A paper mill required an updated bearing lubrication system with precision monitoring.
Bearing lubrication insights:
- The paper millโs upgraded system ensures precise bearing lubrication, reducing downtime risk while optimizing equipment performance and efficiency.
- Bearing lubrication upgrades with advanced monitoring now deliver consistent oil flow, extend bearing life and improve overall plant reliability.
A paper mill faced a critical challenge: its large paper machineโs bearing lubrication system was outdated and unreliable. Without the advantage of precision monitoring, inefficiencies disrupted production and increased downtime risk. In collaboration with the mill and a key bearing supplier, the Motion team designed and installed a comprehensive lubrication system upgrade. For a seamless implementation, experts planned a phased approach.
The yearlong project was meticulously designed to minimize disruption to the millโs operations and was executed in phases during scheduled machine shutdowns. Phase 1 involved replacing 13 flowmeter stations with state-of-the-art monitoring meters, enabling controlled oil lubrication for the paper machine rollsโ rotating spherical bearings.
This critical phase involved detailed planning, careful removal of outdated equipment (see Figure 2), precise installation, plumbing modifications and thorough system commissioning (see Figure 3). Future phases will focus on replacing the remaining flowmeter stations, ensuring a complete system overhaul.
Flowmeter accuracy over changes in temperature and viscosity are integral in the upgrade to provide consistent flow levels to each bearing lubrication point (see Figure 4). The monitor systems measure and feed individual oil flows directly to each point. Though oil temperature and viscosity can change, monitors provide accurate results. They calculate the flow rate by measuring the turbine rotation time and considering the user-entered viscosity grade. The onboard temperature sensor measures the oil temperature for improved precision.
The paper millโs bearing lubrication system is delivering tangible benefits. The meters precisely monitor and control lubricant flow, optimizing bearing performance and extending service life. This translates to enhanced lubrication reliability and significantly reduced risk of unexpected breakdowns and costly production stoppages.
Additionally, the modernized system ensures optimal bearing lubrication delivery, minimizing waste and boosting overall equipment efficiency.
The monitoring stations were installed with new stainless-steel tubing connections over the course of various plant outages during the year. Thirteen monitor stations were installed to handle the total number of oil lubrication points in the system.
The project’s success is due to the seamless collaboration between key players, especially during the crucial first phase. One team brought invaluable on-site expertise, project management and technical execution, while another supplied its advanced monitoring meter technology. The teams worked closely together on the system design, with the millโs success as the shared goal.
Phase 2 involves the installation of a dual-line grease system (see Figure 5), which is close to completion and being implemented during sequential plant outages.
The system upgrades, both oil and grease, provide an accurate and efficient solution that can be monitored by the plant control system and detect problems early before any harm comes to the rolling devices. System maintenance can be better planned during scheduled outages, increasing machine uptime.
