DRYER INSPECTION PROGRAM
PAPER MACHINE DRYER INSPECTION -
PART II - SHELLS
Algis P. Mockaitis
Director, Mechanical Engineering
Stone Container Corporation
Burr Ridge, IL 60521
U.S.A.
ABSTRACT
Ultrasonic thickness testing of dryer shells is a major part
of periodic dryer inspection programs. The variations of
ultrasonic velocity in gray cast iron from dryer to dryer
require calibration procedures that take this into account.
The most successful calibration methods have been found
to combine use of a mechanical caliper and the “wedge”.
The variations in ultrasonic velocity found in dryers are
presented together with an analysis of errors that can be
expected if calibration is not correct. Common faults
found during inspection of dryer shells are discussed
along with criteria for their evaluation.
INTRODUCTION
Periodic inspection of paper machine dryers has become
an established industry practice. A dryer inspection
program is an effective means to detect early signs of a
dryer component failure in order to maintain a safe
working environment and avoid equipment downtime. A
complete inspection program for dryers includes visual
inspections, magnetic particle testing of heads for cracks,
ultrasonic testing of bolts for cracks, and ultrasonic
thickness measurements of the shells. This paper deals
with the inspection of dryer shells. The inspection of
heads, journals and bolts is covered by M. Moskal in
Part I.
In-service inspection of pressure vessels, such as paper
machine dryers, is governed by local jurisdictional
requirements (State, County and City Codes), insurance
underwriter requirements, and OSHA. Many of these
requirements reference the American Society of
Mechanical Engineers (ASME) Code and the National
Boiler Inspection Code (NBIC). The ASME Code is
intended to provide requirements for the design and
fabrication of pressure vessels. It is a Code for new
construction. The NBIC Code covers the inspection and
evaluation of pressure vessels that are in service. These
Codes cover requirements for all types of pressure vessels
and do not provide details for inspection of specific
vessels such as paper machine dryers.
Inspection of dryers is normally conducted by an
independent agency (NDT inspector) contracted by the
owner to perform a comprehensive inspection and
provide a report documenting their findings to the owner.
The inspection is done by technicians who are competent
in performing the inspections but who are not expected
to be qualified to judge the serviceability of the dryer.
Evaluation of the test results remains the responsibility of
the owner.
Inspection Procedures
The most comprehensive guidelines for inspection of
paper machine dryers is the TAPPI Technical
Information Sheet TIS 0402-16 (1). It provides
guidelines for testing that should be considered when a
testing program is being conducted. Nondestructive
testing contractors who inspect dryers frequentlywill have
a written procedure that is followed for the inspection of
dryers. It will describe the type of equipment used,
calibration methods, and reporting format. It will serve
as a good starting point for the mill that does not have its
own inspection standards. However, the mere existence
of a written procedure does not imply that the desired
results will automatically be obtained. The owner must
still determine that the written procedures are
appropriate to his situation. The contractors procedures
will not necessarily include all of the inspections that
should be done. The scope of inspection must still be
defined by the owner.
Responsibilities of the owner
As a first step in a testing program, the owner should
develop a database on the dryers to be inspected which
would include manufacturer’s drawings, National Board
registration forms, material test reports, and records of
previous inspections. This will provide the inspectors
with the information needed to conduct accurate testing.
A review of the ASME Code requirements will establish
the minimum Code thickness. A reporting procedure
should be established for immediately informing the
owner when problems are detected.
Before the start of a testing program the scope of the
testing must be defined by the owner. This includes
specifying the types of tests to be conducted on the
selected dryers. Since most inspection programs are
carried out during annual mill outages, the scheduling of
the testing must be done realistically to avoid
interference with other work in progress. The need to
rotate dryers for ultrasonic thickness scans could interfere
with work such as felt roll, dryer gear or bearing
1997 Engineering & Papermakers Conference /769