Lubrication systems in Pulp & Paper industry

Lubrication systems in Pulp & Paper industry

Grupo Técnico RIVI (Zaragoza, Spain) – Tel. +34 976 126585 / Fax: +34 976 126579 / Email: [email protected] / Websites: www.rivi.es – www.rivi.net



Our technicians and engineers, study the lubrication processes inthe customer facilities, the machinery operation and the workconditions by collecting the following information:

• Machinery, equipment and list of components.• Points to localize and identify. Critical points.• Ideal lubrication system.• Environmental conditions, productive process, work conditions

of the equipment and elements.• Requirements of the Quality Normative (ISO), risk prevention

and environmental protection.

After getting this information, it is analyzed and through theEngineering and Technical Office departments, a centralizedlubrication project is developed according the customer needs. Theproduction area of Grupo Técnico RIVI starts the manufacturing ofthe equipment to install, only after the approval of the contractcompany.

According to the delivery times required by the customer, the Assembly Team completes the assembly,commissioning and start‐up of the centralized lubrication system.



Experience. Quality. Service.

For the Pulp & Paper sector, all the machines must operate continuously even under the most rigorous workconditions (misty & wet areas, extremely high temperatures, chemical agents…). Here is where RIVI’sequipment, systems and products, highlights for their quality and reliability, and it comes to represent anstandard in production centers, as well as for OEMs of machinery for paper mills, cardboard, cellulose pulp,and others.

Grupo Técnico RIVI offers long lasting experience, quality and service, for any automatic lubrication project,giving a tangible and immediate productivity increase, cost reduction in maintenance, and reduction in energyconsumption of the machinery.



A lack of lubricant might cause undesired breakdowns in the machines. The high cost of the mandatorymaintenance and lubrication tasks, join to a big value of the machines, lead to the need of install centralizedand automatic lubrication systems.

The accumulation of hostile agents like dirt, contamination, moisture as well as the high mechanic loads, arethe reason of excessive wearing of the friction points. So, the lubrication is absolutely necessary to providethe right protection. RIVI lubrication systems are a reliable way to ensure a right lubrication. While themachine operates, the right volume of lubricant is distributed to every lube points connected to theautomatic system, on the right time.

The lubrication ensures that the lubricant willbe distributed optimally and evenly to everyfriction points, and it will avoid friction andpremature wearing.

Big Cost Reduction = Fast ROI(return of investment)

Installing a lubrication system reduces the costof repairing and maintenance drastically. It alsoreduces the lubricant consumption and itextends the useful life of the machinery.

Centralized & Automatic Lubrication



Grupo Técnico RIVI offers the most appropriate lubrication solutions for every pulp & paper productionprocess. In fact, by giving a right lubrication, breakdowns and failures attributable to a inefficient greasing , areimmediately reduced; moreover, an optimal performance of the machine is ensured.

More of the 50% of the failures in bearings come from inadequate lubrication. In 97% of them are manuallylubricated.

Advantages

Productivity:• Increase of availability of the machine• Increase of production• Improve of the ratio cost/production• Increase in the competiveness of the company

Maintenance:• Decrease of number of no programming stops• Improve on effectiveness• Cost reduction for repairing• Cost reduction for automatized activities• Eliminate cost in tools of manual lubrication• Extend the intervals for maintenance

Energy efficiency:• Less wearing• Decrease of energy

consumption due to frictionis minimized

• Reduction of CO2 emissions

Security and occupational health:• Elimination of risks for access to

dangerous areas for manuallubrication

• Less contamination and lubricantresidues, and less risks of slidinglesions.

Environmental protection:• Less acoustic contamination• Reduction of residues (for use more

efficient of the lubricants)• Reduction of costs for manipulation

and waste container of lubricants.




The professional team who compounds Grupo Técnico RIVI, work toprovide you the technique solutions and the services which bestoptimize the lubrication of your paper mill, avoiding problems andensuring the best continuous lubrication.

Few of our products have been specifically developed to be used in pulpand paper industry, in order to work continuously under the worstenvironmental and operation conditions.

It is possible to undertake centralized lubrication projects step‐by‐step,by gathering individual points or lubrication areas, centralizing themlater on, and finally completing the automating process with differentlevels of monitoring and control.

1. Isolating lubrication points. Manual lubrication point to point2. Lead/distribution. Manual lubrication gathering. It is reduced the

number of points.3. Centralization through lubrication equipment. First phase of the

centralized system.4. Integrated control. Centralize and automatic system .5. Automation and control system from PLC/DCS in plant.




Process diagram:



RIVI’s single line systems are used when the lubrication needing's are different among diverse lube points ofmachinery. The lube injectors – direct action – has a metal to metal adjustment, and pistons capable ofdeliver lubricants even at high pressures. Each injector is individually driven, and supply to only onelubrication point. It can be adjusted with high precision to supply the exact quantity of lubricant required.Whenever the pumpstation be powerful enough, and piping size be appropriate, the entire lube system canbe expanded at anytime.

Technical systems: Single Line

• Individual lubricant injection for eachlubrication point.

• Visual and electric (optional) monitoring.

• Lubricant supply in high pressures.

• Simplicity – easy to understand and install.

• Extendable.

• Stainless steel injectors available.



Technical systems: Single Line

Single line injectors installed on Reel Up Single line system for Dry‐end PulperProducts Portfolio



This system uses pumpstations of multiple outlets, radialpumps that have been successfully used since the earliestindustrialization. With these pumps the lubrication – eitherwith oil or grease – takes place by means of individual outletsfrom a central station in a metered way. Each outlet houses apumping element in radial position which is driven by aneccentric, and supplies an adjustable volume of lubricant.

Features:

• All the points are connected directly with tubes to differentoutlets of the pumpstation, without distributors.

• The dosage to each single point is regulated in thepumpstation itself, by means of pumping elements.

• By means of progressive metering devices the possibility ofpoints to lubricate is extended. The system continue workingwhile the pump is switched on. When the pumpstation turnsoff, the progressive metering device stops, and it willcontinue from the same point when the system starts again.

Technical systems: Multiline



Technical systems: Multiline

Multiline systems installed for automatic lubrication of coating calender, winder, presses…



The progressive RIVI’s systems have been designed tosatisfy the most restrictive lubrication requirements ofmachines and equipment. Its reliability is based on theprinciple of progressive function, where the lubricant isdelivered to the lubrication points by pressure‐drivenpistons. The lubrication occurs in intervals regulated amaximum pressure of 350 bar. So that, the lubrication ofthe lube points is also feasible even against highbackpressures.

Benefits of Quicklub system:• There is not corrosion of the pump housing, make in

fiber reinforced resin, especial for hard activities.• Pump engine is protected for wear and wet.• Few sizes of resevoir available.• Safety valve, also equipped with visual indication and

return line to reservoir.• Integrated Control Plate (optional) and Touch Display

and Data Logger to collect lube information.• Monoblock design of Lincoln progressive Metering

Devices prevents from leakages, and allow operationup to differential pressure of 100 bar (inlet vs outlet).

Technical systems: Progressive

QLS301 system (progressive) for bridge crane



Technical systems: Progressive

Progressive systems can be used either for grease – sheet cutter, conveyors.. – or even for oil (dryers), up to 0,5 lts/min (higher flow on request).



In heavy duty conditions like extreme temperatures (very coldor very high), dirty or moisture environment, RIVI double linesystems provides the most efficient way to lubricate frictionpoints. Just one centralized equipment is able to supplylubricant to a huge number of lube points in the right way.RIVI double line systems can be also extended at anytime.

Features:

• Perfect for disperse lubrication points.• A maximum pressure of 400 bar avoid the use of tubes

with a diameter more small.• Visual or electric monitoring for each couple of outsides

(optional) .• Simple and individual dosage – each couple of outsides

can be adapt individually.• Stainless steel version (AISI 316Ti) available

Technical systems: Double Line

DLS/C: Conventional double line system DLS/S: Smart double line system



Technical systems: Double Line

Dual Line installations in different paper machines (calender, wet area, presses…)



Technical systems: Double Line SMART (DLS/S)


Half cycle nº1

Half cycle nº2

SMART

Control Cabinet

The SMART Control Cabinet (SCC) records thedifferential pressure value between both mainlines. This way the operation pressure of eachline only have to reach the relief pressure of theother main line plus the minimum operationpressure of the metering devices. This value isnot constant, and therefore the automaticlubrication system works only at requiredvalues.Smart Double Line systems designed by RIVI areself‐adjustable and allows different greaseswithout changes. Monitoring is more efficient.Lubricants does not suffer bleeding. Fittings andconnections works at the minimum pressurelevels required .



* Which components are different to clasical Double Line Systems?

1. End‐of‐Line switch is differencial‐type 4‐20 mA2. The Smart Control Cabinet includes a new software3. The Change‐over valve has to be electrical or pneumatical driven

* Are the rest of components valid?

Yes, of course. Metering devices, pipes, interconnection fittings and even Pumpstation are usually compatible with the DLS/S.

* Can be a classical DLS be transformed into a new DLS/S?

Yes, of course. Only three elements above stated must be replaced.Just contact G.T.RIVI for further assistance.

Technical systems: Double Line SMART (DLS/S)



By means of any centralized lubrication system (simpleline, double line, multiline, etc.) either oil or grease ismetered by nozzles that, throughout the inlet ofcompressed air, sprays the lubricant to the surfaces.

Depending on the products (pumps and nozzles) used,the operation and control of the installation takes placein different ways.

Spraying is mainly used to lubricate heavy open gears,where an insufficient or inadequate lubrication isinacceptable, due to consequences that it might cause.

So, it is essential to study and to define the systemcomponents, in order to avoid failures or breakdownsduring the useful life of the machine.

Technical systems: Spraying



This system is considered as an excellent solution for multipleapplications. It mainly used to cold bearings down and to avoidpollution inside the bearings. The lubricants used are oils.

A pump suction oil from the tank and pump it through the filters,heat exchangers, etc… until it is continuously and evenly supplied tothe different lubrication points. Later on oil returns to the tank byeffect of gravity, where it is recirculated again.

Features:

• Tanks, containers & reservoirs, up to 50.000 liters, with surfaceprotection, RAL on request, indirect heating, visual and electriclevel monitoring, temperature & pressure control, etc…

• Screw & gear pumps, up to 2000 lt/min with safety valve• Motor types on request• Simple or change‐over filters, clogging indication, etc…• Adjustable valves, for temperature, flow and pressure• Piping & Instrumentation.

Technical systems: Oil Circulation




Oil Circulation Stations must be carefully designed according the lubrication requirements of the papermachine. Every component must be selected based not only on specifications but also on experience.

4.‐ OCS station installed on basement 5.‐ OCS for recycled‐paper machine 6.‐ OCS without tank

1.‐ Typical OCS for Paper Machine 2.‐ Paper machine 3.‐ OCS stations for Pulper Tridyne




OCS for Paper Machine (300 lts/min, ISO VG 220)

Isolated and heated tank

3D modelling

Twin systems




Every installation of OCSsystems in paper mills requiresa huge responsibility level, dueto this task must be achieved ontime, with very restrictivedeadlines.

Quality and efficiency ofwelders & fitters are essential,as well as experienced teamleaders, in order to finish theassembly, installation, flushing,commissioning, and start‐upwithin the timeline expected.



Standard Documentation‐ General Arrangement (GA)‐ Process & Instrument Diagram (P&ld)‐ Quality dossier (Tests, calibration certificates,

material certificates…)‐ Technical data sheets & Bill of Material (B.O.M)‐ Start‐up & Maintenance User Manual‐ Spare parts & Operation instructions

Optional Documentation (on request)‐ Sectional & specific drawings‐ Logic diagrams‐ Calculation of components‐ Special certificates

• NDT (Not Destructive Test)• PMI (Destructive test) positive ID rawmaterials

‐ Welding procedures

Project Management, Quality & EHS

The quality policy of Grupo Técnico RIVIpromotes constant improvement andcontinued in the design, fabrication andold of equipment and installations. Thecertifications and homologations ISO,ASME, APII… as well as the security andenvironmental normative pertinent,making part of our company philosophy.

Guarantee of functionality, effectiveness, durabilityand reliability of installations under adverseconditions.

Strict compromise of fulfillment of delivery dates,ensure the start‐up of production beforedeadlines requested.

After every project, is delivered completedocumentation and personal training, for thecorrect operation, adjustment and maintenanceof the installed automatic lubrication systems.



RIVI’s scope of supply in Pulp & Paper industry:

Technical AssistanceCalculation& Design

Proposals & Alternatives

Integration

Manufacturing

DeliveryAssembly &Installation

Commissioning& Start‐up

Documentation

Guarrantee

Maintenance

Training



Under the hardest operation conditions is where RIVI’s lubrication systems stands out for reliability,effectiveness, accuracy and durability. Each single system has been design specifically to satisfy therequirements of each application. Our customers are our best guarantee.

Documents

Lubrication systems in Pulp & Paper industry