Condition monitoring detects wire roll bearing damage with HD Technologies

Using the Intellinova Parallel EN continuous monitoring system with patented HD Technologies, a bearing fault was detected in a wire roll on paper machine PM at DS Smith’s Zarnesti paper mill in Romania. Condition monitoring enabled the mill to plan for bearing replacement during a scheduled stop, thereby avoiding unplanned downtime and production losses.

Application and monitoring setup

The monitored application was a wire roll bearing in the paper machine. The mill implemented a condition monitoring project between 2021 and 2024, utilizing Intellinova Parallel EN online systems and DuoTech accelerometers for shock pulse monitoring and vibration monitoring, with continuous data collection and analysis via SPM HD and HD ENV technologies.

Results and benefits

In early January 2023, shock pulse levels increased rapidly, and the spectrum showed a clear BPFO match, indicating outer race damage. The bearing was replaced during a planned stop on February 18th, and the outer race damage was confirmed after disassembly. Early detection supported planned corrective action, minimized production risk, and supported condition-based maintenance.