Large paper mill in Texas, USA reduces breakdowns and maintenance costs by adopting Tan Delta real-time oil condition analysis.
The plant is highly automated and operates 24/7, processing over 4 million tons annually. Equipment reliability and efficiency are critical, and the mill has a long term program of active equipment management.
The Challenge
Unexpected water contamination of the lubrication oil in drying and press equipment (caused by humidity), was going undetected. This resulted in expensive oil sampling and analysis, breakdowns, maintenance disruption and accelerated equipment wear. Analysis showed that 10% of the system lubrication points represented 90% of breakdown origins.
The Solution
Tan Delta OQSx-G2 sensors have been installed at strategic points across the mill to provide real-time continuous oil analysis. Each sensor analyses and tracks the condition of the oil enabling plant managers to plan optimal maintenance schedules, as well as detect any contamination, including water.
The analysis accuracy of the OQSx-G2 enables contamination detection, however in this case the customer’s focus was humidity (water) which is detected and tracked by the sensor from concentrations as low as 20ppm, enabling detection and alert at the very earliest stages prior to any damage. The sensors were installed on the grinder central lubrication system and on the generator turbines, integrated with the existing PLC control system.
The Benefits
Plant managers receive an alert when water is detected and an accurate indication of contamination level, allowing effective maintenance planning. During the first 12months post installation, they have detected and resolved 6 unexpected contamination incidents which they believe would have resulted in a breakdown, as well as been able to further optimise regular maintenance. The result has been a substantial 35% reduction in maintenance costs, as well as a verifiable contribution towards the group’s ESG targets through reduced oil use.