Paper Rolls Reliability Inc.

Internal-Mill Rolls Maintenance Software Program c

Software Description and Benefits

Forward

Paper Rolls Reliability Inc., established in 2007, is based on the concept of supplying the paper
and liner board industry with a comprehensive software package that fills a present need for a
professional Internal-Mill rolls maintenance program to allow companies to increase machine
efficiencies throughout their process lines, and reduce their cost of roll parts and external roll
rebuild services.

To be competitive and successful in the paper producing market of today, and in the future, mills
must acquire the right tools to ensure that all their assets are running at peak efficiency with
reliability built into their system to keep them there.

Paper Rolls Reliability Inc. provides such a tool by supplying a customized rebuild quality control
system, and a separate management system for the in-house maintenance and rebuilds of all
machine rollers throughout the paper machine line. Reliability is achieved by focusing on the
critical machined fits of the rolls and performing regular inspections of the most critical of the
machine rollers such as suction rolls, press rolls and other nipped rolls. The most important of
the machined fits are bearing housing bores, bearing journals, bearing internal clearances
during bearing drive-ups and head fits. Components such as axial seals, internal showers,
suction boxes, suction roll shells and chilled iron roll shells also deserve special attention.

Unscheduled paper machine downtime due to mechanical roll failures can be reduced by a
minimum of 50% and can be as high as an 80% reduction depending on the quality of a mill‟s
current roll maintenance system.
About the product

The rebuild quality control portion of the system consists of a complete set of customized
digital inspection and measurement forms for each different roll design for every machine in the
process line. Each form includes applicable roll specifications and OEM tolerances for all critical
fits. They contain auto-generated calculations to standardize measurements to standard shop
temperature, and calculate interference fits, average diameters, taper, roundness, and such
things as suction roll shell cycles.

The software is designed to maximize “user friendly” features, and with OEM tolerances and
auto-generated calculations embedded within the inspection forms maintenance supervisors
and tradesmen immediately gain speedy references and full potential from the system.
Absolutely no additional calculations are required by mill staff. With the features of this software
the efficiency and effectiveness of the rolls supervisor and his/her trades people can increase by
as much as 15% or more. There will no longer be a requirement to seek OEM specifications and
tolerances from multiple sources.

All forms and document templates are digital, can be copied and become part of the roll
maintenance history data bases after inspections and roll rebuilds are completed and signed off
by the roll supervisor.

Types of Quality Control Inspection and Measurement Forms:

 Inspection and mounting of roll bearings (including drive-up method)
 Inspection and measurements of roll journals
 Inspection and measurements of bearing housing bores (including shell bores)
 Roll shell/head fit measurements
 Inspection of suction roll shells and/or covers
 Inspection of chilled iron roll shells
 Inspection of suction roll internal lubricating shower and piping
 Inspection of suction roll internal shell cleaning shower and piping
 Inspection of suction roll suction boxes
 Measurements of suction roll axial seal strip wear
 Inspection of newly rebuilt bowed rolls
 Measurement of roughness of ceramic press roll covers (includes graph of roughness
measurements, averages and standard deviation)
 Measurement of installed housing center distances for dryer felt rolls (short and standard
felt rolls)

The roll management portion of the system is sold separately and also includes customized
documents which allow the rolls supervisor, and other mill personnel to track the current status
of all in-service and spare paper rolls. The system‟s “current roll service duration and scheduled
prioritized change out document”, which contains graphics for easy roll reference, contains auto-
generated calculations for setting priority for roll changes according to planned service times.
The “current service and spare rolls inventory document” separates rolls by design type,
indicates their current status and where each roll is located or stored.

The “live” documents in the rolls management system allows the roll supervisor to gain control
of the massive workload involved in rolls maintenance, as well as provide a quick reference on
the status of all rolls.

Types of Roll Management Forms and Documents:

 Current roll service duration and scheduled prioritized change out
 Current roll service and spare rolls inventory
 Control document for roll rebuild (can itemize detailed step-by-step sequence of tasks
involved in any roll rebuild)
 Document for setting priorities for roll rebuilds
 Document for setting priorities for roll grinding
 Document for setting priorities for roll balancing
 Summary record document for roll service and maintenance (common rolls)
 Summary record document for roll service and maintenance of suction rolls (contains
auto-generated calculations for cumulative service life cycles for shells, which reach their
fatigue life at 1 billion cycles)
 Reel spool inventory document with history summary
 Document for tracking the diameters of supercalender filled, or composite rolls (includes
graph of diameters for quick reference)
 Document to provide verification that oil flow checks were completed for disconnected
rolls prior to start up after being shut down
 Document to provide verification that disconnected vibration monitoring sensors were
reconnected prior to start up after being shut down.

Benefits of the product software

 Increase safety and decrease liability (due diligence)

 Perform required inspections and roll changes on a regular schedule to mitigate

the risk of catastrophic failures such as suction roll shell failures and cover de-
lamination, chilled iron roll shell failures and „burn out‟ of bearings with
associated shaft loss. Brittle fracture failures of chilled iron roll shells are by far
the most dangerous with no fore warning and large pieces of shell being thrown
from the machine.

 Minimize the risk of liability due to inadequate roll maintenance practices. This
software provides proof that roll maintenance is performed in a professional
manner with regular schedules, critical tolerance checks and history gathering.
 TIP: If the company collective agreement allows, it is highly recommended that a dedicated
team of trained millwrights (two per mill line) perform all roll rebuild tasks. This leads to
performance efficiency with the familiarization of all required tools, rigging and procedures. This
especially applies to the dangerous tasks of roll change outs. The dedicated trained millwrights
from other mill lines can be utilized to form a roll change team during machine shutdowns.

 Increase rolls reliability

 Utilization of this software and attention to detail and tolerances during roll
rebuilds will increase reliability to a minimum of 95% and extend roll service
periods for all roll types.

 Achievement of 18 months and beyond for suction roll service periods is

realistic and has been achieved at some mills. The maximum service
period for covered suction rolls is dependent upon cover type, and must
have supplier input to determine the maximum service time frame
allowable for press nip loading and machine speed. Polyurethane covers
are now available that can easily reach an 18 month service period. Note:
The existence of corrosion pitting in the bores of shell suction holes will
seriously undermine an extended service period by becoming a
mechanism for accelerated shell blockage.

TIP: Two of the weakest links for suction roll reliability are axial seal strip wear and shell
blockage. Production personal must buy into this concept and keep seal strip lubrication flow to
the maximum possible and keep seal strip loading pressure to the minimum value. Flooding
showers should come on automatically on machine shutdowns.

 Increase rolls availability

 The software provides a systematic approach to roll rebuilds and roll change
outs. Minor defects and wear which otherwise could have been missed are much
more likely to be detected and remedied before they progress to more
destructive failures with associated high cost and long durations for required out
of mill roll repairs. When a roll is off site it is no longer under your direct control.

 Within one to two years of program initiation a mill will have control of close to
100% of rolls availability. This goes hand-in-hand with reliability.

TIP: Have an adequate quantity of spare parts, such as bearings, available for critical roll
applications and high frequency roll changes such as supercalender filled rolls.

TIP: At least two spare bearing housings should be available for reel spools, supercalender
filled and chilled iron rolls, and paper machine press & dryer felt rolls.

 Increase roll maintenance effectiveness

  The use of this software program provides the maintenance team the tools, in the
form of inspection forms with tolerances and auto-generated calculations, to
professionally perform the correct checks on rolls to verify that they are within
OEM specified running condition. Absolutely no additional calculations are
required by the roll supervisor or trades people when using the inspection forms.

 The program provides specialized inspection forms for suction rolls, chilled iron
rolls and bowed rolls to ensure that the critical checks for these rolls are
performed.

 Priority setting documents for roll rebuilds, grinding and balancing allows
maintenance personal a mechanism to systematically co-ordinate these
functions, and minimizes the risk of rolls being forgotten and „falling through the
cracks‟ after they have been changed out.

 Retrieval of Control documents for roll rebuilds, once pre-built by the roll
supervisor, allows a rebuild for any roll to be performed without the risk of
forgetting items such as critical checks, cover changes, minor/major repairs or
modifications flagged during the last rebuild.

 Implementation of this software allows a mill‟s internal rolls maintenance program

to obtain ISO 9001 Certification. Certification is optional, but highly
recommended to ensure the program remains on track and continues to provide
substantial benefits to the mill.

 The rolls supervisor will obtain the ability to regain control of the vast workload
associated with roll maintenance.

 The system effectiveness will greatly increase if the millwrights performing roll
rebuilds have the responsibility for digital data entry on all required inspection
sheets and rebuild control sheets.

 Increase roll maintenance efficiency

 The structure of the inspection and measurement forms create efficiency by

saving time researching required tolerances and performing calculations for
taper, ovality, average diameter, and average diameter corrected for standard
temperature for bearing housing bores and journals; and actual interference fits
corrected for standard temperature for roll head fits.

 Time will be saved with auto-generation of calculations for average roughness,

standard deviation and graphical formation for roughness measurements on
ceramic press rolls.

 Substantial time saving will be realized for information searches for report writing
and for roll status checks.
  Based on roll service period targets, maintenance personal will be able to make
better informed decisions in conjunction with their operational partners to
schedule regular roll changes for preventive maintenance during the planning for
felt and wire changes, and other machine shutdowns.

 With the availability of fast information retrieval from the „in-service‟ and „spares‟
documents the time required for roll maintenance personal to prepare for regular
planned shutdown meetings will be greatly reduced. This is especially important
in emergency shut downs.

 Increase mill competitiveness

 Increase machine uptime by reducing roll failures.

 Reduce roll maintenance cost by minimizing catastrophic failures with associated

loss of rolls, fabrics and surrounding equipment; and performing more internal-
mill roll maintenance at a much reduced cost for labour and parts as opposed to
performing roll rebuilds at external roll rebuild shops.

 ROI

 Paper rolls are the most expensive portion of a paper mill maintenance budget.
This software application will minimize expenditures for roll maintenance by
doing things right and keeping assets in top running condition. The premature
loss of one large suction roll bearing can cost as much as $25,000.00. It is
estimated that a minimum saving of $75,000.00 per year for bearings alone will
be realized. Other cost savings will certainly be realized in the prevention of
damage to other roll parts such as roll journals and bearing housings in a
relatively minor failure; not to mention the huge cost of roll cover, or shaft loss
and damage to associated equipment in the event of a catastrophic failure. The
annual cost saving for these “other” events is conservatively estimated at a
minimum of $150,000.00

 After implementation of this program a saving of at least 1 wet felt, 1 forming

fabric and 1 dryer felt per year will be realized due to the prevention of
unscheduled downtime, or fabric damage, caused by roll failures and the
associated requirement for a roll change during the service life of these fabrics
where fabric removal is necessary in order to accomplish the roll change. A
conservative estimate for cost savings on fabric losses is $125,000.00 per year.

 Loss of production due to roll failures that cause unscheduled machine

shutdowns can add a significant cost to these failures. Depending on the type of
failure and roll position the unscheduled shutdown may last anywhere from 4
hours for an easy roll change to several days and more for a catastrophic failure.
An increase of 3% in paper machine uptime efficiency can be achieved.