The time is now to be prepared.
How do you ensure maximum run time and output from your machines? The key to accurate execution of outage and preventative maintenance programs is proper planning. OASIS partners with you during planning to provide alignment assistance to help reduce downtime.
Learn how you can improve outage efficiency with proper alignment planning.
Planning Leads to Success
American Eagle Paper Mills knew they had a serious issue when they lost a drive bearing on a dryer can in their No. 3 paper machine. The failure caused severe journal damage. Though the mill was able to complete an emergency field repair allowing them to run for several more weeks, they knew they had to explore options that would provide a permanent fix. After looking into in-place machining, dryer head replacement and other alternatives, they came to the conclusion that their best choice was to replace the dryer can.
OASIS was asked to assist with the project and immediately met with the team from American Eagle to develop a plan to replace the dryer can. Working closely with the American Eagle team, OASIS engineers meticulously mapped out all related tasks and responsibilities and created a project timeline. The project included the removal of the damaged dryer can, the installation of the new dryer can and optical alignment of all rolls within the section. Within a very short period of time, an OASIS team of thirteen field service technicians and alignment engineers were on site with an OASIS mobile machine shop and began working around the clock for four twelve-hour shifts. Due to the extensive planning prior to the start of the project and the teams working together throughout, OASIS completed the entire project in two and a half shifts instead of the estimated four. Additionally, because OASIS was in constant communication with the American Eagle crew, the mill was able to quickly change employee schedules, allowing them to begin production a full day earlier than planned. The mill gained 30 hours of machine time due to the success of the project.
Alignment Issues Avoided
When new major components of a paper machine are being installed or upgrades made to existing components, there are typically many teams involved including maintenance planners, project managers, and outside mechanical contractors. One such project at a large papermill involved all of these groups and more – including a team from OASIS. The project involved the installation of a new headbox, upgrades to the drive (removal of line shaft and installation of direct drives) and upgrades to the Bel-Former.
OASIS was contracted to provide alignment support, which required collaborating with each group during the planning phase. Once the headbox installation portion of the project began, OASIS metrology engineers used laser tracker technology to locate specific dimensions of the headbox, breast roll and pins during installation. These components were also leveled and aligned square to the machine baseline. OASIS metrology engineers also used laser tracker technology to provide alignment support for the installation of a new Uniroll in the dryer section. Additionally, the OASIS teams used both laser trackers and a LSAS (laser shaft alignment system) to provide alignment support during the drive upgrade. Because OASIS was heavily involved during the project planning stage, alignment related issues were avoided upon start up.
Preparation Key to Relocation
An expansion for a large coating and laminating company required the relocation of some of their converting equipment to a new larger facility. OASIS was contacted to assist with the project. Because the move would affect current production, they were hopeful that all parties involved in the relocation project could devise a plan that would be timely and efficient, so as to get the relocated lines back up and running as soon as possible. Planning began several months before the move.
OASIS participated in numerous meetings with mill personnel, the local rigging company, and the electrical contractor, to identify everyone’s capabilities and responsibilities for this project. OASIS made a number of trips to the old facility to take measurements and dimensions of the current placement of the equipment, record the spacing between the units, and identify the required anchoring and grouting requirements for all pieces of equipment. All groups worked cohesively to devise an overall plan and detailed schedule to identify the process and timing associated with the move. The project involved extensive communication between all contractors involved including the rigging company, OASIS, and the electrical contractors. Once the riggers relocated the equipment to the new location, OASIS began the final positioning, which involved anchoring the equipment to the floor, performing the final alignment of all the rollers within the equipment, and then grouting of the bases where required. The electrical contractors were then given the go-ahead to begin their responsibilities. At times, OASIS and the electrical contractors worked in conjunction to allow access to the machine. Because this was planned for, the schedule was not affected. As each line was completed, it went “on-line” for production. The majority of the move was completed in a two-month period, consisting of twelve converting lines as well as auxiliary equipment. As a result of the in-depth planning and the professional nature of all involved, the relocation of the equipment occurred without incident and the plant was able to meet production needs.
From the initial planning stages of the job to the execution, OASIS and American Eagle were able to work together extremely well. After all of the preparation work and planning, the job completed nearly 24 hours early! The communication between OASIS and the mill allowed the mill to take full advantage of the early completion.Andrew Symons