FM Global

Property Loss Prevention Data Sheets 7-4

April 2010
Interim Revision January 2022
Page 1 of 37

PAPER MACHINES AND PULP DRYERS

Table of Contents
Page

1.0 SCOPE ..................................................................................................................................................... 3

1.1 Hazards ............................................................................................................................................. 3
1.1.1 Machine Fires .......................................................................................................................... 3
1.1.2 Roll Failures ............................................................................................................................. 3
1.2 Changes ............................................................................................................................................ 4
2.0 LOSS PREVENTION RECOMMENDATIONS ......................................................................................... 4
2.1 All Machines ...................................................................................................................................... 4
2.1.1 Introduction .............................................................................................................................. 4
2.1.2 Location and Construction ...................................................................................................... 5
2.1.3 Protection ................................................................................................................................ 5
2.1.4 Equipment and Processes .................................................................................................... 12
2.1.5 Operation and Maintenance .................................................................................................. 14
2.1.6 Contingency Planning ........................................................................................................... 20
2.2 Tissue Machines .............................................................................................................................. 20
2.2.1 Protection .............................................................................................................................. 20
2.2.2 Equipment and Processes .................................................................................................... 21
2.2.3 Operation and Maintenance .................................................................................................. 21
2.3 Airborne Pulp Dryers ....................................................................................................................... 23
2.3.1 Protection .............................................................................................................................. 23
2.3.2 Operation and Maintenance .................................................................................................. 24
2.4 Flash Pulp Dryers ............................................................................................................................ 24
2.4.1 Location and Construction .................................................................................................... 24
2.4.2 Protection .............................................................................................................................. 24
2.4.3 Equipment and Processes .................................................................................................... 24
3.0 SUPPORT FOR RECOMMENDATIONS ............................................................................................... 25
3.1 Supplemental Information ................................................................................................................ 25
3.1.1 All Machines .......................................................................................................................... 25
3.1.2 Cleaning With Flammable Solvents ...................................................................................... 25
3.1.3 Oil and HTF Fire Hazards ..................................................................................................... 26
3.1.4 Suction Rolls and Pressure Rolls .......................................................................................... 26
3.1.5 Cast Iron Dryer Rolls ............................................................................................................. 26
3.1.6 Shoe Presses ........................................................................................................................ 26
3.1.7 Yankee Dryers and MG Cylinders ......................................................................................... 27
3.1.9 Creping Machines ................................................................................................................. 27
3.1.10 Airborne Pulp Dryers ........................................................................................................... 27
3.1.11 Flash Pulp Dryers ................................................................................................................ 28
3.1.12 Fire Causes at Paper Machines .......................................................................................... 28
3.2 Loss History ..................................................................................................................................... 28
4.0 REFERENCES ...................................................................................................................................... 30
4.1 FM Global ...................................................................................................................................... 30
4.1.1 FM Global References ......................................................................................................... 30
4.2 Others ............................................................................................................................................. 31
APPENDIX A GLOSSARY OF TERMS ....................................................................................................... 31
APPENDIX B DOCUMENT REVISION HISTORY ....................................................................................... 32
APPENDIX C RELEVANT FM GLOBAL DATA SHEET REFERENCES .................................................... 33

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7-4 Paper Machines and Pulp Dryers
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APPENDIX D BOILER AND MACHINERY MACHINE ROLL MAINTENANCE JOB AID ......................... 34

List of Figures
Fig. 1. Example dryer hood with partial width concealed plenum .................................................................. 6
Fig. 2. Example dryer hood with full-width concealed plenum ....................................................................... 7
Fig. 3. Example of dry-type economizer automatic sprinkler arrangement .................................................... 7
Fig. 4. Example of wet-type economizer automatic sprinkler arrangement ................................................... 8
Fig. 5. Example nozzle locations (elevation and cross machine view of shoe press) ............................... 10
Fig. 6. Example nozzle locations (operating floor elevation and machine direction of a shoe press) ......... 11
Fig. 7. High stress areas on shell and heads. ............................................................................................. 18
Fig. 8. Head-to-shell joint configuration ....................................................................................................... 19
Fig. 9. Head-to-shell lap joint configurations ............................................................................................... 19
Fig. 10. Common Yankee dryer head and shell areas warranting examination .......................................... 22

List of Tables
Table 1. Automatic Sprinkler Design for Machine Areas ................................................................................ 8
Table 2. Machine Losses By Peril ................................................................................................................ 29
Table 3. Paper/Board Machine Losses by Section and Peril ....................................................................... 29
Table 4. Tissue Machine Losses by Section and Peril ................................................................................. 30
Table 5. Pulp Machine Losses by Section ................................................................................................... 30
Table 6. Machine Roll Maintenance Guide ................................................................................................... 35
Table 6. Machine Roll Maintenance Guide (continued) ................................................................................ 36

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Paper Machines and Pulp Dryers 7-4
FM Global Property Loss Prevention Data Sheets Page 3

1.0 SCOPE
This data sheet contains property loss prevention guidance unique to paper, board, tissue, and pulp machines
with steam-heated dryer rolls as well as airborne and flash pulp dryers. The machine sections covered include
forming, press, drying, and reel as well as operations that may be online or offline such as calendering and
coating.
This data sheet focuses on guidance unique to these machines and their utility and support systems, and
is intended to supplement the guidance provided in other data sheets. When evaluating hazards not
addressed by this data sheet, apply the applicable FM Global data sheet. A few examples of data sheets
offering guidance on hazards found at mills, but outside the scope of this data sheet, include the following:
• 5-4, Transformers
• 5-19, Switchgear and Circuit Breakers
• 7-98, Hydraulic Fluids
• 7-99, Heat Transfer by Organic and Synthetic Fluids
• 9-0, Asset Integrity
• 10-8, Operators
Appendix C contains a more comprehensive list of data sheets that may be applicable at paper, board, tissue,
and pulp mills.

1.1 Hazards

1.1.1 Machine Fires

Regardless of product type (board vs. tissue), historically machine fires have primarily occurred in the dryer
hood and attached exhaust, and below the machine due to the nature of products being produced. Spilled
pulp, fiber, broke, and parent/jumbo reels on the dry-end of machines combined with spilled oil were often the
combustibles involved. Automatic sprinklers proved to be effective at managing the risk posed by these
combustibles.
Over the last few decades with technological improvements and increased production rates, the combustible
loading in and round the machine has changed. Lubrication and hydraulic systems have become larger and
more complex, while in some instances oil has entered the footprint of the machine rather than being limited
to the ground floor and sides of the machine. The addition of HTF heated rolls in calenders has introduced
the potential for a high flow rate, heated oil release.
With these more intense ignitable liquid hazards, automatic sprinklers alone are often not sufficient for
reducing fire risk as evident in recent machine fires. Other ignitable liquid safeguards are required to mitigate
the oil fire risk at a machine, especially when a large oil release is possible. Safeguards that limit an oil release
become more critical as the system size, pressure, and flow rates increase. Such safeguards may include
an automatic fire interlock and proper oil-containing equipment (e.g., metallic construction vs. rubber or
plastic). These safeguards limit the quantity of oil released thereby the fire intensity and duration by promptly
shutting down the machine and depressurizing the release point, while also preventing secondary oil releases
and guarding against a sustained gravity release of oil hold-up following depressurization. After taking steps
to minimize the release, controlling the flow and pooling of that released oil with containment and drainage,
and/or controlling the fire and cooling the fire area with automatic sprinklers become key to further limit fire
spread and thermal damage.
Another change in the machine fire risk is the increased amounts of power cabling and control wiring. While
adding combustible loading in hard to access areas (e.g., ground floor ceilings), if damaged by a fire, splicing
or pulling replacements can significantly increase the downtime of even after a smaller, controlled fire.
Routing cabling and wiring runs away from combustibles and providing protection when appropriate reduce
the potential for damage.

1.1.2 Roll Failures

The hazards presented by pressurized dryer rolls are well documented. Failure of a bearing, journal, head,
or shell can result in roll displacement or rupture releasing a large amount of stored energy in an explosion
and also producing projectiles. Recovery times following a dryer roll failure can be substantial. Maintenance,
safety devices, and operators are key in managing dryer roll hazards.

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7-4 Paper Machines and Pulp Dryers
Page 4 FM Global Property Loss Prevention Data Sheets

While not as dramatic, a functional roll failure or crash or wreck in the forming, press, calender, or reel section
can also lead to long recovery times. Failure of roll covers, shells, heads, journals, and bearings can lead
to roll displacement or debris damage throughout the section. With few workarounds for damaged functional
rolls, maintenance and equipment contingency planning are key to reducing the likelihood and consequences
of a functional roll failure.

1.2 Changes
January 2022. Interim revision. Minor editorial changes were made.

2.0 LOSS PREVENTION RECOMMENDATIONS

2.1 All Machines

Paper and pulp are produced on various types of machines. Recommendations in this section are applicable
to all types of paper machines. Protection for ignitable liquid hazards is provided in two subsections. The
introduction section contains protection guidance on ignitable liquid supplies supporting the machine (e.g.,
lubricating oil reservoir and pumps), while protection for ignitable liquid transfer piping and use-points at or
near the machine is provided in the sections that follow (e.g., lubricating oil manifolds and supply/return
lines).

2.1.1 Introduction
2.1.1.1 The loss prevention guidance contained in this document is unique to the machines identified within
the scope and supplements the guidance contained in other data sheets. For hazards not covered in Section
2.0 of this data sheet, adhere to loss prevention recommendations in the relevant data sheet. A list of data
sheets that may be relevant is included in Appendix C.
2.1.1.2 Use FM Approved equipment, building materials, and services whenever applicable and available.
Select and install FM Approved products and services in accordance with their Approval Guide or RoofNav
listing. Refer to the Approval Guide and RoofNav, online resources of FM Approvals, for a list of FM Approved
products and services.
2.1.1.3 Use a hydraulic fluid that is either nonignitable (i.e., does not have a flash point or fire point) or is
an FM Approved industrial fluid. When a nonignitable or FM Approved fluid is used, provide fire protection
in the subject hydraulic equipment areas based on the surrounding occupancy. When such fluids are not used,
provide ignitable liquid protection for hydraulic equipment areas per this data sheet.
2.1.1.4 For lubrication and hydraulic oil system supplies, provide ignitable liquid protection in accordance
with Data Sheet 7-98, Hydraulic Fluids, and the following modifications. These oil system supplies, or
consoles, may consist of a reservoir, pump(s), and oil-conditioning equipment.
2.1.1.4.1 Locate a lubrication and hydraulic oil system supply on the ground floor within a dedicated cutoff
room of at least 1-hour fire-rated construction.
2.1.1.4.2 Provide spill containment dedicated to the subject oil system supply sized based on the largest
expected oil release (e.g., reservoir).
2.1.1.5 For an HTF system supply and transfer piping, provide ignitable liquid protection in accordance with
Data Sheet 7-99, Heat Transfer By Organic And Synthetic Fluids. The HTF system supply may consist of
a heater, pump(s), expansion tank, and conditioning equipment.
2.1.1.6 Avoid using ignitable liquid performance and formation additives, and cleaning solvents whenever
possible. If unavoidable, select one of the following ignitable liquid protection schemes for machine areas.
A. For low-flash point ignitable liquid additives or solvents, limit the quantity of liquid within the machine room.
Provide a dedicated, remote dispensing station. Locate, protect, and arrange the dispensing station in
accordance with Data Sheet 7-32. Limit dispensed quantities within the machine room to less than 5 gal.
(19 L) contained within FM Approved safety containers.
B. For all pumped/pressurized transfer of ignitable liquid additive or solvent systems, locate the additive/
solvent supply on the ground floor and provide ignitable liquid safeguards in accordance with Data Sheet
7-32.

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Paper Machines and Pulp Dryers 7-4
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2.1.2 Location and Construction

2.1.2.1 Use noncombustible building materials and assemblies around the machine including roof, ceiling,
flooring/walkways, and wall construction. If plastic building materials are needed, use FM Approved building
materials installed in accordance with their listing.
2.1.2.2 Use noncombustible materials to construct dryer hoods and exhaust ventilation systems. If insulated
metal panels are used for dryer hood construction, use FM Approved plastic materials installed in accordance
with the listing.
2.1.2.3 Locate lubricating and hydraulic oil distribution manifolds such as lubrication metering stations, and
hydraulic control valve stations and accumulators on the ground floor.
2.1.2.4 Provide containment and drainage around lubricating oil distribution manifolds. When possible,
channel released oil toward process drainage.
2.1.2.5 Evaluate the need for containment and drainage on the operating floor around machine areas with
the potential for a significant release of lubricating oil, hydraulic oil, and/or heat transfer fluid (HTF). Such
machine areas may include a concentration of flexible supply/return hoses subject to mechanical impact
upon drive shaft or rotary joint failure. The intent is to prevent a pool of oil or fluid from spreading across the
operating floor or collecting under the machine. When possible, channel released oil or fluid toward process
drainage or the ground floor. If utilizing process drainage is not an option, provide spill containment and
emergency drainage in accordance with Data Sheet 7-83. The following are examples of machine areas that
may warrant containment and drainage.
A. Online and offline calenders under flexible supply and return hoses for bearing lubrication and hydraulic
cylinders.
B. Online and offline calenders under flexible supply and return hoses as well as rotary joints serving
HTF-heated rolls.
C. Under shoe presses with a lubricated elastomeric sleeves, and under lubricating and hydraulic flexible
supply and return hoses.
D. Control crown roll (CCR) under with lubricating and hydraulic flexible supply and return hoses.
2.1.2.6 Locate dust collectors outdoors in accordance with Data Sheets 7-73, Dust Collectors and Collection
Systems, and 7-76, Prevention and Mitigation of Combustible Dust Explosions and Fires.

2.1.3 Protection

2.1.3.1 Protection of General Machine Areas

2.1.3.1.1 Provide ceiling-level automatic sprinkler protection above and 20 ft (6 m) beyond the machine areas
considered as a combustible occupancy. General guidance is provided below to assist defining the
combustible occupancy in paper and board machines, and tissue machines.
As an alternative to ceiling-level automatic sprinklers, provide machine-level automatic sprinkler, deluge, or
fixed-water spray protection over combustibles in the machine and adjacent areas per this data sheet and
other applicable data sheets. In some instances, machine-level protection may be preferred to ceiling-level
automatic sprinklers, such as under tall ceilings (e.g., 60 ft or 18 m) and when obstructions such as felts
or rolls delay sprinkler response and sprinkler discharge effectiveness. For an example, in a press section,
upper felts likely obstruct sprinkler discharge from reaching burning surfaces early in the fire.
A. For paper and board machines, the combustible occupancy typically starts after the forming section and
extend downstream through the dry end of the machine (i.e., press, drying, and reel machine sections).
B. For tissue machines, the combustible occupancy typically starts downstream of Yankee and through-air
dryer hoods. Do not provide automatic sprinklers directly over a Yankee dryer hood.
2.1.3.1.2 Provide automatic sprinkler protection within the hood, plenum, economizers, and exhaust system
based on the following. Refer to Figures 1 and 2 for example sprinkler locations. As an alternative to automatic
sprinklers, automatic deluge or fix-water spray systems are acceptable if designed in accordance with this
data sheet and other applicable FM Global data sheets.
A. Provide automatic sprinklers within concealed air plenums created by any false ceilings.

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7-4 Paper Machines and Pulp Dryers
Page 6 FM Global Property Loss Prevention Data Sheets

B. Provide automatic sprinklers inside exhaust ducts in accordance with Data Sheet 7-78, Industrial Exhaust
Systems.
C. Position sprinklers inside hoods over drive and tending side frames, and below multi-level open grated
walkways or below every solid walkway.

ROOF

Ceiling sprinklers as needed for

Exhaust fan combustible occupancy below

Economizer
(Refer to Figures
3 & 4 for details)

Plenum

Felt Roll Walkway

Exhaust Ducts

DRIVE TENDING
Dryer

Gear Box
OPERATING FLOOR Motor
Dryer

Cable trays
Metering Station

HYD BROKE PIT Lube

GROUND FLOOR

Fig. 1. Example dryer hood with partial width concealed plenum

D. Provide automatic sprinklers within an economizer in accordance with Data Sheet 7-78, Industrial Exhaust
Systems. Refer to Figures 3 and 4 for example sprinkler locations. If HTF is used as the heat transfer media,
refer to Data Sheet 7-99 for guidance on appropriate ignitable liquid safeguards for the economizer. As an
alternative to automatic sprinklers, automatic deluge or fixed water spray systems are acceptable if designed
in accordance with this data sheet and other applicable FM Global data sheets.
E. Provide drainage for sprinkler and hose stream discharge from within dryer hood plenums, economizers,
and exhaust ductwork to prevent collapse from water accumulation.
F. Recirculate air from the economizer to the paper machine room only.
2.1.3.1.3 Provide automatic sprinkler protection in the broke pit and ground floor machine areas containing
combustible construction or combustible occupancy and at least 20 ft (6 m) beyond. As an alternative to
automatic sprinklers, automatic deluge or fixed water spray systems are acceptable if designed in accordance
with this data sheet and other applicable FM Global data sheets. Typically, the combustible occupancy starts
within the broke pit and extends at least 20 ft (6 m) beyond into the aisles on both sides.
2.1.3.1.4 Provide sprinkler protection for trays of power cabling and control wiring in accordance with Data
Sheet 5-31, Cables and Bus Bars.
2.1.3.1.5 Design ceiling-level, hood, and broke pit sprinkler protection based on Table 1.

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Paper Machines and Pulp Dryers 7-4
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ROOF

Ceiling sprinklers as needed for

combustible occupancy below
Exhaust fan

Sidewall
Economizer Sprinkler
(Refer to Figures
3 & 4 for details)
Plenum

Exhaust Ducts Felt Roll Walkway

DRIVE TENDING
Dryer

Gear Box
OPERATING FLOOR Motor
Dryer

Cable trays
Metering Station

HYD BROKE PIT Lube

GROUND FLOOR

Fig. 2. Example dryer hood with full-width concealed plenum

Fresh air
Exhaust stack Swing check doors Louvers intake
Exhaust
Water supply

fan
exchanger

Fresh
air Auxiliary 6 in curb
Fresh air fan
Heat

inlet steam (105 mm)

coil
Roof chamber
To fresh air fan Small dry-
Elevation pipe valve
Deluge valve

Elevation
Dust
Exhaust from
stack machine Heat exchanger
hood
Motor room
Water supply

Small dry-
Plan pipe valve
Exhaust Key
fan Dry pipe line
Plan Open sprinklers
Automatic sprinklers
Heat actuating device

Fig. 3. Example of dry-type economizer automatic sprinkler arrangement

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7-4 Paper Machines and Pulp Dryers
Page 8 FM Global Property Loss Prevention Data Sheets

Clean Supply Air

Hot / Fiber Laden Air

From Hood

Heating Coils To Pocket

Ventilation

Heat Recovery

Fig. 4. Example of wet-type economizer automatic sprinkler arrangement

Table 1. Automatic Sprinkler Design for Machine Areas

Density/Operating Area, Hose Stream
gpm/ft2/ft2 (mm/min/m2) Allowance,
Machine Area Wet Dry gpm (Lpm) Duration, minutes
Dryer Hood & Plenum 0.2/3000 (8/279) 0.2/4000 (8/372) 250 (950) 60
Broke Pit 0.2/3000 (8/279) 0.2/4000 (8/372) 500 (1900) 60
Hood Exhaust System (Duct Data Sheet 7-781
and Economizer)
Machine area (excluding Data Sheet 3-26 (HC-2)
calenders and parent roll
Staging/Deck)
Calenders Data Sheet 3-26 (HC-3)
Parent Roll Staging/Deck Data Sheet 3-26 (HC-3)
1
Hydraulically balance protection in the dryer hood and exhaust system.

2.1.3.1.6 Design and install automatic sprinkler, deluge, and fixed water spray systems in accordance with
the respective data sheet along with the following machine-specific design and installation aspects. For
automatic sprinkler and deluge systems, refer to Data Sheet 2-0, Installation Guidelines for Automatic
Sprinklers. For automatic fixed water spray systems, refer to Data Sheet 4-1N, Fixed Water Spray System
for Fire Protection. Specific design and installation guidance offered in this data sheet supersedes that of other
data sheets.
A. When automatic sprinklers are recommended in this data sheet, automatic deluge or fixed water spray
are an acceptable alternative when designed and installed in accordance with this data sheet.
B. Select automatic sprinklers with temperature ratings abased on the maximum ambient temperature at
the respective ceiling or hood level in accordance with Data Sheet 2-0.
C. Within broke pits, avoid running fire protection piping in the cross machine direction underneath the
machine in the broke pit to protect it against falling rolls, sheet breaks, and felt runoffs. Use sidewall sprinklers
located at the perimeter of the machine and below machine clothing. If the machine is wider than 20 ft
(6 m), provide an automatic deluge or fixed water spray system arranged to wet down the entire broke
collection area.

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D. Supply fire protection systems within ground floor areas independently from fire protection systems on
the operating floor. Locate the control valves outside the protected area in an easily accessible location.
E. Position sprinklers or nozzles in a manor to limit obstructing discharge in accordance with Data Sheet 2-0.
Common obstructions include pipe racks, trays of power cabling and control wiring), and ventilation ducts.
F. Above calenders, locate ceiling sprinklers outside the plan area of individual calender rolls to avoid drips
or solid streams from sprinklers striking any heated rolls. Drips and streams can form when the sprinkler
system is draining after being shutoff.
G. Use corrosion resistant piping, nozzles/sprinklers, hangers, and other materials when installing ceiling-level
and local automatic sprinkler protection in or near wet-end machine areas (e.g., press section).
H. For automatic deluge and fixed water spray systems, apply the following additional design and installation
aspects:
1. Provide automatic fire detection within the anticipated fire area to automatically actuate the fire protection
system and sound an alarm in a constantly attended location such as a control room. Fire detection
options may include optical flame detectors (i.e., UV/IR), video flame detectors (e.g., thermal imaging),
and linear or spot heat detection.
Design and install fire detectors and the detection system in accordance with FM Global Data Sheet 5-48,
Automatic Fire Detection, and the applicable FM Approval listing. For additional guidance on detector
spacing and layout, refer to Data Sheet 7-98.
2. Provide an operator interface (e.g., push button) to manually actuate the fire protection system from
the control room and at least one remote location that will remain accessible under anticipated fire
conditions.
3. Install blow-off plugs on open nozzles to prevent moisture and debris (stock or fiber) from clogging
piping or discharge orifices.
2.1.3.1.8 Provide automatic fire protection within machine control rooms and rooms containing machine
control equipment in accordance with Data Sheet 7-110, Industrial Control Systems.
2.1.3.1.9 Provide 1.5 in. (38 mm) hose valves along both sides of the machine, arranged so at least two
fire hoses can reach anticipated fire areas containing lubrication oil, hydraulic oil, heat transfer fluid, fiber,
fiber dust, and broke. Similarly, provide fire hose stations in ground floor areas to supplement automatic
sprinklers.
2.1.3.1.10 Provide combination spray-type nozzles at the hose valves to avoid application of solid stream
to a steam or HTF-heated roll or an oil pool fire.

2.1.3.2 Protection of Oil Distribution Equipment At the Machine

2.1.3.2.1 Provide automatic sprinkler protection over and at least 20 ft (6 m) beyond lubricating and hydraulic
oil distribution manifolds, such as lubrication metering stations, hydraulic control valve stations, and
accumulators, in accordance with Data Sheet 7-98.

2.1.3.3 Protection of Specific Oil Use Points At the Machine

2.1.3.3.1 Provide automatic deluge or water spray protection for a shoe press as follows.
A. Position nozzles to discharge over the following areas. Refer to Figures 5 and 6 for examples of nozzle
locations.
1. Top nip roll.
2. Full length of hydraulic and lubricating oil flexible supply and return hoses to the rolls.
3. Operating floor level beneath intermediate walkways, or other shielded areas such as beneath flexible
hoses where released oil may flow and/or accumulate.
4. Ground floor areas beneath the shoe press and beneath the flexible hoses on the side of the machine
where released oil may flow from the operating floor level and accumulate plus 20 ft (6 m) beyond the
anticipated oil fire area.

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OPERATING FLOOR

From Supply

Automatic
Control Valve
GROUND FLOOR

Fig. 5. Example nozzle locations (elevation and cross machine view of shoe press)

B. Design each nozzle at the operating floor level to deliver a minimum of 30 gpm (113 L/min). If an open
sprinkler is used for the deluge system, install a minimum K11.2 (K160) sprinkler.
C. Design deluge or water spray protection over ground floor areas to deliver 0.3 gpm/ft2 (12 mm/min) over
the protected area.
D. Design the protection on the operating floor and on ground floor for simultaneous operation plus a 500
gpm (1900 L/min) hose stream allowance for a duration of at least 60 minutes.

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From Automatic
Control Valve From Automatic
Control Valve

Fig. 6. Example nozzle locations (operating floor elevation and machine direction of a shoe press)

2.1.3.3.2 Provide automatic sprinkler protection for a control crown roll (CCR) as follows.
A. Position sprinklers over the following areas.
1. Full length of hydraulic and lubricating oil flexible supply and return hoses to the rolls
2. Operating floor level beneath intermediate walkways, or other shielded areas such as beneath flexible
hoses where released oil may flow and/or accumulate
3. Any ground floor areas or pits beneath the roll and flexible hoses on the side of the machine where
released oil may flow and accumulate plus 20 ft (6 m) beyond the anticipated oil fire area
B. Design sprinklers at the operating floor level to deliver a minimum of 30 gpm (113 L/min) using K11.2
(K160) sprinklers rated for quick response and appropriate temperature rating based on the maximum ambient
temperature (refer to Data Sheet 2-0).
C. Design sprinkler protection over operating floor pits or ground floor areas to deliver 0.3 gpm/ft2 (12 mm/min)
over the protected area.
D. Design the protection at ceiling-level, on the operating floor, and over any ground floor pits for simultaneous
operation plus a 500 gpm (1900 L/min) hose stream allowance for a duration of at least 60 minutes.
2.1.3.3.3 Provide automatic sprinklers for online and offline calenders as follows.
A. Position sprinklers over the following areas.
1. Full length of hydraulic and lubricating oil flexible supply and return hoses to the rolls.
2. Full length of HTF flexible supply and return hoses to rolls.
3. Over and under HTF rotary joints (if a spray shield is provided, within the enclosure).
4. Operating floor level beneath the top elevated walkway, intermediate walkways, on the calender sides
where clusters of obstructions may be found (e.g., flexible hoses, driveshafts, or piping), and beneath
any other shielded areas where released oil may flow and/or accumulate.

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7-4 Paper Machines and Pulp Dryers
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5. Ground floor areas or pits beneath the calender where released oil and fluid may flow and accumulate.
B. Design sprinklers at the operating floor level to deliver a minimum of 30 gpm (113 L/min) using K11.2 (K160)
sprinklers rated for quick response and appropriate temperature rating based on the maximum ambient
temperature (refer to Data Sheet 2-0).
C. Design sprinkler protection over operating floor pits or ground floor areas to deliver 0.3 gpm/ft2 (12 mm/min)
over the protected area.
D. Design the protection at ceiling-level, on the operating floor, and over any ground floor pits for simultaneous
operation plus a 500 gpm (1900 L/min) hose stream allowance for a duration of at least 60 minutes.

2.1.4 Equipment and Processes

Ensure the machine controls meet the recommendations in Data Sheet 7-110, Industrial Control Systems.
2.1.4.1 Avoid leaving ignitable liquid systems, including oil systems, pressurized during machine outages.
2.1.4.2 Provide a means to automatically depressurize oil systems such as lubrication, hydraulic, and HTF
systems in response to a fire emergency at the machine or in the oil system supply (i.e., oil fire interlock).
Design and install the oil fire interlock in accordance with Data Sheet 7-45, Safety Controls, Alarms, and
Interlocks (SCAI), and the following considerations.
Model the machine shut down logic sequence after the procedure for a manual emergency shut down. The
goal is to depressurize oil systems as fast as is reasonably possible without risking equipment damage. This
type of machine shut down may be referred to as a ″soft″ or ″controlled″ shut down (i.e., conversely to a ″hard″
or ″crash″ type shut down). Of critical importance is first depressurizing hydraulic and HTF systems followed
by lubrication oil, which may require a longer delay for the machine to slow or stop.
A. Initiate a controlled machine shut down and system depressurization using fire detectors and detection
system designed and installed per Section 2.1.3.1.6.G.1 (automatic actuation of fire protection systems). To
alleviate concerns of a false trip leading to a production outage, a trip delay of less than 60 seconds with
a momentary contact-type abort switch may be installed.
B. Complete the controlled machine shut down and oil system depressurization within 5 minutes of initiation.
2.1.4.3 Provide a means to automatically depressurize and isolate HTF from heated rolls in response to a
rotary joint failure (i.e., fluid release interlock). This may be accomplished by installing breakaway fittings on
the HTF flexible hose connections, or a position switch with two safety shutoff valves on the HTF supply
and return flexible hose connections. In either case, attach the fittings or valves to the rigid supply and return
piping.
2.1.4.4 Provide a means to automatically depressurize ignitable performance and formation additives, or
cleaning solvents (e.g., felt cleaners) in response to a fire in the subject machine section (i.e., ignitable additive
interlock).
2.1.4.5 Provide a means to automatically shut down exhaust ventilation fans upon sprinkler actuation inside
the hood, economizer, over the machine (above the hood), or under the machine (broke pit) to minimize
fire spread and thermal damage to the fans (i.e., dryer hood fire interlock). Additionally, either slow down the
drying section to a crawl or stop rolls in the section as recommended by the OEM.
2.1.4.6 Provide a means to manually perform oil fire, ignitable additive, and dryer hood fire interlock
functionality. Install these manual shut down controls in the control room and in at least one set of controls
in a remote location that will remain accessible under anticipated fire conditions. Refer to Section 2.1.5.1
for the human element portion of this manual response.
2.1.4.7 Arrange ignitable liquid transfer piping between supply and use-points to provide the most direct route
possible. Additionally, route ignitable liquid transfer piping in a manor that limits fire exposure to utilities and
support systems equipment areas, and any concentration of combustibles (e.g., parent reel or roll paper
storage).
2.1.4.8 Install ignitable liquid transfer piping and piping at use points in accordance with Data Sheet 7-32.
2.1.4.9 Install flexible oil supply and return hoses serving lubricating, hydraulic, or HTF use points on the
machine designed in accordance with Data Sheet 7-98.

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Paper Machines and Pulp Dryers 7-4
FM Global Property Loss Prevention Data Sheets Page 13

2.1.4.10 Install lubrication, hydraulic, and HTF flow or level instrumentation, gauges, and/or sight glasses
in accordance with Data Sheet 7-32. Preferably for flow measurements and verification of oil flow, use indirect
measurement such as ″armored″ flow meters that use metal tubes in place of transparent variable-area float
tubes. If sight glasses are needed, use FM Approved sight glasses.
2.1.4.11 Provide the following condition monitoring for HTF rotary joints with alarms surfacing in constantly
attended area (e.g., control room). Establish alarm thresholds derived based on the rotary joint or bearing
OEM input.
A. Temperature of the bearing outer race
B. Bearing vibration
C. Both lubricating oil temperature, and the differential between the lubricating oil inlet and outlet temperature
2.1.4.12 Avoid routing hot steam or HTF piping through broke collection areas and other spaces where broke,
pulp, or dust may accumulate dry, overheat, and ignite. Alternatively, provide insulation and shielding to
prevent materials from accumulating and contacting the hot surfaces.
2.1.4.13 Equip all machine hoods, plenums, economizers, and exhaust ductwork with openings for cleanout
and manual firefighting.
2.1.4.14 Provide dust collection points along the machine to minimize dust accumulation.
2.1.4.15 Provide fuel combustion controls for any gas-or-oil fired heaters on the machine as recommended
in Data Sheet 6-9, Industrial Ovens and Dryers.
2.1.4.16 Evaluate the machine controls using OS 7-110 to determine the risks associated with connectivity
to larger ICS, and if the overall risk of the ICS meets thresholds, perform an ICS assessment. Then we need
to re-number after.
2.1.4.17 Provide the following machine permissive-starting and protective-tripping interlocks to prevent
equipment damage.
A. Permissive to Start
1. Satisfactory lubrication oil temperature and flow or pressure to engage machine drive
2. Machine at minimum speed to begin warm-up of dryers
3. Machine at minimum speed to start any auxiliary heating equipment on low fire or minimum heat
4. Machine at minimum speed to load any pressure rolls
5. Machine at minimum speed to start any sprays on heated rolls
6. Spray liquids at least 70°F (22°C) to start any sprays on heated rolls
7. Web on dryer(s) to engage high fire or maximum heat for any auxiliary heating equipment
B. Protective Tripping
1. Auxiliary heaters to low fire or minimum heat upon loss of web with possible actions including rotating
radiant heaters away from the web or flame sliding shield
2. Sprays stopped if liquid temperature less than 70°F (22°C)
3. Sprays stopped if machine speed below minimum
4. Flame failure of auxiliary heaters
2.1.4.18 Protect all steam-heated dryer rolls from excessive steam pressure with relief valves set at or below
the maximum allowable working pressure (MAWP). Provide relieving capacity equal to or greater than the
maximum let-through capacity of the pressure reducing station, maximum flow capacity of the
thermocompressors or maximum flow capacity of the manual bypass, whichever single source is greatest
(Refer to Data Sheet 12-43, Pressure Relief Devices).
2.1.4.19 Limit the mean temperature of any pressure-containing part on a non-standard cast iron dryer to
the saturated steam temperature coincident with the MAWP.
2.1.4.20 Reevaluate dryer MAWP if the machine speed is to be increased. An increase in machine speed
on the order of 10% will significantly increase hoop stresses. This is particularly important if both an increase
in MAWP and an increase in operating speed are being considered. In addition, determine that heads, shafts,
bearings, and machine frame are suitable for the increased loading. Review all of these items with the paper
machine manufacturer or a recognized paper machine consultant.

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7-4 Paper Machines and Pulp Dryers
Page 14 FM Global Property Loss Prevention Data Sheets

2.1.4.21 For can-type cast iron dryers, hydrostatically test one dryer of each different design at twice the
calculated MAWP if evaluation indicates a MAWP may be increased to 110% or more of a documented MAWP,
or if there is no documentation of MAWP (i.e., MAWP is established by evaluation). Support the dryer during
the test so as not to subject the bearings, shafts, heads, and shell to the weight of the water. Ensure
temperature of the dryer and the water is above the transition temperature prior to applying pressure. Do
not perform a pneumatic test on cast iron dryers. Prior to and after hydrostatic test, fully examine the dryer
high stress areas by visual inspection (VT) and other NDE methods as described in this data sheet.

2.1.5 Operation and Maintenance

2.1.5.1 Implement an emergency response plan (ERP) for the prompt and effective reaction to a machine
fire in accordance with Data Sheet 10-2, Emergency Response, and the following.
A. Develop the plan addressing the various fire scenarios involving: combustibles such as pulp, fiber dust,
broke, felts/roll covers, and/or power cabling; or ignitable liquids such as lubricating oil, hydraulic oil, HTF,
and/or performance/formation additives. These fire hazards may be present in the footprint of the machine,
in the hood exhaust system, on the operating floor, or on the ground floor. Authorize responders to execute
the necessary actions, which may include shutting down the machine and interrupting production.
B. Specify response actions and assign those responsibilities to personnel. Example actions include the
following.
1. Confirm any automatic machine responses (e.g., shut down section, or bring the dryer section to a
crawl), and if any interlocks failed to do so or are not present, manually initiate the response.
2. Confirm automatic depressurization and/or isolation of ignitable liquid systems such as HTF, hydraulic
oil, or ignitable additives/cleaners, if any interlocks failed to do so or are not present, manually initiate
those responses.
3. Confirm automatic depressurization of roll bearing lubricating oil upon machine section shut down, and
if any interlocks failed to do so or are not present, manually initiate depressurization.
4. Confirm automatic isolation of steam supply to dryers, and if any interlocks failed to do so or are not
present, manually isolate the steam supply.
5. Confirm fire protection system operation, and if the system failed to operate automatically, manually
actuate the system.
6. Manually operate water-based felt showers.
7. Confirm automatic hood and pocket ventilation system response, and if any interlocks failed to do so
or are not present, manually initiate the response.
8. Confirm automatic interruption of fuel-fired equipment, and if any interlocks failed to do so or are not
present, manually isolate burners.
9. Isolate the fuel supply to the building.
C. Instruct any responders that may use a hose stream to not direct solid, cold-water hose streams in the
vicinity of hot rolls whether steam or HTF heated. Such rolls may include dryers, Yankee dryer, MG cylinders,
and chilled HTF rolls. Instead use a spray nozzle and ensure the spray or fog is oscillated when near these
hot rolls.
Note: The common initial response to a fire on a tissue machine with a Yankee dryer should be to maintain
the Yankee rotating to limit the potential for a cold water spray or stream from stressing the hot cylinder.
During this period, operators and responders should systemically depressurize and isolate support systems
and attack the fire when safe to do so. However if the initial response fails to control the fire, the procedures
should outline circumstances when damaging the unpressurized, hot Yankee becomes a secondary concern
such as when the fire escalates to a structural fire threatening the building or an oil release is driving fire
intensity and duration. In these instances, the Yankee lubricating oil system should be depressurized and
Yankee rotation stopped.
2.1.5.2 Conduct pre-incident planning with the public fire service in accordance with Data Sheet 10-1,
Pre-Incident Planning. Highlight the importance of controlling hose streams around hot rolls and oil pool fires,
and the location of ignitable liquid system supplies and use points.

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Paper Machines and Pulp Dryers 7-4
FM Global Property Loss Prevention Data Sheets Page 15

2.1.5.3 Provide initial and periodic refresher training for the emergency response team on the ERP for prompt
and effective reaction to a machine fire.
2.1.5.4 Conduct pre-incident planning with the fire service on fluid fire and explosion scenarios in accordance
with Data Sheet, Pre-Incident Planning.
2.1.5.5 Conduct exercise drills on machine fire procedures including operators and the emergency response
team. When possible, involve the fire service.
2.1.5.6 Test fire interlocks and any HTF leak detection interlocks (e.g., position switch at rotary joint) as follows.
A. Perform a functional test of the interlock at commissioning.
B. Perform a functional test of the interlock impacted by changes as determined through the management
of change program. Of concern are changes to any field devices and control equipment or logic.
C. Perform loop testing of the interlock at least annually (i.e., simulated testing).
2.1.5.7 Develop a procedure for interlock testing to verify proper operation, connectivity, and settings of the
following interlock hardware and software. Include the following aspects in the test procedure.
A. List the machine equipment involved in interlock testing such as field sensing devices (e.g.,
instrumentation), operator interfaces (e.g., manual push buttons), controller and logic loops, field control
devices (e.g., valves and power disconnect switches).
B. Develop a checklist for documenting interlock testing. At a minimum record: individuals performing the
test; date; interlock tested; field devices and equipment involved; type of test; results (e.g., pre-trip conditions,
trip point, post-trip conditions, and time required); and as found and as left conditions.
C. Conduct functional testing with equipment in a safe operating condition (e.g., low machine speed).
D. Initiate a functional test using a single field device, while verifying all other field sensing device and operator
interfaces separately via loop testing.
2.1.5.8 Test fire detectors and detection systems in accordance with Data Sheet 5-48.
2.1.5.9 Implement a housekeeping program to manage spilled pulp and broke accumulations as well as spilled
oil and grease and transient combustibles (empty IBCs). Keep the machine, and utility and support equipment
areas clean, orderly, and free from unnecessary combustibles. Establish inspection and cleaning schedules
during scheduled shutdowns to clean up spilled oil and grease, and remove pulp, fiber, and broke
accumulations before they become excessive. The following are areas of focus.
A. On machine surfaces, in/on hoods, on/in ducts, in plenum spaces, in economizers, on support system
equipment (e.g., motors, power cabling, and steam lines), and interior building surfaces (deck above machine,
columns, ceiling or bottom of roof deck). Clean up accumulations of broke and spilled pulp promptly.
B. Steam piping near oil systems and all HTF piping for oil-soaked insulation. Promptly replace oil-soaked
steam pipe or HTF pipe insulation with clean insulation and repair the oil leak.
C. Unnecessary combustibles near machine equipment and from within electrical, control equipment, and
control rooms. Promptly remove combustibles.
2.1.5.10 Implement a housekeeping program to manage combustible dust accumulations in machine
equipment areas and within equipment in accordance with Data Sheet 7-76. For removal of dust, wash-down
with water hoses or vacuuming are preferred methods.
2.1.5.11 Implement a fire protection system inspection program. During scheduled outages, inspect sprinkler
or open-nozzle position, presence of blow-off plugs on open nozzles, sprinkler/nozzle and piping corrosion,
condition of any fire detectors, and status of any fire control panels for trouble alarms and automatic mode.
At a minimum, inspect fire protection in all machine areas at least annually, while conducting inspections more
frequently when fire protection equipment may be exposed to impact during maintenance outages (e.g.,
clothing changes).
2.1.5.12 Implement a hot work permit program to manage grinding, cutting, welding and similar hot work
operations in accordance with Data Sheet 10-3, Hot Work Management.
2.1.5.13 Implement a program to reduce fire risk at the wet-end of the machine during outages. Of particular
concern are wet-end machine areas where automatic fire protection is not provided. Focus the program on

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7-4 Paper Machines and Pulp Dryers
Page 16 FM Global Property Loss Prevention Data Sheets

the following: controlling ignition sources (hot work and temporary electrical equipment); removing
combustible accumulations such as fiber, dust, and spilled oil; and limit unnecessary combustibles such as
packaging and empty IBCs. Additionally, provide fire monitoring of these unprotected machine areas
throughout the outage.
2.1.5.14 Inspect, maintain, and rebuild/replace drive shafts for driven rolls, shoe press roll sleeves/belts,
and flexible oil hoses per original equipment manufacturer (OEM) guidelines. Of particular importance are
equipment failures that could result in an oil release (e.g., shoe sleeve rupture, drive shaft tearing supply and
return hoses, or flexible hose abrasion, fatigue, or connection fatigue).
2.1.5.15 Inspect, test, and maintain rotary joints in accordance with OEM guidelines. Instruct operators to
isolate calender roll heating if the joint operating parameters exceed established safe operating limits.
2.1.5.16 Establish procedures governing overhead crane positioning/parking when not in-use. Park overhead
cranes where they are not subject to fire, will not obstruct ceiling-level sprinkler discharge, or will not alter
sprinkler discharge directing streams of water onto hot rolls (steam or HTF heated).
2.1.5.17 Implement a program to inspect structural elements above and around the machine for corrosion.
At a minimum, verify the structural integrity of the roof and operating floor, and any false ceiling assemblies
as well as supporting columns and load-bearing walls. Of particular concern is the roof and any false ceiling
directly above the machine wet-end. Develop the inspection program based on input from a competent
structural engineer (e.g., licensed). Have a structural engineer perform a baseline inspection, then follow-up
with a visual inspection at a minimum of every 5 years to verify program effectiveness and revise the program
as needed. Depending on the inspection findings, more frequent follow-up inspections by a structural
engineer or mill personnel may be warranted.
The following are additional measures that may be useful in addressing corrosion. To further monitor active
corrosion, have mill personnel perform periodic visual inspections or conduct nondestructive examinations.
To slow the rate of corrosion, implement ventilation controls to reduce condensation and humidity in the
subject areas, and/or limit use of corrosive agents for cleaning clothing and other machine surfaces. To
prevent the onset of corrosion, apply a protective coating structural members.
2.1.5.18 Promptly evaluate the affect of any incident or condition that occurs during dryer roll operation.
Examples of such incidents or abnormal conditions include the following:
• Press roll shell, journal, or cover failure
• Objects passing through the nip
• Bearing damage or failure (vibration, sudden stop)
• Unauthorized repairs
• Steam leaks
• Broken head or journal bolts
• Process interlock override or failure such as continued hood or air cap heating after loss of Yankee
rotation
• Operating excursion outside of control or operating limits such as steam pressure, temperature, speed,
or nip load
• Emergency stops or power failure
• Localized or excessive temperature such as an exposure fire involving fiber, dust, released oil or broke
at machine
• Cooling rates quicker than that specified by the OEM
• Application of solid water stream whether for cooling, cleaning, or during a fire response
• Heating rates quicker than that specified by the OEM
• Stationary warm-up
• Increasing differential pressure or steam flow
• Uneven shell wear or doctor blade chatter
• Loss of coating
• Holes or picks in the sheet
• Mechanical noises internal to the dryer
• Loss of dynamic balance
2.1.5.19 Post the manufacturer’s operating instructions and precautions at the paper machine.

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Paper Machines and Pulp Dryers 7-4
FM Global Property Loss Prevention Data Sheets Page 17

2.1.5.20 Follow the machine manufacturer’s recommendations for startup and shutdown of the machine.
Particular concerns are loading and unloading of all pressure rolls; warm-up and cool-down of all dryers; start,
stop, and application rate for any cooling or process sprays on dryers and startup, switch to high fire and
shutoff of any auxiliary dryer roll heating systems.
2.1.5.21 Calibrate instrumentation, controls, and safety interlocks (pressure, vibration, temperature, speed,
fuel combustion controls, oil system shutoffs, etc.) per OEM. Document the calibration and test procedures
and maintain records of the results.
2.1.5.22 Monitor, record, and trend bearing vibration levels of all rolls, and open or enclosed drive gears.
Perform spot vibration monitoring at least quarterly. Do not overlook abnormal vibration levels. Abnormal
vibration indicates increased stress that may damage rolls or the machine frame.
2.1.5.23 Minimize mechanical and thermal stresses on all paper machine rolls by following the manufacturer’s
recommendations for lubrication of bearings, bearing and shaft tolerances, maintenance of drive gears and
clutches, and machine startup and shutdown.
2.1.5.24 Test dryer roll steam supply relief valves by manually lifting or operationally (pressure) testing at
least every 12 months.
2.1.5.25 Maintain comprehensive records on all dryer rolls. Include date of manufacture, MAWP, allowable
working temperature, operating pressure, operating temperature, results of VT, MT, and UT examinations, and
AET location of any indications, and detailed repair history in the records. Maintain records for the life of
the roll.
2.1.5.26 Implement a dryer roll operating program covering the following minimum aspects.
A. At least once each shift make an operating inspection of all dryers. Inspect for correct operating
temperature, pressure, machine speed, unusual noise (inside dryer, gear, and journal bearing), lube oil
pressure, temperature and flow, nip loading pressure, steam or condensate leaks, and condition of the
condensate removal system. Look for any unusual movement of rolls or the machine frame. Log this
information if it is not automatically recorded. This inspection may be done by the machine operator. Organize
the data to permit adverse operating trends to be identified.
B. At least once each week, have the person most knowledgeable in dryer operation conduct a similar
operating inspection. As part of this weekly inspection, review the shift inspection logs for adverse trends.
Variations in differential pressure, control valve position, steam flow, sheet moisture uniformity, sheet moisture
content, machine speed, and steam pressure are indicators of potential adverse conditions needing further
investigation.
2.1.5.27 Isolate steam to any dryer roll having cracks or crack indications until an evaluation by a dryer
specialist can be completed. If mechanical integrity is in doubt, remove the dryer from service.
2.1.5.28 Confirm that all dryers have functioning condensate removal systems at least weekly. This may
be accomplished by measuring dryer temperature by infrared thermometer, surface pyrometer, or contact
thermometer on the condensate pipe at the rotary union. A lower temperature for any dryer indicates
condensate is not being removed. Excessive condensate (flooding) increases mechanical loads and stress
on the dryer.
2.1.5.29 Conduct an visual inspection of dryer roll internals for shell grooving if there are unusual sounds
(loose balance weights, broken siphon, or loose spoiler bars) or if the temperature indicates the condensate
removal system is not functioning properly. Remove any loose parts from the dryer. If grooving has occurred
reevaluate the MAWP.
2.1.5.30 Use only nondestructive examination personnel qualified and certified according to the employer’s
(agency) written practice. Verify that ASNT Recommended Practice SNT-TC-1A or a similar standard has
been used as a guideline by the employer (agency) to establish the written practice. Use only nondestructive
testing agencies that meet the requirements of ASTM E543-04, Standard Practice for Agencies Performing
Nondestructive Testing.
2.1.5.31 For cast iron and steel dryer rolls, perform the following examinations for indications of cracking,
thinning, corrosion, or other damage to the pressure boundary.
A. Conduct a visual inspection of the external roll surfaces including shell, heads, journals, and handhole
or manhole rims at least every 12 months.

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7-4 Paper Machines and Pulp Dryers
Page 18 FM Global Property Loss Prevention Data Sheets

Where accessibility to the drive side head for external visual inspection is impeded by gears and frame,
internal surface examination of that head becomes increasingly important.
B. Conduct a visual inspection of internal shell and head surfaces at least every 60 months. Dryers having
handhole access only may be examined by remote VT (video camera) combined with UT shell profile.
C. Conduct a volumetric examination (e.g., ultrasonic testing) to examine 20% of head cap screws or head
bolts at least annually (i.e., complete examination at least every 60 months). Ensure a different 20% grouping
of the head cap screws or head bolts are examined at each test interval (i.e., not the same bolts tested
repeatedly).
2.1.5.32 Perform a volumetric examination (e.g., ultrasonic testing) of any head cap screws or head bolts
where there are signs of steam leakage. Replace any cracked screws or bolts and stop the steam leakage.
2.1.5.33 In areas of previously identified cracks and damage that are not repaired, re-examine as discussed
in Section 2.1.5.30 at least every 12 months until the indications are determined stable or are proven
nonrecurring.
2.1.5.34 For cast iron and steel dryer rolls without a center shaft, perform the following additional examinations
for indications of cracking, thinning, corrosion, or other damage to the pressure boundary or journal at least
every 60 months.
A. Conduct surface examinations of external high stress areas of heads (transitions and reinforcement areas).
See Figure 7 for location of high stress areas.
B. Conduct volumetric examinations (e.g., ultrasonic testing). to determine shell profile and thickness.
Continuously measure shell thickness starting just inside the shell flange across the length of the shell. Record
thickness continuously, or at the minimum thickness within each 12 in. (0.30 m) segment of shell length.
Perform four scans, equally spaced around the circumference of the shell. Alternatively for shells with a
metalized coating, perform a magnetic lift off (MLO) test to verify a sufficient coating remains.

Examine Head
Surface Around
Openings Both
Sides
Examine Ribs
At Head
Surface

Examine Ribs
At Head
Surface

Fig. 7. High stress areas on shell and heads.

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Paper Machines and Pulp Dryers 7-4
FM Global Property Loss Prevention Data Sheets Page 19

2.1.5.35 For steel dryer rolls, perform the following additional maintenance activities.
A. On startup, conduct a visual inspection of rolls for evidence of steam leakage. Remove any steel dryer
rolls found to have steam leaks or cracking, and replace or repaired as applicable.
B. Conduct applicable surface and volumetric examinations of pressure containing welds per OEM guidelines.
However for rolls fabricated with lap joint construction, perform UT to examine the head-shell joint at least
every 60 months.
C. Monitor condensate return from steel dryers. Maintain the condensate parameters within the control limits
and under the established safe operating limits specified by the OEM.
2.1.5.36 When the opportunity arises, replace any steel dryer roll having the lap joint configuration shown
in Fig. 8 or Fig. 9 with a roll having a butt-type head-to-shell joint.

Fig. 8. Head-to-shell joint configuration

Fig. 9. Head-to-shell lap joint configurations

2.1.5.37 Review repair procedures for all dryers with FM Global prior to commencing the repair. Repair by
welding or brazing is not permitted for cast iron dryer parts.
2.1.5.38 Perform repairs in accordance with the National Board Inspection Code (NBIC). For code constructed
dryers, the original construction code, such as ASME Boiler and Pressure Vessel Code, may be used as
guide.
2.1.5.39 Apply metalized coatings (a.k.a., thermal spray) by skilled and experienced personnel, for cosmetic
surface defect repairs is acceptable and is preferred to plugging of cast iron dryer rolls. However, this is not
a strength repair.
2.1.5.40 Complete all repairs expediently and maintain a record of all dryer repairs or repair of other equipment
affecting the safety of dryers. Also, maintain a record of any dryer repairs that are deferred, with the reason
for the delay.
2.1.5.41 For all suction rolls, conduct a visual inspection of external shell surface and drilled holes at least
every 3 years of operation. For additional guidance on suction roll shell inspections, refer to TAPPI TIP
0402-19 Guidelines for Nondestructive examination of suction roll shells.

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7-4 Paper Machines and Pulp Dryers
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2.1.5.42 For suction press rolls, conduct an visual inspection of the internal shell surface and drilled holes
at least every 2 years of operation. A flashlight can be useful in identifying indications and other damage.
2.1.5.43 For suction press rolls, perform a surface examination of the external shell surface shell at every
cover replacement.
2.1.5.44 For all covered functional rolls (e.g., forming, press, and control crown rolls), conduct visual
inspection of the cover at every schedule machine outage. A hammer can be useful in assessing cover-roll
bonding.
2.1.5.45 For granite rolls, perform volumetric examination (e.g., ultrasonic testing) of center shaft and all
tension rods at a minimum of every 2 years of operation.
2.1.5.46 Implement an asset integrity program to manage maintenance examinations of all other machine
rolls and roll parts not specifically addressed in this data sheet. Refer to Data Sheet 9-0, Asset Integrity for
guidance on developing and managing the program, and OEM and industry best practices such as TAPPI
for examination guidance. At a minimum, perform routine visual examination of structural roll components
(e.g., shell, heads, and journals), coatings (e.g., metalized or ceramic), and attachments (e.g., balance
weights) at an established frequency based on operating duration, and scheduled roll and machine
maintenance outages. Supplement visual inspections with periodic surface and/or volumetric examinations
(e.g., die penetrant and ultrasonic testing), and coating examinations (e.g., magnetic lift off MLO testing) and
when VT identifies suspect conditions. Based on loss history, these supplementary examinations may be
warranted for shell/roll, heads, journals, and/or suction box small shaft (spigot). Establish a frequency for
inspections and examinations, and adjust the frequency based on positive and negative examination results,
operating conditions, and history. The following are other roll components and rolls not specifically addressed
in this data sheet that warrant routine evaluation mechanical integrity and component attachment based on
loss history. The list below is not all-inclusive.
• Other parts of suction roll, suction press roll, granite roll including heads and journals, and suction roll suction
boxes.
• Shoe press
• Felt guide and wire roll
• Ceramic press roll
• Vacuum dryer roll
• Dryer roll with steam isolated
• Calender roll
• Winder Drum
• Spool-Reel

2.1.6 Contingency Planning

2.1.6.1 When a machine breakdown would result in an unplanned outage to site processes and systems
considered key to the continuity of operations, develop and maintain a documented, viable equipment
contingency plan per Data Sheet 9-0, Asset Integrity. See Appendix C of that data sheet for guidance on the
process of developing and maintaining a viable equipment contingency plan. Also refer to sparing, rental,
and redundant equipment mitigation strategy guidance in that data sheet.
2.1.6.2 Sparing can be a mitigation strategy to reduce the downtime caused by a machine breakdown
depending on the type, compatibility, availability, fitness for the intended service, and viability of the sparing.
For general sparing guidance, see Data Sheet 9-0, Asset Integrity.

2.2 Tissue Machines

2.2.1 Protection
2.2.1.1 For tissue machines with fuel-fired air heating systems, provide explosion vents on the air cap air
recirculation systems in accordance with Data Sheet 6-9, Industrial Ovens And Dryers.
2.2.1.2 Provide infrared spark detection over the web at the dry end, arranged to sound an alarm when sparks
are detected. Burning paper sometimes escapes from the hood or air cap and doctor blades may generate
sparks. When sparks are detected, segregate the roll being wound at the time from other storage, preferably
to an outside area away from combustibles, or re-pulp the roll.

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Paper Machines and Pulp Dryers 7-4
FM Global Property Loss Prevention Data Sheets Page 21

2.2.2 Equipment and Processes

2.2.2.1 Provide a pressure relief device on the supply to the pneumatic or hydraulic loading system for suction
press or pressure rolls to prevent damaging the Yankee dryer. The set pressure of this device may be up
to 110% of the allowable loading (adjusted for remaining dryer shell thickness) to avoid nuisance operation
of the device. Base the capacity of the device on the maximum let-through capacity of the upstream control
or pressure reducing valve.
2.2.2.2 Provide positive means of preventing a Yankee dryer from exceeding the maximum rotational speed
recommended by the manufacturer. This is particularly important for dryers having stay-bar construction.
For a turbine-driven machine, the overspeed protection provided on the turbine may be used to prevent
overspeed of the Yankee dryer. For an electric motor-driven machine, if the motor can cause the Yankee dryer
to exceed the maximum recommended speed, provide a tachometer-type device or other type device on
the paper machine, arranged to trip power to the drive motor at or below the maximum allowable speed. For
both types of drivers, trip of the driver should also trip any air cap heater, any water sprays, release the
pressure roll(s), and trip steam to the Yankee dryer.

2.2.3 Operation and Maintenance

2.2.3.1 For cast iron and steel Yankee dryers with through-bolted head construction, perform the following
inspections and evaluations at least every 12 months. Runout or head tilt measurements may be done
pressurized or cold, but the same condition must be followed each examination, so measurements can be
compared.
A. Conduct a visual inspection of the gap in the head to shell joint.
B. Conduct head tilt evaluation. Measure the head tilt at every tenth bolt. Any single measurement 0.030
in. (0.762 mm), or a progressive change in tilt over several bolts, indicates immediate inspection for head-shell
cracking is necessary.
C. Conduct shell runout evaluation. Measure the shell runout at 6, 9, 12, 15 in. (150, 230, 300, 380 mm),
at quarter shell length from each end, and at the centerline. Radial shell runout that is greatest near the end
of the shell and decreases toward the centerline, or that suddenly changes by 0.030 in. (0.762 mm) or more,
indicates inspection for impending or existing head-shell cracking is necessary.
2.2.3.2 Perform examinations discussed in Section 2.2.3.1 any time indications are visually detected or either
shell runout or head tilt measurements indicate corrosion is present in the head-shell joint.
2.2.3.3 Conduct a visual inspection of internal surfaces of the shell and heads, and center shaft at least every
24 months for indications of cracks or other defects. If indications are found in the cast parts, increase
inspection frequency until the indications are determined stable or are proven non-recurring. Check the
condensate removal system and balance weights to ensure they are securely fastened and properly
positioned. Confirm internal fasteners (i.e., nuts, their tack welds, securing wires, shims, and spacers) are
in place and secure.
2.2.3.4 For cast iron and steel Yankee dryers, perform surface and volumetric examinations of at least every
72 months of the following susceptible areas as shown in Figure 10. The 72 month frequency assumes
baseline data is complete for the dryer. If not, perform a complete examination within 12 months to establish
a baseline.
A. Head flanges (through-bolt head only)
B. Shell outside diameter at head joint (cap screw head only)
C. Head-shell and center stay bolts (UT only)
D. Shell or shell ribs where drilled and tapped for bolting of condensate piping supports or spoiler bars.
2.2.3.5 For Yankee shells with a metalized coating, perform a magnetic lift off (MLO) test to verify a sufficient
coating remains.
2.2.3.6 In areas of previously identified cracks and damage that is not repaired, re-examine as discussed
in 2.2.3.3 at least every 12 months until the indications are determined stable or are proven nonrecurring.
2.2.3.7 Maintain the following baseline data for each Yankee dryer:

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7-4 Paper Machines and Pulp Dryers
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Shell
2

8
6

3
7
Head

5 6

5
4

Center Shaft

CL

1. Surface of shell at head bolts (cap screw construction only) for shell cracking
2. External bolting surface on head at OD
3. External surface of head
4. External transition journal to shaft
5. Internal transitions journal to shaft and center shaft to bolting flange
6. Internal nut stop flanges on head
7. Internal surface of head
8. Any drilled and tapped holes in shell

Fig. 10. Common Yankee dryer head and shell areas warranting examination

• Manufacturer’s data sheet

• Chemical and physical tests on heads, shell, and center shaft
• Heat treatment records
• Photomicrographs of the shell, heads, and center shaft castings
• Radiographs of cast iron shell and a radiograph layout chart
• Magnetic particle examination reports for all castings and welded joints
• Chemical and physical test certificates for purchased materials (bolts and nuts, steel plate, and piping)
• Dynamic balancing record
• Nameplate facsimile
• Journal and shell runout, hot and cold
• Shell finished diameter
• Shell thickness, total and root (as applicable)
• Journal bearing taper measurements
• Insulating sleeve test certificate
• Shell crown profile

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Paper Machines and Pulp Dryers 7-4
FM Global Property Loss Prevention Data Sheets Page 23

• Bolt torque requirements (head, journal, center shaft, stay bar)

• Head tilt measurements, hot and cold
• Spigot fit feeler gage measurements (as applicable)
• Cast iron porosity repair record (size, method, and location)
• Cast iron shell thickness derating curve
• Q. Nip load conversion chart
• Engineering drawings
• Design specifications and calculations
• Cast iron grind reports detailing the date of the last grind and remaining shell thickness
• Hydrostatic test certification
2.2.3.8 Maintain dryer operating parameters (pressure, nip load, rotational speed) within the limits of the
manufacturer’s specifications.
2.2.3.9 Inspect and test the through-air dryer (TAD) cylinder per OEM guidelines.
2.2.3.10 Maintain the dryer lubrication oil system as recommended by the machine manufacturer. Conduct
oil analysis, and filter as required, to ensure clean, dry oil supply to bearings. For additional guidance on
bearing maintenance, refer to TAPPI TIP 0425-03.
2.2.3.11 Provide the following dryer lubrication oil system instrumentation and alarms.
A. Low oil pressure monitor and alarm
B. Low oil pressure trip
When possible, monitor and record discharge oil temperature from bearings. Increasing discharge
temperature may indicate incipient bearing failure.
2.2.3.12 For tissue machines with fuel-fired air heating systems, perform frequent blow backs to remove
dust from inside the hood or air cap (when the system is provided with a blow back duct) and remove dust
from inside the hood or air cap if the system has been running at temperature below 400°F (204°C) for a
prolonged period of time before running the system at a temperature above 400°F (204°C).

2.3 Airborne Pulp Dryers

2.3.1 Protection
2.3.1.1 Provide steam suppression fire protection for airborne pulp dryers at a minimum steam application
rate of 2.5 lb/100 ft3/min (0.4 kg/m3/min) with steam applied for at least 10 minutes. Locate steam injection
nozzles on the bottom or sides of the dryer for maximum suppression effectiveness.
Suppression system design may vary depending on dryer size, configuration, and the potential for combustible
deposits to collect. The following are general guidelines:
A. Place nozzles (preferably) on the bottom or the sides of the enclosure. Steam supplied to the top of
the enclosure may only be effective if the fire is no more than approximately 10 ft (3 m) below the steam
injection nozzles.
B. Ensure nozzles are not smaller than 1 in. (25 mm) nominal orifice size to minimize plugging.
C. Install nozzles in the dryer and within ducts, fan housings, and precipitators if dust or broke can
accumulate. Provide at least one nozzle per 10 ft (3 m) of enclosure or duct width.
D. Multiple or single steam control valves may be used to supply different parts the system.
E. Preferably provide automatic actuation of steam suppression upon dryer temperature exceeding normal
operating temperature by 100°F (38°C). Existing process temperature sensors may be used to detect
fire and actuate the steam suppression system. Manual actuation only is acceptable.
F. Shut down process flow and all fans upon fire detection.
G. Ensure the steam suppression system demand is available in addition to the maximum steam supply
required for plant operation.

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2.3.2 Operation and Maintenance

2.3.2.1 If a manually-actuated steam smothering system is provided, train operators to open the steam control
valves and shut down the dryer promptly upon recognizing fire in the dryer or associated equipment.
2.3.2.2 Provide constant operator attendance for observation of the dryer operation during all periods when
the dryer contains pulp, particularly during shutdowns.
2.3.2.3 Remove pulp from the dryer during any shutdown (before it is permitted to dry out).
2.3.2.4 Keep lights and other ignition sources out of dryer interiors, particularly when any pulp is present.
Ensure lights or any other electrical equipment that must be introduced is suitable for Class II, Division 2
locations in accordance with the National Electrical Code or the equivalent international standard. Ensure high
intensity lights mounted outside have prominent flashing signal lights and are on only for brief inspection
periods.

2.4 Flash Pulp Dryers

2.4.1 Location and Construction

2.4.1.1 Locate flash pulp dryers outdoors. If weather protection is required, provide a dedicated building for
the dryer, separated from the main production building and locate the cyclone collection system outdoors.
Extend relief ducts for dryer explosion vents through the roof or walls to safely vent an explosion outdoors.

2.4.2 Protection
2.4.2.2 Provide explosion vents on drying towers, cyclones, bins, and at the inlet and outlet of fans. Vents
must be smooth and fitted flush on the inside to minimize accumulation of combustible deposits. Refer to Data
Sheet 7-76, Prevention and Mitigation of Combustible Dust Explosions and Fires, for venting guidelines.
2.4.2.1 Provide a spark detection and water spray protection system inside a flash pulp dryer as follows:
A. Locate spark detectors in the duct immediately downstream of each drying tower, with the corresponding
water spray nozzle located upstream of the inlet to each cyclone (including the cooling duct and cyclone).
The water spray system should activate every time a single spark is detected and reset after a few seconds
(if no additional sparks have been detected) permitting the dryer to continue operating. The spark-counting
feature available in some FM Approved detectors can be used to shut down the dryer when an excessive
number of sparks are detected, but this feature should not be used to activate the water spray system.
B. Provide a second “fail-safe” spark detector in the duct between the water spray nozzles and the cyclone
inlets. Detection at this location should be interlocked to safely shut down the dryer as follows:
1. Isolate the dryer cyclone outlet ducts to prevent smoldering material from being conveyed into
downstream process areas. This may be accomplished by a high speed abort gate.
2. Stop material feed to the dryer and shut off all dryer heating sources.
3. Initiate an automatic deluge water spray system in the drying tower and cyclone. Flush-mounted,
spring-loaded “poppet” nozzles (similar to those on the spark extinguishing system) are preferred for
resistance to plugging and not protruding into the air flow, potentially accumulating pulp or being
damaged. Automatic sprinklers may be acceptable in existing installations. For existing installations
with automatic sprinklers, a second detection zone is needed for dryer shutdown.
4. Provide drainage for fire protection water.
5. Continue operating pulp dryer conveying fans to purge the drying system of pulp.

2.4.3 Equipment and Processes

2.4.3.1 Steam heating is preferred over combustion heating. For recommendations on fuel fired safety controls
and devices, refer to Data Sheet 6-9, Industrial Ovens and Dryers.
2.4.3.2 Provide high temperature limit switches on the dryer duct at the inlet to each drying tower and cyclone.
Interlock these limit switches to initiate the same functions as the “fail-safe” spark detector recommended
above.

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FM Global Property Loss Prevention Data Sheets Page 25

3.0 SUPPORT FOR RECOMMENDATIONS

3.1 Supplemental Information

3.1.1 All Machines

3.1.1.1 Sprinkler Protection of Dryer Enclosures

Automatic sprinkler protection is needed inside dryer section hoods, exhaust ducts, air plenums, etc., because
deposits of oily lint and paper dust are generated during operation of the paper machine. Due to high heat
and humidity, it is impossible to clean some of these enclosures without shutting down the paper machine.
Synthetic felts, lubrication, hydraulic and HTF oil systems, and the paper web may also add fuel to a fire.
Sprinkler piping for dryer section enclosures is independent of other sprinkler system piping, so the sprinkler
systems in the other areas remain in service while fused sprinklers inside the enclosures are replaced.

3.1.1.2 Protection of Broke Collection Pits

Sidewall sprinklers may be located under the machine frame so the piping is not in the way and is protected
from mechanical damage. The sprinklers must be located so discharge is not obstructed.
Provision of multiple manual trip stations for an under-machine water spray system at locations readily
accessible by operators during a fire in the protected area are important as operator response may be quicker
than automatic trip.

3.1.2 Cleaning With Flammable Solvents

Kerosene (flash point 110-162°F [43-72°C]) has been used for many years to clean calender rolls. In the
past, and on some existing older machines, the kerosene was applied in small quantities by swabs, watering
cans, and spray cans, and the amount stored at the machine has been typically less than 2 gal (7.6 l). Larger
kerosene and mineral spirits (flash point 105°F [50°C]) cleaning systems are now being used that present
a severe flammable liquid spill fire hazard. Plastic and metal tanks of 50 to 400 gal (190 to 1500 l) capacities,
connected by fixed piping and flexible hose to manually controlled shutoff nozzles at the calender stack,
are being used. Solvent is discharged as a spray or small stream. Transfer from the tank to the nozzles is
by pumping, gravity flow, or, in some cases, by shop air at 20 to 80 psi (1.4 to 5.5 bar).
Flammable liquid transfer methods that maintain constant pressure on combustible flexible hose with the
entire tank capacity behind it present the possibility of flammable liquid escape and resultant serious fire. The
hose could fail mechanically or fail from exposure to a fire involving sprayed kerosene or burning broke,
releasing the contents of the tank. When unavoidable, tanks approved by FM Approvals are preferred, and
protection, including confinement and drainage, are needed.
Some pulp and paper mills have recovered fiber (waste paper) pulping operations. These systems repulp
and remove ink and other contaminants from waste paper. Flammable solvents may be added to the stock
along with other repulping chemicals. A properly designed and operated repulping operation will provide a
stock supply to the paper machine free of solid and liquid contaminants. If the repulping operation does not
remove all contaminants, flammable solvents, such as naphtha, may be sprayed onto the paper machine
forming fabric to control “stickies.” The solvent-laden air may be removed in a ventilation system and
recovered by carbon bed adsorption. The practice of spraying low flash point solvents, such as naphtha,
directly onto machine clothing is hazardous and should be avoided.
Repulping systems may be installed in areas previously having minimal combustibles and may not be
provided with sprinklers or suitable electrical equipment. As an example, a repulping and solvent deinking
operation may be installed at the wet end of the paper machine having neither ceiling sprinklers nor electrical
equipment suitable for flammable vapors. Fire and possibly equipment or room explosion hazards could exist
if low flash point solvents are used, especially if they are heated. Vapors or spilled liquids could enter
drainage systems not designed for solvents and find their way to an ignition source.

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3.1.3 Oil and HTF Fire Hazards

3.1.3.1 Oil Fire Hazard

Lubrication and hydraulic oil system hazards are inherent to nearly every machine. Lubricating oil is commonly
used by roll bearings; however, grease may be used in slower speed or wet applications (e.g., forming
sections). Some roll bearing lubrication systems may also supply dryer gears, enclosed reduction gears, and
large drive motor bearings.
Hydraulic oil can be found at many nips in press and calender sections, while compressed air may be
substituted at some nips (e.g., Yankee dryer press rolls). Hydraulics (or pneumatics) may also be used for
roll movements, felt stretching, and articulate the headbox.

3.1.3.2 HTF Fire Hazard

HTF heated roll operating temperature may be up to 500°F (260°C). Thermal oil may be circulated at more
than 500 gpm (1900 L/min) at a pressure of about 60 psi (400 kPa). Rotary joints are required to circulate
thermal oil through a thermo-roll. Rotary joints require frequent servicing to avoid failure. Thermal oil is typically
piped to a point near the rotary joint and then connected to the joint with 3 in. (75 mm) or 4 in. (100 mm)
steel reinforced flexible hose. Failure of a rotary joint typically results in tearing the hoses apart, releasing the
thermal oil at operating temperature and pressure. Under operating conditions, the thermal oil is easily
ignited.

3.1.4 Suction Rolls and Pressure Rolls

Suction rolls and pressure rolls are machine elements with a finite life. Unlike cast iron dryer rolls, the
combinations of roll loading, limited shell thickness, and, for suction rolls, the multitude of drainage holes,
limits the useful life of these rolls. Suction couch rolls, while not nip loaded, do have a multitude of drainage
holes and are driven to transport the forming wire. Pressure rolls do not have drainage holes but are nip
loaded and are usually driven. Suction press rolls have the combination of a multitude of drainage holes, nip
loading and drive loading.
For all three roll types, the roll supplier works with the machine owner to design the roll for the characteristics
desired for a particular machine. The supplier can calculate the number of cycles (revolutions) the roll can
endure before cracking will likely begin. Some suppliers will guarantee this life while others will only provide
a limited warranty. In either case, the roll has a limited service life that can be adversely impacted by operation
at load greater than original design or operating in a chemical environment differing from the original design.
These rolls have bonded resilient covers that require surface restoration and replacement. A second roll is
generally maintained to exchange rolls during this routine maintenance. The roll supplier typically advises
the operator on type and frequency of roll examination to coincide with the routine maintenance. This permits
detection of impending failure so the roll may be removed from service prior to failure in the machine.

3.1.5 Cast Iron Dryer Rolls

Can-type cast iron roll shells range anywhere from 0.5 to 2.0 inches (12.5 to 50 mm) in thickness, from 24
to 72 inches (610 to 1830 mm) in diameter, and length may exceed 30 ft (9.1 m). The cylindrical face of
each roll is ground to a smooth finish. The rolls are supported by trunnion shafts. The trunnion shafts are
often cast integrally with the head and rotate in bearing housings. The bearing housings may be cast integral
with, or bolted to, the frame of the paper machine. The dryers are driven by electric motors or steam turbines
through open or enclosed gear sets. Modern dryer sections typically are two high but older machines may
have dryer stacks up to twelve high.

3.1.6 Shoe Presses

Shoe press popularity has been growing since the late 1990s given their improved dewatering capabilities.
The fire hazard posed by the shoe presses is much greater than that of the conventional solid roll press.
Shoe presses use significantly more hydraulic and lubricating oil than conventional press sections, and that
oil is no longer limited to the machine frame (sides) but rather spans across the press section. Belt or sleeve
failure (e.g., delamination) as well as mechanical impact to supply or return flexible hoses (e.g., drive shaft
failure) can release tremendous amounts of oil into the press section.

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3.1.7 Yankee Dryers and MG Cylinders

Creping dryers used in tissue machines are commonly referred to as Yankee dryers. Similar dryers used in
production of other paper types are commonly referred to as MG cylinders, as most of these cylinders apply
a smooth or “glazed” surface on one side of the paper (machine glazed). These dryers differ from can-type
paper machine dryers in size and in having a center shaft that both supports the dryer and serves as stay-bar
(pressure containing element). Modern Yankee dryers and MG cylinders are unique rotating pressure vessels,
which are constructed of high-strength cast iron. When fully pressurized and at operating speed, the dryer
contains a tremendous amount of energy. Knowledge of fracture toughness, crack growth rate, and critical
crack size is comparatively limited for high alloy gray cast iron, necessitating frequent inspection. Operating
experience has not shown any uniform life cycle limitation, and the safe operating service life for modern,
high-strength cast iron is not well defined.
Compared to creping dryers, non-creping Yankee or MG dryers typically operate at lower steam pressures,
have significantly lower or no nip loading, do not have a creping doctor, and do not have any process sprays.
The process sprays on creping dryers are a factor in head joint corrosion, and nip loading produces alternating
stress, introducing a fatigue factor. Several creping dryer incidents (damage to the shell) resulted from objects
(bolt, tool, torn rubber cover, torn machine clothing) passing through the nip. Non-creping dryers generally
do not have the air cap or hood common to high speed creping dryers, eliminating a significant thermal stress.
Compared to creping dryers, there are relatively few non-creping Yankee or MG dryers in service. As
machines are updated or replaced, non-creping Yankee or MG dryers are being replaced by calenders. Of
the seven incidents involving non-creped Yankee or MG paper production reported to FM Global for the
ten-year period 1993-2004, none involved a Yankee or MG dryer.
The significant safety concern for these dryers is the devastation that may accompany a catastrophic failure.
Since 1970, twelve explosions of creping Yankee dryers have been reported to the TAPPI Yankee Dryer
Safety Subcommittee. Of these twelve, two occurred in North America. These resulted in extensive property
damage and long production interruption with substantial associated costs. Causes were various: improper
repair, improper operation, joint corrosion, stationary warm-up, inadequate overpressure protection, and
application of solid water streams.

3.1.9 Creping Machines

3.1.9.1 Spark Detection on Tissue Machines

Fires have occurred in warehouse storage of tissue paper. The paper was produced on Yankee dryers
equipped with fuel-fired aircaps or hoods. It is believed that tissue dust, lint, and pieces of tissue from waste
paper stock enter either the recirculating air system or the air inlets of the Yankee dryer aircaps. This material
may be ignited by a burner in a direct fuel-fired hood, the hot-wire grid, or by autoignition in the indirect
fuel-fired hood. Burning sparks or embers are then expelled onto the tissue paper, which is wound and stored
without rewinding. It has been documented that burning embers were produced when the temperature of
the drying air was raised shortly after the Yankee dryer hood had been running at a lower temperature (below
the autoignition temperature of paper) for a prolonged period of time. Burning embers may also occur from
dust or lint accumulations on top of the aircap hood that auto-ignite and fall onto the web. Another possible
ignition source is sparks from doctor or cleaning blades contacting the Yankee.
Whatever the source, these burning embers smolder inside the rolled tissue for several days before bursting
into flame. Good housekeeping in and around the aircap or hood recirculation system, and frequent blow
backs will help prevent embers from developing. Vacuum cleaning of the aircap is preferred over blowdown
to prevent suspension of a dust cloud that may contain embers. In the event that a spark or ember is expelled
onto the web, a spark detection system will alert operators so the roll can be segregated from other storage
or repulped.

3.1.10 Airborne Pulp Dryers

3.1.10.1 Steam Protection

Airborne pulp dryers are large, costly pieces of equipment that are vital to production. A severe fire could
cause warping of the blow boxes. Steam extinguishing is being recommended for these dryers in lieu of more
conventional means of fire protection for the following reasons:

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• Automatic sprinklers or spray nozzles cannot be installed inside the dryers due to space limitations
between the horizontal passes, making inerting of the dryer atmosphere the next best alternative.
• Access for manual firefighting is limited.
• The relatively closed configuration and elevated temperature of the dryers make them suitable for steam
extinguishing.
• Most mills have adequate steam supplies, making steam an economical inerting agent.

3.1.11 Flash Pulp Dryers

3.1.11.1 Protection
Flash pulp dryers are expensive pieces of vital production equipment. The design of these dryers presents
all the conditions necessary for an explosion or severe fire: large amounts of combustible fibers are in
suspension in an enclosed space and a continuous ignition source is present. Wet fiber can impact and stick
to duct walls where changes in direction occur. This is likely to occur upon initial startup when the consistency
of the pulp may be variable or overly wet. The deposits dry out and may reach autoignition temperature.
Spark detection and automatic extinguishing, abort gates, and other protection are recommended to prevent
burning embers being conveyed to process equipment further downstream and possibly causing a fire or
explosion. Explosion venting in the dryer towers and cyclones is needed, particularly in the second stage and
cooling tower.

3.1.12 Fire Causes at Paper Machines

Overheated bearing fires occur primarily with manually lubricated sliding-element bearings that are not readily
accessible with the machine in operation. Other ignition sources are friction of paper chokes between rolls,
friction at belts, brakes, gears, and clutches. Mechanical sparks may be generated by metal contacts from
excessive end play of rolls, broken shafts, gears, and doctor blades.
The surface temperature of exposed steam pipes, dryer hoods and ductwork, de-superheater valves, infrared
radiant heaters, and steam turbines are often near or above the autoignition temperature of paper dust and
oil. The autoignition temperature of paper dust and oils will decrease over a period of time when exposed
to heat, and the autoignition temperature of oily dust similarly exposed to heating will be even lower. These
deposits may rest on the hot surfaces for days or weeks before igniting. Oil-soaked insulation on steam and
HTF pipes is particularly susceptible to autoignition.
Electrical fires result from improper maintenance, overloading of cable trays, poor housekeeping, short
circuits, and static discharge. Over-lubrication of motors results in breakdown of oil-soaked insulation and
accumulations of dust and fiber, which can cause overheating and short circuits. Spliced cables are
susceptible to attack by the constant moisture and dirt commonly found in and beneath the paper machine,
and can lead to arcing. Paper scraps or dust that obstructs motor vents can cause overheating of the motor
and ignition of the paper or dust.
Hot work fires result from carelessness and failure to adopt proper safeguards, including a hot work permit
system. Once ignition occurs, the presence of grease, oil-covered open gears, oily fibers, paper dust, paper
scraps, rags, rope, machine clothing, or other combustibles can cause a hot, rapidly spreading fire. A fire
starting at or below the operating level often is transported into exhaust ducts and economizers by the
ventilation system. Prompt shutdown of ventilation will help limit the amount of fire spread.
All paper machines are subject to fire, justifying installation of automatic sprinkler protection where
combustibles normally are or are likely to accumulate. FM Global experience demonstrates the likelihood
of severe damage to the paper machine and extended business interruption is much greater in the absence
of automatic sprinklers. Within dryer hoods, experience has shown that sprinkler discharge has not caused
cracking, distortion, or other damage to the dryer rolls.

3.2 Loss History

Tables 2 through 5 show the results of a study of FM Global client machine losses (concentrated on fire
and boiler & machinery hazards) spanning a period of over 22 years (1998 through mid-2020).

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FM Global Property Loss Prevention Data Sheets Page 29

Table 2. Machine Losses By Peril

Gross Loss
Peril No. of Losses (US$M)
Collapse 4 11.54
Electric Breakdown 7 8.22
Ensuing Fire 1 1.93
Explosion 3 10.60
Fire Following 1 0.46
Fire 87 282.14
Mechanical Breakdown 163 204.09
Mechanical Impact 1 0.69
Pressure Part Breakdown 24 118.55
Rigging 3 1.26
Service Interruption 3 21.00
Total(s) 295 660.48

Table 3. Paper/Board Machine Losses by Section and Peril

Gross Loss
Peril No. of Losses (US$M)
Forming 24 39.36
Collapse 4 11.54
Electrical Breakdown 1 2.53
Mechanical Breakdown 18 17.82
Press 76 123.01
Electrical Breakdown 3 3.50
Fire 6 43.70
Mechanical Breakdown 65 74.55
Dryer 77 162.55
Fire 32 53.45
Mechanical Breakdown 33 57.58
Pressure Part Breakdown 12 51.52
Reel 9 16.20
Fire 6 10.64
Mechanical Breakdown 2 5.20
Calender 12 77.00
Fire 9 69.88
Mechanical Breakdown 2 6.80
Utility System 2 19.45
Service Interruption 2 19.45
Support System 7 63.12
Fire 4 57.98
Electrical Breakdown 2 1.32
Mechanical Breakdown 1 3.82
Total(s) 207 500.68

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Table 4. Tissue Machine Losses by Section and Peril

Gross Loss
Peril No. of Losses (US$M)
Forming 1 0.26
Press 26 14.50
Fire 3 1.32
Mechanical Breakdown 23 13.18
Dryer 36 79.76
Fire 14 26.64
Mechanical Breakdown 10 6.51
Pressure Part Breakdown 11 42.44
Reel 6 3.05
Utility System 1 1.55
Support System 4 2.20
Total(s) 74 101.32

Table 5. Pulp Machine Losses by Section

Gross Loss
Peril No. of Losses (US$M)
Press 3 15.72
Drying 2 30.56
Total(s) 5 46.28

4.0 REFERENCES

4.1 FM Global

4.1.1 FM Global References

Data Sheet 2-0, Installation Guidelines for Automatic Sprinklers
Data Sheet 3-26, Fire Protection for Nonstorage Occupancies
Data Sheet 4-1N, Fixed Water Spray System for Fire Protection
Data Sheet 5-4, Transformers
Data Sheet 5-19, Switchgear and Circuit Breakers
Data Sheet 5-31, Cables and Bus Bars
Data Sheet 5-48 Automatic Fire Detection
Data Sheet 6-9, Industrial Ovens and Dryers
Data Sheet 7-32, Ignitable Liquid Operations
Data Sheet 7-45, Safety Controls, Alarms, and Interlocks
Data Sheet 7-76, Prevention and Mitigation of Combustible Dust Explosions and Fires
Data Sheet 7-78, Industrial Exhaust Systems
Data Sheet 7-83, Drainage Systems for Ignitable Liquids
Data Sheet 7-98, Hydraulic Fluids
Data Sheet 7-99, Heat Transfer by Organic and Synthetic Fluids
Data Sheet 7-110, Industrial Control Systems
Data Sheet 9-0, Asset Integrity
Data Sheet 10-1, Pre-Incident Planning
Data Sheet 10-2, Emergency Response
Data Sheet 10-3, Hot Work Management
Data Sheet 10-8, Operators
Data Sheet 12-43, Pressure Relief Devices

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4.2 Others
American Society for Nondestructive Testing (ASNT). ASNT SNT-TC-1A, Personnel Qualification and
Certification in Nondestructive Testing.
American Society of Mechanical Engineers (ASME). Boiler and Pressure Vessel Code.
ASTM International (ASTM). ASTM A247, Standard Test Method for Evaluating the Microstructure of Graphite
in Iron Castings.
ASTM International (ASTM). ASTM E8, Test Methods for Tension Testing of Metallic Materials.
ASTM International (ASTM). ASTM E10, Standard Test Method for Brinell Hardness of Metallic Materials.
ASTM International (ASTM). ASTM E110, Standard Test Method for Indentation Hardness of Metallic
Materials by Portable Hardness Testers.
ASTM International (ASTM). ASTM E543, Standard Practice for Agencies Performing Nondestructive Testing.
International Organization for Standardization (ISO). EN 9712, Qualification and Certification of NDT
Personnel.
International Organization for Standardization (ISO). EN 14584, Examination of Metallic Pressure Equipment
- Planar Location of AE Sources.
National Board of Boiler and Pressure Vessel Inspectors (NBBI). National Board Inspection Code.
National Fire Protection Association (NFPA). NFPA 70, National Electrical Code.
Technical Association of the Pulp and Paper Industry (TAPPI). TAPPI TIP 0402-19, Guidelines for
Nondestructive examination of suction roll shells.
Technical Association of the Pulp and Paper Industry (TAPPI). TAPPI TIP 0402-34, Paper Machine Reel-Spool
Journals: Guidelines for Crack Testing and repair or replacement.
Technical Association of the Pulp and Paper Industry (TAPPI). TAPPI TIP 0425-01, Guidelines for Routine
Periodic Inspection and Testing of Cast Iron Yankee and MG Dryers.
Technical Association of the Pulp and Paper Industry (TAPPI). TAPPI TIP 0425-02, Inspection Guidelines
for Yankee Hood Systems.
Technical Association of the Pulp and Paper Industry (TAPPI). TAPPI TIP 0425-03, Design, Monitoring, and
Maintenance Guidelines for Yankee Dryer Bearings.

APPENDIX A GLOSSARY OF TERMS

Allowable Stress: some fraction of the ultimate tensile stress of a material. The fraction selected is generally
based on knowledge of the particular material and operating experience. In the case of cast iron typically
used for dryers, the fraction is 1/10, or the allowable stress is one-tenth of the material ultimate tensile stress.
Chaplet: metal support for holding casting cores in place within sand molds.
FM Approved: references to “FM Approved” in this data sheet means the product or service has satisfied
the criteria for Approval by FM Approvals. Refer to the Approval Guide, a publication of FM Approvals, for a
complete list of products and services that are FM Approved.
Ground Floor: Level below the machine operating floor also known as the ″basement.″
HTF: Heat transfer fluid. An organic or inorganic fluid, usually flammable, used to transfer heat to a process.
Journal: As used in this data sheet, that portion of a dryer head having a shape and increased cross-
sectional area to accept a press-fit shaft or create a transition from the head shape to an integral shaft
MAWP: maximum allowable working pressure. As used in this data sheet, is the maximum pressure to which
a dryer may be subjected during operation. It is code limited and determined by either the manufacturer or
by analysis.
Non-standard dryers: Dryers neither constructed to a manufacturer’s standard nor having stamping or other
documentation sufficient to ensure construction is standard.

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Paper machine dryer (dryer): assembly consisting of shell, heads, shafts, and head bolts. Dryers typically
have internal balance weights, siphons, and may have spoiler bars.
Process drains: Trenches around or under the machine intended to capture and control process water from
de-watering or use of hose for machine clean-up. Drains may be referred to as ″sewers.″
Responsible Person: the individual selected and trained to fill the duties of a “Responsible Person” should
be technically qualified, have some degree of expertise with Yankee drying equipment and systems, and,
using the five stages of mastery (beginner, apprentice, journeyman, artisan, and expert) have attained, at a
minimum, the level of journeyman. It is highly recommended that the company establish or sanction a training
certification program for the Responsible Person at each papermaking facility.
Shoe press, open: A stationary nip roll consisting of a beam-supported, hydraulically loaded concave plate
(shoe) not enclosed by a rotating belt that passes over shoe with the assistance of lubrication. These shoe
presses are typically installed as the bottom roll in the nip and may be opposed by a controlled-crown roll
or solid roll. The open shoe press was the original design also known as the extended nip press (ENP).
Shoe press, closed: A stationary nip roll consisting of a beam-supported, hydraulically loaded concave plate
(shoe) enclosed by a rotating sleeve that passes over shoe with the assistance of lubrication. These shoe
presses may be installed as the top or bottom roll in the nip and may be opposed by a controlled-crown roll
or solid roll.
Standard dryer: “Standard,” as used in this context, is a manufacturer’s standard. That is, a dryer appearing
to be consistent in construction to “code” constructed dryers from the same manufacturer. A “recognized
code or standard” is one that is acceptable to FM Global. Nearly all pressure vessel construction codes are
acceptable to FM Global for the purpose of evaluating dryer rolls. Stamping on a head may not be sufficient
assurance that the entire dryer is standard construction since heads are replaced and stamping may only
be indicative of the replacement head. Manufacturer’s data reports, certificates, or similar documentation that
can be traced to individual dryers, in addition to stamping on dryers, is good indication the dryer is actually
of standard construction.

APPENDIX B DOCUMENT REVISION HISTORY

The purpose of this appendix is to capture the changes that were made to this document each time it was
published. Please note that section numbers refer specifically to those in the version published on the date
shown (i.e., the section numbers are not always the same from version to version).
January 2022. Interim revision. Minor editorial changes were made.
April 2021. Interim revision. Significant changes include the following:
A. Reorganized the document to be consistent with current data sheet requirements.
B. Revised guidance on machine oil hazards.
C. Revised guidance on machine HTF hazards.
D. Revised automatic fire protection guidance for machine areas.
E. Clarified guidance on automatic fire protection coverage within dryer hood plenums and exhaust ducts.
F. Added guidance on roof inspections for corrosion.
G. Revised guidance on maintenance of cast iron and steel dryer rolls.
H. Added guidance on maintenance of other key machine rolls.
I. Revised equipment contingency plan (ECP) guidance.
J. Updated loss history.
K. Added a roll maintenance job aid.
October 2019. Interim revision. Fire protection guidance for shoe presses was added to this data sheet
(Sections 2.7, 3.17, Appendix A, Glossary of Terms).
April 2010. Clarification was made on differentiating the recommended inspection practices for Yankee dryers
of welded steel construction from those of bolted cast iron construction.

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January 2009. Recommendation 2.1.6.13, ″d″ was revised to reduce the scope of recommended inspection.
September 2007. Minor editorial changes were made for this revision.
September 2006. Minor editorial changes were made for this revision.
January 2006. Corrected data sheet number in Section 1.1 (DS 12-30 was incorrectly given as DS 12-24).
June 2005. This data sheet consolidates material formerly contained in Data Sheets 7-4, Paper Machines
and Pulp Dryers; 7-102/12-29, Yankee Dryers; 12-25, Cast Iron Paper Machine Dryers; 12-30, Weld
Fabricated Paper Machine Dryers; and 12-60, Suction Press Rolls.
2.1.4.4 New recommendation to perform an oil fire hazard assessment for lubrication, hydraulic, and heat
transfer fluid (HTF) oil systems.
2.1.6 Recommended inspection for Yankee or MG cylinder not in creping service is now the same as
recommended inspection for can-type dryers.
2.1.6.2 New recommendation to follow machine manufacturer’s recommendations for startup and shutdown
of paper machine.
2.1.6.6 Testing of paper machine steam relief valves (all types of machines) now set at 12-month intervals.
2.1.7.1 New recommendation to improve operator awareness and response to oil fires.
2.3.6.1 Revised recommendation limiting examination of Yankee head joint for corrosion to dryers in creping
service with through-bolt head construction.
2.3.6.3 Revised recommendation limiting examination of head or shell of creping dryer for cracking based
on type of head bolt (cap screw or through-bolt).
2.5.1.1 Revised steam suppression protection for airborne pulp dryers.
May 2005. This data sheet consolidates material formerly contained in Data Sheets 7-4, Paper Machines
and Pulp Dryers; 7-102/12-29, Yankee Dryers; 12-24, Weld Fabricated Paper Machine Dryers; 12-25, Cast
Iron Paper Machine Dryers; and 12-60, Suction Press Rolls.

APPENDIX C RELEVANT FM GLOBAL DATA SHEET REFERENCES

This data sheet contains unique loss prevention guidance tailored specifically for paper, board, pulp, and
tissue production along with their utility and support systems. For brevity, general loss prevention guidance
contained within these other FM Global data sheets was not duplicated within this data sheet, but may be
applicable at a mill. For example, Data Sheet 5-4, Transformers, contains fire protection as well as inspection,
testing, and maintenance guidance that is applicable to power transformers, however this guidance is not
customized for application at a mill. Below is a list of other FM Global data sheets that may be applicable at
mills. This list is not intended to be all-inclusive.
A. Site Selection (Buildings and Utility Services)
• Data Sheet 1-2, Earthquakes
• Data Sheet 1-27, Windstorm
• Data Sheet 1-34, Hail Damage
• Data Sheet 1-40, Flood
B. Building Construction
• Data Sheet 1-11, Fire Following Earthquake
• Data Sheet 1-28, Wind Design
• Data Sheet 1-29, Roof Deck Securement and Above-Deck Roof Components
• Data Sheet 1-54, Roof Loads for New Construction
• Data Sheet 1-57, Plastics in Construction
C. Fire Protection
• Data Sheet 2-0, Installation Guidelines for Automatic Sprinklers
• Data Sheet 2-8, Earthquake Protection for Water-based Fire Protection Systems
• Data Sheet 3-10, Installation/Maintenance of Private Service Mains and Their Appurtenances
• Data Sheet 3-26, Fire Protection for Nonstorage Occupancies

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• Data Sheet 4-1N, Fixed Water Spray System for Fire Protection
• Data Sheet 4-9, Halocarbon and Inert Gas (Clean Agent) Fire Extinguishing Systems
• Data Sheet 4-12, Foam-Water Sprinkler Systems
• Data Sheet 5-48, Automatic Fire Detection
D. Systems and Equipment
• Data Sheet 5-4, Transformers
• Data Sheet 5-11, Lightning and Surge Protection for Electrical Systems
• Data Sheet 5-17, Motors and Adjustable Speed Drives
• Data Sheet 5-19, Switchgear and Circuit Breakers
• Data Sheet 5-20, Electrical Testing
• Data Sheet 5-23, Emergency and Standby Power Systems
• Data Sheet 5-31, Cables and Bus Bars
• Data Sheet 6-9, Industrial Dryers and Ovens
• Data Sheet 7-29, Ignitable Liquid in Portable Storage Containers
• Data Sheet 7-32, Ignitable Liquid Operations
• Data Sheet 7-73, Dust Collectors and Collection Systems
• Data Sheet 7-78, Industrial Exhaust Systems
• Data Sheet 7-83, Drainage Systems for Ignitable Liquids
• Data Sheet 7-98, Hydraulic Fluids
• Data Sheet 7-99, Heat Transfer by Organic and Synthetic Fluids
• Data Sheet 7-110, Industrial Control Systems
• Data Sheet 12-2, Vessels and Piping
• Data Sheet 12-43, Pressure Relief Devices
• Data Sheet 13-3, Steam Turbines
• Data Sheet 13-6, Flywheels and Pulleys
• Data Sheet 13-7, Gears
• Data Sheet 13-24, Fans and Blowers
E. Human Element
• Data Sheet 2-81, Fire Protection System Inspection, Test, and Maintenance and Other Fire Loss Prevention
Inspections
• Data Sheet 9-0, Asset Integrity
• Data Sheet 10-1, Pre-Incident Planning
• Data Sheet 10-2, Emergency Response
• Data Sheet 10-3, Hot Work Management
• Data Sheet 10-4, Contractor Management
• Data Sheet 10-7, Fire Protection Impairment Management
• Data Sheet 10-8, Operators

APPENDIX D BOILER AND MACHINERY MACHINE ROLL MAINTENANCE JOB AID

Table 6 contains an overview of roll maintenance activities recommended for specific machine rolls per this
data sheet. The table also includes examples of maintenance activities that should be considered within
the asset integrity program for other machine rolls.

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Paper Machines and Pulp Dryers 7-4
FM Global Property Loss Prevention Data Sheets Page 35

Table 6. Machine Roll Maintenance Guide

Roll Part Scope Frequency
Couch and Pick-up Heads Magnetic particle (MT) or liquid Each roll maintenance
penetrant (PT)
Shell, External Visual (VT). 36 months of operationor at each
roll maintenance
Suction box Visual inspection (VT) of the box. Each roll maintenance
Ultrasonic (UT) and magnetic Each roll maintenance
particle (MT) of the suction box
small shaft (spigot).
Suction Press Heads Magnetic particle (MT) or liquid Each roll maintenance
penetrant (PT) in high stress and
transition area.
Shell, Internal Visual (VT). 24 months of operation or at each
roll maintenance
Shell, External Liquid penetrant (PT). Every roll cover replacement
Roll Cover Visual (VT). Every scheduled machine
maintenance
Suction box Visual inspection (VT) of the box. Each roll maintenance
Ultrasonic (UT) and magnetic Each roll maintenance
particle (MT) of the suction box
small shaft (spigot).
Grooved Press Heads/Journals Magnetic particle (MT) or liquid Each roll maintenance
penetrant (PT) in high stress and
transition area including bearing
journal (axial UT as an option).
Roll Cover Visual (VT) of roll covers. Every scheduled machine
maintenance
Granite Press Heads/Journals Magnetic particle (MT) or liquid Each roll maintenance
penetrant (PT) in high stress and
transition area including bearing
journal.
Central shaft Ultrasonic (UT). 12 months of operation
Tension rod Ultrasonic (UT) of all rods. 18 months of operation
Ceramic Press Heads/Journals Magnetic particle (MT) or liquid Each roll maintenance
penetrant (PT) in high stress and
transition area including bearing
journal (axial UT as an option).
Roll Coating Visual (VT). Each roll maintenance
Felt, Wire, Guide Journals Ultrasonic (UT). Depending on material
Heads Magnetic particle (MT) or liquid Each roll maintenance or by vast
penetrant (PT) in high stress and campaign if never done
transition area including bearing
journal.
Roll Remove all felt rolls in operation
that have been balanced with
welded balancing weight in the
center

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Table 6. Machine Roll Maintenance Guide (continued)

Roll Part Scope Frequency
Cast Iron and Steel Heads, External Visual (VT) in operation. Daily
Dryer Visual (VT). 12 months
Magnetic particle (MT) or liquid 60 months
penetrant (PT) in high stress area.
Alternatively, AET.
Heads, Internal Visual (VT). 60 months
Magnetic particle (MT), as needed. 60 months
Alternatively, AET.
Head-Shell Joint, Ultrasonic (UT) to examine head 60 months(incrementally at 20%
Bolted screws or bolts. (AET is annually)
acceptable.)
Head-Shell Joint, NDE of circumferential weld per OEM. Alternatively, AET.
Welded
Shell, External Visual (VT). 12 months
Shell, External Non- Ultrasound (UT) to profile the shell 60 months
Metalized thickness. Alternatively, perform
internal VT and AET.
Shell, External Magnetic lift off (MLO). 60 months
Metalized
Shell, Internal Visual (VT). 60 months
Cast Iron Yankee Heads, External Visual (VT) in operation. Daily
Dryer Visual (VT). 12 months
Magnetic particle (MT) or liquid 72 months(Up to 144 months)
penetrant (PT) of high stress areas
defined in Fig. 6. Alternatively, AET.
Heads, Internal Visual (VT). 24 months
Magnetic particle (MT) or liquid 72 months(Up to 144 months)
penetrant (PT) of high stress areas
defined in Fig. 6. Alternatively, AET.
Journal/Center Visual (VT). 12 months
Stay, External Magnetic particle (MT) or liquid 72 months(Up to 144 months)
penetrant (PT) of high stress areas
defined in Fig. 6. Alternatively, AET.
Ultrasonic (UT) to 72 months(Up to 144 months)
examine bolts.
Alternatively, AET.
Journal/Center Visual (VT). 24 months
Stay, Internal Magnetic particle (MT) or liquid 72 months(Up to 144 months)
penetrant (PT) of high stress areas
defined in Fig. 6. Alternatively, AET.
Head-Shell Joint, Visually (VT) the head to shell joint. 12 months
Bolted Perform head tilt. 12 months(Up to 72 months)
Shell Runout. 12 months
Ultrasonic (UT) to examine head 72 months(Up to 144 months)
screws or bolts. Alternatively, AET.
Shell, Internal Visual (VT). 24 months
Magnetic particle (MT) or liquid 72 months(Up to 144 months)
penetrant (PT) of high stress areas
defined in Fig. 6. Alternatively, AET.
Shell, Metalized Magnetic lift off (MLO). 72 months(Up to 144 months)

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Table 6. Machine Roll Maintenance Guide (continued)

Roll Part Scope Frequency
Steel Yankee Dryer Heads, External Visual (VT) in operation. Daily
Visual (VT). 12 months
Magnetic particle (MT) or liquid 72 months(Up to 144 months)
penetrant (PT) of high stress areas
defined in Fig. 6. Alternatively, AET.
Heads, Internal Visual (VT). 24 months
Magnetic particle (MT) or liquid 72 months(Up to 144 months)
penetrant (PT) of high stress areas
defined in Fig. 6. Alternatively, AET.
Journal/Center Visual (VT).12 months
Stay, External Magnetic particle (MT) or liquid 72 months(Up to 144 months)
penetrant (PT) of high stress areas
defined in Fig. 6. Alternatively, AET.
Ultrasonic (UT) to examine bolts. 72 months(Up to 144 months)
AET is acceptable.
Journal/Center Visual (VT). 24 months
Stay, Internal Magnetic particle (MT) or liquid 72 months(Up to 144 months)
penetrant (PT) of high stress areas
defined in Fig. 6. Alternatively, AET.
NDE on structural and pressure welds per OEM. Alternatively, AET.
Head-Shell Joint, Visually (VT) the head to shell joint. 12 months
Bolted Perform head tilt. 12 months(Up to 60 months)
Shell Runout. 12 months(Up to 60 months)
Ultrasonic (UT) to examine head 72 months(Up to 144 months)
screws or bolts. Alternatively, AET.
Head-Shell Joint, External visually (VT) the head to 12 months
Welded shell joint.
Internal visually (VT) the head to 24 months
shell joint.
NDE of circumferential weld per OEM.
Shell NDE on longitudinal weld per OEM.
Shell, External Magnetic lift off (MLO). 72 months(Up to 144 months)
Metalized
Shell, Internal Visual (VT). 24 months
Magnetic particle (MT) or liquid 72 months(Up to 144 months)
penetrant (PT) of high stress areas
defined in Fig. 6. Alternatively, AET.
Cast Iron MG Refer to Cast Iron Dryers.
Cylinder
Steel MG Cylinder Refer to Steel Dryers.
Through-Air Dryer Refer to OEM inspection and testing guidelines.
Vacuum Heads, External Visual (VT). 12 months
Dryer(Steam- Head-Shell Joint, Ultrasonic (UT) to examine head 60 months(up to 120 months)
Isolated Dryer) Bolted screws or bolts.
Calender Roll Visual (VT). 12 months
Heads Magnetic particle (MT) or liquid 3 to 5 years
penetrant (PT) in high stress and
transition area.
Spool-Reel and Roll Visual (VT). 12 months
Winder Drum Heads/ Journals Magnetic particle (MT) or liquid 3 years(Up to 10 years)
penetrant (PT) in high stress and
transition area.

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