DEVELOPMENT

CONSULTANTS
NPPC REVIVAL & UPGRADATION PLAN ……… UPDATED D P R
Appendix 1
Page 1
Table-1 : MACHINEWISE RECOMMENDED REMEDIAL MEASURES

I. MF Machine Complex

Sl. Observations on Physical Condition Inference/Remedial Measure

No.
A. Stock Preparation : MF Machine

1. Incoming pulp cy. variation – Reported by Cy. control needed at the outlet of Bleached
operating personnel of NPPC HD Tower

2. All cy. control valves are installed on high As maintenance of control valves is difficult
altitudes and their outlet NRVs are vertically they will be lowered down and NRVs to be
downwards relocated in horizontal lines .

3. All instruments are pneumatic type and their All instruments shall be electronic type and
tubing are missing shall be controlled thru’ DCS

4. Base plates of all pumps get corroded They are to be replaced .

5. Refiner feed pump capacity is inadequate - Pump to be replaced.

(due to proposed bamboo pulp street only) - Refining capacity to be augmented by
installing new DD Refiners

6. All drains got jammed They are to be cleaned, widened and proper
slope to be provided .

NB : All equipment need thorough overhauling

B. Approach Flow : MF Machine

1. Stuff box got corroded To be replaced .

2. The centri-cleaners are of old model and They are to be replaced with efficient 4-stage
hence are inefficient for the production of the cleaners including Deculator and a Pr. Screen
proposed value added product(s) .

3. Base plates of all pumps got corroded . They are to be replaced.

4. Primary cleaners feed pumps frequent bearing New pump is needed.

failure was reported

5. All instruments are pneumatic type and all They are to be replaced with electronic inst.
tubes are missing And shall be controlled thru’ DCS.

NB : All equipment need thorough overhauling

 DEVELOPMENT
CONSULTANTS
NPPC REVIVAL & UPGRADATION PLAN ……… UPDATED D P R
Appendix 1
Page 2

Sl. Observations on Physical Condition Inference/Remedial Measure

No.
C. M. F. Machine

1. Pressurised Headbox

Condition O.K. New hydraulic headbox to be installed

2. Wire Part - New Top Former to be installed

- All rolls to be replaced with new ones

- Doctor blades to be replaced.
- New synthetic wire for wire part.
- Cleaning & painting of rusted parts are
needed
3. Press Part

- Condition is O.K. - Existing press part to be replaced by Tri-

nip press by using the existing press rolls
and felt rolls.
- Parts (M.S.) exposed to the atmosphere
got rusted
- Framing is rigid enough to withstand any
major vibration at higher speeds. There
was an earthquake on 6.8.1988 early
morning (M.F. machine was running at
that time) . Vibration in press was
observed when the speed was increased
above 200 m/min after earthquake

4. Dryer Section

- Condition is O.K. All Dryer cylinders, Felt - All drying cylinders to be cleaned/ground.
Rolls & Paper Rolls got rusted .
- Hood is O.K. - All felt rolls to be ground, cleaned and
dynamically rebalanced .
- Dryer gears are O.K. - All cylinder & roll bearing assemblies to be
overhauled.
- Additional new dryers with accessories to
be installed.
 DEVELOPMENT
CONSULTANTS
NPPC REVIVAL & UPGRADATION PLAN ……… UPDATED D P R
Appendix 1
Page 3

Sl. Observations on Physical Condition Inference/Remedial Measure

No.
- Framing is O.K. - Stretchers & guides to be overhauled.
Additional new oscillating doctor blades to
be installed in the following locatjons :
2 Nos. each in 2nd and 3rd gr. dryers
The existing felt dryers to be replaced with
PV system & dryer screens to augment
the production .

5. Size Press Section

- Condition is O.K. But rolls got rusted - Complete overhauling required .

- The lead-out roll is very badly rusted & - All rolls to be cleaned, ground and
pitted . dynamically balanced.

6. Calender Section, Beloit fixed queen

calender stack (4 Rolls)

- Condition is O.K. - All the chilled iron rolls to be ground .

- Rolls got rusted - Complete overhauling of calender
required.
- Hydraulic system of C.C. roll is O.K. - One more C.C. roll to be installed
- Doctors are O.K.

7. Reel Section

- Condition is O.K. But got rusted - Complete overhauling required .

- Reel drum, spools, spreader rolls to be
reground & rebalanced .

AUXILIARIES : MF Machine

1. Steam System

- Certain portion of steam & condensate - New steam-condensate system to be

piping got damaged. installed.

- Conditions of steam separators &

condensate pumps are very bad.
- New electronic type instruments shall be
controlled thru’ DCS
 DEVELOPMENT
CONSULTANTS
NPPC REVIVAL & UPGRADATION PLAN ……… UPDATED D P R
Appendix 1
Page 4

Sl. Observations on Physical Condition Inference/Remedial Measure

No.
2. Dryer Hood

Conditions of Hood, fans, heaters, air exhaust Need to be overhauled and painted. Hood to
system are O.K. but got rusted in places. be extended for the additional dryers.

3. Vacuum System (Nash Pumps)

Condition is O.K. Overhauling required for the existing vacuum

pumps. Augmentation needed for Tri-nip press.

4. Lubrication System
(Central Oil Lubrication)

- Profuse oil leakage through C-shur tube - New structure for the tube banks to be
banks faced earlier by NPPC . installed.

- The supporting structures of the C-shur (The oil leakage was due to the sagging of
(flowmeters) stations at the basement got the tube banks)
sagged . - System to be augmented for additional
dryers.
5. Control Panels

All instruments for pneumatic & electric - The existing system to be replaced with
controls got damaged/ some components are DCS.
missing .
(Headbox panel is comparatively better)

6. Paper Machine Drive System

- Line shaft, indrive/cardon shaft, geared - Complete overhauling & cleaning /painting
couplings, clutch & brake assembly, belt required.
shiftner assembly, cone pulleys & gear
boxes, conditions are O.K. but got
rusted.

- One floating shaft beside the prime - New sectional drive to be installed for the
mover, geared coupling teeth is wearing entire section.
out very fast. Requires frequent teeth
grinding/ replacement. This is due to
misalignment of shaft.
 DEVELOPMENT
CONSULTANTS
NPPC REVIVAL & UPGRADATION PLAN ……… UPDATED D P R
Appendix 1
Page 5

Sl. Observations on Physical Condition Inference/Remedial Measure

No.
7. Winder (Beloit)

- Condition O.K. - To be cleaned & overhauled.

- Rolls need to be balanced and drive to be
upgraded for the higher speed.

CIVIL : MF & MG Machines

- Drains at the basement & on machine - Drains to be modified by providing proper

floor are poor . slopes, to be made wider & deeper .
- Damaged portion of roof to be repaired.
- Press part beams & columns for MF
Machine to be tested to make vibration
free.

- The drains used to overflow and

damaged the baseframes of equipment NB : Damaged tile lining inside the chests/
- Some portion of the building roof got tanks to be repaired.
damaged .
 DEVELOPMENT
CONSULTANTS
NPPC REVIVAL & UPGRADATION PLAN ……… UPDATED D P R
Appendix 1
Page 6

II. MG Machine Complex

Sl. Observations on Physical Condition Inference/Remedial Measure

No.
A. Stock Preparation : MG Machine

1. Incoming pulp cy. variation – Reported by Cy. control needed at the outlet of Bld. HD
operating personnel Tower

2. All cy. control valves are installed on high Maintenance of control valves are difficult, they
altitudes and their outlet NRVs are vertically will be lowered down and NRVs to be relocated
downwards in horizontal lines

3. All insts. are pneumatic type and their tubings All insts. shall be electronic type and shall be
are missing controlled thru’ DCS

4. Baseplates of all pumps get corroded They are to be replaced with a new one.

5. Refiner feed pump capacity is inadequate Pump to be replaced .

6. All drains got jammed They are to be cleaned, widened and proper
slope to be provided .

NB : All equipment need thorough

overhauling

B. Approach Flow : MG Machine

1. Stuff box got corroded To be replaced .

2. The centri-cleaners are of old model and They are to be replaced with efficient 3-stage
hence are inefficient for the production of the cleaners
proposed value added product(s) .

3. Baseplates of all pumps got corroded . They are to be replaced.

4. All insts. are pneumatic type and all tubes are They are to be replaced with electronic inst.
missing And shall be controlled thru’ DCS.

NB : All equipment need thorough overhauling

 DEVELOPMENT
CONSULTANTS
NPPC REVIVAL & UPGRADATION PLAN ……… UPDATED D P R
Appendix 1
Page 7
Sl. Observations on Physical Condition Inference/Remedial Measure
No.
C. M. G. Machine

1. Pressurised Headbox

Condition O.K. Needs to be cleaned/overhauled

2. Wire Part

- Condition is O.K. - All roll bearings & bearing assemblies to

be checked & overhauled.
- Parts (M.S.) exposed to atmosphere got - Rolls to be ground.
rusted - Cleaning & painting of rusted parts
needed
- Framing is O.K. - Doctor blades to be replaced.
- New synthetic wire for wire part.
- Rolls to be dynamically rebalanced

3. Press Part

- Condition is O.K. - Complete overhauling of all parts required.

- Parts (M.S.) exposed to the atmosphere - All roll bearing assemblies to be
got rusted overhauled.
No undue vibration as reported by NPPC after - Doctor blades to be replaced.
the earthquake .
- Complete realignment of the press rolls
after grinding with proper crowning and
rebalancing .
4. Dryer Section

- Condition is O.K. All Dryer Cylinders, Felt
Rolls & Paper Rolls got rusted .
- Hood is O.K.
- Dryer gears are O.K.
- All drying cylinders to be cleaned/ground.
- All felt rolls to be ground, cleaned and
dynamically rebalanced .
- All cylinder & roll Brg. assemblies to be
overhauled.

Sl. Observations on Physical Condition Inference/Remedial Measure

 DEVELOPMENT
CONSULTANTS
NPPC REVIVAL & UPGRADATION PLAN ……… UPDATED D P R
Appendix 1
Page 8
No.
- Framing is O.K. - Stretchers & guides to be overhauled.

- Doctor blades to be replaced.

5. M. G. Section

- Condition is O.K. - Complete overhauling & cleaning

required.
- M.G. cylinder has been given a - Roll Brgs. & housings to be checked &
protective grease coating to prevent overhauled.
rusting - Rusted parts to be cleaned & painted .
- Framing & doctor got rusted - Doctor blades to be replaced.
- Stretchers & guides of M.G. pressure roll - If patches are found on the M.G. cylinder
got rusted . after cleaning, then it may require to be
ground In-situ for paper finish.
- M.G. hood is O.K.

AUXILIARIES : MG Machine

1. Steam System

- Steam & Condensate Piping got - Damaged piping to be replaced.

damaged at certain places.
- Conditions of steam separators & -
condensate pumps are very bad.
- Steam panels damaged & Inst. are -
missing .
Separators & condensate pumps to be
replaced.
The existing pneumatic instruments to
be replaced by electronic type and shall
be controlled thru DCS.

2. Dryer Hood

Condition of Hood, fans, heaters, air exhaust Need to be cleaned/overhauled/painted .

system are O.K. but rusted in some places.

3. M. G. Hood

Condition is O.K. Needs cleaning and overhauling only.

4. Vacuum System

- Condition is O.K. - Overhauling is required .

Sl. Observations on Physical Condition Inference/Remedial Measure

No.
 DEVELOPMENT
CONSULTANTS
NPPC REVIVAL & UPGRADATION PLAN ……… UPDATED D P R
Appendix 1
Page 9
Lubrication System
(Central Oil Lubrication)

5. - Profuse oil leakage through C-shur tube
banks faced earlier .
- The supporting structures of the C- -
shur (flowmeters) stations at the
basement got sagged.
- New supporting structure for the tube
banks to be installed.
According to NPPC, they have no problem
with the C-shurs now .

6. Control Panels

All instruments for pneumatic & electric - Complete new instruments required for
controls got damaged/some components are each of the sections from headbox to reel
missing . and shall be controlled thru DCS
Headbox panel is comparatively better.
- Complete new internal & field tubing
required.

7. Paper Machine Drive System

- Line shaft, indrive/cardon shaft, geared - Complete overhauling & cleaning/painting

couplings, clutch & brake assembly, belt is required.
shiftner assembly, cone pulleys & gear
boxes, conditions are O.K.
- Alignment of the shaft to be checked.
8. Winder

- Condition O.K. - To be cleaned & overhauled.

 DEVELOPMENT
CONSULTANTS
NPPC REVIVAL & UPGRADATION PLAN ……… UPDATED D P R
Appendix 1
Page 10

III. Converting & Finishing House

(Common for both MF and MG Machine)

Sl. Observations on Physical Condition Inference/Remedial Measure

No.
A. Sheet Cutter – 3 Nos.

1. Condition is O.K. Complete overhauling is needed .

A line of A4 Sheeter & Packer to be installed

B. Guillotine Machine – 1 No.

2. Condition is O.K. Complete overhauling is needed .

 DEVELOPMENT
CONSULTANTS
NPPC REVIVAL & UPGRADATION PLAN ……… UPDATED D P R
Appendix 1
Page 11

IV. Chemical Additives Preparation Plant

(Common for both MF and MG Machine)

Sl. Observations on Physical Condition Inference/Remedial Measure

No.
1. Alum dissolver inside lining totally got worn Relining needed along with a new wooden
out cage having false bottom to be installed.

2. Talcum Dissolver is located adjacent to the Talcum Dissolver to be shifted to the Gr. Floor
control room at the operating floor, due to by which lifting of Talcum bags could also be
which the entire area is dusty and avoided other than keeping control room area
malfunctioning of controllers . clean .

Additional dissolver needed for TiO2

3. Chemical pumps 2 Nos. along with some They need to be replaced .

portion of pipes are missing .

NB : All equipment to be cleaned and

Overhauled .