Q. How long does it take to analyse a particular problem pertaining
to a specific section such as the headbox/approach piping, Press
or dryer for example.
A . In USA and Canada, the duration of the analysis is two weeks. One
week at mill site and one week at PAPYRUS main office for
reconducting the calculations and writing the technical report.
For the one week at mill site, we leave Columbus, Ohio Monday at
the earliest flight available and depart the mill site on Friday
at a convenient time to arrive in Columbus, Ohio no later than
8.00 pm.
In some cases, due to poor flight connections and /or lengthy travel time, we leave Columbus, Ohio on Sunday instead of Monday.
For overseas visits due to the lengthy travel time, the duration of the analysis is two and half weeks.
Q. How do you conduct the analysis?
A. Depending on the kind of design criteria of a section to be
analysed, we fax or mail a comprehensive checklist which is self-
explanatory to be filled out by the papermill.
This checklist is classified into three categories i.e., operating
criteria, design criteria and other measurements which has to be
taken while the machine is shutting down.
Once the checklist is completed, it is a matter of time to conduct
the calculation at the mill site utilizing the PAPYRUS Exclusive
Computer Programs. These complex calculations are done quickly,
accurately, elaborately and easy to understand since we translate
the complex calculation to the practical level at the operating floor. Accordingly, Problem areas are easily identifiable.
Q. Following identifying the problem areas, how do you rate the
success of a remedial solution?
A. We operate "Show and Tell". This means how far the system is
departing from PAPYRUS ideal conditions, the mill will see results.
If the system is running at an ideal condition, there will be no results. But we can assure that these ideal conditions have not always been met especially in the headbox/approach piping systems.
Q. Why did you select the headbox/approach piping systems as always
operating with less then ideal conditions?
A. This is a statement which PAPYRUS has been preaching since its
inception.
Take for example, the calculation to define the jet speed in relationship to the wire speed which is currently performed at the main frame computers and DCS systems. While it is well understood that this is a powerful variable which has a major influence in sheet formation development and its strength properties, the equations in the current industry practice are
considered mediocre and are taken off the shelf and not adapted to the
specific design and application.
This state of inaccuracy has left the machine operator in a state of alarming confusion. As a result, a papermachine making the same grade may run with many different process settings according to the interpretations and preferences of the current Operator instead of a scientifically-based analysis. The result is like a car out of tune. The car runs but ultimately it gives poor gas mileage.
Q. Do you have anything to support evidence of the above statement?
A. Of course we do. In our list of problem areas, you will find that there is a strong connection between what the mill is continuously struggling daily to solve some of these typical problems and the headbox operation. This is an area where PAPYRUS always make substantial contribution. The sheet formation sample in the problem areas category illustrates the dramatic improvement in mills applications when the headbox process settings re applied based on PAPYRUS calculation.