LC Refiner Use: Preparation

1. Minimum 2 hours before trial, switch on all electrical power supplies to the refiner loop equipment to let them warm up (do it first thing in the morning). WAIT to power on refiner voltage box and VFD if plates still need to be installed. Safety Tip: Generally it is good practice to stand aside a bit and face away from the electrical disconnect boxes and the item that is being turned on by it, just in case an arc occurs in the electrical switches. Don’t try to switch them slowly, just throw it fully into the new position.
   1. Turn on high voltage power box
   2. Turn on VFD electrical cabinet power and switch VFD to remote (switch speed ref. source to REM). Use CCW option for rotation direction.
   3. Turn on DAQ board power
   4. Turn on pump VFD
   5. Turn on DAQ computer (password is logic)
   6. Turn on Gap controller power
2. Load tank
   1. Always use tank A for repulping and mixing
   2. Close butterfly valve at bottom of tank
   3. If making 4000 L of suspension, fill tank with 3000 L  water before adding any pulp
   4. Add calculated amount of pulp and enough water to reach 3,600. Set lower mixer to 47 Hz, and overhead mixer at 20 Hz, on Reverse
   5. After the pulp suspension has mixed for long enough, measure consistency to determine how much additional water needs to be added. Because the seal water from the mixer is continually diluting the pulp suspension, wait to add the last required amount of water until immediately before the trial begins.
   6. Shortly before trial, run overhead mixer in opposite direction (forward) for a few minutes to dislodge any pulp flakes. Then, return to reverse direction.
3. Is the correct refiner door installed? If not, it takes 2 people about an hour to change the door.
4. Install plates at this time if necessary. Allow 30 minutes for this. To do so:
   1. Ensure refiner power is locked out.
   2. Very thoroughly, clean plate mounting surfaces and sealing area of door – all fibres must be removed for a proper fit
   3. Plate 1 goes on rotor, plate 2 goes on stator
   4. Align door plate with stamp at top. Align rotor plate with stamp aligned with notch on rotor.
   5. Be sure to use exact socket size to avoid stripping the bolts
   6. All bolts have a torque requirement – use torque wrench and do not exceed requirement posted on VFD
   7. Close refiner door carefully, making sure pipe join above is clear. Close the join but not too tight, using pipe wrench. Some water dripping is ok, fibres will seal it when pulp starts to flow. Install horizontal pipe such that the pressure sensor sits on the bottom of the pipe. Thermocouple will be horizontal.
   8. Plug in thermocouple and pressure sensor wires.
   9. Now it is safe to unlock power for the refiner and power up the VFD.
5. Perform consistency and conductivity tests, if necessary (for the current flow meter, conductivity test is not required)
6. Open NI Measurement & Automation icon on desktop
   1. “Devices and Interfaces”
   2. Under “Configuration”, should see:

i.     NI USB-6218 “Dev 1”

ii.     NI USB-6218 “Dev 2”

iii.     NI cDAQ-9174 “cDAQ 1”

iv.     NI 9265

v.     NI 9211

1. Can compare the list with DAQ Automation example image in Nici folder.
2. If any of the devices are missing in the list, check physical connections for any disconnected wires. Press components together to encourage proper connection.
3. Do a self test for each device.
4. Click the “Test Panel” tab

i.     Click “Start Test” for each device to make sure they are all working. Each device should plot a graph.

1. Open LabVIEW (Aikawa Refiner icon on desktop)
2. Calibrate LabVIEW user interface (UI)
   1. Gap Calibration

i.     Open the drainage valve to the refiner

ii.     Remove refiner shaft cover

iii.     Remove the gap motor connection shaft, if not done during plate installation

iv.     Close gap manually until plates are touching (stiff resistance when turning wheel). Open and close a few times to ensure good repeatable contact before zeroing for good.

1. Open LabVIEW user interface VI on DAQ computer desktop
2. Zero offset adjustments

i.     In LabVIEW, go to Window –> Block Diagram, navigate to the offset adjustments

ii.     Ensure the the offset adjustment values are set to to zero for the following:

1. Pressure out (psi)
2. Pressure in (psi)
3. Gap (mm)
4. Power (kW)
   1. Run program for approximately 10 seconds

i.     Press run button in LabVIEW

ii.     Wait approximately 10 seconds and press the stop button on the UI

1. Set offset adjustments

i.     Write down / copy the displayed values for each of the four readouts mentioned above

ii.     In the LabVIEW block diagram window navigate to the offset adjustments

iii.     Input the negative value of each of the above variables into its offset adjustment constant

iv.     Check your offsets by clicking the run button again, the values should be around zero, then click Stop

1. In the LabVIEW UI input the plate BEL (km/rev) and the consistency (%)
2. Run LabVIEW UI and manually open gap to between 8.5 and 9.0 mm (read on the LabVIEW UI)
3. Stop LabVIEW UI
4. Install gap motor connection shaft
5. Install refiner shaft cover
6. Close refiner drainage valve
7. Turn on refiner seal water:
   1. Turn on blue tap on the wall behind pump controller
   2. Open the labeled valve below the tap, it is the left valve
   3. Open the green handle of the seal water valve at the refiner (can do this now, or when refiner is first started)
8. Ensure that the air is on and that there is 40 psi of pressure on the gauge below the green valve
9. Open valve beneath pulp tank
10. Check all loop valve positions and verify that pulp will circulate as desired. Check with all team members that everyone and everything is ready.

LC Refiner Use: Preparation – Operation – Conclusion – Detailed Guidelines

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