1 PLC. | |