www.tappi.org/frontline

Volume 2, Issue 8

Sponsored by Metso Paper

A ghost in the machine by Fritz Schweigert, Opt. & Control Comm. Manager, GE Energy

Machine induction motor

Universal shaft joint

The term a “ghost in the machine” describes a spirit left behind in the machine by previous interaction or activity. In our story, the ghost in the machine was a variation in vibration levels appearing and causing trouble for 8 years. Our ghost story begins… Periodic above normal vibration levels on one of the critical paper machine drive units was preventing personnel at a mill in Finland from running the machine at full operational speed, resulting in a loss of production ability. The haunting history The drive unit, a paper machine upper wire drive roll consisting of an induction motor, universal joint shaft, planetary reduction gearbox and drive roll, first experienced an increase in vibration levels in 1997. When the vibration problems surfaced, attempts were made to alleviate them through a variety of machine component swaps on the drive side. Yet, even after all the machine work, vibration levels continued to show spikes. One thing was clear from the start, when line speed went up, so did vibration levels. As a result mill operators were forced to reduce speed in order to bring down vibration to a safe level. This reduction in speed resulted in a continuous loss of production capacity and profitability. Ghost busting After swapping out numerous machine parts and having exhausted all their ideas for a possible solution, mill personnel now turned to the paper machine OEM for help in determining root cause for the increased vibration. After visiting the mill and collecting data, OEM investigators offered several ideas, but could find no definitive reason for the periodic vibration spikes. So the plant enlisted the help of a machinery diagnostic service (MDS) engineer. Based on the data already collected by both plant personnel and the OEM group, it was clear that a fundamental change had taken place in 1997. But what was the change?

In This Issue • A ghost in the machine • NEW-Monthly Safety Alerts • Gigging in a small town • LiteAdapt Jämsänkoski

Cover Page Uptime Downtime Up & Running

Copyright 2006 by TAPPI, all rights reserved.

Universal shaft

Machine induction motor

Collecting the Evidence The first important discovery by the MDS engineer was that while the OEM stated that there was no resonance close to 25 Hz, there was indeed resonance occurring at this level. It was further deduced that the existence of a 25 Hz resonance in relation to a 26 Hz operating speed on the problem motor when run at maximum line speed was an important reason for the large change in vibration that first appeared in 1997 and continued through January 2005. The reason that the OEM could not find the resonance was that they did not have machinery diagnostics experience, and therefore never checked for the existence of the resonance at the low speed end of the machine, which is where it was most evident. On other areas of the machine there indeed was no vibration reaching 25 Hz. The MDS engineer collected new measurements using an ADRE® portable diagnostic unit. This data identified a definite balance problem on the machine. The vibration increase from the unbalance condition became more dramatic as machine speed increased. Finally, in terms of vibration in relation to machine location, the new data indicated that the vibration level was low on the motor end of the drive unit, and highest near the planetary gearbox. Fixing the problem At this point, the information provided strong indication that the source of the high vibration was somewhere near the planetary gearbox, so the MDS engineer decided to balance the universal joint shaft from the planetary gearbox end. For those unfamiliar with machine balancing, think of machine balancing as essentially the same process as balancing your tires. Adding or taking away weight from the various tires to achieve a smooth ride cre-

(continued) A ghost in the machine ates balance. The drive unit was stopped and a test weight added to the coupling between the planetary gearbox and the universal joint. After collecting data from the test run, a corrective balance weight was calculated. This initial calculation indicated that in order to achieve a proper balance a large weight would be required on the opposite side of the coupling key. After the addition of this balancing weight, the overall vibration of the system was again recorded and resulted in very low vibration levels.

Paper roll Universal shaft joint

Roll with the Changes I’m having to practice what I preach – not quite as bad as eating crow. You’ve read here before about changes in your life. Well its hit me as I move into a different career personally and work with a different staff for this publication. One thing I’ve noticed right away – you can’t really control anxiety, it just happens and you have to deal with it. Gene Canavan Two personal outcomes – I have a shorter fuse and anger more easily, and my mind wanders off the subject at hand and onto the new challenge coming up. Both can be detrimental to work efficiency and safety. Which brings me to my point. If you are under stress because of life changing situations, please be aware that you are not your normal self. Your mind isn’t as sharp and perhaps your attention isn’t as focused. All this says that you (and I) are open to mistakes that may lead to accidents.

Roll bearing Plantary gearbox (l to r) Paper roll, roll bearing, planetary gearbox and universal shaft joint

So what happened back in 1997? The culprit in the surging vibration first noticed in 1997 and continuing until 2005 was an overly large coupling key that was used between the universal joint shaft and the gearbox during machine maintenance in 1997. The incorrect key was the root cause of the subsequent high vibration levels and was unfortunately missed during all the machine component change work done prior to involving both the OEM and the MDS engineer. The balance provided by the MDS engineer brought vibration levels down enough for mill personnel to run the paper machine at maximum speed allowing them to regain the lost productivity they had suffered for nearly 9 years. So how long did it take to diagnose and correct the problem? Less than half a day! And the cost in terms of lost production? Estimates taken during the 6 months prior to the problem being solved indi-

Plantary gearbox

Universal shaft

Universal shaft joint

(l to r) Planetary gearbox, universal shaft joint, and universal shaft

How can we deal with this? Well, I’m trying to be more careful and deliberate in all tasks but particularly those that involve risks. For me that’s working in the auto shop, driving a vehicle, or using any machinery. I’m also trying to be more patient knowing that I am more prone to anger. Are you under life changing stress? If so, think about how it is affecting you. Ask a close friend if they see changes in you. And above all take positive action to be safe on and off the job. Until next time, remember that life happens – so try to roll with the changes.

Thanks to all of you that notified us of our chemical compound nomenclature error in the July Bleaching 101 feature story. Our Managing Editor has been out of engineering so long he forgot that the numbers of molecules should be subscripted rather than superscripted, tsk tsk... cated that over this half-year period, nearly 10% of their production ability was lost. Imagine the resulting loss calculated over nearly 9 years of under-performance! The busters missed one final “ghost” Shortly after the balancing work was done, vibration levels began to creep up again, but this time it was clearly not a balance problem. The MDS engineer was quickly called in, and identified the source of increasing vibration as a rusty gear coupling that effectively prevented free axial movement of the coupling. After proper cleaning and greasing, vibration once again returned to acceptable levels. The lesson learned was that a rusty gear coupling does not allow the universal joint shaft to adapt its length to position changes brought on by the drive roll’s wire tightening function…case closed with productivity and profitability returned! FF Contact Fritz at [email protected]

Uptime New Feature

The investigation revealed that the employee was not wearing protective gloves, and was cutting towards his body. He had an improper hand and body placement to safely perform the task.

The Pulp and Paper Safety Association, located at www.ppsa.org, has graciously and enthusiastically agreed to provide FF with regular safety alerts. PPSA receives many notices of safety incidents and their resolutions each month, and you have requested more safety content – so here we go! We’ll launch our Safety Alert section this month with some PPSA background and a few recent alerts.

Cutting “snips” have now been placed at the palletizer (and all other machine centers in the plant) and the procedure changed to require their use when cutting straps. Plant wide meetings have emphasized the use of snips, wearing gloves when cutting, cutting away from the body, and focusing on the task at hand.

The Pulp & Paper Safety Association is a non-profit, non-political, international organization, devoted to the continuous improvement of safety throughout all aspects of the paper industry. PPSA membership ranges from forest products to paper mills, converting plants, and recycle collection centers. The association began in the 1940's as the Southern Pulp and Paper Safety Association, later changing their name to reflect their widening membership base. They currently have members throughout the United States, Mexico, Puerto Rico, Jordan and Canada. Their recent Annual Safety and Health Conference in June was their 63rd! The PPSA goals are to promote safety, to set reasonable and attainable goals, to educate their members, and to give members a forum for discussion. Here are some recent safety alerts submitted by PPSA member mills. Utility Knife An employee was cutting a band from a unit of boxes with a utility knife. He grabbed the band with his left index finger to pull it away from the unit. He took his right hand with the utility knife and cut towards his body to cut the band. Result: laceration to the left index finger requiring 5 stitches.

During the incident investigation it was discovered that the outer two wires on the bale broke during unloading. The employee pushed the bale to the conveyor with the remaining center wire in contact with the concrete floor. The friction generated enough heat to ignite the bale. We recommend that bales never be pushed with the wires in contact with a concrete floor. Winder Bolts The bolts that secure the winder left side rider roll lift and lowering table cylinder mount bracket broke off causing the bracket to pull away from the main frame of the winder. Operation of the winder ceased immediately and attention was focused on securing the rider roll and lowering table cylinder until the bolts could be replaced. Backside bolts were inspected and also found to be stretched and loose.

Incorrect use of utility knife

Bale Fire A fire occurred in one of our paper mills. An employee was unloading bales of furnish from a truck. A bale broke and was pushed over to a conveyor for immediate feeding. The bale was pushed approximately 200 feet to the conveyor. The employee returned to unloading the truck. Another employee entered the building near the conveyor and noticed flames near the bottom of the conveyor. He immediately notified the mill via a paging system of the fire. Employees responded and fought the fire until the fire department arrived. The fire department continued to fight the fire while a pulper was emptied and made ready. The smoldering bale was fed into the pulper where it was completely extinguished.

Bumper Stickers “Ever stop to think, and then forget to start again?”

Faulty bolts (circled) were replaced with higher-grade bolts

Investigation revealed that the bolts used to secure the housing to the frame were a grade 5 bolt and nut. The bolts appeared to stretch over time and became fatigued and failed/broke. Bolts were replaced with superior grade bolts. A Winder Safety Symposium will be held September 19 and 20 in Atlanta, sponsored by PPSA, TAPPI and AF&PA. Visit www.ppsa.org/windersaftey.htm for more information. FF

Downtime Gigging in a Small Town Tom Wroblenski, Energy Engineer, Stora Enso When I’m not at work as an Energy Engineer at Stora Enso or busy with home/family life I’m gigging. For those of you not familiar with the term, a “gig” is a musical performance of some type. My avocation for several years now has been playing piano (keyboards) with three local Wisconsin bands. While benefit events like “Princess for a Day” feature in my schedule, most of my gigs are play-for-pay.

Gotta have a support structure Though my musical background started in Milwaukee, after coming to Wisconsin Rapids to work for Stora Enso, I’ve found there are a lot of highly talented musicians here! Meeting my guitar player, Richie, three years ago was a positive step-change event for me musically. Our association provided a musical partnership with very similar interests, work ethic, musical direction, common goals, and yet I am able to maintain my diversity in music genres. My children love “Uncle” Richie, which helps integrate band life into family life. The kids see dad and his musician friends working hard as well as having fun both rehearsing at home as well as performing at various venues and charity Richie (left) and Tom in concert benefits. My wife, Sue, is extremely supportive, creating rehearsal space in our home, tolerating the sometimes loud volumes, and even preparing meals for musician friends who sit down with our family. I spend a lot of time with my family, and I really could not do this music stuff, or at least as well or as often, without all of their awesome support.

Practice, practice, practice When I was in fourth grade I asked my parents if I could take piano lessons, to which they wholeheartedly agreed. After my first year, I solemnly informed my teacher that I was going through a major life change, and would be changing to electric guitar, growing my hair long, and getting “granny” glasses (this was about 1970). A week later… after a memorable discussion with my parents … I told my piano teacher that “I’m sorry, but I was mistaken.” In all, I had about 45 months of weekly lessons, and was pretty good, but certainly not great, and was nervous at the thrice-annual recitals. Thirty minutes a day (minimum parental requirement) was inadequate practice time, and at age 14 I quit piano altogether. In my junior year of

high school I regained interest in music through choir, and with encouragement of football teammates and choir members alike, restarted piano on my own, playing the music of Billy Joel, Elton John, The Beatles, and Queen. Performing a role in Jesus Christ Superstar my senior year sparked a love for musicals and show tunes. I overcame stage fright in two ways: by playing music that I enjoyed and loved, and by voluntarily performing weekly during lunch hours at the Grand Avenue Mall in downtown Milwaukee.

And now for an unashamed plug… When I solo, as Play It Again Tom, I sing and play harmonica, and play two keyboards to background rhythm tracks, to almost any kind of music – Bach to rock. Probably know a thousand songs by heart, but my favorites are Billy Joel’s Piano Man and the theme song to the Peanuts show. My rock/variety trio, Cloud 10 (i.e. happier than Cloud 9), combines guitar and a vocalist from Chicago with keyboards, harmonica and rhythm. We have fun Play It Again Tom and get people singing and dancing – while staying true to the original artist’s style. Check us out at www.cloud10.bravehost.com. Rock Soup, a rock band in which I play keyboards, does covers of classic rock (a cover is when a band plays a piece originally performed by and associated with another band). We do pretty much anything from Allman to Zeppelin, but really love Pink Floyd. Important Safety Tip: Bring your own earplugs! The boys from Rock Soup

Music is my life I regularly gig out anywhere from one to three times per week, for example, a solo gig on a Tuesday or Thursday evening, Cloud 10 on a Friday night, and Rock Soup on a Saturday night. In my life, I have been blessed musically by my mom, my childhood teacher, Phyllis Chang – and all the artists who have influenced me, including: Bach, Beethoven, Chopin, Mozart, and Scott Joplin, as well as Andrew Lloyd Webber, Jonathon Barry, George Winston, Sigmund Snopek, Otis Spann, Professor Longhair, Chuck Leavell, Billy Powell, Neil Young and Rick Wright. That’s another reason charity gigs are so important – there’s so much to pay back to all these people! Contact me at [email protected] for upcoming gig dates. FF

www.tappi.org To receive Frontline Focus at your mill each month for FREE, contact Mary Beth Cornell at 770 209-7210; [email protected]

Just What the Doctor Ordered: LiteAdapt at Jämsänkoski UPM-Kymmene’s Jämsänkoski mill in Finland has installed composite LiteAdapt doctor blade holders at two demanding doctoring positions on their PM 4, the 3rd press and cylinder No. 38 after the coater in the dryer section. Superintendent Ari Siltanen says persistent problems have stopped since the LiteAdapt installations in July and October 2004, respectively.

“We had tested several types of doctor blades and changed the holder, but to no avail. After the installation of the LiteAdapt holder the problem has not occurred. If things continue this way, there will be a tangible benefit from increased productivity,” notes Siltanen. Shock resistant, easy maintenance

Positive experiences with Metso Paper’s earlier launched rigid LiteFit composite doctor blade holder was one important reason why UPM wanted to try the new adjustable holder, which also promised the benefits of elasticity and easy maintenance. “We wanted to test this composite holder which keeps its shape in the rough and tumble of production,” explains Siltanen.

So far LiteAdapt has fulfilled its promise. Previously, there was a recurring problem with the 3rd press doctor blade. Especially when the machine was being run up, water dripped through the blade assembly on to the roll and consequently on to the web, causing holes and broke. “Despite several service and repair attempts and alignments we did not succeed in eliminating the problem. Since the installation of the LiteAdapt holder in July there have been no dripping problems. We played it safe and installed a dripping trough, but it has stayed dry,” Siltanen says. There was a persistent problem at cylinder 38, too. Besides doctoring the cylinder, the blade has the job of guiding the web down to the pulper for tail threading. Every so often the web got past the blade and started to wind on the roll, resulting in lost production.

Hannu Eerikäinen & Ari Siltanen

LiteAdapt can be simply pulled out after detaching the pneumatic hoses, making it easy to clean the blade groove. The detachable top plate further facilitates maintenance.

“This holder is much easier to maintain because the blade holder comes off the machine body without having to undo lots of bolts,” points out Siltanen. He also adds that the installation of the holder proved fast, as fast as that of a doctor blade. Benefits

Metso Paper’s new compact and adjustable composite LiteAdapt doctor blade holder is suitable for all doctoring positions. The benefits of LiteAdapt include: • Superior self-profiling characteristics combined with easy installation and maintenance • A flexible structure which keeps its shape and dimensions well.

LiteAdapt & LiteFit Composite doctor blade holders

LiteAdapt adjustable doctor blade holder Metso Paper has invented a new compact and adjustable composite holder featuring superior self-profiling characteristics along with easy installation and maintenance. The patented LiteAdapt holder is suitable for all doctoring positions. Due to its engineered composite design the profiling characteristics of the holder are excellent. A uniform blade load can be optimized for every position. This holder is designed Doctor blade Blade carrier Top plate for easy replacement of adjustable DST type and rigid K35A type holders.

Unload hose Loading hose

Hinge body

Revolutionary LiteFit composite holder Metso Paper has also developed a completely new type of doctor blade holder. Thanks to its unique construction and advanced composite structure, the LiteFit holder is extremely durable and flexible. The adjustable top plate comes in a wide range of different composite materials. The width, thickness and fiber orientation of the holder can be tailored to achieve the best possible doctoring result in each machine position. LiteFit is extremely lightweight, has excellent flexibility and shock resistance, and is easy to clean.