Paper360 - January/February 2018 - 35
R&M Tips: Better Grouting Practices
scaffolding work for a shutdown (now we are missing
lube points), or for planners to substitute as supervisors
(now we have no planning for the area.)
So, how can a mill start improving the relationships
between operations and maintenance?
First, I think it is important to understand each other's
role and expertise. Operations staffers are the experts in
the process and should be responsible for process reliability. Maintenance staffers are experts in equipment
and should be responsible for equipment reliability. We
haven't touched on engineering in this article yet, but
engineers are experts in design and project management
and should be responsible for design reliability. There is
a lot of overlap and interaction between the departments,
but each department's key responsibility must be defined.
Second, the mill and corporation need to agree on
joint goals. Most paper companies would agree that the
goal is to improve reliability (measured by OEE) and
reduce total cost/ton. The common tug-of-war is the time
frame for the goals. Production often tries to improve
shift and daily production numbers, while maintenance
often focuses on long-term equipment reliability, but
can sometimes be slow to reduce the total backlog of
work in the mill.
If the partnership were to be put into practice, the
long-term thinking could, for example, mean that:
* Operations would allow maintenance the time to
align a pump to 2/1000 of an inch instead of starting
up the paper machine early during a shutdown.
* We would prioritize work according to established
criteria and remove unnecessary work orders from
* We would train our people in trade skills and
maintenance management work processes.
Operators would be trained in the operation of
equipment from a reliability perspective.
* We would not defer repairs more than absolutely
* Operations and maintenance would have a weekly
priority meeting to jointly prioritize work orders.
* Operations and maintenance would solve problems
jointly using a root cause process.
As a starting point for improving reliability and
building a partnership between your departments, I
suggest the following:
* Define and communicate the partnership
relationship between departments.
* Clarify the "product" of maintenance. It is
reliability, not "wrench time."
* Define roles for each department.
* Set long-term joint goals and act according to
* Reward departments according to the
As our infrastructure ages, some say that grout failures are inevitable.
However, poor base installation practices often reduce the life of our equipment. Here are some examples.
FAILURE TO REMOVE LAITANCE
The strength in concrete comes from the aggregate. When a concrete base is
poured, the top 1 or 2 inches contains no aggregate and should be removed before
grouting to allow the grout to bond to the aggregate.
POOR BASE LEVELING TECHNIQUES
Grout needs to be placed
into compression to be effective. A common practice is
to use hard shims placed
close to the sole plate anchor
bolts to level the base prior
to grouting (Fig. 1). Upon
torqueing the anchor bolts, Fig. 1: Common practice-the anchor bolts only
the shims are placed in com- compress the hard shims when torqued.
pression and not the grout.
This leads to premature failure of the grout.
A better technique is to use
independent leveling screws
to level the sole plate. The
grout is then poured as usual
(Fig. 2). Once the grout has Fig. 2: Best practice-anchor bolts compress the
grout when torqued (after removing leveling screws).
cured, the leveling bolts are
removed and the anchor bolts torqued to the correct specification. This places
the grout into compression.
Contributed by Reliability Solutions: www.reliabilitysolutions.net
R&M Tips: Lubrication
Inspecting sight glasses is oil analysis in its
simplest form. When done correctly, machine
inspections can often uncover potential issues
before they become catastrophic. Aside from
checking for oil level, also be concerned with oil
color, clarity, signs of foam or water, and staining on the glass itself. Getting more from lube
inspections is achievable by digging just slightly
deeper than the surface level.
Always inspect the sight glass.
CONTROLLING OIL CONTAMINATION IN PAPER MACHINES
Oil filters should be employed on every paper machine circulating system.
Without the ability to remove contaminants, the oil and machine surfaces will
degrade rapidly. Choose filters with a focus on smaller particles, such as 10
microns or less, as these smaller particles often cause the greatest damage. Also,
keep in mind that the oil must be able to pass through the filter at all expected
operating temperatures. In addition, as oil flows through the filter, the additives
must remain in the oil and not be stripped by the filter.
Contributed by Noria Corp. www.noria.com
Paper360º JANUARY/FEBRUARY 2018