PAPER MACHINE FORMING ROLL ( Bearing Defect )

The forming roll shown below is positioned in the wet end of the paper m/c. It runs
between 150 rpm - 200 rpm depending on the type of paper being made. In this case
the machine was running at 816 meters per minute, this equated to a speed of 181
rpm on the roll. The roll has two large supporting bearings and an internal bearing
where the inner race is fixed.





















Monthly vibration readings were taken on the front and back bearings. Upon analysis
of the readings it was noticed a set of harmonics were found to be developing. The
spectrum below shows the defect harmonics starting from 8.91 orders. This pointed
towards a bearing defect, all the bearing defect frequencies were overlaid and a
match was found with the inner race of the internal bearing skf 22334. This confirmed
a defect on the inner race of the 22334 brg.
PS76 - Wire Forming Roll (1435mm)
Frm/Roll -DSA Forming Roll Drive Side Axial
Label: INNER RACE DEFECT ON SKF 22334CC
Route Spectrum
29-JAN-00 14:52:03
OVRALL= 2.10 V-DG
PK = .0915
LOAD = 100.0
MPM = 816.
RPM = 181.
0 10 20 30 40 50 60
0
0.01
0.02
0.03
0.04
0.05
0.06
Frequency in Order
P
K

A
c
c
e
l
e
r
a
t
i
o
n

i
n

G
-
s
8
.
8
1
1
7
.
6
2
2
6
.
4
3
3
5
.
2
4
4
4
.
0
5
5
2
.
8
6
Ordr:
Freq:
Spec:
8.810
1593.7
.04402
>SKF 22334CC
M=BPFI : 8.81
M M M M M M

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On tracking the bearing fault over the coming weeks it was noticed that the bearing
was deteriorating rapidly. After discussions with production and maintenance it was
decided to take advantage of the next wire change and replace the roll within a
planned shut. Wire changes occur every 3 months to ensure paper quality is
maintained. This action would incur no downtime because it was a planned outage.
The multiple spectrum plot below shows the bearing defect deteriorating over time.


The next plot below shows a trend of the overall value. The bearing was rapidly
deteriorating The monitoring frequency was increased to once a day so the fault could
be monitored closely until the planned shut arrived.

P
K

A
c
c
e
l
e
r
a
t
i
o
n

i
n

G
-
s
Frequency in Order
PS76 - Wire Forming Roll (1435mm)
Frm/Roll -TSA Forming Roll Tender Side Axial
0 10 20 30 40 50 60
0
0.02
0.04
0.06
0.08
0.10
Max Amp
.11
28-AUG-99
21-SEP-99
15-NOV-99
06-JAN-00
12-JAN-00
13-JAN-00
14-JAN-00
14-JAN-00
17-JAN-00
19-JAN-00
22-JAN-00
24-JAN-00
27-JAN-00
28-JAN-00
29-JAN-00
04-FEB-00
15-FEB-00
Bearing detected
Bearing Changed

PS76 - Wire Forming Roll (1435mm)
Frm/Roll -TSA Forming Roll Tender Side Axial
Trend Display
of
OVERALL VALUE
-- Baseline --
Value: .475
Date: 02-JUL-98
240 300 360 420 480 540 600
0
1
2
3
4
5
6
Days: 31-JUL-98 To 15-FEB-00
R
M
S

V
e
l
o
c
i
t
y

i
n

m
m
/
S
e
c
ALERT
FAULT
BEARING CHANGED









The roll was replaced for the spare roll in the planned shut. The roll was stripped and
the inner bearing was inspected for damage. As predicted the inner race was badly
spalled ( see below ). The bearing would not of lasted much longer. Failure of this
bearing would have incurred heavy production losses and expensive damage to the
30 ton forming roll. The bearing was sent away for analysis to find the root cause of
the damage.




Estimated Cost Savings











Actual Costs ( Action Taken ) Costs ( No Action Taken )

Parts : New Bearings Skf 239/710 35% of ERV ( Estimated replacement
Value Skf 230/500 0.35 x 150000 ( Cost of New Roll )
Skf 22334 = 52500
= 22000
New wire needed if unplanned breakdown
Labour : 6 men , 10 hours @ 30/ hour occurred = 24000 ( New Wire )
To remove and replace roll
= 1800 Labour : 6 men, 12 hours @ 45 /hour
= 3240
Production Losses: None, job planned in
with routine wire change Production losses:
12 hours downtime @ 3600 / hour
= 43200

Total Cost = 23800 Total Cost = 122940


23800 - 122940


Estimated Avoided Cost = 99140


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