MAINTAINING MILLS

By Kelly H. Ferguson Editor, Pulp & Paper

 

Talking with mill maintenance managers these days, you get the sense that getting employees away from the mill for training and education is a struggle. With only minimal capital investment going on in North America and corporations demanding more from existing mill assets, skilled maintenance managers and team members are required to be on call almost constantly.

The key word, however, is “skilled,” and how can mill personnel remain skilled if they are kept updated on new technologies and techniques for maintaining equipment throughout the pulp and paper mill? Managers, too, need education time to hone their skills at managing the maintenance function, working with production personnel as a team, and selecting the right equipment and services.

The Paper Industry Maintenance ’99 Conference and Exhibition—October 11-15, 1999, at the Cobb Galleria Centre in Atlanta, Ga.—has been designed with all these training, education, and teambuilding needs in mind. This special report, highlighting some of the maintenance-related products and services available to the industry, is a mini-preview of PIM ’99. In addition to the product offerings shown here (for more information, circle the appropriate number on the Reader Service Card on p.67 of this issue), you’ll find a preview of the program and an exhibitor list and exhibit floor plan.

This year’s conference program was designed to provide more educational value to attendees than ever before. In addition to the general sessions, free workshops, tutorials, teambuilding games, and an exhibit hall presentation theater will give delegates a smorgasbord of opportunities to learn and interact. And there’ll even be a few fun and relaxing activities, as well.

The main conference kicks off with keynote presentations from Goran Ericsson, mill manager of Korsnas AB in Sweden, and John Crowe, vice president of Buckeye Cellulose in Perry, Fla. Some of the topics in the general session include the integration of operations and maintenance as a team, whether maintenance outsourcing works in the paper industry, extending the life of major components, and improving maintenance planning and scheduling. Some of the companies represented on the program include Willamette, Fletcher Challenge Canada, Siemens, Fortek, Phillips Service Industries, and A.W. Chesterton.

Workshops and tutorials at PIM ’99 cover such topics as selecting the right computerized maintenance management system (CMMS), predictive maintenance techniques, machinery alignment, condition monitoring, high-performance work systems and teambuilding, lubrication strategies, and methods for reducing water use. New this year to PIM ‘99, exhibitors will be allowed time during exhibition hours to make short presentations on cost saving opportunities and efficiency improvements through some of the new technologies and services that those exhibitors offer.

We invite you and your team to join us at this year’s Paper Industry Maintenance Conference and Exhibition (for more information, see p.S16 of this special section and experience all the educational benefits this event has to offer).

—Kelly H. Ferguson Editor, Pulp & Paper

 


Uhle boxes

Nash-CVN uhle boxes are designed to provide uniform airflow and dewatering across the entire felt to prevent streaking and poor sheet moisture profile. The results are improved press efficiency, enhanced felt performance, and better paper quality. The stainless steel, open-throat design will operate successfully for horizontal, vertical, or inverted felt runs and is available in a variety of constructions. Additionally, a standard accessory with all uhle boxes is a built-in lubrication shower, designed to provide consistent flows for optimum cleaning and low drag loads.

Nash Engineering Co.

 



Shower driver

The new design of the Nash-CVN Rolltech shower driver utilizes low friction roller packages instead of traditional ball screw construction and provides twice the force and strength of previous models. It is capable of continual operation in excess of 1,000 lb of linear force and the rollnut efficiency remains constant. Features include adjustable stroke rate and length, ability to handle any shower length, synchronous motor, and a universal control panel. The compact design allows easy installation and maintenance and carries an 18-month warranty.

Nash Engineering Co.

 



Automated brush showers

Nash-CVN automated brush showers provide programmable cleaning of shower nozzles on a regular basis to maximize felt and fabric performance. Cycle times may be adjusted from six times/hour to once every 12 hours and manual cleaning may be initiated with the push of a button. The brush rotation system is available on all new showers and can be retrofitted to most existing Nash-CVN showers in a matter of minutes. All wetted parts are 316 stainless and the 110v control panel is supplied in a NEMA 4 enclosure.

Nash Engineering Co.

 



Cooling towers

The Splash Series of cooling towers from Nash are a counterflow forced draft monoblock type that, unlike traditional configurations, will handle the dirty seal water without clogging. Suspended solids, highly corrosive or acidic water, and scaling are all easily handled since all components of the tower that come in contact with the cooling water are of plastic or stainless steel construction. Models are supplied in sections, depending on the cooling requirements, which may be bolted together at the job site.

Nash Engineering Co.

 



Video catalog

An updated video catalog that features Victaulic’s line of pipe preparation tools and accessories is now available. The catalog covers roll and cut grooving tools for both shop and field use, power drives, pipe stands, and specialty tools, including a new joint alignment tool for joining large-diameter pipe. Hole-cutting and hot-tapping tools, pipe cutters, and tools for cleaning, deburring, and marking pipe are also featured.

Victaulic

 



Automatic sprinklers

The new line of FireLock automatic fire sprinklers from Victaulic features a proven Teflon seal and Belleville spring design that incorporates glass-bulb technology. Standard and quick-response ratings are available in a variety of models for different hazards and temperature and pressure requirements. Designed and manufactured to ISO 9001 standards, the sprinklers are smaller than conventional offerings and cover most applications with just two frame styles.

Victaulic

 



Mechanical piping systems

An 8-pg., full-color catalog on Victaulic’s mechanical piping systems for pulp and paper applications is now available. The catalog covers Victaulic’s grooved-end and Pressfit systems, both of which provide faster, easier installation and substantial savings compared with welded, threaded, or flanged systems. Also discussed in the catalog are applicable specifications, typical pulp and paper industry applications, and the problem solving capabilities of Victaulic’s Technical Services group.

Victaulic

 



Lightwall stainless piping

The Victaulic Pressfit lightwall stainless piping system joins Type 316 and Type 304/304L (Vic-Press 304) in 1/2 in. through 2 in. sizes. It includes a complete selection of couplings, fittings, and valves. Requiring no welding, threading, or flanges, the system is ideal for pulp and paper piping that is subject to corrosion.

Victaulic

 



Pneumatic mechanical chuck

The Deublin pneumatic mechanical chuck operates by pressurizing the sealed chamber behind the moveable piston/cam assembly, extending the lugs to grip the core. Release of the air pressure allows the return springs to force the piston/cam assembly back, retracting the lugs. Deublin pneumatic chucks are suitable for rewind stands, unwind stands, and other shaftless applications.

Deublin

 



Self-supported steam joint

The FSB 100 steam joint with stationary siphon is suitable for speeds up to 3,000 fpm with a steam pressure of 60 psi. Many of the older, open-gear machines may now be upgraded to stationary siphons that offer the benefits of reduced differential pressure requirements and reduced blow-through. Also, the F Series steam joint with stationary siphon allows mills to increase production on dryer-limited machines while reducing downtime and maintenance. The balanced mechanical seal offers improved seal life—typically 2 to 4 times the current joint seal life.

Deublin

 



Steam joint

Deublin introduces the DMS steam joint featuring the dual mechanical seal. Many medium-speed paper machines are fitted with rotating siphons and pressure type joints. While the siphon may operate satisfactorily, the pressure type joint typically has maintenance problems. The DMS is designed to retrofit into most existing rotating siphon installations. With dual mechanical seals, the contact pressure at the seal faces is reduced. Consequently, the seal operates with reduced torque, reduced heat generation, and reduced wear—providing increased seal life and reducing maintenance.

Deublin

 



Turbulence bars

Deublin turbulence bars break down the rimming condensate layer that forms and impedes heat transfer as the speed of a dryer increases. Deublin turbulence bars do not employ springs or self tapping screws—there are no wearing components. While these bars appear to be a very basic product, they are actually part of a complex formula and should be customized to each application. Bar sizing, spacing, and siphon clearance are critical to optimum performance.

Deublin

 



Synthetic paper machine oils

Chevron Clarity synthetic paper machine oils meet the critical demands of paper equipment. ISO 150, 220, and 320 may be used as AGMA 4 EP, 5 EP, and 6 EP oils, respectively. These oils boast greater lubricant film thickness at high operating temperatures, as well as enhanced thermal and oxidative stability as compared with mineral-based oils. The oils are also well suited for use in the following applications: extreme temperature bearing and circulating oil systems, gear boxes, dryer section accessories, moisture profiler, calender rolls, crown control rolls, and oil-heated rolls.

Chevron

 



Turbine oils

Chevron turbine oils GST are designed to address the critical demands of gas, steam, and hydroelectric turbine bearings, while meeting or exceeding specifications of OEMs. ISO 32, 46, and 68 are approved in accordance with Cincinnati Milacron specifications. The oils yield excellent thermal and oxidation stability over long periods of time. Chevron turbine oils GST provide long oil service life and increased turbine uptime. Chevron turbine oils GST are recommended for use in all turbines including gas, steam, and hydroelectric models.

Chevron

 



Synthetic grease

Chevron Ulti-Plex synthetic grease EP is a multipurpose, high performance grease formulated specifically for extreme pressure bearing applications operating in severe conditions where extended lubrication intervals are required. Chevron Ulti-Plex synthetic grease EP is approved for NLGI Certification Mark LB. The grease minimizes friction between moving parts and provides enhanced performance over a wide range of temperatures. Pulp and paper applications include: sludge press bearings, lime kilns, pumps, wood yard heavy equipment, doctor oscillator bearings, felt roller bearings, pulp refiner bearings, roper sheaves, and exhaust fan bearings.

Chevron

 



Gear lubricants

Chevron Ultra gear lubricants are premium, multipurpose gear lubricants ideally suited for gear sets and bearings exposed to extremely high temperatures and loads. ISO 68, 150, 220, 320, 460, and 680 meet the demulsibility specifications of U.S. Steel 224 and AGMA 9005, offering protection against water-related damage. These lubricants create a non-corrosive protective layer on gear teeth, resulting in superior wear protection, extended service life, and lower operating temperatures. They are recommended for all types of industrial gears, including spur, helical, herringbone, spiral-bevel, and worm.

Chevron

 



Metal seated ball valves

Designed to withstand corrosion, high-input torques, extreme pressures, and frequent cycling, DeZurik FPB metal seated ball valves perform under severe conditions. The FPB valve’s massive stem delivers maximum torque transfer, and the floating ball design provides a tight, bi-directional seal. The heavy-duty body and flanges are designed to provide reliable, longlasting service, even under the extreme pressures produced during batch digester blow-down. A scraper seat and optional phantom port ball are available for scaling and plating applications.

DeZurik

 



Metal seated butterfly valves

The new Intelli-Seal metal-to-metal seat for DeZurik BHP and HPI high-performance butterfly valves offers extra tight, bi-directional shutoff, exceptional durability, and ease of operation in high temperatures and other demanding applications. The seat is mechanically energized at low pressures and pressure energized at high pressures to perfectly conform to the single-offset disc. Butterfly valves with the Intelli-Seak metal seat meet or exceed the shutoff requirements of ANSI B16.104 Class VI, API 598 7th edition, and DIN 3230 leakage rate 1.

DeZurik

 



Rotary control valves

Maxum rotary control valves from DeZurik deliver precise 0.1% to 0.2% throttling accuracy, 90° range of motion, and bi-directional flow capabilities so mills can optimize the performance of their control loops. Available in 316/117 stainless steel, carbon steel, Hastelloy C, and other alloys, these valves are an excellent choice for tough services—kaolin slurry, black liquor, and more. The optional titanium package is ideal for processes involving sodium chlorate, wet chlorine, terephthalic or hot acetic acid. An optional steam service package is also available.

DeZurik

 



Valve diagnostics system

DeZurik’s VDSvalve diagnostics system is an affordable and easy-to-use tool for maintaining and optimizing rotary control valves. The self-contained system includes a 486 industrial-grade computer, a monitor, and signal conditioners in an aluminum case. The diagnostic software package contains pre-programmed test parameters and calculations to measure and calculate performance values such as speed of response, overshoot, accuracy, and breakaway pressure. VDS provides information in real-time while the valve is inline and can also be used for foot printing new valves and bench testing.

DeZurik

 



Paper machine oils

Paper machine oils from Mobil help keep paper machines running efficiently by reducing fatigue, improving cleanliness, and offering high filterability. They keep bearings immune to premature fatigue caused by water exposure. In addition, because Mobil paper machine oils reduce deposits, there is less debris accumulation on the filter, saving time and money for filter replacement. These oils also offer stable viscosity under severe high-temperature conditions. This stability maximizes oil life, reduces varnish deposits, and extends component life.

Mobil Oil Corp.

 



High-performance grease

Mobilith SHC PM from Mobil is a high-performance grease that combines a synthetic base fluid with a lithium complex soap and synthetic thickeners. The thickener system provides wide operating temperatures ranging from -40°F to 350°F. In addition, Mobilith SHC PM offers excellent resistance to rust, corrosion, and oxidation in paper mills. Its properly additized, wax-free, synthetic base fluid provides excellent EHL contribution, thermal stability, low-temperature mobility/pumpability, and low volatility. This grease is recommended for various critical rolling element bearing applications.

Mobil Oil Corp.

 



Lithium soap-base grease

Mobil grease XTC is an extreme-pressure, unleaded high-temperature NLGI No. 1 lithium soap-base grease. It is made with a very viscous oil and an effective heavy-duty additive package. In addition to EP and high EHL properties, Mobil grease XTC is formulated to provide low-bleed properties critical to modern couplings, as well as high-temperature stability. Mobil grease XTC fully meets AGMA Type CG-2 requirements for high-speed flexible gear and grid couplings. It maintains its high-performance characteristics in ambient temperatures up to 250°F.

Mobil Oil Corp.

 



Hydraulic oils

Mobil DTE 20 Series high-quality hydraulic oils were developed in cooperation with pump and component manufacturers specifically for severe hydraulic systems using high-pressure, high-output pumps. These oils provide anti-wear and film strength characteristics necessary for critical systems. The stabilized additive system of the Mobil DTE 20 Series neutralizes the formation of corrosive materials, provides antiwear properties, and offers multimetal compatibility. This additive also provides better thin oil film protection against rusting, retention of oil cleanliness, and improved compatibility with water.

Mobil Oil Corp.

 



Sampling valve

The new True Stock sampling valve from Strahman Valves is designed to provide the most representative pulp samples possible. The valve is specially designed with a unique coupling that extends into the main stream of flow, allowing the extraction of live samples. The True Stock sampling valve’s body is cast (not fabricated) in a choice of alloys and is sealed with two compressible packing rings to eliminate leaking.

For more information about the True Stock valve and other maintenance-related products from Strahman Valves, Strahman’s website – www.strahmanvalves.com – provides detailed category-by-category information and photography. It also allows users to submit online requests for product catalogs.

Strahman Valves

 



Conical fillings

Sold and serviced by The Lawton Co., conical fillings from Pilao S.A. are fabricated by welding cold re-rolled steel bars to a steel cone. The bars are extremely hard, have a true 90º leading edge, a consistent bar/groove geometry, and long life. Current users of Pilao conical fillings report filling life of two to three years. Conical fillings are available for Jordan and Claflin type conical refiners produced by any manufacturer. Bar patterns are available for all refining applications.

The Lawton Co.

 



Double disc refiner

The RTD double disc refiner incorporates the patented Tri-Disc refining system. This system reduces no-load horsepower by 15% to 20% and improves stock flow to the two refining areas through the open hub. In addition, 50% less plate mounting bolts equates to increased refining area. The Tri-Disc system uses Pilao fabricated plates with 50% to 300% longer life, or conventional cast plates. Also, all rotating parts can be removed from the refiner door side. The RTD refiner is manufactured by Pilao S.A. and is sold and serviced by The Lawton Co.

The Lawton Co.

 



Enterprise asset management software for AS/400

New enhancements to Marcam’s AS/400 enterprise asset management (EAM) solution—Avantis.XA—allow mills to increase operational efficiency, reduce total cost of equipment ownership, and optimize asset performance. With Avantis.XA, mills can track the product life cycle of capital-intensive machinery, determining when an asset should be repaired or replaced. New Reliability-Centered Maintenance (RCM) enhancements let mills monitor assets, eliminate emergency work, and increase equipment reliability. If an asset is not performing optimally, it is identified, and the user can make changes to achieve operational efficiency. In addition, the user can track capital expenditures and determine inefficient use of capital.

The latest Avantis.XA release offers advantages in inventory and purchasing control for AS/400 users. With these, users can reduce costs associated with damaged or obsolete supplies and materials. The enhanced Repairable Spares feature allows companies to define a material as a part or entity that can be new, rebuilt, or repaired, and then returned to inventory.

Marcam

 



Enterprise asset management software

Marcam’s Avantis.Pro 3.1 enterprise asset management (EAM) solution offers new Preventive Maintenance (PM) and Reliability-Centered Maintenance (RCM) enhancements. Avantis.Pro provides mills with solutions to maximize equipment uptime and help eliminate unplanned breakdowns. It monitors the complete life cycle of a mill’s assets, tracking everything from productivity and reliability statistics to inspections and equipment failures. An Inspection Management module allows users to define and track detailed PM inspections, recording the activities performed on the equipment.

Avantis.Pro 3.1 also features three powerful failure analysis tools, allowing users to examine past breakdowns to help prevent future ones. The Root Cause feature allows companies to examine the relationship between equipment reliability and operations productivity. Time-to-Failure calculates the amount of time between equipment breakdowns, helping determine the optimal time for maintenance. Thirdly, Entity Downtime Analysis documents any maintenance delays, including planned PM functions, unexpected failure, or shutdown.

Marcam

 



Water scale and rust solvent

Rydlyme from Apex Engineering cleans water scale and rust that has deposited on vacuum pumps, heat exchangers, evaporators, digesters, and even green liquor lines. Rydlyme is fully biodegradable, so after just a few hours of dissolving your deposits into the solution, it then safely rinses down the drain. In addition, Rydlyme is so safe that you can hold the liquid in your hand.

Apex Engineering Products Corp.

 



Biodegradable descaler

Rydlyme from Apex Engineering is designed to dissolve tough lime and mud deposits—as well as rust and water scale—from virtually any piece of water-based equipment. This safe liquid is non-hazardous, noncorrosive, and completely biodegradable, so it will not harm personnel, equipment, or the environment. Rydlyme allows mills to clean their equipment in place without the need for expensive, labor intensive equipment dismantling.

Apex Engineering Products Corp.

 



Positive displacement pump

The Moyno 1000 high-performance positive displacement pump is engineered for trouble-free operation in a variety of services, including shear-sensitive chemical feeds and viscous transfer applications. The pin-type universal joint is sealed and lubricated for long life and minimum maintenance. The pump handles flow rates from 0.38 gpm to 320 gpm and has pressure capabilities to 350 psi. A new feature of the Moyno 1000 pump is a two-piece drive shaft that allows easy assembly, maintenance, and mechanical seal access. This new drive shaft configuration eliminates the need for complete pump disassembly when servicing the mechanical seal.

Moyno Industrial Products

 



Metering pump

The Moyno metering pump provides economical and efficient performance when metering chemicals and other low-flow liquids in a wide range of paper processing applications.

The progressing cavity design of this pump results in a smooth flow—free from pulsations and variations in velocity and volume. This prevents material waste or mixture imbalance. Other features include sealed universal joints for longer life, on-site maintenance for reduced costs, low power consumption and operating costs, pressures to 300 psi, and flows from 1 gph to 190 gph.

Moyno Industrial Products

 



Progressing cavity pump

The Moyno 2000 progressing cavity pump is ideal for efficient, cost-effective handling of a wide range of formulations used in paper coating applications to help achieve surface uniformity and to preserve coating integrity. Numerous models are available in a variety of construction materials with many different options, allowing customization to specific needs. The Moyno 2000 Pump offers unique product benefits in providing low maintenance, minimal downtime, and long life. Its benefits include a metered non-pulsating flow, high-pressure capabilities to overcome line blockages, and low internal velocities to prevent shearing.

Moyno Industrial Products

 



Pulp & Paper Magazine, August 1999 CONTENTS
Columns Departments Focus/Features News
Editorial News of people More efficient drying Month in Stats
Maintenance Conference Calendar Mid-year industry outlook Grade Profile
Comment Product Showcase Boiler feedwater treatment options News Scan
Career Supplier News Maintaining Mills  
  Mill Operations Dryer section upgrade  
    Ergonomics regulations likely