Paper mill in Sweden uses wireless instruments to fulfill environmental requirements
Rosemount conductivity transmitters help Korsnäs Gävle prevent discharging pollutants into local waterways.
Korsnäs Gävle has deployed a group of wireless conductivity and temperature transmitters from Emerson Process Management to collect critical leak-detection monitoring data at its board and paper production unit at Gävlebukten, Sweden. Improved monitoring enables the company to verify its compliance with environmental monitoring legislation.
Water from heat exchangers at the plant is carefully monitored prior to its return to the sea. Small internal leaks may result in discharges of hazardous chemicals into the local environment. Any leak of acids, bases, or salts will raise the electrical conductivity of the water and is easily detected using a conductivity sensor. A renovation project within the utilities section meant that I/O supporting existing instrumentation was to be removed. The mill therefore needed an alternative way to transmit the required measurements to the main control room.
“Initially we considered installing new cable runs, but the process would have taken too long and would have delayed the planned renovation project.” said Peter Hallenberg, project leader process automation for Korsnäs Gävle. “The application presented a great opportunity for us to install and evaluate Emerson’s Smart Wireless technology, which takes advantage of the WirelessHART communication standard.”
The Smart Wireless devices that Korsnäs Gävle installed include a Rosemount Analytical 6081-C transmitter connected to a conductivity probe. The transmitter sends the measurement data via a wireless gateway to the existing control and data acquisition systems, where it is used to ensure compliance with the environmental monitoring legislation.
The mill also needed to establish new continuous monitoring of emissions from aerated basins and ponds. Technicians installed 22 new sensors measuring pH, dissolved oxygen, and water temperatures, that send data to the central monitoring system. There were no available cable runs, and new cable infrastructure presented a considerable challenge with a cost of €200 per meter. Rather than laying cables, the mill installed six Rosemount wireless transmitters, each with four available inputs, to relay data from the analytical sensors. The wireless instruments provide the necessary data to meet the environmental requirements.
“Less than two months after ordering the Smart Wireless devices, the whole system was fully operational. That is very fast for implementing 30 new measurement points,” said Hallenberg. “Now that the network is in place, we have also found that adding additional devices becomes very simple.”
Specifically, Korsnäs Gävle has installed seven Rosemount 648 wireless temperature transmitters to automate the monitoring of water temperatures in wastewater pits that feed the aerated basins and ponds. A further eight Rosemount wireless transmitters will be installed to identify plugged filters on two wood chip digesters within the main processing section of the plant.
Edited by Peter Welander, pwelander(at)cfemedia.com
Case Study Database
Get more exposure for your case study by uploading it to the Plant Engineering case study database, where end-users can identify relevant solutions and explore what the experts are doing to effectively implement a variety of technology and productivity related projects.
These case studies provide examples of how knowledgeable solution providers have used technology, processes and people to create effective and successful implementations in real-world situations. Case studies can be completed by filling out a simple online form where you can outline the project title, abstract, and full story in 1500 words or less; upload photos, videos and a logo.
Click here to visit the Case Study Database and upload your case study.
Annual Salary Survey
In a year when manufacturing continued to lead the economic rebound, it makes sense that plant manager bonuses rebounded. Plant Engineering’s annual Salary Survey shows both wages and bonuses rose in 2012 after a retreat the year before.
Average salary across all job titles for plant floor management rose 3.5% to $95,446, and bonus compensation jumped to $15,162, a 4.2% increase from the 2010 level and double the 2011 total, which showed a sharp drop in bonus.