The development strategy continues with the installation of SAEL\u2019s ONE Drive Platform, utilizing Long Life inverters with the \u201cONE DCS in Drive\u201d system that allows monitoring and managing any control issues. <\/p>\n\n\n\n
Technical details<\/p>\n\n\n\n
<\/p>\n\n\n\n
- \n
- Motor power: 2 MW, distributed over 38 inverters that constitute the MC2 drive.<\/li>\n\n\n\n
- Standardization: the inverters have been standardized to reduce spare parts to just 5 sizes, facilitating maintenance and operational efficiency.<\/li>\n\n\n\n
- Spares: complete spares of PLCs and inverters to ensure immediate restart in case of failure.<\/li>\n\n\n\n
- ONE Board: use of a single board that constitutes the spare package, also standardized for Mastercan technology boards, which have maintained the same hardware since 2011.<\/li>\n\n\n\n
- DCS stations: two redundant DCS stations for the supervision of the control and plant management, with advanced software tools to monitor every operation performed by operators, particularly useful in case of paper breakage.<\/li>\n\n\n\n
- Operator panels: six operator panels (redundant to the DCS) that allow the visualization and control of each motor, facilitating all necessary maneuvers for machine operators. The new control system immediately proved its effectiveness, fully rewarding the paper mill\u2019s efforts. The start-up was very smooth and perfectly met the deadlines set by the paper mill. Thanks to the adoption of SAEL\u2019s ONE Drive Platform, the Fedrigoni Group continues to improve efficiency and sustainability of its operations, reaffirming its leadership in the paper production sector. <\/li>\n<\/ul>\n\n\n\n
Sectional controls of PM1 and PM3 at Fedrigoni (Verona) <\/p>\n\n\n\n
In the not too distant 2015, after the well-known and devastating fire that developed in the two continuous machines in July, the management chose to recover part of the drives of the two continuous machines to fix MC3 and to completely redo the control of MC1, newly commissioned to SAEL. <\/p>\n\n\n\n
Drawing from the experience gained, in which the control was completed in record time and started during the second week of September in just over 2 months from the fire, and with the extremely high reliability numbers obtained during the 7 years of operation of the MC1 control, the decision to rely on SAEL for the MC3 control was deemed strategic. <\/p>\n\n\n\n
The MC3 sectional control, already in Siemens Masterdrive alternating technology, was replaced by installing the ONE Drive Platform and using Long Life inverters with the ONE DCS in Drive system, from which it is possible to understand and manage every single control issue. <\/p>\n\n\n\n
\u201cA standing ovation to the SAEL team who managed to react even in the significant difficulties of material procurement that plague every single realization in this period. The strong spirit of collaboration, the high availability of technicians, and the high competence that SAEL demonstrated – say the paper mill technicians <\/strong>– immediately allowed us to react together with our internal team to overcome all these problems. Step by step, during the design\/ realization of the control, we always found a valid alternative to every system that was unavailable. The gratifying result offers us unparalleled tranquility today, and with a great sigh of relief after the great work done, we can say that we are, considering also the performance of the PM1 control carried out in 2015, in full safety for the next 30\/40 years\u201d. <\/p>\n\n\n
\n\t\n\t\t\n\t\t\t![](\"https:\/\/www.cartaecartiere.com\/wp-content\/uploads\/2024\/10\/PUBB-ottobre-46.jpg\")
\n\t\t<\/a>\n\t<\/div>\n<\/div>\n\n\n\nThe ONE Drive Platform with liquid cooling<\/p>\n\n\n\n
SAEL\u2019s liquid-cooled inverters, practically free of tangential fans (one for each inverter), have allowed the elimination of all fans previously mounted on each door inside the electrical panels, also eliminating the maintenance of the filters. <\/p>\n\n\n\n
The new electrical cabinets, where our panels are installed, previously obligatorily sealed and abundantly air-conditioned, today become normal rooms or areas of the plant near the motors, as the system is autonomously cooled. The electrical panels, where the inverters are mounted, have closed air recirculation, guaranteeing no contamination of dust, humidity and air acidity; they preserve the electronics, electromechanical and internal components perfectly over time. <\/p>\n\n\n\n
![\"\"](\"https:\/\/www.cartaecartiere.com\/wp-content\/uploads\/2024\/10\/ARTICOLI-ottobre-97-647x1024.jpg\")
<\/a>PM3 Cabinet Drive 2022, Intelligent Drive SAEL, born for paper Industry.<\/figcaption><\/figure>\n\n\n\n To date, the company has already applied this technology in several European paper mills and after more than 6 years since the first implementation, the internal components of the electrical panels still look like new. The experience gained and the excellent performances monitored over the years allow the paper mill a significant annual energy saving: operational and maintenance energy costs of the air conditioners, filters and fans are now eliminated, and heated water is recovered and reintroduced into the pulp preparation circuit, especially during the winter period. <\/p>\n\n\n\n
Fedrigoni Group 2020-21: energy saving study on pulpers<\/p>\n\n\n\n
SAEL\u2019s projects aimed at achieving maximum energy savings in managing the plant pulpers were launched at the Verona and Varone sites. The collaboration between the technical part of the paper mills and SAEL led to the development of a specific solution for pulper control, focusing not only on regulation with specific tools in the drive but also on a refined regulation to emphasize energy savings. <\/p>\n\n\n\n
With the challenging energy situation and its almost prohibitive costs, after several meetings aimed at identifying possible savings, energy meters were installed, one for each utility, to monitor area consumption. SAEL\u2019s Scalink DCS with a free application developed for this purpose – applied in several paper mills – stores and creates targeted summaries (from date to date) to perform selective research for each installed meter. <\/p>\n\n\n\n
![\"\"](\"https:\/\/www.cartaecartiere.com\/wp-content\/uploads\/2024\/10\/ARTICOLI-ottobre-95-1024x800.jpg\")
<\/a><\/figure>\n\n\n\nThis led to the study phase to determine, through automation and regulation with Platform ONE Drive inverters, what savings could be achieved for each area of the plant. After demonstrating with data that the project was feasible, SAEL proceeded with a test by providing a 400 kW inverter – specifically designed, studied, automated and dedicated to rental – to verify the achievable energy savings with adjustments on pumps, liquid ring vacuum pumps and pulpers. <\/p>\n\n\n\n
Only after 2 weeks of testing on a pulper, the paper mill was able to confirm the benefit. With the intelligent Management\/ Drive developed, the first 315 kW pulper in Verona was implemented and after seeing the consolidated results, the second and subsequently the three in Varone followed.<\/p>\n\n\n\n
The applied system, in addition to dedicated automation tailored to the requests of the two plants, took into account the need for accurate monitoring of absorbed energy to document and request the white certificates obtained from energy savings. <\/p>\n\n\n\n
For this, the Scalink DCS was installed, ensuring and providing, in addition to diagnostics, plant operation and the ability to calculate kWh absorbed per ton of pulped raw material. The payback period for the investment, due to the dual effect of energy savings and the valuation of TEE, was very short.<\/p>\n","protected":false},"excerpt":{"rendered":"
After the successes achieved in 2015 with the MC1 control in Verona and energy savings improvements in the pulpers and vacuum pumps at the Verona and Varone plants in 2020-21, and subsequently in 2022 with the MC3 sectional control at the Verona site, Fedrigoni has entrusted SAEL with a new task. Fedrigoni Group is a … Continued<\/a><\/p>\n","protected":false},"author":2,"featured_media":6735,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"inline_featured_image":false,"footnotes":""},"categories":[154],"tags":[145],"class_list":["post-6724","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-ottobre-24","tag-automation-in-paper-mill"],"acf":[],"_links":{"self":[{"href":"https:\/\/www.cartaecartiere.com\/en\/wp-json\/wp\/v2\/posts\/6724","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.cartaecartiere.com\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.cartaecartiere.com\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.cartaecartiere.com\/en\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/www.cartaecartiere.com\/en\/wp-json\/wp\/v2\/comments?post=6724"}],"version-history":[{"count":3,"href":"https:\/\/www.cartaecartiere.com\/en\/wp-json\/wp\/v2\/posts\/6724\/revisions"}],"predecessor-version":[{"id":6739,"href":"https:\/\/www.cartaecartiere.com\/en\/wp-json\/wp\/v2\/posts\/6724\/revisions\/6739"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.cartaecartiere.com\/en\/wp-json\/wp\/v2\/media\/6735"}],"wp:attachment":[{"href":"https:\/\/www.cartaecartiere.com\/en\/wp-json\/wp\/v2\/media?parent=6724"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.cartaecartiere.com\/en\/wp-json\/wp\/v2\/categories?post=6724"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.cartaecartiere.com\/en\/wp-json\/wp\/v2\/tags?post=6724"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}