DD®4600/3600 OEM Upgrades

General Equipment Descriptions

© 2016 GL&V. ALL RIGHTS RESERVED.

 DD®4600/3600 Splined Rotor and Equa Flo® Hub
Improves the refining performance
and lowers the the operating cost
DD®4600/3600 Splined Rotor and Equa-Flo® Hub
The DD4600 splined rotor and Equa-Flo hub is our lat-
est design in splined technology. It eliminates uneven
plate wear, eliminates the force imbalance on the rotor,
improves refining performance, optimized flow distribu-
tion, and lowers operating cost. The upgrade kit locks the
shaft from moving axially and allows the rotor to float on
a splined hub.
The splined rotor and hub combination allows the rotor to
float freely and hydraulically balance between the stators
without being hindered by the wear items on the refiner
shaft. As refiners operate, wear items such as the cou-
pling, bearings, and packing sleeve can prohibit the ro-
tor from properly centering between the stators since the
refiner shaft is not allowed to move axially. The results of
uneven plate wear and/or high no load readings are signs
that the rotor and shaft are not moving properly. Since the
shaft must move freely through the packing box, bearing
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housing, and coupling, it is important that these areas
are inspected frequently and kept in good order. Gener-
ally, this is not the case. As the packing sleeve wears
and becomes grooved, scored, or burred, the shaft will
not float freely through the packing box and prevent the
rotor from centering. The slide coupling is another wear
item that can prevent the rotor from centering properly.
Locking the shaft in place with bearing spacers and al-
lowing the splined rotor to move freely on a splined hub
will ensure proper centering of the rotor for uniform fiber
development and lower maintenance cost.
The DD4600 upgrade eliminates the force imbalance that
acts on the shaft end. This is the force that pushes the
rotor toward the motor end and prevents proper center-
ing, which can lead to uneven plate wear and insufficient
fiber development. The splined rotor retrofit will elimi-
nate the force imbalance and improve rotor centering.
The port openings are now located in the hub eliminating
the pressure differential across the rotor providing a truly
balanced rotor with optimized flow distribution. We have
increased the size of the hub to include the ports which
provides 60% more teeth than the original spline design
of the DD4500/3500 equipment. With the increased num-
ber of teeth the stress load per tooth is minimized provid-
ing an extended spline life. The rotor and hub are revers-
ible to provide two life cycles.
DD®4600 Rotor and Equa Flo® Hub
 DD®4600 Power Savings
The Rotor Removal Arm will lower the
downtime for plate changes by up to 30%

DD®4600 Power Savings @ 90% Motor Load

Find your payback below

Size Connected Power Power Savings (15%) 345 Days Payback 345 Days Payback 345 Days Payback
Inches HP kW HP kW $ 0.05/kWhr Months $ 0.075/kWhr Months $ 0.10/kWhr Months
20 200 149 27 20 $ 8,339 <35 $ 12,508 <25 $ 16,678 <20
20 250 187 34 25 $ 10,423 <30 $ 15,635 <20 $ 20,847 <15
20 300 224 41 30 $ 12,508 <25 $ 18,762 <15 $ 25,016 <15
20 350 261 47 35 $ 14,593 <20 $ 21,889 <15 $ 29,186 <10
24 400 298 54 40 $ 16,678 <20 $ 25,016 <15 $ 33,355 <10
24 450 336 61 45 $ 18,762 <15 $ 28,143 <10 $ 37,525 <10
26 500 373 68 50 $ 20,847 <15 $ 31,270 <10 $ 41,694 <10
26 600 448 81 60 $ 25,016 <15 $ 37,525 <10 $ 50,033 <10
30 700 522 95 70 $ 29,186 <15 $ 43,779 <10 $ 58,372 <10
30 800 597 108 81 $ 33,355 <15 $ 50,033 <10 $ 66,710 <5
34 900 671 122 91 $ 37,525 <10 $ 56,287 <10 $ 75,049 <5
34 1000 746 135 101 $ 41,694 <10 $ 62,541 <10 $ 83,388 <5
38 1250 933 169 126 $ 52,117 <10 $ 78,176 <10 $ 104,235 <5
38 1500 1119 203 161 $ 62,541 <10 $ 93,811 <5 $ 125,082 <5
42 1750 1306 236 176 $ 72,964 <10 $ 109,447 <5 $ 145,929 <5
42 2000 1492 270 201 $ 83,388 <10 $ 125,082 <5 $ 166,776 <5
46 2250 1679 304 227 $ 93,811 <10 $ 140,717 <5 $ 187,623 <5
46 2500 1865 338 252 $ 104,235 <10 $ 156,352 <5 $ 208,470 <5
54 2750 2052 371 277 $ 114,658 <10 $ 171,988 <5 $ 229,317 <5
54 3000 2238 405 302 $ 125,082 <10 $ 187,623 <5 $ 250,164 <5

Rotor Removal Arm

The rotor removal arm is a hinged assembly that can
be installed in the field on the opposite side of the door
hinge and has been engineered with minimal deflection
and ease of operation in mind. This mechanism will elimi-
nate the need for an over-head crane or chain fall during
plate changes. The rotor arm will attach to the rotor and
remove the rotor from the refiner during plate changes
lowering downtime for plate changes by up to 30%.

The Rotor Removal Arm will lower the downtime for plate changes by up to 30%

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 Rotor Rebuild Program
Rotor Rebuild Program – A cost effective
solution for upgrading your DD®refiners

Rotor Rebuild Program

GL&V has engineered a cost effective solution for upgrad-
ing your DD refiners. We can successfully convert your
existing solid stainless steel DD3000 or 4000 rotor into
a DD3500, 3600, 4500 or 4600 rotor for much less than
purchasing a new one. If you do not have a spare rotor to
convert, you can participate in our convenient swap out
program. Upon availability, GL&V can provide you with
a rebuilt rotor of a designated series with your existing
solid stainless steel rotor in trade. The swap out program
is available for customers with existing splined rotors or
with non-splined DD4000 and 3000 rotors.

This program is cost effective and available for sizes 34”
through 54”. Depending on the rotor size, on average 20%
can be saved by purchasing an upgrade kit with a rebuilt
rotor compared to purchasing new. Upgrading refiners at
80% of the cost of new upgrade kits will generate quicker
payback and make your projects even more attractive.
DD®4000/3000 Rotor
Experience
Hundreds of customers have reduced gross power con-
sumption by up to 15% to produce the same fiber quality.
Now, we can rebuild your existing DD3000 and 4000 ro-
tors and save you even more.

Rebuilt DD®4600 Rotor Rebuilt DD®4600 Rotor

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Variable Frequency Drive – DD®Refiner Plate Adjustment
Variable Frequency Drive (VFD) – Improves the plate adjustment
during refiner operation and minimizes the fiber quality variation
Variable Frequency Drive for
DD Refiner Plate Adjustment
The GL&V Variable Frequency Drive Package includes an
Allen-Bradley variable frequency drive with an inverter
duty gear motor designed to replace the two speed plate
adjustment gear motor for your DD Refiner. The variable
speed drive allows for improved plate adjustment during
refiner operation, which improves the refiner’s respon-
siveness to process conditions (e.g. flow, consistency)
and hence minimizes fiber quality variation.
The traditional plate adjustment gear motor operates
with two separate speeds. The fast speed is used to load
and unload the refiner quickly whereas the slow speed is
used to make small adjustments to maintain the process
setpoint as the process conditions change. If the dead
band around the setpoint is too small, the gear motor will
over-shoot the setpoint and then make another correction
resulting in under-shooting the setpoint (a.k.a. “hunting”).
“Hunting” can be reduced by increasing the dead band
around the setpoint yet this leads to an overall reduction
in refining responsiveness.
The operation of the VFD allows the gear motor to auto-
matically vary the speed to maintain the process setpoint.
The VFD can load and unload the refiner 25% quicker than
a traditional two-speed gear motor. In addition, the VFD
maintains the process setpoint up to 93% tighter dead
band than with a two-speed gear motor. The tighter dead
band allows the refiner to be more responsive to process
changes, hence minimizing fiber quality variation. The
GL&V VFD technology also offers a mechanical advan-
tage to the traditional two-speed gear motor.
The GL&V VFD system is specially programmed with ac-
celeration and deceleration times that are more gentle
on the refiner gearing and shear pins than the traditional
two-speed plate adjustment gear motor. When running,
the traditional two-speed gear motor operates at full
speed and full torque without any ramp up time. In this
manner the full torque of the gearmotor is transferred to
the gearing and over time can cause wear. By using ac-
cel/decel times, the VFD technology is more gentle on the
gearing resulting in increased life of the refiner adjusting
mechanism and longer shear pin life.
The following is a summary of the benefits and features
for the GL&V VFD plate adjustment gear motor:
• A 93% increase in refiner responsiveness, which leads
to less fiber quality variation
• A 25% increase in refiner loading and unloading speed
• The two speed gear motor starter panel is eliminated
• Conversion Kits are available for DD3000 and
DD4000 refiners
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 Anti-Plate Clash System
GL&V’s patented solution for
preventing plate clashing

Anti-Plate Clash System
Plate clashing occurs because there is not enough pulp
in the refining zones to support the applied load or there
is a mechanical issue preventing the rotor from hydrau-
lically centering. This scenario can greatly reduce plate
life, increase operating cost, and is detrimental to fiber
development. Excessive plate clashing can even damage
your refiner ultimately increasing downtime and cost.
The Anti-Plate Clash System utilizes special and easily
mountable sensors to monitor axial vibration generated
when the refiner plates on the rotor come into contact
with the refiner plates mounted on the stationary posi-
tions.

GL&V has developed a patented solution to this costly

problem. The Anti-Plate Clash System, APCS, can be in-
stalled as an option on rebuilt refiners, new refiners, or
as a field upgrade on your existing low consistency refin-
ers. The APCS technology will notify the operator with
an alarm when plate clashing occurs, at which time, the
operator can unload the refiner below the alarm set point.
The alternate and preferred method is to integrate the
APCS system into the DCS system where the signal can
be recorded and will automatically unload the refiner be-
low the alarm set point when plate clashing is detected. Prevent plate clashing with GL&V´s patented Anti-Clash System, APCS

The sensors detect axial vibration generated by the physi-

cal contact between the rotating elements and stationary
plates converting the vibration into an electrical signal.
This signal is integrated to the DCS system where it is
compared to a predetermined baseline based on the re-
finer’s resonance frequency when plate clashing is not
present as illustrated in the figure below.

GL&V is known for providing customers with cost saving

solutions. Now, you can implement the patented Anti-
Plate Clash System and prevent severe plate clashing,
which prematurely shortens plate life and can potentially
cause mechanical damage to the refiner.
The Anti-Clash System will alert the operator when plate clashing occurs

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 Spiral Trac Kit
Sprial Trac Kit – Improve sleeve life and
significantly reduce seal water consumption

Spiral Trac Kit

The Spiral Trac Version P is field proven technology that
can ultimately improve sleeve life and significantly reduce
seal water consumption with minimal or no sewer losses.
Now, only through GL&V, this technology can be utilized
and enjoyed on your DD4000 and DD3000 refiners. The
Spiral Trac supplied for the DD refiner product line has
been specifically designed according to OEM specifica-
tions for the DD packing box. This approach allows GL&V
to deliver an optimized Spiral Trac for the best utilization
of seal water flow.

Mechanical Seal

1730 Packing with our Spiral Trac Kit. The Mill Pack 1730
Packing is white, non-staining, and most importantly will
not glaze.

Common paper mill packings require more time and pa-

tience to install properly. Gland load must be carefully
Left: The Spiral Trac Version P applied or the packing will glaze due to frictional heat.
Right: Spiral Trac designed for a split mechanical seal for DD®4600 refiners
The hardened, glazed surface material scores the shaft
sleeve and causes leakage. Mill Pack 1730 is resistant to
The end result is significantly reduced seal water con- heat and will not glaze like common mill packings. Since
sumption and considerably improved sleeve life. The Spi- there is less friction around the shaft sleeve, the result
ral Trac can also be used with a specially designed split is not only improved sleeve life but also reduced power
mechanical seal for our DD4600 refiners to further reduce consumption.
seal water consumption, extend sleeve wear, and reduce
power consumption. The split mechanical seal design has The no load power can be reduced by up to 8% with the
also been engineered from our OEM drawings for the DD Mill Pack 1730 and can be further reduced with the split
refiner product line so that GL&V can again deliver an mechanical seal option by up to15%. The split mechani-
optimized product with quicker pay back. cal seal option can only be enjoyed on the fixed shaft de-
sign of the DD4600 refiners.
The Spiral Trac Version P greatly reduces seal water con-
sumption through enhanced utilization of the seal water
flow and centrifugal effects around the rotating shaft.
Contaminants are captured and guided away from the
lower packing ring, thereby reducing sleeve wear. We
recommend that a high quality packing is used in con-
junction with the Spiral Trac to reduce leakage to a drip
rate or even none at all, therefore sending very little or
no seal water to sewer and lowering overall seal water
consumption by 72 to 100%. This is why we use Mill Pack

Spiral Trac with Mechanical Seal

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© 2016 GL&V. ALL RIGHTS RESERVED.
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