As capital spending tightens and energy costs rise, mills are closely focusing on how to effectively maintain their valuable assets so that unnecessary downtime is minimized and equipment life is extended. Equipment efficiency has a huge impact on a mill's bottom line, so maintenance managers and engineers need information about products that can help keep processes running smoothly. The following special section provides information about the latest equipment and services from suppliers for continuous improvement of mill maintenance. This section also offers information on IDCON Inc.'s 15th annual Paper Industry Reliability & Maintenance Conference. The conference will be held November 5-9, 2001, at the Sheraton Gateway Hotel in Atlanta, Ga., and Pulp & Paper is the official magazine sponsor of the event. The program is designed for maintenance and operations professionals in the pulp, paper, and associated industries and features an exhibit, mill case studies, and workshop presentations. Topics covered include results oriented maintenance management, stores cost reduction, benchmarking data, wireless predictive maintenance, and more. We invite you to use this special section to learn more about maintenance products and services that can help mills operate more efficiently and to attend IDCON's Paper Industry Reliability & Maintenance Conference for information on effective maintenance practices.

Monica Shaw Editor, Pulp & Paper

Motors to 1,500 hp

Baldor Electric has expanded its AC motor line to 1,500 hp. Available enclosures and ratings are ODP, WPI, & WPII through 5810 frame. Design and construction features include Inverter Spike Resistant (ISR wire), rugged cast-iron frames, Vacuum Pressure Impregnation insulation system, and Exxon's new POLYREX EM polyurea grease that better protects motor bearings, providing improved lubrication life, greater shear stability, and superior resistance to washout, rust, and corrosion.

Baldor Electric Co.

Crusher duty motors

Baldor Electric announces the immediate availability of a new line of crusher duty motors, available from stock. The new crusher duty motors are available in 100 through 300 hp, 1,780 or 1,180 rpm, in NEMA frames 405T through 449T. These severe duty motors are designed for belt-driven loads only. Applications include rock crushers and pellet mills. They are available from 34 Baldor warehouses across North America.

Baldor Electric Co.

Premium efficient motors

Baldor Electric announces major improvements to the efficiency ratings and overall performance of the Baldor Super-E line of premium efficient motors. Originally introduced in 1983, Baldor's Super-E motors have consistently delivered some of the motor industry's highest efficiencies and energy savings. With the latest improvements Baldor Super-E motors will now provide even greater energy savings and faster paybacks. Baldor has raised the efficiency level of over 125 individual ratings and some now exceed 96%.

Baldor Electric Co.

IEEE Std 841 motors

Baldor Electric offers a full line of premium efficient chemical processing motors, recently upgraded to exceed IEEE Std 841-1994. These motors are available for immediate delivery; 1 through 250 hp; 460 volt; in 2, 4, and 6 pole designs. Other voltages and speeds through 5,000 hp can be built with Baldor's three-week lead-time. Baldor IEEE Std 841 motors feature Baldor's Super-E premium efficiency designs, including ISR magnet wire. In addition, Inpro/Seal seals at both the drive and fan ends provide extra protection.

Baldor Electric Co.

Actuator-ready ball valve

Conbraco's actuator-ready ball valves are shipped without handles and feature an ISO 5211-style mounting pad designed to simplify actuator mounting. Designed to make process automation easier and more reliable, the new valves can function in a range of applications including papermaking and chemical processing. The valves are available in sizes 1/4 in. to 3 in. and are offered in stainless steel, bronze, and carbon steel. All valves feature a multi-stacked "V" ring stem packing that can be live loaded.

Conbraco

Extended bonnet design

The Apollo 4-in. extended bonnet from Conbraco is designed for both new valve installations and retrofit applications. The gasketed, pressure-containing bonnet bolts directly to an ISO 5211 mounting pad, which is standard on Conbraco flanged valves. Unlike conventional extensions that can sideload a stem and lead to premature leakage, this stationary bonnet is formulated to move the packing and handle away from hot or cold pipeline medium. The extended bonnet is available on flanged ball valves up to 6 in.

Conbraco

Ball valve

The new three-piece AR ball valve from Conbraco can operate in both manual and automated operations. Though it is offered standard with a lever operator, it is built actuator ready. Each three-piece valve includes an ISO 5211-type mounting pad for easier actuation and is equipped with advanced packing and mounting elements designed to meet demanding service requirements. The ball valve is offered in carbon or stainless steel and has a one-piece seat and seal design and a true swing-out body section.

Conbraco

Electric actuators

Available in five output torques between 200 and 1,000 in.-lb, these actuators feature an anodized die cast aluminum housing and fiberglass reinforced nylon covers with UV stabilizers for corrosion resistance in NEMA 4, 4X applications. A push and turn manual override shaft, a position indicator, and a female output are standard on all models. All torque sizes are designed to fit in a single housing type and are reversible.

Conbraco

Steam joint/siphon combination

The Deublin FS Series and the Deltasint stationary siphon are designed to handle the requirements of high-speed paper machines and to function more efficiently than rotating siphons. The FS/Deltasint combination provides a joint and siphon that are rigidly supported by the machine frame and does not require internal support or bushing. This is intended to eliminate the need for periodic inspections and replacing parts. The FS Series joint design incorporates a balanced end face mechanical seal instead of the conventional pressure type joint commonly found on paper machines.

Deublin

Specialty steam joint

The FSC, a variation of Deublin's FS Series steam joint, is designed for dryers fitted with CARB bearings. A compact angular roller bearing (CARB) allows axial thermal expansion of the supported journal and eliminates the need for rocker supported bearing brackets. Using the flexiblity designed into the "stroke" of its floating seal, the FSC joint provides 1 in. of axial thermal expansion.

Deublin

Steam joint

Deublin's FSB is a self-supported steam joint featuring ball bearings and a balanced mechanical seal for high-speed open gear machines. The steam joint with stationary siphon is suitable for speeds up to 3,000 fpm with a steam pressure of 60 psi. Many older open gear machines may now be upgraded to utilize stationary siphons that are designed to offer the benefits of reduced differential pressure requirements, and, consequentially, reduced blow-through.

Deublin

Unloading mechanism

The FS unloading mechanism from Deublin unloads the springs of the steam joint's mechanical seal, reducing seal face contact pressure. This minimizes seal wear during intermittent "dry run" conditions that may occur when adjusting the drying capacity of a paper machine, which requires shutting off the steam flow to certain dryers. The unloading mechanism is designed to reduce the premature wear and failure of seals that results from shutting off steam flow and running the seal faces dry.

Deublin

Multi-nozzle spray desuperheater

The new multi-nozzle spray desuperheater (MNSD) from DeZurik offers Class V tight shut off with high temperature capabilities up to 150°F. The MNSD V is designed to provide mechanical atomization and cooling water control all in one unit, eliminating the need for a separate cooling medium valve. The cooling medium passes through specially designed swirl discharge nozzles that are formulated to maintain low exit velocities to promote rapid absorption. The MNSD V provides turndowns of 150:1 or higher while accommodating variable flow rates.

DeZURIK

Linear control valves

Severe duty linear control valves from DeZurik are designed to handle critical service applications like cavitation, flashing, high noise, and/or extreme pressure drops. These severe duty control valves are available in sizes from 3/4-in. to 20-in. with ANSI pressure classes of 150 to 4,500 as standard. The valves can be tailored to meet specific needs with a selection of standard and specialty trims, including Raven, DeZURIK's patented disc stack trim technology designed to reduce and attenuate velocity, erosion, and noise.

DeZURIK

Sampling valve

The Strahman True Stock Sampling Valve is designed to provide the truest, most representative pulp samples. It features a unique coupling that extends into the main stream of flow, allowing live samples to be extracted. When the valve is closed, the piston fills the valve body and extends flush to the end of the coupling, eliminating dead space and preventing clogs. When open, the piston is retracted into the body allowing a free-flowing sample. An opening indicator shows the position of the piston for product flow anticipation.

Strahman Valves

Drain valves

Strahman Valves offers a new 40-page catalog featuring its complete line of ram type drain valves. The catalog provides product features, applications, sizes, and installation instructions. Also included are a variety of operating mechanisms, optional equipment, and full details on drain valve nozzles, inserts, and adapters. The ram type drain valve features a fully retractable piston that allows for full free flow when opened. The piston is also designed to extend into the vessel when closed to prevent clogging by dislodging any accumulated sludge.

Strahman Valves

Bearing isolator

Inpro/Seal offers its patented bearing isolator, featuring a seal that is designed to effectively retain lubrication and exclude contamination for bearings in rotating equipment. This seal also improves reliability as compared with a lip seal or simple labyrinth. Other expected benefits of the design include the reduction of maintenance costs and less downtime. Typical applications include: pumps, motors, gearboxes, turbines, and other rotating equipment.

Inpro/Seal

Paper roll bearing isolator

Inpro/Seal roll bearing isolators are designed to increase the reliability of paper machine rolls while extending the life of paper machines. The result of extensive research and development as well as comprehensive field testing, Inpro/Seal bearing isolators were specifically developed for use with wet and dry end paper machine rolls to prevent catastrophic bearing failure and minimize unnecessary downtime. These bearing isolators can be retrofitted to Beloit, EPM Tech, Black Clawson, Gorman, Voith Sulzer, Valmet, Toschi International, Over Meccanica, Perry Machinery, Martco, and other paper machines.

Inpro/Seal

Oil seal

Inpro/Seal's product for oil seal applications is the patented VBXX-D bearing isolator. Its non-contacting design is formulated to never wear out, unlike a lip seal, which has a maximum life of three months running at 24 hours per day. The bearing isolator is formulated to both retain lubrication and keep contaminants out. A lip seal can only do one or the other, not both. Inpro/Seal bearing isolators are designed to reduce plant maintenance costs.

Inpro/Seal

Powder seal

The Inpro/Seal Air Mizer-PS powder seal utilizes bearing isolator technology. These powder seals are enhanced with a solid wall of air to function as a barrier for powders and bulk solids for conveyors, valves, mixers, and feeders. This design is intended to have no wearing parts and to never need rebuilding. The AirMizer-PS is available in both solid and split designs and can be retrofitted with little or no modifications to existing equipment.

Inpro/Seal

Doctor blades

Essco offers a full line of high-performance doctor blades that can increase productivity and save mills money. Essco blades include various metal alloys, plastics, abrasive blades, and the Fiberline family of products. Essco's synthetic blades include several premium epoxy-based fiberglass and carbon fiber products, which have been developed to meet specific needs by the company's in-house laminating division. Fiberline AC and Fiberline AC3 carbon fiber doctor blades are designed to improve blade life, reduce roll wear, and reduce maintenance costs.

Essco Inc.

Blade holder

Essco's ETUniform blade holder provides uniform blade pressure along the entire length of the holder. This provides even cross-machine blade loading on the roll, which results in highly efficient doctoring. The ETUniform holder consists of a heavy-duty, extruded mounting base assembly that is precisely machined and a double pressure plate assembly for long service life and durability. All metal components and fasteners are 316L stainless steel. Essco's investment-cast blade retainers minimize maintenance and are intended to extend pneumatic tube life.

Essco Inc.

Blade holder

The RJGIII holder is a rigid holder made with a 316L stainless steel top plate and 316L cast stainless steel blade retainers that include a proprietary release coating agent. The RJGIII holder is designed for use in applications where foreign particle buildup occurs inside conventional holders, which can cause difficult blade changes. The open design of this holder is formulated to minimize surface area for buildup, simplifying blade changes and reducing holder maintenance. The RJGIII holder can be supplied with new doctors or easily retrofitted on virtually any existing doctor.

Essco Inc.

Double doctors for suction rolls

Mills can improve their moisture profile, sheet consistency and production efficiency with Essco TwinFlex Double Doctors for couch rolls, suction rolls, and blind drilled rolls. A double doctor is also intended to extend roll life and reduce roll maintenance costs. TwinFlex doctors use the efficient ETUniform blade holder and can run either standard doctor blades or a foil blade in the lead position. Depending on machine configuration, a TwinFlex doctor can often be designed to also function as a save-all pan, reducing capital expenditures.

Essco Inc.

Couplings

The Falk Corp. has introduced its new line of couplings. The Wrapflex line of non-lubricated, low-cost couplings features a replaceable elastomer element designed to facilitate easy change-out that is intended to eliminate the tasks of removing hubs and realigning shafts. This element also provides wear and chemical resistance with a 95°C temperature rating for longer life. Currently available in six sizes, the couplings can accommodate shafts up to 4-in. and torque loads up to 22,100 lb-in. Close-coupled designs are currently offered, with multiple spacer designs in development.

Falk Corp.

Gear drives

Falk's Drive One family of medium-torque gear drives combines low initial and lifetime costs with mounting configuration flexibility and global compatibility. These drives provide six-sided mounting capabilities for use as general-purpose parallel or right-angle shaft drives, or in application-specific duties such as shaft-mounted drives, mixer drives, or alignment-free drives. These drives feature a hard metric design with 60% fewer parts than traditional gear drives. Currently available in four sizes, Drive One covers torque requirements from 150,000 lb-in. to 500,000 lb-in.

Falk Corp.

Concentric gear drives

UltraMax concentric gear drives, combining the high performance of parallel-shaft drives with the economy of a gear motor, have been introduced by the Falk Corp. Representing a new product line for Falk, the UltraMax concentric drives combine low maintenance requirements and superior durability resulting in low lifetime operating costs and improved operating efficiencies. The high-torque density UltraMax drives are said to offer initial savings of up to 30% over comparably rated parallel-shaft gear drives.

Falk Corp.

Grid couplings

Through the application of precision technology used in the aerospace industry, the Falk Corp. has developed its line of Steelflex grid couplings, a coupling that provides a dramatic increase in rating–up to 10% in some instances. In addition, Steelflex combines the high-load capacities of a gear coupling with the flexibility of an elastomer design, creating a cost-effective, general-purpose coupling that dependably protects expensive driving and driven equipment from misalignment, vibration, and shock and thrust loads.

Falk Corp.

Disc coupling

Lovejoy has developed a new disc coupling featuring discs with optimized profile and thickness to provide a higher torque-to-o.d. ratio, higher service factors, and up to 50% greater misalignment capabilities with smaller reactionary forces on bearings. Three standard types offer many sizes, with six-, eight-, and ten-bolt disc-to-hub attachments, covering a nominal-torque range from 5,100 to 7,700,000 in.-lb (600 to 87,000 Nm). The disc coupling design utilizes high-grade stainless steels for strength and resistance to hostile environments.

Lovejoy

Motor bases

Rosta MB70 tensioning motor bases from Lovejoy Inc. are designed to extend the benefits of self-tensioning belt drive performance to power-transmission systems using motors ranging from 100 hp to 200 hp at 1,750 rpm. These motor bases employ a swivel-mounted base plate supported by an elastomeric suspension unit. Rosta elements combine bearing, spring, and vibration-damping functions. Set to user-determined tension through an integral mechanical preloading device, the MB70's elastomeric suspension system continuously adjusts to variations in drive-load fluctuations and belt stretch so that slipless torque transmission is guaranteed throughout the belt life.

Lovejoy

Technical brochure

NSK, manufacturer of anti-friction bearings and related precision products, now offers a technical brochure on the advantages of TL Spherical roller bearings for the paper mill industry. This piece of literature takes an in-depth look at the major roadblocks to increased uptime from capital investments: inner ring fracture, high temperature, and reduced life cycle. The TL Series from NSK is designed to address all of these concerns with higher strength, greater dimensional stability, and increased hardness.

NSK

Bearing application guide

NSK's bearing application guide is written for machine designers and engineers. The free, 20-page guide explains how NSK bearings can dramatically increase productivity and reduce downtime. It includes photographs and detailed information on NSK's full line of bearings, including a section specifically addressing issues important to the pulp and paper industry. NSK bearings are designed for reliability and performance in extremely harsh environments.

NSK

Metering pump

Moyno Inc. offers the Moyno Metering Pump for economical and efficient performance when metering low-flow liquids in a wide range of pulp and paper applications including dosing, sampling, and metering. The progressing cavity design of the Moyno Metering Pump results in a smooth flow free from pulsations and variations in velocity and volume. This prevents material waste or mixture imbalance. The pump is available in bare-shaft, close-coupled, and motorized configurations

Moyno

Progressing cavity pump

The Moyno 2000 Progressing Cavity Pump from Moyno Inc. is the right solution for pumping a wide range of paper coating formulations. This versatile, cost-efficient unit provides a low-shear, metered, non-pulsating flow that results in superior surface uniformity and preserves coating integrity. Numerous models are available in a variety of construction materials with many different options, allowing customization to specific needs.

Moyno

Pump performance optimization

Moyno's five Ultra Technologies optimize the performance of its progressing cavity pumps to provide greater customer value. Ultra-Shield rotor coatings assure peak performance under highly-abrasive and corrosive service conditions. Ultra-Pro rotor/stator configurations allow end users to optimize or upgrade their pump flow rate and pressure capability. Ultra-Drive drive train configurations are designed to handle the torque transmission of demanding applications. Ultra-Flex stator elastomers re formulated to meet specific fluid conditions.

Moyno

Control valves

RKL Controls offers RKL Series LAF Control Valves for efficient, cost-effective operation in a variety of process applications. Series LAF Valves are pneumatically operated, fully enclosed and available in a variety of sizes and configurations. LAF Control Valves are operated by the Rollomotor rolling diaphragm pneumatic actuator which causes a single, direct-acting pinch bar mechanism to close an elastomer sleeve bubble-tight. A positive opening feature, fully molded into the valve sleeve and attached to the pinch bar, ensures complete opening.

Moyno

High-efficiency doctoring systems

PHD proprietary high efficiency doctoring systems from Thermo Web are engineered to reduce energy costs by increasing the efficiency of the doctoring operation. High efficiency doctoring is achieved by a system where design, advanced components, and technology work together with the application. Proprietary high efficiency doctoring components, featuring advanced synthetic materials intended to reduce friction and improve conformability, are designed to produce a more uniform sheet and reduce energy consumption.

Thermo Web Systems

Blades and holders

Thermo Web blades, which are manufactured to industry standards from a wide range of patented lightweight composite and metal materials, are formulated to reduce roll drag and lower energy consumption. Patented synthetic top plate materials, available in both removable and oscillating holders, are designed to enhance roll conformability for increased efficiency and lower energy costs in creping, cleaning, and sheet shedding applications. High efficiency doctor blades and holders are available for most paper grades and machine applications.

Thermo Web Systems

Doctor bearings

Thermo Web Systems engineers have attempted to lower overall operating costs with the development of the split doctor bearing. The split bearing technology, with patented long-life wear components, is designed to provide low friction for reduced oscillator loading. The split housing and block design are intended to maintain doctor setting and alignment while repairs or replacement of doctor bearings are made on-machine. These long-life, anti-friction bearings are designed to provide easy access and lower maintenance costs.

Thermo Web Systems

Oscillators

Smooth oscillation prevents particle build-up, reduces roll surface scoring, and helps maintain uniform blade wear for longer blade life. The more efficient the oscillator, the more efficient the doctoring system. Thermo Web oscillators, available in standard or stainless steel, are designed to produce improved sheet quality, even blade wear, and increased doctoring efficiency for all wet/dry end and heavy-duty applications. Gear train designs are intended to reduce frictional drag and variation in roll speed.

Thermo Web Systems

Bearing services brochure

Timken is now offering an eight-page brochure outlining its industrial bearing services. "The Value of Bearing Remanufacture" describes three types of services provided by the company for complete bearing refurbishment. Timken Services offers pulp and paper mills custom solutions for bearing refurbishment, regardless of the brand, type, or size of bearing. The brochure discusses the various types of bearing damage, as well as how to accurately assess a bearing.

Timken

Tapered roller bearing refurbishment

For refurbishment of tapered roller bearings, Timken's facility in Canton, Ohio, is equipped to handle any degree of remanufacture by using Timken high-grade steel and precision grinding equipment. The facility's refurbishing capabilities can accommodate bearings in excess of 84-in. o.d. and up to 19,000 lb. Servicing can range from cleaning and polishing to a complete regrind of all faces, including new rolling elements. The facility also hosts a team of customer service personnel, engineers, and technicians to provide pulp and paper mills with support.

Timken

Industrial bearing services

Refurbishment of spherical, tapered, ball, and cylindrical bearings is available from the Timken Co. and its industrial bearing services operation in South Bend, Ind. Whether for a couch roll, press roll, or breast roll, the South Bend operations provide the infrastructure and engineering support required for restoring spherical roller bearings to near-original condition – an important preventive maintenance activity for mills.

Timken

Online offerings

Timken.com has been redesigned with the intention of providing users with a more interactive, more easily navigated, and useful resource on a wide range of bearing and related information.Visitors can access detailed product and technical data, regardless of the application. Additionally, timken.com features a comprehensive review of its full line of steel products, including seamless alloy mechanical steel tubing, carbon steel and microalloy steel mechanical tubing, alloy steel bars, billets, and tubing from vacuum arc remelted steel.

Timken

Split mechanical seal with anti-slurry device

Pump, agitator, and refiner applications can be more cost effectively sealed with the combination of the Chesterton 442 split seal and the SpiralTrac anti-slurry device. Using this combination, water use can be reduced by more than 90% in many cases, and has even been eliminated on processes handling white water, stock, effluent, and sludge. The anti-slurry device is designed to minimize air entrapment and continuously remove particulate from the stuffing box. As a result, flush water requirements are minimized or eliminated.

Chesterton

Plantwide pump packing

Chesterton's Mill Pack 1730 is a thermoset fiber packing that controls leakage effectively without harming shafts. It is also designed to provide heat resistance, reduced power consumption, and will not glaze like common mill packings. When used in conjunction with a flow control device, Mill Pack 1730 has been shown to reduce flush and leakage rates. It is a plantwide pump packing and isapplicable for use in temperatures to 550° F and shaft speeds to 2,000 fpm. Milll Pack 1730 is lubricated with PTFE and further coated with a break-in lubricant. Its interbraided, prelubricated synthetic fibers are non-staining and chemically resistant in a wide pH range of 1 to 13.

Chesterton

Installation, rebuild services

Installation and rebuild services from Johnson include training for mill personnel and outside contractors prior to installation, supervision and installation of Johnson equipment, and inspection of all equipment installed. Specific services include: training on the proper techniques for installing Johnson equipment; supervising or performing the actual installation; providing inspection services to assure a quality installation; and rotary joint repair—onsite or offsite exchange program.

Johnson Corp.

Dryer inspections, machine surveys

Dryer inspections from Johnson will ensure that all internal dryer equipment is functional and secure for worry-free operation. This service includes a detailed report listing all equipment repairs required. Johnson's machine surveys provide a complete report with recommendations on rotary joint installation, piping, and seal-wear measurements, and can be provided as an integral part of a preventative maintenance program.

Johnson Corp.

Troubleshooting and systems analysis

Johnson Services' troubleshooting team can provide analysis of why a problem is occurring and how best to resolve it. This is particularly important when machine operation conditions change. This service includes: installation and piping review with corrective action recommendations; onsite assistance to determine the cause of equipment or systems problems; analysis of equipment size to ensure existing equipment can operate under machine conditions; and recommendations for improving runability and machine performance.

Johnson Corp.

Training and education services

Training programs from Johnson are designed to provide mills the greatest impact in the shortest period of time. All seminars are designed to benefit both new personnel and more experienced employees. Specific training includes: an explanation of the function of the rotary joint and siphon equipment; tips and techniques to improve performance and life of wearing components; a guide to installation, repair and maintenance of Johnson equipment; recommendations on spare parts usage, ordering, and lead times; and troubleshooting and preventive maintenance sessions.

Johnson Corp.