Ahlstrom Optimizes Paper Machine Reliability with ACOEM's Vibration Monitoring Solution

Country: France
Application: Pulp & Paper

EXECUTIVE SUMMARY

Ahlstrom, a major international player in the paper industry, deployed a vibration monitoring solution across multiple production sites in France to optimize the reliability of its paper machines (PM). The objective was to ensure continuous production in a challenging environment characterized by extreme temperatures and high humidity. Thanks to ACOEM Reliability solutions, Ahlstrom improved preventive maintenance and equipment performance, reducing the risk of unexpected downtime and excessive maintenance costs.

The Challenge

Before working with ACOEM, Ahlstrom faced several challenges in managing its paper machines:

Extreme Working Environment: High humidity in the forming table and press section, extreme heat in the dryer, and limited access to the upper parts during normal operation.
Complex Safety Conditions: Dangerous access for sensor installation, especially in the transmission section and dryer equipment.
Low and Variable Rotational Speeds: The dryer rolls operated at speeds ranging from 1.5 Hz to 2.5 Hz, making it difficult to monitor rotating machinery with standard vibration tools.
Measurement Instability Issues: Variations in paper speed, influenced by paper type and grammage, made it challenging to replicate measurements reliably.

Potential Consequences

Risk of unexpected failures in critical equipment, leading to production disruptions and paper quality issues.
Increased maintenance costs and reduced equipment lifespan due to the absence of vibration monitoring.

Impact on Ahlstrom’s Operations

Without effective vibration monitoring, Ahlstrom experienced unplanned stoppages, high maintenance costs, and reduced operational efficiency on its production lines.

The Solution

To address these challenges, Ahlstrom implemented the following ACOEM Reliability solutions:

Advisor: AI-powered diagnostics using vibration data from EAGLE and FALCON to provide expert analysis and actionable insights. Measurement frequency is monitored under a vibration monitoring contract, with increased checks after component replacements. Measurements can be conducted either by ACOEM or Ahlstrom, linked to Advisor for advanced diagnostics.
EAGLE: Deployed for long-term remote monitoring of inaccessible (safety-critical) equipment and for temporary monitoring of machines in critical condition.
FALCON: Used for on-site spot measurements on high-risk equipment.
Machine Defender Spot Measurements with Accurex AI: Implemented to detect bearing defects and lubrication issues, particularly on components experiencing high vibration and acceleration (e.g., refiners)

Why choose ACOEM ?

Ahlstrom has partnered with ACOEM since 2015, transitioning from systematic or reactive maintenance to a condition-based maintenance approach, significantly improving machine reliability and efficiency.

Addressing Specific Needs :

ACOEM solutions met several key requirements:

Managing Extreme Environments: Robust sensors and contactless solutions enabled reliable vibration measurements in harsh conditions.
Precise Monitoring of Low Rotational Speeds: The systems ensured reliable detection of issues despite low and variable rotational speeds.
Securing Installations: Remote boxes for sensor connections ensured the safety of technical teams, minimizing risks during interventions in hazardous areas.

The Results

After implementing the ACOEM solutions, the following results were achieved:

Reduced Unexpected Downtime: The predictive maintenance approach reduced unplanned downtime by 30% on critical equipment.
Prolonged Equipment Lifespan: Continuous vibration monitoring extended the lifespan of bearings and motors by 15%.
Improved Safety: Installing sensors in remote boxes increased the safety of the technical teams by reducing the need for direct interventions in hazardous areas.
Lower Maintenance Costs: The predictive maintenance strategy reduced corrective maintenance costs by 20%.