Overview
This section covers day-to-day operational procedures for the Dilution Control System. Proper operational practices ensure optimal control performance and system longevity.
Grade Management
Create, edit, and apply grade-specific settings for different paper products.
Valve Flushing
Automated and manual valve flushing procedures to prevent clogging.
Daily Operations
The following tasks should be performed regularly to maintain optimal system performance:
System Startup Checklist
Normal Operation Monitoring
During normal operation, periodically check the following:
- Profile 2-Sigma: Should remain within acceptable limits (typically < 2%)
- Valve Positions: Should not be saturated at limits
- Control Actions: Position deltas should be small and stable
- Alarms: Address any new alarms promptly
Use the trend displays to monitor long-term performance. Look for gradual drift in valve positions which may indicate changing stock conditions or valve wear.
Grade Changes
Grade changes involve switching from one paper product to another, requiring different basis weight targets and control parameters.
Quick Grade Change Procedure
- Select the target grade from the Grade Manager
- Optionally switch to Manual mode for large changes
- Apply the grade settings
- Wait for basis weight to stabilize
- Enable Auto mode when ready
View complete Grade Change documentation →
Valve Flushing
Regular valve flushing prevents fiber buildup and maintains accurate valve positioning.
Flushing Options
| Flushing Type | Description | When to Use |
|---|---|---|
| Automatic | Scheduled flushing at configured intervals | Normal operation |
| Manual Single | Flush one specific zone | Addressing stuck valve |
| Manual All | Flush all zones sequentially | After extended downtime |
View complete Valve Flushing documentation →
Routine Maintenance
Regular maintenance tasks help ensure system reliability:
Weekly Tasks
- Review alarm history for recurring issues
- Check valve position trends for any zones showing drift
- Verify automatic flushing is functioning correctly
Monthly Tasks
- Backup system configuration and grade database
- Review control performance statistics
- Check PLC and network equipment indicators
- Verify scanner calibration status with QCS vendor
Annual Tasks
- Full system backup including all logs
- Review and update grade database entries
- Valve inspection and calibration check
- Software update assessment
Always create a backup before performing software updates or making significant configuration changes.