Condition monitoring
solutions for the pulpand paper industry

The opportunity
Pulp and paper, together with the printing press invented in the 15th century, has greatly catalyzed man’s innovation andprogress by sharing knowledge far and wide. The manufacture of paper is itself a remarkable innovation, combining highlysophisticated production processes with the art of papermaking. The result? A multitude of paper-based products used for
creativity, communication, packaging and beyond.
Today, although overall pulp and paper growth rates are slowing, certain categories of paper are in high demand, creating
pockets of opportunity and profit potential for those manufacturers who remain nimble and current.

The challenge
Concurrent with that opportunity, pulp and paper mills are facing rising lumber, process chemical and energy costs andglobal competition that challenges price points. As cost increases erode profitability, leading pulp and paper manufacturers
have found ways to both maximize asset availability and output while optimizing processes to reduce maintenance costs.
In pulp and paper operations, reactive, time-based maintenance approaches create higher order maintenance costs andincreased risk levels. Thus, maintenance is an underleveraged opportunity, ripe for operational optimization with proactive
maintenance via condition monitoring solutions.

The solution
Proactive maintenance via condition monitoring solutions enables pulp and paper operations to use data-driven insights tomanage operations and reach the proper balance point across competing priorities:

OutcomeEnablerMaximize ‘smart’ uptime

Understanding asset health, asset life

Minimize downtime

Preventing unplanned downtime before it occurs

Ensuring/enhancing safety

Automating machine monitoring to reduce risk

Meeting regulatory complianceTracking key metrics

Minimizing maintenance costs

Repairs made at lowest possible cost (before damage escalates
prior to full failure and scheduled during planned outages)

Condition monitoring
Condition monitoring obsoletes reactive, time-based maintenance approaches which are based on calendar intervals or
running hours. Time-based approaches are only valid for about 15% of operational assets, and are poor “predictors” of failure
for many assets, resulting in two major issues. First, the majority of assets are getting “maintained” when they don’t need to be,creating a wasteful, overspend in maintenance. Second, it doesn’t prevent full failures and can allow asset issues to escalate
to unplanned downtime, causing costs to escalate in kind.

2Failure is a process
By contrast, condition monitoring supports a proactive approach, based on the premise that failure is a process, not anevent. The Extended P-F curve depicts this concept by delineating a distinct span of time between the potential for failure andfunctional failure.
Potential for failure is detected by monitoring asset health by measuring properties, such as, vibration, temperature, efficiency,
oil chemistry/particulates, and other physical parameters. Together with tailored algorithms, customized configurations andset points, these parameters can identify both root cause failure mechanisms, in progress as well as irreversible physicaldamage that has already started. As a result, failure can be averted, sound data-driven decisions made and repairs
scheduled at the most advantageous times and lowest possible costs.

The Extended P-F Curve
Root cause failure
mechanism in play

Irreversible damage – inception
to failure progression

Actual damage starts
P-Proactive

FunctionalHealthGoodNo damage
No degradation

P-Preventive$$$Damage causing
conditions exists
Damage is present
and is progressing

FailedTime
Monitoring methods that alert on
conditions that lead to damage,before damage actually starts

Time

Source: “Reliability-Centered Maintenance” by John Moubray, 1992.

Monitoring methods
that alert to the fact thatdamage has started
and is progressing

FFailure

Cost consequences of unexpected failure

Consequence-based technology implementation

Expected early warning durationIn terms of proactive condition monitoring, all assets are not created equal. Each asset has its own warning duration before
failure and asset failure can also result in varying consequences, described below as Important, Essential, and Critical. For
critical assets with shorter warning durations, operators monitor their performance with a continuous, on-line condition
monitoring system. For essential assets with a longer warning duration, periodic on-line systems work well. Lastly, important
assets that also have a longer warning duration are typically monitored with walk-around portable devices. Matching asset
characteristics and impact on production is important for aligning the proper condition monitoring approach and achieving
production optimization.

3

Condition monitoring
applications in pulp and paper

Boilernu Barking
drumnu Chipper
l Generatorl Turbine
Bleaching

Additionally, we monitor the following
assets throughout the process.
Pumps nul Refiners

Motors nu
Compressors l

Cleaners

He4

Digester

Cleaners

nu Washer
screens

Blackliquor
oxidation

Evaporatorsln Limekiln

Water treatment lnu
nu Recovery
boiler fans

Contact your representative formore information on condition
monitoring for these assets.

ead boxln Winder
lnu Pressrolls
nu Dryers (many bearingson these rolls needcondition monitoring)nu Calendar5

Bently Nevada
Unreliable and underperforming assets have enormous consequences. Industry studies show that the average facility spends
approximately 5% of its Replacement Asset Value (RAV) on maintenance each year. In comparison, best performers spend
60% less—just 2% of RAV—while enjoying better uptime, efficiency, and profitability. It’s not simply about spending less onmaintenance, it’s about working differently—and smarter—to achieve more reliable pulp and paper operations.
Bently Nevada helps customers get started.

6

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Bently Nevada service menu
Key benefits
Be proactive, get it right the first time

Implementation
services• Ensure your assets are protected andmonitored when you’re ready to startup• Avoid costly delays and rework• Use one source to design, plan, manage,and execute the installation• Prevent startup trips due to improper
installation and configuration

Up to$1M/day

100%

Cost mitigationfrom lostproduction,secondary
process &equipment
damageService work
guarantee
1 year warranty
standard on
all service work

Keep your system healthy and optimized

Proactivesupport• Prevent instrumentation related false trips• Avert and minimize potential data loss events• Keep up to date and compliant with the best
technologies available• Access the expert support you needwhen you need it mostGenerate actionable insights you can trust

Asset healthand consulting• Understand your asset health to optimize
outage and maintenance planning• Plug in to our global network of machinery
experts with remote monitoring• Get professional OEM agnostic machinery
diagnostics when and where needed• Customize analytic development andtuning to pinpoint specific conditions
Stay ahead of evolving cyber threats• Ensure your system is up to date and protected
as threats continually evolve

Cybersecurity1

Training
and education• Identify and mitigate cybersecurity risks
to your operation• Keep your system both secure and accessible
with advanced security technologies andarchitectures by leveraging data diodes anddatabase replication
Augment critical skills that amplify yourmachinery management capabilities• Enable your personnel to operate and maintainyour monitoring and protection system• Enable your operation to maximize the value ofyour system by leveraging expert product andapplication training and knowledge

80%

Machineryalarms andevents due to
instrumentation>90%

Typical reduction
in non-actionable
alarms and events

100% ROI

5-10X

Savings froma single machine
often results infull monitoring
contract
payback
and more

Cost reduction
for well planned
maintenanceoutage vs.
unplanned reactive
outage29%

243 days

Patchmanagement
can reduce
your attack
surface up
to 29%

Average time
lapsed before
detection thata system iscompromised

400+

Customer courses delivered eachyear in 10 languages and to over
45 global locations

1. h ttps://www.us-cert.gov/sites/default/files/documents/Seven%20Steps%20to%20Effectively%20Defend%20Industrial%20Control%20Systems_S508C.pdf

89

Why partner with Bently Nevada?
We are a trusted partner with a proven track record anddeep expertise. For six decades the Bently Nevada experts
and offerings have supported the most demanding proactive
maintenance applications across multiple industries. Ourquantified results speak volumes, and we create significant
benefits for our customers. Even as we protect and monitor
your machinery, we constantly strive to refine and improve
our offerings—and help enable your success.
We design and deliver integrated solutions for all of yourmonitoring needs—including sensors, distributed and rackbased monitors, software, and supporting services—with thefollowing goals:• Increased availability and production• Reduced risk in safety, environmental, andasset performance
Quantifiable, proven results:• 60+ years of innovation in asset protection,
condition monitoring• 240+ international patents, including 150+ U.S. patents• 350+ international patents pending,including 95+ U.S. patents• 8+ million sensor monitoring points• 1,600+ System 1 software users worldwide• Extensive services support provided globally• Lowered maintenance costs

You can rely on us
For more than 60 years, we’ve been supplying condition
monitoring solutions to machinery-intensive industries.
We also bring two decades of experience implementing
reliability improvement projects. Customers turn to us fora simple reason: lasting value. Our solutions demonstrate
their worth, day in and day out, and often result in expanded
implementations because of their proven ROI. We combine
the highest quality products and responsive customer
support with a service team that takes the time to understandthe uniqueness of your plant, your personnel, and your goals.

Copyright 2021 Baker Hughes Company. All rights reserved.
BHCS14784D		 (08/2021)

Our products can be found in many of the world’s mining
plants. Today, many of those same plants are turning
to Bently Nevada for a more comprehensive solution totheir needs, moving beyond just machinery protection
instrumentation on a few assets to plant-wide strategies
and systems for improved environmental compliance,
safety, asset production, quality and reduced operationand maintenance costs.

bently.com