Solutions for Pulp & Paper

1. Solutions for
Pulp & Paper
FAG Industrial Services
Premium Maintenance Partners

2. Our experience in pulp & paper
Online Systems for condition monitoring
of dryer section, press section, yankee cylinders, winder,
pumps and sorter in paper mills
Installation in paper, tissue and board mills
Mounting and dismounting
of bearings at big press rolls, section rolls and cylinders
Training of technical staff
on site or at our training centre
And a lot of trouble shooting
with the portable system BA (Bearing Analyser)

3. F’IS Online Monitoring systems in paper
Paper Plant Witzenhausen, Germany
Online Monitoring of a paper machine with 380 sensors
Paper Plant Technozell, Germany
Online Monitoring of a paper machine with 280 sensors
Metsa Tissue Oy, Finland
Online Monitoring of tissue paper machine
Paper Tissue Mill, Fort James, Turkey
Online Monitoring of suction press roll and yankee cylinder

4. F‘IS Online Monitoring systems
DTECT X1
Online monitoring modul
for frequency selective
monitoring
Vibro Check
Online monitoring system
with expert system

5. DTECT X1
Alarm outputs for fast
machine shutdown
Monitoring system
Analog output signals for
central control room
Simple alarming functions

6. Condition monitoring online
Central diagnosis centre
Monitoring system
Detailed machine diagnosis
Remote alarming with diagnosis option

7. Vibro Check principle
Customer
VC-MUX 1
Data
Cable
VC-MUX 8
VC-Basicstation
Junction BoxJunction Box
Junction BoxJunction Box
Junction BoxJunction Box
Junction BoxJunction Box
Sensor 1-8Sensor 1-8
Sensor 9-16Sensor 9-16
Sensor 113 -120Sensor 113 -120
Sensor 121-128Sensor 121-128
F‘IS Service Centre
Modem
LAN
Internet

8. VC advantages
 Easy to use - userfriendly customized data visualisation
 For complex Machinery with multiple vibration sources
up to 1024 sensors with one server
 Detect and identify Bearing Damage in it´s
earliest Stadium
 Detect automaticaly:
Imbalance, Misalignment, Gear and Bearing Faults
 Send Warnings via e-mail to Service Centre
 Attend bearing life till final damage stadium

9. VibroCheck Expertsystem Display
Dryer section 4, drive end, with RED-alarm allocated to dryer roll 41

10. Additional Information
In this case damage of the bearing outer ring at guide mill 23
VibroCheck Expertsystem Display

11. VibroCheck Analysis
FFT spectra - Bearing ok

12. VibroCheck Analysis
FFT Spectra - Final Bearing Defect + Expert Diagnosis

13. Case history (example)
Spherical roller bearing defect in dryer unit
The defect was detected in September 2001
Two bearings were detected as damaged or necessary to observe. The
bearing change was scheduled with the next planned maintenance stop
one week later. On two bearings pittings of ca 100 mm lenght were
observed. An Unplanned shutdown due to a total failure of these
bearings were reliably avoided.

14. Case history (example)
The parameter (blue curve) increased for 3 weeks and remained above the
red alert. The expert system reported an outer ring damage, and the
generating curve spectrum verifies this by an unambiguous frequency
sample at the distance of the BPFO.

15. Success stories
Monitoring of suction press roll and yankee cylinder at the
paper plant Eczacibasi / Fort James in Turkey
Cover of the suction press roll may explode due to several reasons.
On the beginning of this stage some small bubbles exists on the
cover which creates vibration on 1xRPM. If the amplitude increase on
1x RPM the roll will be seperated from the Yankee Cylinder to reduce
the damage.

16. Success stories
Monitoring of dryer and press section in a board plant in
Germany
Since installation of the Vibro Check system 31 increasing bearing
defects especially on drying cylinders but also press rolls could be
detected in an early stage. Thus, expencive damages of the board mill
could be prevented

17. “F‘IS Diagnosis Garantee“
since October 1999
Monitoring Bridle bearings inside a 6 h mill

18. Bridle Monitoring in a 6 high
• Monitoring with 10 sensors und DTECT X1
• Telediagnosis with GSM-Modems
• Analysis in the F‘IS Diagnosis center
Monitoring Bridle bearings inside a 6 h mill

19. F‘IS reports mothly about the
condition of the bridle bearings
 Information instead of data
Monitoring Bridle bearings inside a 6 h mill

20. In case of an alarm a F‘IS-
Diagnosis expert analyses the
vibration and reports machine
faults immediately to the customer
Detected Bearing Defects
• 15.09.2000
• 03.08.2001
Monitoring Bridle bearings inside a 6 h mill

21. Defect on a Gear Box

22. Defect on a Gear Box

23. Speed and harmonics
Small gear crack on one tooth
Defect on a Gear Box

24. Bearing defect on the sun wheel
Double planetary gear box with bevel gear stage
and gear reducer unit.

25. Bearing defect on the sun wheel

26. Bearing defect on the sun wheel
Defect was detected in October 1998
The bearing was removed in
February 1999 because of planned
maintenance work. In the time in
between no significant trend
changes were observed.

27. Gearing defect in the 1st gear box stage
Double planetary gear box with bevel gear stage and gear reducer
unit.
Defect on the ring gear

28. Gearing defect in the 1st gear box stage
Spectrum of demodulation
Spectrum of raw signal

29. Bearing defect on a slow running bearing
Bearing running with 5 rpm: rollers and outer race is defect!
Outer race Rollers

30. The defect was detected on the 18th of March 1999. The bearing was
removed in October 1999.
Bearing defect on a slow running bearing

31. Customer advantage (example)
 1 hour shutdown creats costs of
US$ 12.000,- to US$ 17.000,-
 Undetected damage of a bearing
defect in an early stage needs at
least cylinder grinding 13 hours
 Complete
Cylinder change 72 hours
Ref: Paper mill with 1.000 to/day
6 detected bearing defects a year