Predictive Maintenance In Paper Industry

2. A Global Solution Provider withPatented Mechanical PredictiveAnalytics.

4. WHY CHOOSEUS

5. INDUSTRY GAP: LACK OF SCALABLEMECHANICAL PREDICTIVE ANALYTICS 20% of breakdown Hydraulics 5% of breakdown Thermal • • Pressure Temperature Flow Rate Contamination Density Temperature ThermalMapping Thermal Flux • • • • • • • • Standard IoT (sensors +wireless transmission) Standard IoT (sensors +wireless transmission) 70% of breakdown 5% of breakdown Electrical • • • • • • Mechanical • • Wear Deterioration Backlash Increase inclearances Vibrations Acoustics Electronics Life Power surge Current Voltage Power factor EnergyEfficiency • • • • • • Very high frequencydata Difficultto decipher signal from noise Bandwidthlimitations Storage limitations Standard IoT does not work:-/ Standard IoT (sensors +wireless transmission)

6. Technology &Features

7. IDE: DIGITIZE ANY EQUIPMENT IN UNDER 1MINUTE Installs on any machine within seconds through a magneticconnection. Immediate feedback through visual fault-detecting indicators. Monitor remotely and wirelessly, to mirror notifications and record data. 1 2 3

8. IMPORTANCE OF PAPER INDUSTRY ✓ The pulp and paper manufacturing is among the world's most energy -intensive industries. ✓ The industry plays an important role in sustainable development because its chief raw material—wood fiber—is renewable. However, nowadays waste or reused paper is also recycled as an alternative to conserve forests. ✓ The Indian Paper industry produces 10.11 million tonnes of paper per annum. This is possible with the existence of 55 paper mills with an installed capacity of 260 lakh tonnes. ✓ The turnover of the industry is likely to touch Rs. 60,000 crores mark by 2025. ✓ The industry employs at least 3 lakhs of people directly and 10 lakhs indirectly. ✓ The per capita consumption of paper in India is still at 5.5 kg. ✓ The paper industry is treated as the basic sector of the economy and it helps all the human beings for the growth of education, reading, writing, storing, knowledge, quality of life, culture, and other sectors of the economy. ✓ As Pulp and paper is the third largest industrial polluter to air, exhaust fans are used on a large scale to combat the pollution.

9. WHY PREDICTIVE MAINTENANCE IS ESSENTIAL? ✓ Maintaining availability, maximizing uptime and avoiding secondary damages are the main reasons for applying condition based monitoring in pulp and paper. ✓ Vibration in calender machines is difficult to analyze with traditional vibration measurement. ✓ Calender rolls running for too long become worn, resulting in vibrations throughout the stack. ✓ Excessive vibration levels in the calender require less speed, sequentially leading to potential quality and production losses. ✓ Besides, high vibration levels in the stack overall also increase wear on the other rolls in the stack. ✓ The bearings of the suction roll used in extractors if unmonitored, can lead to a downtime which can cost as much as $10,000 per hour and stretch into days. ✓ The extraction of moisture from the wood (raw material) is generally done within 24 hours, else the wood pulp converts in to waste. This accounts for a direct loss.

10. WHAT ARE THE IMPORTANT PROCESSES IN PAPER PLANT?

11. WHAT ARE THE IMPORTANT EQUIPMENT IN PAPER PLANT? ✓ Typically conveyor belts, twin wire presses, chippers, chip classifiers, blowers, screw conveyors, refiners, pressure screens, agitators, nip monitoring, felt rollers, spreader rolls, suction rolls, yankee cylinders, drying cylinders, vacuum pumps, realers, paper finishing machines, electrical motors, pumps, fans cutters, bearings and gears require condition monitoring in a Paper & Pulp Industry. ✓ In a paper processing line, rollers are used in wet press as well as dry press. In wet press, the rollers are used to compress the pulp. In dry press they are used to extract the excess moisture . Rollers used in both press have suction-roll bearing which need to be monitored. ✓ The paper finishing machine powered by a motor is used to press the dried mesh from the drier to form a sheet which can further be processed. The machine must operate at a very high frequency, else the quality of the paper generated is affected. Hence monitoring the motor of the machine is vital. ✓ A single paper plant has several calender machines. Each calender machine has multiple rollers. Some rollers are soft, and others are of steel. Low vibrations (Soft rollers) cause reduction in the speed of the machine. High vibrations (steel roller) cause wear and tear of the roller. Hence the vibration range of the rollers is defined under stable conditions and set as a threshold. Change in the vibrations of one roller affect the other rollers. Vibration on each roller should be monitored to capture the performance of the machine. ✓ Monitoring the bearings of the twin wire presses is extremely important as the quality of the paper (its thickness, inking, rolling) is directly affected with the pressing operation.

12. Case Study: Remote Vibration monitoring on the bearing of a two-chambered twin wire press predicts its failure; subsequently saving USD 33 Thousand Industrial Data Enabler (IDE), a patented remote vibration monitoring tool installed on the bearing on the Two-chambered twin wire press pointed the loosening of the set screws adversely affecting the bearing. This manifestation could not only affect the roller bearings to spin on the shaft, damaging both the shaft & bearing but also costly repairs with at least 10 hours’ of production loss. THE NEED One of the twin wire press machine operated 24 X 7 to fulfill the production demands of quantity and quality. The efficient working of the press is the prime need to maintain the quality of the pulp. The availability of the machine is directly dependent on its bearings. Hence monitoring the bearings is crucial. IDE DEPLOYMENT The IDE was installed on the roller bearings of the shaft . The IDE collected the triaxial vibrations and noise levels of the bearings instantly. This data could also be seen on the mobile and dashboard by the end user from a remote location. Looking at the steady state vibrations, at the time of IDE installation, thresholds were set. IDE OUTCOME After 2 months of continuous monitoring, IDE detected a gradual rise in the vibrations. An alert was generated indicating the rise and notifications were sent in terms of an email and SMS to the registered authorities.

13. Case Study: Remote Vibration monitoring on the bearing of a two-chambered twin wire press predicts its failure; subsequently saving USD 33 Thousand Rise in vibrations, crossing the threshold Normal vibrations Taking cognizance of the alerts, maintenance department carried out a close examination of the bearings. Further, Fast Fourier Transform (FFT) method to analyze the rise in vibrations detected the loosening of set screws used to hold bearing on the shaft. Timely remedial measures to tighten the setscrews prevented the spinning of the roller bearing on the shaft and its damage. The bearing wear and wreckage was avoided. The IDE profited directly by saving 10 hours of production, repairs and replacement of roller bearings, the shaft destruction and an amount of USD 33 Thousand.

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