Machine monitoring saves paper

Paper machines are complex blends of process and mechanical engineering, with large amounts of data needing to be monitored from all parts of the process. A minor fault in any one piece of equipment can result in costly downtime. But some problems, such as intermittent faults and derived control actions, can be very difficult to identify and remain untraceable for some time.

Just such a problem had been in the control system at Chartham Papers for several months. To avoid more downtime and trace the precise nature of the problem, Chartham hired an Overpower Monitor Lite portable diagnostic system from Cegelec Projects.

Smaller than an equivalent chart recorder, the Overpower (pictured) can be configured to trigger on a particular event and store the plant data before and after the trigger point - and it can also be configured to reset itself and await the next problem.

Unlike a chart recorder, however, the monitor uses the IBM ThinkPad as its recording and visual interface. Up to 16 inputs can be monitored simultaneously and recorded on a laptop PC. Avoiding the huge amounts of paper often associated with long term investigations, the monitor gives each recording its own reference which can contain batch or product identity, or simply the recording date and time, so making recovery of the information quick and simple.

Following one week's analysis with the Overpower, Chartham identified its fault as being in a drive gear mechanism. After stripping the assembly a collapsed bearing was found to be the root of the problem. Once the equipment was reassembled, the process operated faultlessly again.

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