Machinery monitoring reduces shutdowns for South African paper mill


discrete control

Bearing failure on air fans can result in the shutdown of a recovery boiler for 6 to 8 hrs. Installation of an online vibration monitoring system from Emerson Process Management reduced unplanned shutdowns.

Austin , TX —The number of unplanned shutdowns has dropped significantly for the Mondi Business Paper’s Richards Bay Mill in South Africa, thanks to an online vibration monitoring system. Using Emerson Process Management ’s CSI 4500 Machinery Health Monitor, the mill can detect changes in fan behavior and alert operators, so that remedial response can be taken to prevent unexpected fan failures and boiler shutdown. The mill produces bleached hardwood pulp made from eucalyptus fiber and white top kraft linerboard.

In seven months, the newly installed technology has “prevented seven incidents due to fan imbalance and early bearing defects that could have shut us down,” said the mill’s Nico Groenewalk, senior mechanical technician, condition monitoring. “We estimate that the savings, in lost revenue from these incidents would have been $542,118. Not only are we more productive, but this is a safer workplace.”

Uneven build-up of deposits on the runners of fans providing air to the recovery boilers can change fan balance and lead to a number of problems. Bearing failure on air fans can result in a shutdown of the recovery boiler for 6 to 8 hrs. Downtime costs are estimated at $17,306/hr, not including repair costs.

The online monitoring program, which is a component of PlantWeb digital plant architecture, provides a continuous flow of information about fan condition. Operators are made aware of any changes in operation immediately so that a faulty fan can be shut down and cleaned or repaired before a failure occurs. System also trends fan behavior over time using Emerson’s AMS Suite: Machinery Health Manager software and allows remote monitoring.

—Control Engineering Daily News Desk

Jeanine Katzel , senior editor

No comments
The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
The System Integrator Giants program lists the top 100 system integrators among companies listed in CFE Media's Global System Integrator Database.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
This eGuide illustrates solutions, applications and benefits of machine vision systems.
Learn how to increase device reliability in harsh environments and decrease unplanned system downtime.
This eGuide contains a series of articles and videos that considers theoretical and practical; immediate needs and a look into the future.
Make Big Data and Industrial Internet of Things work for you, 2017 Engineers' Choice Finalists, Avoid control design pitfalls, Managing IIoT processes
Engineering Leaders Under 40; System integration improving packaging operation; Process sensing; PID velocity; Cybersecurity and functional safety
Mobile HMI; PID tuning tips; Mechatronics; Intelligent project management; Cybersecurity in Russia; Engineering education; Road to IANA
This article collection contains several articles on the Industrial Internet of Things (IIoT) and how it is transforming manufacturing.

Find and connect with the most suitable service provider for your unique application. Start searching the Global System Integrator Database Now!

SCADA at the junction, Managing risk through maintenance, Moving at the speed of data
Flexible offshore fire protection; Big Data's impact on operations; Bridging the skills gap; Identifying security risks
The digital oilfield: Utilizing Big Data can yield big savings; Virtualization a real solution; Tracking SIS performance
click me