An Online Method for Correcting Bearings in Paper Machines
Bearings are critical wear parts of paper machines. When they lose their effectiveness, it's necessary to stop the machine and replace them, which can cause significant economic losses for paper mills. Ensuring the continuous operation of bearings is crucial for the smooth functioning of the entire paper machine.
The most vulnerable components include the bearings in the forming section, press section, and calender, especially those in the super calender and soft calender. These parts operate under harsh conditions—high temperature, high humidity, and high-speed environments. As a result, traditional lubricants often fail to meet the required performance standards, leading to frequent failures and unplanned shutdowns.
Modern high-speed paper machines have transitioned from time-based maintenance (TBM) to condition-based maintenance (CBM). However, many domestic paper mills still rely on lubricants that lack sufficient wear resistance and water resistance, making it difficult to handle the demanding operational conditions of high-speed machines.
This article introduces an online correction method for paper machine bearings. Instead of replacing faulty bearings immediately, using a high-performance lubricant with advanced properties can help restore bearing functionality. This approach not only reduces unplanned downtime but also saves significant repair and replacement costs.
1. Online Correction Method for Paper Machine Bearings
When abnormal temperature increases or excessive vibration occurs due to the use of standard lubricants, a high-performance lubricant with correction capabilities can be used. By replacing the original lubricant with a more advanced one, the bearing can be corrected without stopping the machine. Over time, this process helps reduce temperature and vibration, allowing the machine to continue operating until a full replacement is needed.
One example of such a product is Purple Crown, a high-performance lubricant developed by American Purple Crown Co., Ltd. Its ability to correct worn bearings has proven effective in reducing downtime and saving costs.
2. Principle of High-Performance Lubricants in Bearing Correction
The main function of a lubricant is to maintain a stable oil film between moving parts. Poor lubrication leads to insufficient film strength, resulting in metal-to-metal contact, increased wear, and elevated temperatures. High-performance lubricants provide a stronger oil film, reducing wear and enhancing bearing life.
Some advanced lubricants also have micro-polishing properties, which can smooth out worn surfaces and improve surface finish. This not only restores normal operating conditions but also reduces friction and heat generation, extending the life of the bearing.
3. Case Studies of Successful Bearing Corrections
3.1 Fraser Paper – USA
In November 2000, the No. 1 vacuum press transmission bearing of Fraser Paper’s No. 6 paper machine experienced a sudden temperature rise to 120°C. After applying Purple Crown UPG2 grease, the temperature dropped to 71°C within one hour, and the machine resumed normal operation. This prevented a potential loss of over $36,000.
3.2 Guangshen Line Blue Arrow – China
In April 2003, the traction motor bearings of the Blue Arrow train suffered damage. Instead of replacing the bearings immediately, engineers used Purple Crown lubricant. After 80 hours of monitoring, six out of eight bearings reached acceptable performance levels, avoiding the need for expensive replacements and saving nearly 10 million yuan in costs.
3.3 Gulf of Mexico Chemical Plant – USA
A Roots blower at a chemical plant was experiencing severe vibrations. After switching to Purple Crown Synfilm GT 320, the issue was resolved within three days, restoring the equipment to safe operating conditions.
4. Conclusion
Using high-performance lubricants with micro-polishing properties offers a practical solution for online correction of paper machine bearings. It improves machine uptime, reduces unplanned stops, and enhances overall efficiency. For paper mills, this method provides a cost-effective way to maintain operations and avoid major financial losses.
Related Bearing Knowledge:
- Common quality defects after bearing heat treatment
- Method for loosening the ring of a plane thrust bearing
- Three common methods for bearing repair
- Classification of sliding bearings
- Quenching and tempering process of large thin-wall bearing outer rings
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