nipco soft calender

GOODWILL GROUP LIMITED QINGDAO FOCUS PAPER CO.,LTD

1

THE DESIGN PROJECT FOR

1NIPS NIPCO SOFT CALENDER

Nipco-4450/900

segmentally camber control

Model:FP14GM081701

GOODWILL GROUP LIMITED.

QINGDAO FOCUS PAPER CO.,LTD.

August,14, 2014


Content

Overview: .......................................................................................................................................................... 1

1. Technical parameter .................................................................................................................................... 2

2. Function description .................................................................................................................................... 4

3. Configuration and scope of supply ........................................................................................................... 9

4. Main purchased parts ............................................................................................................................... 17

5. Spare parts list ........................................................................................................................................... 18

6. Special tools ............................................................................................................................................... 19

7. The documents to be submitted .............................................................................................................. 20

8. Power, oil, water and compressed air consumption ............................................................................ 21

9. The professional service and price ......................................................................................................... 22

10. The pictures for reference ...................................................................................................................... 24


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Overview:

The nipco soft calender adopts the last advanced technology in the world wide, including the hydraulic

pressure loading system, multi-zone nip correct technology, hot oil heat conducting and circulating system,

PLC control system etc. Nipco soft calender is designed for high quality calendering for various kinds of

papers, the Nipco rolls are used as deflection compensation for improving the profiling the paper web.

Herewith the soft nipco calender is designed for grey back and white top coated board.

The high product quality depends on the uniform CD profiles in the paper. When the coating machine is

running, the hard roll and soft rolls will be loaded together with high linear pressure. After that, the rolls will

deform on some extent due to high pressure load. The solution for this problem is that the camber of nipco

roll can be segmentally adjusted, so that the equipped oil-filled pressure unit in the soft roll carries out the

deflection compensation for the calender rolls. The deflection compensation between the calender rolls can

ensure the uniform linear pressure in the nip over the entire width of the paper web to ensure optimal

profiling of the paper board web.

Nipco calender can correct caliper variations of the paper web with good benefit in cross-machine direction.

The Nipco profiling rolls with Nipco technology were developed for the systematic correction of long-wave

and short-wave CD profile deviations. Zone-controlled Nipco rolls are ideal equipment for the long-wave

range. In addition, Nipco rolls also correct short-wave CD profile distortions by means of individually

controlled supporting elements in the shaft.


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1. Technical parameter

1.1 Product parameter

1.1.1 Paper variety： wood free printing paper and newspaper

1.1.2 Basis weight: g/m2

1.1.3 Net width of paper web： 4400mm

1.1.4 Paper roll width at winding stand： 4460mm

1.1.5 Paper web temperature before calendaring: ℃.

1.1.6 Finished paper dryness: %

1.1.7 Surface smoothness of finished paper:

1.1.8 PM arrangement and layout: Installed in two layers, left hand driving (viewing from Winding stand to

the headbox of PM, the drive side is on the left hand)

1.2 The main parameter of the Nipco soft calender

1.2.1 Model: 2 rolls on-line soft calender, single side calendering, hot roll mounted on upside.

1.2.2 Nipco soft roll: Segmentally control camber, The dimension of the soft roll：Ф657×4500mm

1.2.3 Hot roll: With borehole drilled along the roll shell periphery

Dimension of the hot roll: Ф800×4750mm

1.2.4 Paper width: 4460mm

1.2.5 Gauge of calender: 5600mm （To be confirmed)


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1.2.6 Distance between leading line and center line of calender:

1.2.7 Working speed: 880m/min,

Design speed: 900m/min

dynamic balance working speed: 1000m/min

crawling speed: 25m/min

1.2.8 Working linear pressure： 20-200n/mm.

1.2.7 Hot roll surface temperature： max180℃.

Heating system: heating conducting oil circulation system.


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2. Function description

This soft calender is 2 rolls on-line Nipco soft calendar, and the camber can be adjusted segmentally. The

CD variation of the paper web can be regulated finely via calendering by the nipco soft calender. The high

temperature of the hot calender roll can achieve better effect of final paper. As the two part of linear pressure

and hot roll temperature could be controlled separately and accurately, that makes the surface of finishing

paper is improved. The two side difference and CD variation is very small. The using of the segmental nipco roll

and imported covered rubber, also oil heating system, hydraulic system, electronic control system and bearing

sealing elements all are collected form the top international brand suppliers. The configuration and

performance of this machine is high advanced class in international market.

2.1 The soft roll is multi-zone adjustable camber roll with 9 zones.

The thickness of the coated composite rubber is 13.5mm, hardness is 91±1shored. Roughness Ra0.4

The crown can be regulated precisely so as to get the perfect calendering effect. Through button screen,

the operator can adjust the camber segmentally and control CD parameter of paper web in good condition. It is

convenient to operate with high delicacy with outstanding effect.

2.2 Hot roll consist of roll body as middle part and journals of both ends.

The material of roll body: forged roll steel,

The hardness: 750HV; Hardened Layer is 15mm

The roughness： Ra0.1


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The roll body is drilled borehole along the shell. The hot oil heating is designed for temperature control.

The double pass hot oil rotary joint is installed on the driving side. The roll surface temperature can be adjusted

by the hot oil temperature control.

2.3 Hot roll heating and control system

Hot roll is equipped with oil heating and linear control system for oil temperature. Gas heating oil furnace is

equipped with spare high temperature circulating pumps. The power of heating system is about 200kw for hot

roll. This system has high precision of control, long service life. The control of heating and cooling speed is in

linear way. The Speed is 1℃/min, ensure the safe operation of equipment.

The optimized design can ensure the high efficiency of heat, high temperature hot conductivity and

insulativity. The system is equipped with overheat, overpressure, pressure difference, low liquid level protection

mechanism.

2.4 The nip closing, pressure loading and unloading control system

The top roll of the calender is fixed. The nip closing, pressure loading and unloading of the calender roll is

performed by the hydraulic cylinder under the bottom roll. First feed paper web when the calender rolls open,

and then the calender nip closing is controlled by the high-precision hydraulic and servo synchronization

control system to perform the nips loading. The nip linear pressure can be continuously adjusted on the

operating panel with digital display. The two bottom cylinders is controlled by logic program can perform the

bias operation reasonably. When the paper web breaks, the two calender rolls will automatically be released.


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2.5 Hydraulic control system for Nipco soft roll

The crown is adjusted with automatic tracking according to the set line pressure by programmable control

system. At the same time, the crown of a certain section can be individually adjusted according to the press

situation to achieve a satisfactory calendering effect. The oil pressure of the bottom cylinder and the crown

controlled roll can be adjusted with continuous automatic tracking according to the set line pressure. It can be

sub-controlled and the lateral index of the paper can be controlled conveniently and precisely. That could

ensure the calendering effect. When the paper web breaks, the calender rolls will automatically be released.

The hydraulic system is equipped with backup pumps, motors, oil filters and oil temperature control

system, and adopts the efficient energy-saving design with lower power consumption, longtime service life and

good reliability.

2.6 The driving system

Including converter motor, coupling, gear reducer, universal coupling, controlled synchronous belt

transmission device, install pedestal etc. Each calender roll is equipped with 1 set of driving system. The

transmission motor control of calender roll, arc roller is designed by the seller.

Hot roll driving motor power: 1X55kw.

Soft roll driving motor power: 1X75kw.

arc roller driving motor power: 4kw.


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2.7 The Electrical control system

All of the operations are carried out on the electrical-control operation panel and operator station. The

system is equipped with PLC control, the operation panel with color touch screen, as well as other relevant

instruments, buttons, switches, indicator lights, etc. And the interface is arranged for the future integration with

the related paper machine control system.

2.8 Interlock protection system

2.8.1 The drive motor of the calender roll will not start without the oil pump motors of the hydraulic stations

running.

2.8.2 If the nip is not close, the speed of calender roll driving motor is controlled synchronized. After the

nip is closed, the calender roll will be controlled by torque control.

2.8.3 The calender nip releases automatically when paper breaks.

2.8.4 Safety protection is designed for bottom cylinder bias loading.

2.8.5 The temperature monitoring, temperature difference control, alarm and safety protection are

equipped at edge of both ends for the coated rubber.

2.8.6 The hydraulic system is equipped with oil level alarm and filter block alarm, interlock controlled with

the driving system.

2.8.7 Oil temperature auto control and alarm are available for hydraulic system.


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2.8.8 Auto switch-on control for standby motor of hydraulic system.

2.8.9 Bearing thin oil lubrication alarm is equipped for hot roll.

2.8.10 The complete protection and alarm system, fault monitoring, and acoustic and optic alarm, short

circuit, overcurrent, over-temperature, over-pressure difference for oil, and overload protection for oil pump.


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3. Configuration and scope of supply

3.1 Soft roll 1set.

Roll shell: High grade steel, forging , hot treatment and crack detection.

Rubber cover coating: Stowewoodward

Bearing: Spherical roller bearing , SKF 2 sets.

Support stand: 2 sets

Support material: nodular cast iron

Installing position: Installed on the loading arm or frame.

Driving device: timing belt drive, big belt wheel is installed on the shell, universal coupling,

reducer, motor driving.

Weight(including support ): 1×10500kg.

3.2 Hot roll 1set.

Type Borehole drilled along the periphery of the shell, roll steel forged.

Dimension: Φ800×4700mm

Bearing house 2sets.

Bearing material: nodular cast iron, 2 sets

Bearing: Spherical rolling bearing, SKF 2 sets.


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The bearing lubrication: Buyer supply thin oil source.

Heating system Hot oil circulation.

Rotating joint Double pass, imported. With 2sets of metal hoses.

Installation Installed on the frame or loading arm

Driving motor Motor gear, reducer, universal coupling drive

Weight (including support): 1X15500kg.

3.3 Nip close and pressurizing device 1set.

Type: Electrical hydraulic servo control, 2sets.

Nip close: Precise synchronization control

Pressure loading for rolls: Precise proportional control. The two cylinders can be adjusted separately.

3.4 Arc roll: 1 sets, equipped by user.

Type: Fixed camber, rubber covered. The direction can be adjusted manually. Equipped

with paper threading rope, wheel and belt wheel

Roll surface dimension: ～Φ240×4700mm.

Others: Installing support 2sets. Motor support 1 set. Small belt wheel device 1 set.

Motor 1 set. Fasteners and shield, etc.

Installation: fixed installation


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Transmission:1X4KW converter motor, triangle belt transmission. The electronic control is equipped

according to paper machine.

3.5 Break detector 2sets, before and after nip, each 1 set

3.6 Doctor 2sets.

Doctor body material Low carbon steel

Blade support material SS steel

Configuration Form

Application Quantity Scraper blade Pressurizing and knife lifting Swing

Hot roll, soft roll 2 Carbon Fiber Compressed air pipe AC motor

Compressed air pipeline: Seller supply the air pipe, and connected to the air control box on the frame.

3.7 Paper threading rope, wheel and support:

3sets. Seller supply, Installation will be finished in buyer side according to their need.

3.8 Soft roll cooling and air blowing system in two side 1set.

Type: 2 sets of air blowing head, multi-nozzle, adjustable.

Installation: fixed installation

Cold air capacity: ～40m3/min，～4000Pa，≦30℃

Air source: 1 set of converter motor, including electronic control. Buyer supply.


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Body pipeline: seller supply, with the interface

The pipeline from fan to body: 1 set, buyer supply, and connect to body interface.

3.9 Soft roll temperature detecting device

Position: beside the paper edge on soft roll

Type: with infrared alarm

Installation and detecting: fixed installation, moveable detection

Driving type: hydraulic cylinder, the stay time is adjustable on both ends

3.10 The hot roll heating and Temperature control system 1set.

Application: hot roll heating and temperature control

Heating type: Hot oil circulation.

Heating medium: Conduction oil, to be purchased by buyer, the seller shall recommend the

brand.

Heat Source: natural gas

Composition Hot oil stove and temperature control device: 1 set,

electrical control system: 1set

oil filling pump device: 1 set,

expansion tank: 1set,


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oil storage tank: 1 set,

hot oil piping system: 1 set

Hot oil piping system: supplied and installed by buyer, seller provide the technical guidance.

Cooling water pipeline: supplied and installed to the specified interface by buyer, the seller provide

technical guidance.

Electric Wire & Cable: power cord and control line of hot oil system supplied by buyer, the seller provide

installation guide.

3.11 Soft roll hydraulic control system: 1 set. Pumping station and valve stand share it.

Application: the controlling of segmental nipco soft roll

Features: Constant pressure variable proportional pressure control system, with spare motor, oil pump, oil

filter. And also equipped with hydraulic oil temperature automatic control system and electric heater. Automatic

interlock protection

Body material: Low-carbon steel, surface plated with nickel.

Oil tank: SS, surface painted.

Hydraulic piping system: 1 set, including pipe joint, steel pipe, hose, pipe clamp. The seller supply it and

provide the installation guidance.

Cooling water piping: To be supplied and installed by the buyer, including pipe, joint, valve and


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connect to condenser of hydraulic pressure station.

3.12 Nip close and pressuring hydraulic control system 1 set (shared by hydraulic pressure

station, valve stand and nipco soft roll)

Application: The nip closing, pressure loading and unloading of the calender roll.

Type: Constant pressure variable proportion and servo control system, with spare motor, oil pump, oil filter.

Body material: Low-carbon steel, surface plated with nickel.

Oil tank: SS, surface painted.

Hydraulic piping system: 1 set, including pipe joint, steel pipe, hose, pipe clamp. The seller supply it and

provide the installation guidance.

Cooling water piping: To be supplied and installed by the buyer, including pipe, joint, valve and

connect to condenser of hydraulic pressure station.

3.13 Operation panel and electrical control system 1set.

Application: Control the operation of Calender.

Content: Calender control cabinet, host computer, operating panel (SS material, including

PLC touch screen). The interfaces related to the paper machine production line control are available.

Electric Wire & Cable: The electric wire & cable which connect hydraulic pressure station, PLC control

cabinet, operating panel should be supplied by buyer, the seller provide installation guidance.

3.14 Piping configuration To be supplied by the buyer, and connect to the corresponding position


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on soft calendar.

Application: Pneumatic control, cooling water, thin oil lubrication and heat oil pipe line.

Material: Low-carbon steel

Scope: The cooling water pipe is connected to the hydraulic station cooler, hot oil station cooler and the

reducer cooling water tubes. Thin oil lubrication connected to the hot roll bearing base and small belt pulley

bearing house. The compressed air connected to the operation panel and pneumatic control box.

Pipes and piping components: should be supplied by the buyer.

3.15 Frame and the related components

3.15.1 Machine frame 1 set. Consists of 2 single frame.

Type: Open type frame.

Material: Low carbon steel, welding, stress-relief annealing, sandblast, antirust painting, CNC

machining.

3.15.2 Connecting beam 3 sets.

Material: Low-carbon steel, welding.

3.15.3 Loading arm of the bottom roll 2 sets.

Material: Low-carbon steel, welding, stress-relief annealing, sandblast, antirust painting,

CNC machining.

3.15.4 Catwalk ,handrail, guardrails: 1 set,by the buyer.


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3.15.5 Base plate: 2 sets, by the buyer, the seller provide the drawing.

3.16 The driving devices of the Calender roll: 2 sets, including motor, reducer, universal coupling

and coupling sleeve, should be supplied by the buyer

Converter motor power: hot roll 2×55kW, with coder.

Soft roll 2×75kW, with coder.

Other transmission: reducer 2 sets, coupling 2 sets, universal coupling 2 sets

Coupling sleeve 4 pieces, transmission base 2 pieces, Shield, anchor bolt, etc.


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4. Main purchased parts

Sl. No. Name Supplier Remark

1 Hot roll

2 Soft roll metal shell

3 Soft roll rubber coating Stowewoodward Hardness is 90-92 ShorD

4 Rolling bearing SKF/FAG

5 High precision proportional valve

and servo valve

ATOS Italy

6 Pressure sensor ATOS Italy

7 Position sensor Balluff Germany

8 Hydraulic seals elements MERKEL，FP Germany, Italy

9 Hydraulic pipe joint, hydraulic steel

tube PARKER，EMB U.S.A

10 Double-pass hot-oil rotary joints Maier Germany

11 The main heating linear controller JM Germany

12 Nonlinear Adjuster JMSR Germany

13 Electric 3-way regulating valve ARI Germany

14 Zero leakage manual valve Taiwan

15 Hot oil pump KSB Germany

16 PLC SIEMENS，S7-300 Germany

17 10’’ touch screen SIEMENS Color

18 Soft roll temperature detector U.S.A

19 Paper web Break detector U.S.A

20 Low-voltage components ABB

21 Doctor holder and doctor blade Suzhou jinggang Japan

22 Soft roll timing belt Shanghai Fulong China

23 Hydraulic components


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5. Spare parts list

Sl.No. Item Specification Qty Used for Remark

1 Timing belt 20M 1 Soft roll drive Shanghai Fulong

2 Rotary oil seal 4 Nipco soft roll Italy

3 Filter 8 Hydraulic

system China hytek


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6. Special tools

6.1 1 set grinding tools for Nipco roll

Including connection chuck 2 sets, taper sleeve 2 sets, bolts etc.

6.2 The tools for uninstallation and installation of Nipco roll

Including 2 sets support stand, 4 sets long bolt, support plate 1 set, lifting jack 1 set, the plastic guiding ring

1 set.

6.3 spindle head covered with rubber: 2pcs


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7. The documents to be submitted

7.1 layout drawing

7.2 Master drawing

7.3 Electrical hydraulic control drawing.

7.4 Oil heating system document

7.5 Operation manual (Including wearing parts drawing)

7.6 The inspection certificates of the purchased parts and the related technology literature


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8. Power, oil, water and compressed air consumption

8.1 The total consumption of power:～440kw, including:

8.1.1 Driving motor for calender roll, arc roll, guide roll:～130kw

8.1.2 Heat Oil system：～250w

8.1.3 Hydraulic system motor: ～50kw.

8.1.4 Others：～10kw

8.2 Bearing thin oil lubrication: according to the design

8.3 The total cooling water consumption for hydraulic system, reducer, and hot oil system: according to the

design.

8.4 Hear conducting oil: according to the design.

8.5 The oil for hydraulic system: according to the design.

8.6 Compressed air: small amount consumption


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9. The professional service and price

9.1 The professional service

9.1.1 after the contract entering into force 90-120 working days Qingdao Focus Paper Co., Ltd should finish the

production of all equipment within the scope of the contract.

9.1.2 Qingdao Focus Paper Co., Ltd will offer design paper of equipment, the introductions, Spare parts table

according the above list.

9.1.3 Qingdao Focus Paper Co., Ltd is responsible for the local suppliers within the scope of mechanical,

electrical installation and commissioning of the guidance, while the buyer is responsible for the installation

experts.

9.1.4 Qingdao Focus Paper Co., Ltd is responsible for the guarantee of quality, and provide the necessary

production technology consulting services to the demanding side in one year

9.1.5 Qingdao Focus Paper Co., Ltd. will dispatch 2-4 engineers to guide the installation and commissioning

and give the local workers training for system operation. The Buyer will afford the double fly tickets and the fee

of the room and board. And afford the salary of $200/engineer/day


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9.2 The Price

CIF Chittagong: USD$1,368,000.00

Payment: 30% T/T in advance, 65% LC at sight, 5% TT when the machinery normally run.

Lead Time: 90-120 days after 30% T/T in advance

Valid date : Confirm the contract before 30/10/2014

Thanks &Best Wishes…..

GOODWILL GROUP LIMITED.

Qingdao Focus Paper Co.,Ltd.

Add: No.2.Minjiang Road, Qingdao, China

Tel: 0086-532-80795991/80795992/85816882

Fax: 0086-532-85816772

Mobile: 0086-138-542-58666

Email: [email protected] / [email protected]

MSN: [email protected] Skype: focuspaper

mailto:[email protected]


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10. The pictures for reference


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nipco soft calender

Documents

soft nipco calender

nipco rolls

calender rolls

soft rolls

nips nipco soft calender

paper web

camber of nipco roll

high linear pressure