Valmet Consistency Samplers

Sampling and laboratory consistency tutorial

Consistency definition

Consistency is defined as percentage of The dry material consists of all dry solid
dry material in total amount of sample. components in the stock:
 Fibrous materials
 Fillers: China clay, titanium dioxide, talc,
calcium carbonate, etc.
 Possible pigments or coating materials
 Dyes and other additives
 Contaminants such as printing ink

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Consistency definition

𝐷𝑟𝑦 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑠𝑢𝑠𝑝𝑒𝑛𝑑𝑒𝑑 𝑠𝑜𝑙𝑖𝑑𝑠

𝐶𝑜𝑛𝑠𝑡𝑒𝑛𝑐𝑦 % = * 100
𝑇𝑜𝑡𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑜𝑙𝑙𝑒𝑐𝑡𝑒𝑑 𝑠𝑎𝑚𝑝𝑙𝑒

Total consistency = Fiber consistency + Filler consistency

EXAMPLE
Total consistency = 3% and Ash content (amount of fillers) = 10%

This gives: Fiber consistency = 3 % - 0.3 % = 2.7 % 1 % consistency = 10 grams/liter

0.1 % = 1 gram/liter = 1000 mg/liter
Filler consistency = 10 % of 3 % = 0.3 % Ash content is specified as % of the total consistency

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Consistency definition

 Absolute consistency = laboratory consistency

– An absolute consistency sensor does not exist.
– All consistency sensors measure something else and
that measurement value will be related to consistency.

 The transmitter will never be better than lab.

– Transmitter performance is justified by laboratory.
– Calibration requires laboratory samples.
– Follow-up requires laboratory samples.
– Laboratory error = transmitter error?
– Transmitter better than laboratory?
 Sampling & laboratory → person dependent
 Transmitter → process dependent

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Sample accuracy

 Many sources for errors

– Sampling equipment PROCESS
– Sampling routine
SAMPLING
– Sample processing EQUIPMENT

– Laboratory evaluation
SAMPLING
ROUTINE

SAMPLE
PROCESSING

LABORATORY
EVALUATION

PROCESS LABORATORY
CONSISTENCY ERRORS CONSISTENCY

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Why to use a pulp sampler?

 Personal safety:
– This is 1st priority

 Representative samples
– Non-person dependent
– Critical for calibration and follow-up

 Synchronized with sensor

– At sampling → “Sample” function activated

 No clogging problems
– Works in unscreened/screened pulp and high consistency

 Manual and pneumatic operation

– Available in different materials
– Metal to metal seal against process

 Remote operation (pneumatic models)

– High process pressure / high process temperature
– Special sample collector available for harsh and dangerous conditions

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The ball valve
Not designed for safety nor for collecting representative pulp samples

Takes sample at pipe wall → Not representative sample Water film Pipe wall
collecting water film

Dewatering if not fully open → Not representative sample

fibers form a filter pad

Influenced by operator → Not representative sample

High pressure gives big → Dangerous and uncomfortable

volume and uncontrolled flow

Risk for plugging → Dangerous and uncomfortable

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Pulp sampler
Designed to take representative samples safely

Sampling inside water film → Representative sample Water film Pipe wall

Fully open → Representative sample

Operator independent → Representative sample

Adjustable flow → Safe and comfortable

Flushing water → Representative sample

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Sampler installation point

 Installation point is vital

 Must be installed close to the consistency sensor
 Must collect, as well as possible, the same sample
as the sensor measured on
 Display unit must be located close to the sampler
– Easier to use ”Sample” function
– Easier to read sensor consistency value

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Sampling advice
Follow a routine that everybody uses

1. Open the water and clean the sampler. Previous user could have
forgotten.
2. Open fully and wait for a stable flow A sampler have an
(manual sampler). adjustable flow.
3. Put the sample cup in the flow. Use a 1-liter cup.

4. Collect 0.7-0.8 liters, remove the sample

cup.
5. Close the sampler.

6. Put a cover on the sample cup, to avoid Mark the sample with tag #,
evaporation. sensor value, date, time.

7. Open the water and clean the sampler. Cleaning is important to

avoid collecting old dried-up
pulp in the next sample.
Flushing water connection
must be used

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Sampling summary

 Sampling is the main source for errors

 Always use a sampler
– Designed for pulp sampling
– Personal safety
– Representative samples
 Install the sampler close to the transmitter
– Collect the same sample as the sensor measured on
– Note down sensor value (not from the DCS system)
– Use the “Sample” function (if available)
 Follow a sampling routine
– Open water valve and clean the sampler
– Open sampler fully (manual sampler)
– Wait for stable flow – Collect sample – Close sampler
– Cover sample cup to avoid evaporation
– Open water valve and clean the sampler

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Follow-up
Decide rules to follow up Normal routine samples
(frequency depending on installation point)

 Set limits depending on how Set a Cs

< 0,15 % Cs
acceptance level
important the application is.
 Set actions what to do when • Take several extra samples to
Set a Cs level
outside the limit ─ how many lab that requires > 0,15 < 0,25 % Cs
verify the offset.
• Make an offset adjustment.*
samples to collect, how often they more samples
• Two-point calibration?
should be collected, etc.
 Perform the action when needed
and depending on the situation • Take several extra samples to verify the
offset.
Set a Cs level • Make an offset adjustment.*
that requires > 0,25 % Cs
• Two-point calibration?
 This is an example how the extra investigation
• Check transmitter function, service and
structure could look like. repair of the unit if needed.
Some actions are not specified.
(𝐿𝑎𝑏 𝑣𝑎𝑙𝑢𝑒 − 𝑆𝑒𝑛𝑠𝑜𝑟 𝑣𝑎𝑙𝑢𝑒)
* To avoid overcompensation use: 𝑂𝑓𝑓𝑠𝑒𝑡 =
2

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Follow-up

 Only laboratory samples can verify transmitter  Follow up when the process is stable
performance, DCS trends will not give that information – Quick process changes can be impossible to catch in a
 Trust the transmitter laboratory sample
– Don’t adjust the transmitter for every single lab sample  Frequency of follow-up samples
 Set approved limits – Depends on the importance of measurement
 Take repeated samples  Once/shift, once/day, once/week, etc.
 Many components in the Cs control loop can give  Follow the transmitters over a period of time
errors
– Note down all follow-up that has been done
– Dilution water (pressure, quality), dilution valve, – Note down any adjustments (offset, etc.)
mixing condition, chest level, process changes,
pulp quality changes, controller tuning

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Laboratory standards

 Consistency
– Scan M 1:64 (Scan C17:64)
– US Tappi T240 om-88
– ISO 4119:1995
– These standards give total consistency

 Ash content
– ISO 1762:2001
– US Tappi T211 om-85
– The ash (filler) content is determined after
the above consistency analysis

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TAPPI T 240 om-93 Consistency of pulp suspensions

NOTE
The accuracy of the reported
method depends mainly on the
sampling procedure.

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Laboratory standards precision

• TAPPI standard precision rating

✓ Repeatability = 10 %
✓ At 3 % Cs this means 3 % Cs +/ 0.3 % Cs
• According to experience
✓ Best possible equipment
✓ Follow routines as accurate as possible
✓ Stable process conditions
✓ Repeatability = 4 %
✓ At 3 % Cs this means 3 % Cs +/- 0.12 % Cs
• Repeatability can be improved
✓ Always follow the same routine
✓ Sampling, sample treatment, lab evaluation
✓ Sufficient number of samples
✓ 3–5 samples when calibrating a transmitter
✓ 1–3 samples at follow-up

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Dilution of the sample

Water
Sample volume 5 L (A) 5 x ~100 ml of
~700 ml 10 L (B) diluted sample

Sample net weight Dilution bucket 15 L

a (g) +/-0.1 g

a = SAMPLE net weight +/-0.1 gram

A = Dilution water weight, 5 L (Cs = 1–4)
B = Dilution water weight, 10 L (Cs > 4 %)

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Preparing of the filter paper, filtering
Original Cs ≤ 1 % or
diluted Cs > 1% sample

Filter paper Drying oven Exsiccator Filter paper weight: Sample net weight: Water
105 °C +/- 3 °C b (g) +/-0.01 g c (g) +/-0.1 g vacuum
pump

b = Dry FILTER PAPER weight +/-0.01 gram

c = SAMPLE net weight +/-0.1 gram

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Drying and weighing Alternative combinations
a - b - c most accurate
d-e-b-c
g d-g shortest

d f
e

Dryer
110–150 °C

a
Drying oven b Exsiccator c Weight of the
105 °C +/- 3 °C dry pad and
filter paper:
d = DRY PAD and FILTER PAPER +/-0.01 g d (g) +/-0.01 g

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Consistency calculation
Depends on whether the sample was diluted or not and if was diluted - how much.

 Consistency up to 1 %, no need for dilution

100(𝑑 − 𝑏) a = weight of a sample from process

𝐶𝑜𝑛𝑠. = %
𝑐 b = weight of a dried filter paper
c = weight of a sample to be analyzed
 Consistency 1–4 %, dilute to approx. 5 liter d = weight of a dried sample (including filter paper)

𝐴 + 𝑎 100 𝑑 − 𝑏 A = weight of dilution water, approx. 5 liter

𝐶𝑜𝑛𝑠. = ∗ % B = weight of dilution water, approx. 10 liter
𝑎 𝑐

 Consistency > 4 %, dilute to approx. 10 liter All weights in grams

𝐵 + 𝑎 100 𝑑 − 𝑏
𝐶𝑜𝑛𝑠. = ∗ %
𝑎 𝑐

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Valmet Consistency Sampler
(Valmet Nove)
Representative samples from the process
Valmet pulp samplers

Valmet Consistency Sampler (Valmet Nove)

 Manual or pneumatic
 Screened pulp
 0 – 8% Cs

Valmet High Consistency Sampler (Valmet Nove H)

 Pneumatic
 Screened and un-screened pulp
 Cutting piston for shives, knots, sticks
 0 – 16% Cs

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Pressure needed for sampling
Valmet Consistency Samplers (Nove & Nove H)

33 66
Pressure (bar)

Pressure (bar)
22 44

22
11

0
00 0
0
0
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8 00 22 44 6
6 8
8 10
10 12
12 14
14 16
16 18
18 20
20
Consistency (%) Consistency (%)

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Valmet Consistency Sampler (Valmet Nove)

 Installation S P M
– S = Clamp coupling (type Sandvik)
– F = Flange mounted
– T = Thread
 Material
– 2 = AISI 316L
– 6 = Titan ASTM B348 gr.2
 Process coupling
– 2 = AISI 316L
– 3 = Hastelloy C276 F
– 4 = SMO 254 T
– 6 = Titan ASTM B348 gr.2
– 8 = Fiberglass-reinforced Plastic
 Activation
– M = Manual
– P = Pneumatic
 Open/close detector (option)
– 0 = No detector
– 1 = Part of pneumatic version
 E.g.: Valmet Nove S 22 M0 NOTE: Not all combinations are possible, please check with Valmet for availability

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Valmet High Consistency Sampler (Valmet Nove H)
 Installation
– S = Clamp coupling, (type Sandvik)
– F = Flange mounting
 Material
– 2 = AISI 316L
– 3 = Hastelloy C276
– 4 = SMO 254
– 6 = Titan ASTM B348 gr.2
 Material process coupling
– 2 = AISI 316L
– 3 = Hastelloy C276
– 4 = SMO 254
– 6 = Titan ASTM B348 gr.2
– 8 = Fiberglass-reinforced Plastic
– 0 = Coupling not included
 Installation
– 1 = Standard, process coupling 1
– 2 = Blow tank, process coupling 2
 Open/close detector (option)
– 0 = No detector
– 1 = Limit switch
 E.g.: Valmet Nove H S 22 10 NOTE: Not all combinations are possible, please check with Valmet for availability

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Muki H sample collector
To use with Valmet Nove H sampler

 For safe sample collection

 Even to be used at digester blow line
 Consistency range 4–18 % Cs
 Sample volume 0.36 liter
 Clamp mounted directly on Valmet Nove H
 Material: AISI 316 L
 For safety reasons
– No extension pipe allowed on overflow pipe
– Overflow pipe should be connected to an overflow basin,
the basin must have a lid to avoid splashing pulp.
– Use personal protection gear that follows local instructions

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Muki H sample collector

Flush
water  Important notes
– Overflow pipe on Muki H MUST NOT be extended.
Valmet Nove H – Pipe between Valmet Nove H and Muki H should be as
short as possible, max. 1 meter.
– Manual shut off valve on the pipe between Valmet Nove H
Flush
water and Muki H increases safety, in case the sampler cannot
Overflow pipe be closed.
– Flush water for cleaning the Valmet Nove H sampler and in
MUKI H the overflow basin for cleaning the basin to avoid plugging
the drainpipe.
Covering lid
for personal
safety to avoid Overflow basin
splashing pulp

To drain

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Valmet consistency samplers (Valmet Nove) for personal safety

Sampling with ball valve: PERSONAL RISK Valmet Nove: SAFE SAMPLING Valmet Nove H + Muki H: TOTAL SAFETY

 Risk for plugging  Priority 1: Personal safety  Pneumatic for remote activation
 Difficult and dangerous to take a  Priority 2: Representative samples,  Sample collector, Muki H
sample critical for an optimal measurement  Screened or un-screened pulp
– High process pressure result  Piston that cuts sticks, knots, uncooked
– High process temperature  Manual or pneumatic chips, etc.
 No representative samples  Screened pulp  Adjustable pulp flow
 Adjustable pulp flow  Water connection for cleaning
 Water connection for cleaning  0–16 % Cs
 0–8 % consistency

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Sampler installation

 Vertical installation  Horizontal installation

– After pump, 200 mm, 45˚ in relation to sensor – After sensor, 600 mm
– After sensor, 600 mm, 45˚ in relation to sensor – On opposite side of pipe as sensor
– At pipe bend, always after sensor 600 mm and – Manual or pneumatic (most common)
45˚ in relation to sensor
– Manual or pneumatic

200mm

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Samplers’ summary

 Suitable for all applications in pulp and paper mills

– From low to high consistency
– Screened and unscreened pulp
 Available in different materials
– AISI 316L
– Hastelloy C
– Titanium
 Available with different process fittings
– Clamp coupling
– Flanged
– Thread
 Manual or pneumatic operation
 Safe to use
 High repeatability, not dependent on person

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