PowerFlow Paper Solutions

Introduction to Dilution Control System

On This Page

Overview

The PowerFlow Dilution Control System is an advanced Cross-Direction (CD) control solution designed to optimize basis weight uniformity across the paper web. By precisely controlling dilution water flow to individual headbox zones, the system automatically adjusts the fiber consistency to achieve a flat, uniform basis weight profile.

The system integrates seamlessly with existing paper machine infrastructure, including Quality Control Systems (QCS) from major vendors and Programmable Logic Controllers (PLCs) from various manufacturers.

Note

This documentation covers software version 1.0.0 and later. For earlier versions, please contact PowerFlow support.

Key Benefits

Implementing the Dilution Control System provides significant operational and quality improvements:

Improved Profile Uniformity

Reduce basis weight variation (2-sigma) by up to 50% compared to manual control, resulting in more consistent paper quality.

Reduced Operator Workload

Automatic control eliminates constant manual adjustments, allowing operators to focus on other critical machine parameters.

Lower Raw Material Costs

Tighter basis weight control means less over-production and reduced fiber consumption per ton of paper produced.

Faster Grade Changes

Stored profiles for different grades enable quick transitions with automatic setpoint recall, minimizing transition waste.

Features

The Dilution Control System includes a comprehensive set of features for professional paper machine control:

Control Features

  • Multiple Control Modes: Static, Integrating, Dynamic, and Manual modes to suit different machine characteristics
  • Configurable Response Matrix: Define zone-to-zone coupling to account for cross-machine effects
  • Adaptive Gain Control: Automatically adjusts control gain based on operating conditions
  • Deadband Control: Prevents unnecessary valve movement for small errors
  • Position Constraints: Configurable limits for stepping, bending, and adjacent zone differences

Profile Processing

  • Edge Detection: Automatically identifies paper web edges
  • Spike Removal: Filters out measurement outliers
  • Exponential Filtering: Configurable profile smoothing
  • Zone Mapping: Maps scanner databoxes to actuator zones

Integration Capabilities

  • QCS Compatibility: Supports ABB, Honeywell, Valmet, Yokogawa, JASCH, and generic Modbus interfaces
  • PLC Communication: Modbus TCP/RTU, Siemens S7-TCP, Beckhoff ADS protocols
  • OPC Support: OPC DA server for SCADA integration

Operations & Maintenance

  • Grade Management: Store and recall setpoint profiles for different paper grades
  • Valve Flushing: Automated flushing sequences to prevent valve clogging
  • Alarm Management: Comprehensive alarm system with severity levels and acknowledgment
  • Trending: Historical data logging and visualization

Applications

The Dilution Control System is suitable for a wide range of paper machine applications:

Application Paper Type Typical Configuration
Writing & Printing Fine paper, coated paper 48-96 zones, high precision
Packaging Kraft, testliner, fluting 24-48 zones, robust control
Tissue Facial, toilet, towel 24-48 zones, fast response
Board Folding boxboard, white-lined chipboard 48-72 zones per layer
Specialty Filter paper, release paper Custom configuration

System Requirements

Ensure your system meets the following requirements before installation:

Hardware Requirements

Component Minimum Recommended
Processor Intel Core i3 or equivalent Intel Core i5 or better
Memory (RAM) 4 GB 8 GB or more
Storage 10 GB available space 50 GB SSD
Display 1280 x 720 1920 x 1080 or higher
Network 100 Mbps Ethernet 1 Gbps Ethernet

Software Requirements

  • Operating System: Windows 10/11 (64-bit) or Windows Server 2019/2022
  • Runtime: Python 3.10 or later (bundled with installer)
  • Dependencies: All required libraries included in installation package

Network Requirements

  • Static IP address for the control PC
  • Network access to PLC (Modbus TCP port 502 or configured port)
  • Network access to QCS scanner interface
  • Firewall exceptions for Modbus communication
Tip

For best performance, use a dedicated industrial PC located in the control room with a reliable network connection to the PLC and QCS systems.