Maximizing profit with proactive
maintenance in the pulp andpaper industry

Reactive maintenance is expensive$10000-$12000

63%

63% of unplanned
downtime results insignificant losses.

60%

Downtime increases
maintenance costs by$10,000-12,000 US dollars/hour

60-80% of equipment
malfunctions are due to incorrect
or lack of maintenance

Proactive maintenance

Proactive maintenance via condition monitoring predicts
potential failures, saving 15+% of maintenance costs.

Avert these potential pulp and paper equipment failures
DigesterBarking
drum

Chip Belt
Conveyer(BearingFailure)

Boiler(BearingFailure)
Chipper(High Vibrationand Intense load)

Washerscreens

Pulp washers
Generator(Slow speed bearing
Bleachingfailure)(Lubricati on andTurbine (Lubricati onBearing Failure)& Bearing Failure,
Dislocation ofJoints)

Evaporators
Lime kiln(Overheating)Refiners
Recoveryboiler fans
(Bearing failure)

Black liquor
oxidation(Excessivetemperatureand steampressure)

Cleaners

Water
treatment

Pumps Bearing
Failures in lubrication

HeadboxPress Rolls(Bearing Failure)

Most critical nodes
that need condition
monitoring

WinderDryers(BearingFailure,Breakage ofguide rolls)

Critical Nodes: Paper press rolls, dryers, andbleaching towers are most critical equipmentthat require condition monitoring followed bypumps, motors, and turbines.

CalendarBoiler (Bearing Failure)
Boilers are prone to lubrication and bearing failure.

Lime kiln (Overheati ng)
Plastic deformation due to overheating of the casing.

Chipper (High Vibration and Intense load)
High vibration and continuous loads can cause breaking of chipper blades.

Chip Belt Conveyer (Bearing Failure)
can occur due to low lube oil supply and excessive load on the bearing.

Turbine (Lubricati on & Bearing Failure, Dislocati on of Joints)
Bearing failures due to structural misalignments and lubrication oil defects.
While in operations, the turbine casing bolts may get loosen causing
dislocation of joints.

Bleaching (Lubricati on and Bearing Failure)
Bleaching towers: Common problems occur in rotating parts and gear boxes
due to bearing and lube oil failures.

Press Rolls (Bearing Failure)
Paper press rolls have many moving and rotating parts prone to bearing failurethat can be reduced with the help of vibration and laser.

Recovery boiler fans (Overheating)Explosion of water tubes due to overheating in the boiler section.

Dryers (Bearing Failure, Breakage of guide rolls)
Non-optimum temperature and sudden expansion and contraction due to temperature fluctuations can cause dryer walls to develop cracks. Breakage of guide rolls
and other rotating equipment can bring the entire machine to a halt.

Remaining challenges
EmployeesafetyHarsh operations

Machineaccessibility

Skill loss

High retirement
rates

Challenging

Pulp and paper conditions

Customized workflows, algorithms &bearing diagnostics needed

How Bently Nevada's extensive portfolio of products and services canhelp you reach your productivity goals

User-driven
condition monitoringand diagnostic
workflowsHigh resolution trend,
alarm, and startup/
shutdown data

Modern and intuitive
interface andcontinuous user
involvement

Remote portabledata transfer

Best-in-class rolling
element andhydrodynamic
bearing diagnostics

Adoption of Artificial Intelligence (AI) / Machine Learning (ML)33%

Of the pulp and paper
manufacturers
have implemented AI/ML into theircondition monitoring system.

Condition Monitoring systems can help
reduce maintenance costs by

10-15% annually

The rising adoption of cloud-based condition monitoring enables use of the latest technologies, such as the Industrial
Internet of Things (IIoT) and advanced analytics, to make pulp and paper processing safer and more efficient. Having
equipment interconnected through the cloud and other communication technologies allows for cloud-based
predictive maintenance. A recent trend is to transform operations into ‘smart plants’, where maintenance is datadriven, with sophisticated sensor infrastructure deployed to keep equipment condition the prime focus.

Incorporation of AI/ML (with AI/ML Vs without AI/ML)
NORTH AMERICAEUROPE

ASIA PACIFIC

77%

10%

31%

8%

20%

15%15%
0%

50%
20%

31%
23%

Considering

Very Interested, underway

Very interested, not yet underway

Already using

Implementing Bently Nevada condition monitoring systems can prevent production
losses of up to hundreds of thousands of dollars per day

Please contact us at

Bently.com