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1/<strong>2017</strong> www.maintworld.com<br />
maintenance & asset management<br />
Ethernet for<br />
the Process<br />
Industry PAGE<br />
12<br />
MIXED REALITY OF IIOT PAGE 20 POWER PLANT MAINTENANCE PAGE 32 ASSET MANAGEMENT BUILDS SUCCESS PAGE 44
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A New Dimension<br />
in HMI/SCADA<br />
Introducing the world’s first 3D Holographic<br />
Machine Interface. ICONICS has redefined “HMI”<br />
in this era of the Industrial Internet of Things by<br />
integrating its automation software with Microsoft’s<br />
HoloLens. This groundbreaking technology allows<br />
users to superimpose real-time information over a<br />
real world production environment or facility, reducing<br />
downtime and increasing operational efficiency.<br />
Experience it for yourself at Hannover Messe!<br />
Visit ICONICS in Hall 7, Stand C40<br />
Celebrating 30 Years of Automation Software<br />
www.iconics.com<br />
VISUALIZE ANALYZE MOBILIZE CLOUD
EDITORIAL<br />
Text: Kai Portman<br />
The Changing Face<br />
of Maintenance<br />
VISITING 20 plus Industry and Maintenance events each year in all<br />
continents has given me a chance to see first-hand the changing face of<br />
Maintenance.<br />
Years ago maintenance was conceived as a blue collar toolbox kind<br />
of a job. Nowadays, it is understood that maintenance is a fundamental<br />
part of the working and planning of industry itself. The beauty and at<br />
the same time complexity of it is that it is probably the only area of expertise<br />
that runs through all areas of industry.<br />
Maintenance professionals and engineers are<br />
more and more involved in high-level decision<br />
making procedures in organisations, and it is<br />
universally recognized that calculating failure<br />
mode in order to prevent it, is of utmost importance<br />
within the mechanics of industry itself.<br />
In regards to condition monitoring, the technology<br />
behind it has made quantum leaps in the<br />
past years. From smart bearings to 3D-mapping,<br />
from complex IT programs to smart communication.<br />
Having said this, the work concept in the field has become more<br />
of analysing rather finding fault as the latter has already been brought<br />
to light thanks to technology.<br />
At trade shows around the world, I have found that the message is<br />
the same and it almost seems that people are focusing on a common<br />
goal: advancement in digital technology. At the events of the EFNMS,<br />
SMRP and GSMP the topics of the conferences in these past years<br />
have been orientating also in this same direction, and the associations<br />
themselves as regulatory bodies within the sphere of maintenance<br />
have shown support for this.<br />
What I have personally noticed during my expo-travels, especially<br />
in Europe, is a hype for industry 4.0, IoT and Cloud communication.<br />
I must say that I feel very lucky to be living in such an exciting era<br />
for industry and to have the opportunity to experience it first-hand<br />
with my travels. Thus, I hope our publication will help reflect this period<br />
in time and share it with all you readers.<br />
At trade shows around the world, I have found<br />
that the message is the same and it almost<br />
seems that people are focusing on a common<br />
goal: advancement in digital technology.<br />
Kai Portman<br />
<strong>Maintworld</strong>-magazine<br />
34<br />
Packaging<br />
and bottling<br />
equipment manufacturers<br />
will often design equipment<br />
with shock absorption<br />
to the specifications that<br />
meet safety and industry<br />
requirements.<br />
6 maintworld 1/<strong>2017</strong>
IN THIS ISSUE 1/<strong>2017</strong><br />
12<br />
It can be more difficult for<br />
plants in process industries to<br />
adopt and benefit from many<br />
advances, such as industrial<br />
Ethernet and IP technologies.<br />
52<br />
The goal of vibration<br />
diagnostics is to receive<br />
the information about<br />
the current machine<br />
condition and decide if<br />
the condition is good,<br />
or if some repairs or<br />
adjustments need to be<br />
made.<br />
6 Editorial<br />
8<br />
12<br />
16<br />
20<br />
24<br />
How to Thrive in the Oil and Gas<br />
Industry<br />
Ethernet for the Process<br />
Industry<br />
Leveraging OPC UA to Help Meet<br />
Site Security Requirements<br />
Mixed Reality of IIoT<br />
Using Nodeset Files to Exchange<br />
Information: A Case in MDIS<br />
26<br />
30<br />
32<br />
34<br />
38<br />
Industrial Communication in the<br />
Context of Industry 4.0 and IoT<br />
Cardan Shaft Measurement –<br />
Working in Confined Spaces<br />
Leveraging Planned Outages at<br />
Power Plants<br />
Small Cost, Big Savings<br />
in Packaging and Bottling<br />
Industries<br />
The parallel paths of<br />
maintenance and lubrication<br />
42<br />
44<br />
48<br />
52<br />
Reliability and Maintenance<br />
Management Beliefs –Part 3<br />
Extracting Maximum Economic<br />
Value from Ageing Assets<br />
Building the Foundation<br />
for a Successful Ultrasound<br />
Programme<br />
When Vibration Fails to Work<br />
Issued by Promaint (Finnish Maintenance Society), Messuaukio 1, 00520 Helsinki, Finland tel. +358 29 007 4570 Publisher<br />
Omnipress Oy, Mäkelänkatu 56, 00510 Helsinki, tel. +358 20 6100, toimitus@omnipress.fi, www.omnipress.fi Editor-in-chief<br />
Nina Garlo-Melkas tel. +358 50 36 46 491, nina.garlo@omnipress.fi, Advertisements Kai Portman, Sales Director, tel. +358 358<br />
44 763 2573, ads@maintworld.com Subscriptions and Change of Address members toimisto@kunnossapito.fi, non-members<br />
tilaajapalvelu@media.fi Printed by Painotalo Plus Digital Oy, www.ppd.fi Frequency 4 issues per year, ISSN L 1798-7024, ISSN<br />
1798-7024 (print), ISSN 1799-8670 (online).<br />
1/<strong>2017</strong> maintworld 7
ASSET MANAGEMENT<br />
How to Thrive in the Oil<br />
and Gas Industry<br />
Don’t just wait for an increase in oil prices to achieve profitability. Oil and gas leaders<br />
need to act on technology innovations to make a difference in <strong>2017</strong> and beyond.<br />
RICHARD IRWIN,<br />
Bentley Systems, Inc.,<br />
Richard.irwin@<br />
bentley.com<br />
8 maintworld 1/<strong>2017</strong><br />
IN TODAY’S market climate companies<br />
operating in the oil and gas industry<br />
should take advantage of the proliferation<br />
of sensors, big data and analytical techniques,<br />
coupled with the advancements<br />
in asset performance modelling, reality<br />
modelling, and 3D visual operations.<br />
The oil and gas industry has always<br />
strived to reduce costs, improve performance,<br />
and eliminate risk. The last<br />
few years however, have seen the community<br />
hit by a series of blows with serious<br />
consequences. With declining oil<br />
production, plummeting oil prices and a<br />
dramatic cutback in spending, things appeared<br />
bleak. Yet there are still technologies,<br />
processes, and applications available<br />
that allow producers to innovate and<br />
become agile and forward-looking, even<br />
in tough times. Instead of waiting for oil<br />
prices to recover in order to start spending,<br />
some oil and gas CIOs and COOs<br />
are working together to take advantage<br />
of digital advancements to help them<br />
achieve operational excellence.<br />
Integrated Planning and<br />
Operations<br />
Ideally in any business, efficiency and<br />
performance can only be improved if<br />
everyone works together, but this is<br />
sometimes harder in practice than it<br />
first seems. In the oil and gas industry,<br />
it would be ideal if exploration were in<br />
touch with what is happening in production;<br />
if production were working with<br />
operations; if operations were synchronizing<br />
with the inspection team and so<br />
on. In other words, a seamless connected<br />
environment used to manage different<br />
business functions and pinpoint inefficiencies.<br />
For instance, Emerson Process Management,<br />
a supplier of products, services,<br />
and solutions that improve processrelated<br />
operations across many industries,<br />
created a data control centre that<br />
brought together groups from disparate<br />
departments across multiple locations
ASSET MANAGEMENT<br />
Despite the downturn, there<br />
are many opportunities for<br />
growth<br />
to one central hub using state-of-the-art<br />
technologies around communications,<br />
conferencing, analytics, and more. The<br />
integrated operations centre is called<br />
iOps and leverages Bentley’s AssetWise<br />
Operational Analytics application. The<br />
iOps centre helps clients simulate business<br />
conditions and make decisions in<br />
a matter of minutes rather than days or<br />
weeks. The predictive operational analytics<br />
software on the connected servers<br />
provides the centre’s clients with an<br />
array of readily-mapped inputs within<br />
user-driven dashboards for full visibility.<br />
Operational Performance<br />
Monitoring Creates Clarity<br />
With the Internet of Things (IoT) adding<br />
more to a world already overloaded<br />
WITH SO MUCH DATA<br />
FLYING AROUND,<br />
THE PROBLEM IS HOW TO<br />
CAPTURE IT AND USE IT TO<br />
YOUR ADVANTAGE.<br />
Converge<br />
operational,<br />
information,<br />
and engineering<br />
technologies for a<br />
greater understanding of<br />
asset performance.<br />
with data, from wearable technology to<br />
self-driving cars, asset-intensive industries<br />
are quickly jumping on board and<br />
embracing this revolution. With so much<br />
data flying around, the problem is how to<br />
capture it and use it to your advantage.<br />
Applications that help optimize the use<br />
of assets give user groups the ability<br />
to see a holistic view of the day-to-day<br />
running of the operation, from production<br />
performance against targets, KPIs,<br />
chemical usage and spend, corrosion<br />
levels, maintenance plans, inventory and<br />
more. It also gives the operational or integrity<br />
management leader the information<br />
and support they need to make the<br />
right decision.<br />
More importantly, engineers won’t<br />
need specialized data analysts to carry<br />
out analyses. Saving time on data manipulation<br />
is based on any user, from a<br />
wellhead engineer to a CFO, creating<br />
dashboards tailored to what they want<br />
to see for their role, while the embedded<br />
analytics does the job for them in the<br />
background.<br />
Reduce Costs and Operational<br />
Risk with Improved Asset<br />
Reliability and Integrity<br />
Although spending has been drastically<br />
reduced, cost reduction and risk are still<br />
at the top of any CIO’s list. Now the focus<br />
is on the remaining assets and optimizing<br />
them to gain the best performance,<br />
reduce failures, and maintain availability.<br />
Key to this is reliability and maintenance<br />
to extend the life of aging assets<br />
safely and reliably. Having a programme<br />
in place for inspections, maintenance,<br />
integrity, and performance will significantly<br />
reduce risk and associated operating<br />
costs, while increasing the life of assets<br />
that would normally be replaced.<br />
Asset reliability and integrity management<br />
cover a wide variety of areas,<br />
from risk-based inspections analysis<br />
and safety integrity management to<br />
condition-based monitoring with dynamic<br />
measurement points, asset health<br />
indexing, and, in the same system,<br />
reliability-centred maintenance, maintenance<br />
task analysis, and root cause<br />
analysis. With these strategies in place, it<br />
is easier to identify and predict the failure<br />
of assets that pose the greatest risk<br />
to the operation. Identification leads to<br />
controlled and proactive inspection and<br />
maintenance practices that are crucial<br />
in running an efficient and productive<br />
operation.<br />
Deliver More Insight with<br />
Advanced Analytics<br />
Advanced analytics provides more depth<br />
to the levels of insight by doing more<br />
complex analysis from wider sources of<br />
data, as well as visualization and data<br />
mining. With the power to predict, it<br />
adds an extra level to not only what happened<br />
and why, but when will it happen<br />
again. For instance, predictions can help<br />
with calculating production against<br />
chemical costs, the corrosion levels of a<br />
pipe in terms of when it will need replacing<br />
and the subsequent maintenance<br />
required. The next logical step from this<br />
form of logic is prescriptive analytics –<br />
not only predicting an outcome, but also<br />
what is the best action to take next with<br />
1/<strong>2017</strong> maintworld 9
ASSET MANAGEMENT<br />
sight into the performance and efficiency<br />
of any operation. What is often forgotten<br />
is the information on the assets themselves.<br />
Asset lifecycle information management<br />
provides structured control of<br />
asset information and managed change<br />
from cradle to grave, ensuring engineers,<br />
maintenance and operations always have<br />
accurate information.<br />
Knowing what and where assets are<br />
located exactly, what condition they are<br />
in, how they are performing and what is<br />
their remaining life is critical to knowing<br />
you have control over your operation<br />
with line of sight. Maintaining a<br />
seamless information stream between<br />
asset data, documents, organizations,<br />
requirements, people, and processes;<br />
asset lifecycle information management<br />
assures information integrity. For example,<br />
BP sees asset information becoming<br />
increasingly important and valuable<br />
within the business. By using cuttingedge<br />
technology solutions BP expects to<br />
provide new understanding of how to derive<br />
value from data. This will help drive<br />
standardisation and project execution<br />
efficiency that will be driven out across<br />
the enterprise rather than each project<br />
working on their own.<br />
Incorporate asset design data with designs to help risk based inspections.<br />
Display all of your operational data and more on a single dashboard and explore deeper.<br />
the most advantageous outcome. With<br />
machine learning, this becomes a reality.<br />
Machine learning involves doing the<br />
tasks engineers perform but with the<br />
ability to make the right decision from<br />
a variety of options. By using historical<br />
condition data from assets (corrosion,<br />
vibration, and so on) as well as current<br />
conditions (for example, temperature,<br />
pressure, turbidity), machine learning<br />
can sort through large data sets and<br />
identify patterns or connections, predict<br />
outcomes based on knowledge, and<br />
make predictions and recommendations<br />
to decision makers on the best course of<br />
action to take.<br />
Asset Lifecycle Information<br />
Management Leads to Agility<br />
and Value<br />
With so many assets producing so much<br />
data around the world, this information<br />
can be used to provide much more in-<br />
The Digital Transformation<br />
Has Already Started<br />
Advances in analytics, generated data,<br />
and hardware can lead to significant<br />
advantages across all areas of the oil and<br />
gas spectrum when it comes to leading<br />
the digital innovation charge, culminating<br />
in the ‘digital oilfield.’ Key to this is<br />
the convergence of operational technology<br />
(OT) and information technology<br />
(IT) for improved decision-making.<br />
While this is a step forward, converging<br />
engineering technology (ET) will provide<br />
more significant improvements to asset<br />
performance. With asset-related information<br />
linked to the digital engineering<br />
model, it facilitates efficient modifications<br />
and renovations. Before and during<br />
design, functional definitions and requirements<br />
define expected asset behaviour.<br />
With model data being used more<br />
often in the oil and gas industry, often<br />
in separate locations, it makes sense to<br />
incorporate them into the whole system<br />
for improved visibility.<br />
Engineering data (models that are in<br />
the form of networks, schematics, catalogues,<br />
3D designs, and so on) are not<br />
a static view, but can be a continuously<br />
evolving living thing, as assets change<br />
over time in terms of functions and repairs.<br />
Engineering modelling data is the<br />
‘digital twin’ of the physical asset. These<br />
digital representations of the physical<br />
asset allow producers to understand,<br />
predict and optimize the performance of<br />
their assets and their business. With real-time<br />
information from the OT laid on<br />
top of the models, they can then navigate<br />
and display all information relating to<br />
that asset or process, only recommending<br />
an engineer for inspections purposes<br />
if necessary, and all done remotely. The<br />
true value of convergence lies in reduced<br />
asset downtime and maintenance costs,<br />
which will only become more accelerated<br />
with the inclusion of machinelearning<br />
technology.<br />
You don’t have to wait for an upturn in<br />
demand and oil prices. Change can only<br />
take place if you embrace the technology<br />
that is already out there and available.<br />
10 maintworld 1/<strong>2017</strong>
Successful reliability<br />
programs have one thing<br />
in common…<br />
a strong condition monitoring team.<br />
As a condition monitoring<br />
professional or manager, you may be<br />
faced with starting a condition monitoring<br />
program or<br />
iLearnReliability<br />
tasked to get a program back on<br />
<br />
track. There is a lot to know; multiple technologies,<br />
monitoring practices, analysis, fault-reporting<br />
and trending, not to mention proper corrective and<br />
routine maintenance to reduce the likelihood of faults from<br />
reoccurring. Where can you start? Where can you learn what you<br />
need, that is economical in respect to time and expense? And where<br />
can you get training that is practical, going further than just filling you<br />
with facts and figures?<br />
iLearnReliability <br />
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iLearnReliability [Condition Monitoring] is an<br />
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that teaches your team everything needed to become champions at condition<br />
monitoring, and will provide the necessary guidance to setup or revitalize your plant’s<br />
condition monitoring program.<br />
LEARN MORE TODAY!<br />
www.mobiusinstitute.com/iLRcm<br />
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AUSTRALIA · BELGIUM · UNITED STATES of AMERICA
PROCESS AUTOMATION<br />
Ethernet<br />
for the Process<br />
Industry<br />
Today’s process industries share many challenges with hybrid and discrete industries,<br />
such as increasing global competition. While users are looking to latest automation<br />
technologies to help address challenges, it can be more difficult for plants<br />
in process industries to adopt and benefit from many advances, such as industrial<br />
Ethernet and IP technologies.<br />
KATHERINE VOSS,<br />
President & Executive<br />
Director, ODVA, Inc.<br />
Contact:<br />
Adrienne Meyer,<br />
ODVA, Inc.<br />
(ameyer@odva.org)<br />
WITH AN AGING installed base of process<br />
automation systems and the need for<br />
additional capacity to meet consumer demand<br />
in emerging economies, the previous<br />
norms are about to change. It is projected<br />
that the process industries will invest<br />
over 100 billion US dollars globally in<br />
new control systems for process automation,<br />
split equally between modernization<br />
and new installations. As a result, many<br />
users in process industries will be looking<br />
to develop new strategies for maintaining<br />
cost-effective, sustainable production<br />
capacity. To achieve all of the business<br />
results needed, these strategies must take<br />
into account the efficient integration of<br />
the plant’s network infrastructure into<br />
the existing business applications.<br />
TODAY’S PROCESS<br />
INDUSTRIES SHARE MANY<br />
CHALLENGES WITH HYBRID<br />
AND DISCRETE INDUSTRIES.<br />
12 maintworld 1/<strong>2017</strong>
PROCESS AUTOMATION<br />
Moreover, these strategies call for<br />
a network architecture that provides<br />
the best integration, not only within<br />
the process plant but also with external<br />
systems. Unfortunately, the diverse and<br />
often complex nature of field devices<br />
in process plants has made integration<br />
complicated because users have needed<br />
to deploy a range of specialty process<br />
fieldbuses in the network architecture.<br />
This fact, combined with the often extreme<br />
nature of applications in process<br />
industries – extreme plant size, hazardous<br />
areas, climate, environmental<br />
hazards, or remoteness – have made<br />
it difficult for users to realize all the<br />
benefits possible from process integration.<br />
However, standard Ethernet and<br />
IP technologies – already proven in<br />
hybrid and discrete industries – stand<br />
to change this situation for the process<br />
industries.<br />
Convergent, Compatible and<br />
Scalable OPI<br />
ODVA envisions an approach to the optimization<br />
of process integration (OPI)<br />
that will be convergent, compatible,<br />
scalable and open for users and their<br />
suppliers. The approach will simplify exchange<br />
of configuration, diagnostic and<br />
production data between field devices<br />
and higher-level systems such as supervisory<br />
control and data acquisition systems<br />
(SCADA). In addition, plant asset<br />
management (PAM) and secure remote<br />
access of field installations will be enabled<br />
and plant-to-enterprise communication<br />
simplified. This, together with<br />
the proven benefits and cost advantages<br />
of commercially available, off-the-shelf<br />
Ethernet and Internet technologies will<br />
help businesses improve productivity<br />
and competitiveness.<br />
ODVA has a broad overall approach<br />
to OPI based on the three principle<br />
domains of the industrial ecosystem –<br />
production, enterprise and power grid.<br />
The focal point of OPI is the production<br />
domain and the process plant. This approach<br />
is characterized by the need for<br />
the integration of field and functional<br />
safety devices with the control systems,<br />
along with the business value of providing<br />
process information from the field<br />
to enterprise systems. The foundation<br />
of OPI is an interoperability framework<br />
achieved through a unified communication<br />
system using standard Ethernet and<br />
Internet technologies. This framework<br />
also covers other requirements particularly<br />
relevant to applications in the process<br />
industries such as intrinsic safety<br />
and configuration of field devices with a<br />
large number of parameters.<br />
ODVA’s plan for OPI leverages its core<br />
competency in information and communication<br />
technologies. These are grounded<br />
in ODVA’s media-independent Common<br />
Industrial Protocol (CIP) and in<br />
EtherNet/IP, its network technology<br />
which is based on standard, unmodified<br />
Ethernet and Internet technologies. For<br />
OPI between field devices and industrial<br />
control systems or ICS, often referred to<br />
as DCS or PAC, ODVA seeks to include<br />
objects, services and device profiles in<br />
EtherNet/IP that are optimized for applications<br />
in the process industries and<br />
permit the transparent and seamless<br />
exchange of production, logistics, configuration<br />
and diagnostic information.<br />
In the long term, ODVA envisions physical<br />
layer implementations that allow for<br />
the integration of devices on Ethernet<br />
that are intrinsically safe and networkpowered.<br />
ETHERNET AND IP TECHNOLOGIES HELP BUSINESSES IMPROVE<br />
PRODUCTIVITY AND COMPETITIVENESS.<br />
The production domain in process<br />
plants – where the tight integration of<br />
field devices with industrial control<br />
systems is required – is the focal point<br />
of OPI. Although integration of field<br />
devices is essential, plant engineers have<br />
not been provided with standard ways<br />
to facilitate this integration. Originally,<br />
process plants relied on 4-20 mA analogue<br />
signals for transmitting process<br />
values to and from field devices. More<br />
recently, these analogue signals have<br />
been often replaced with digital communication<br />
technologies in the form of specialized<br />
process automation fieldbuses.<br />
However, these fieldbuses traditionally<br />
require specialist training, knowledge<br />
and tools to integrate with higher-level<br />
networks and, in many cases, have not<br />
1/<strong>2017</strong> maintworld 13
PROCESS AUTOMATION<br />
Industrial Enterprise Domain<br />
Financial and Cost<br />
Accounting<br />
Utilities and Material Cost,<br />
Demand and Delivery<br />
Business Planning<br />
and Analytics<br />
Utility<br />
Energy<br />
Cost<br />
Manufacturing Execution Systems<br />
Supervisory Control and<br />
Data Acquisition Systems<br />
Utility<br />
Energy<br />
Price<br />
Field Facility<br />
& Energy<br />
Infrastructure<br />
Systems<br />
Batch ProcessesProcess Plant Continuous Processes<br />
Industrial<br />
Control Systems<br />
Industrial<br />
Control Systems<br />
Plant<br />
Asset<br />
Management<br />
Systems<br />
Energy<br />
Production<br />
& Delivery<br />
Systems<br />
Field Devices<br />
Hazardous Production Area<br />
(IS classified Ex Zone)<br />
Safety Instrumented Systems<br />
Process Plant<br />
Power Grid Domain<br />
Industrial Production Domain<br />
been designed for the transmission of<br />
large amounts of data available from<br />
today’s instrumentation. Remote access<br />
is also complicated, requiring additional<br />
hardware in the form of gateways to allow<br />
remote access connections to the<br />
plant and its field devices, industrial control<br />
systems, and interrelated systems<br />
using IP-based technologies.<br />
An Evolved Approach to OPI<br />
ODVA, with its expertise in standard<br />
information and communication technologies<br />
for industrial automation, combined<br />
with its large community of device<br />
vendors, who make and sell EtherNet/<br />
IP-compliant products for industrial<br />
automation, can provide the process<br />
industries with an evolved approach to<br />
OPI that is:<br />
• Convergent in its long term approach<br />
to support the deployment<br />
of standard Ethernet and Internet<br />
technologies in the process industries<br />
across all domains of the industrial<br />
ecosystem;<br />
• Compatible by enabling users to<br />
integrate new devices and systems<br />
with their installed base while evolving<br />
their automation architecture<br />
to complement the architecture for<br />
supervisory and enterprise systems;<br />
• Scalable from simple field devices<br />
to complex systems of automation<br />
ODVA HAS A BROAD OVERALL APPROACH TO OPI BASED ON<br />
PRODUCTION, ENTERPRISE AND POWER GRID.<br />
equipment in the enterprise environment;<br />
and<br />
• Open by virtue of its use of multivendor,<br />
interoperable standards<br />
managed by an independent, vendor-neutral<br />
organization<br />
Despite wider acceptance and use of<br />
Ethernet and IP technologies in process<br />
automation, there are still gaps between<br />
the field, control and enterprise levels.<br />
Plus, different control systems favour<br />
different fieldbuses. OPI will ease this<br />
situation by providing users with a<br />
unified communication solution that<br />
includes the information and communication<br />
standards for the objects, services<br />
and profiles needed.<br />
Learn more about ODVA’s vision for<br />
the Optimization of Process Integration<br />
by downloading the full vision white<br />
paper and connecting with ODVA for<br />
updates on technical releases. To learn<br />
more about ODVA’s technical work on<br />
OPI, visit www.odva.org/OPI.<br />
About ODVA<br />
Founded in 1995, ODVA is a global association<br />
whose members comprise the<br />
world’s leading automation companies.<br />
ODVA’s mission is to advance open,<br />
interoperable information and communication<br />
technologies in industrial<br />
automation. ODVA recognizes its media<br />
independent network protocol, the<br />
Common Industrial Protocol or “CIP” –<br />
and the network adaptations of CIP –<br />
EtherNet/IP, DeviceNet, CompoNet<br />
and ControlNet – as its core technology<br />
and the primary common interest<br />
of its membership. ODVA’s vision is to<br />
contribute to the sustainability and<br />
prosperity of the global community by<br />
transforming the model for information<br />
and communication technology in the<br />
industrial ecosystem. For future interoperability<br />
of production systems and the<br />
integration of the production systems<br />
with other systems, ODVA embraces the<br />
adoption of commercial-off-the-shelf<br />
(COTS) and standard, unmodified Internet<br />
and Ethernet technologies as a guiding<br />
principle wherever possible. This<br />
principle is exemplified by EtherNet/IP<br />
– the world’s number one industrial Ethernet<br />
network. For more information<br />
about ODVA, visit odva.org.<br />
14 maintworld 1/<strong>2017</strong>
The Industrial Interoperability Standard<br />
Much more than a protocol …<br />
That is why it’s mandatory for Industrie 4.0<br />
OPC UA is a framework for Industrial Interoperability<br />
➞ Modeling of data and interfaces for devices and services<br />
➞ Integrated security by design with confi gurable access rights for data and services –<br />
validated by German BSI security experts<br />
➞ Extendable transport protocols: Client/Server and Publisher/Subscriber and roadmap for TSN<br />
➞ Scalable from sensor to IT Enterprise & Cloud<br />
➞ Independent from vendor, operating system, implementation language and vertical markets<br />
Join our OPC-booth at<br />
Hanover Fair: Hall 9, A 11<br />
Information models of different branches are mapped onto OPC UA to make them interoperable with<br />
integrated security. The OPC Foundation closely cooperates with organizations and associations from<br />
various branches:<br />
TM<br />
Verband für Automatische<br />
Datenerfassung, Identifikation und Mobilität<br />
OPC Unified Architecture<br />
Interoperability for Industrie 4.0 and the Internet of Things<br />
IoT<br />
4.0<br />
Industrie<br />
M2M<br />
1<br />
OPC DAY<br />
EUROPE <strong>2017</strong><br />
IT meets Automation<br />
May 30 th /31 hosted by<br />
Microsoft Center Copenhagen<br />
© fotolia.com, Sergii Figurnyi<br />
Download of<br />
Technology brochure:<br />
opcfoundation.org/<br />
resources/brochures/<br />
www.opcfoundation.org
INTERNET SECURITY<br />
Leveraging OPC UA<br />
to Help Meet Site<br />
Security Requirements<br />
Today’s industrial control systems leverage the latest OPC Unified Architecture (UA)<br />
standards, which provide cross-platform interoperability between software applications<br />
and devices. This allows for the vendor-independent exchange of real-time,<br />
alarm and condition, historical, and many other types of data.<br />
16 maintworld 1/<strong>2017</strong>
INTERNET SECURITY<br />
TONY PAINE,<br />
Kepware Tecnologies,<br />
tony.paine@kepware.com<br />
only the applications, devices, and users<br />
who are authorized to interact with the<br />
system are allowed to do so. In addition,<br />
this removes the possibility for non-authorized<br />
applications, devices, and users<br />
to impact the operation of the system or<br />
gain access to critical data.<br />
setup and managed. OPC UA’s client/<br />
server architecture also bodes well with<br />
a defense-in-depth strategy, as UA-aware<br />
applications can act as an intermediary<br />
between different layers within a site<br />
and limit the amount of information that<br />
can be exposed or manipulated.<br />
DUE TO THE CRITICALITY of Industrial<br />
Control Systems (ICS) and the desire<br />
to make process and business information<br />
available to anyone, anywhere,<br />
and at any time, the information that is<br />
exchanged between interested parties<br />
must meet the security requirements<br />
of the site. The OPC UA standards are<br />
designed to meet these security requirements<br />
while maintaining the level of<br />
flexibility and control that site administrators<br />
expect.<br />
Security Objectives<br />
Before we discuss how OPC UA can meet<br />
site security requirements, lets review<br />
the security objectives that apply to industrial<br />
control systems. These include:<br />
• Auditability: This provides traceability<br />
on all actions performed within<br />
a system, with the goal of logging<br />
which user performed what action<br />
and when—as well as any attempts<br />
that have been made to compromise<br />
the system.<br />
• Authentication: An ICS is comprised<br />
of hardware, software applications,<br />
and users. Each component<br />
must be able to prove its identity<br />
in order to be considered a trusted<br />
party.<br />
• Authorization: Even though a party<br />
may be trusted, components should<br />
be given the minimum access needed<br />
to perform their functions.<br />
• Availability: This ensures the ICS is<br />
fully operational by limiting factors<br />
that may impact its execution.<br />
• Confidentiality: The information<br />
exchanged between trusted parties<br />
must be hidden from those that are<br />
not trusted or have no reason to view<br />
the information. This requires that<br />
the sender and receiver of information<br />
must be able to encrypt and decrypt<br />
the data they exchange.<br />
• Integrity: The information exchanged<br />
between trusted parties<br />
must not be modifiable.<br />
By meeting each of these security objectives,<br />
a site will be able to ensure that<br />
Security Threats<br />
Though not comprehensive of all possible<br />
threats, some that have plagued ICS<br />
over the years are as follows:<br />
• Compromising User Credentials<br />
• Eavesdropping<br />
• Malformed Messages<br />
• Message Alteration/Spoofing<br />
• Message Flooding<br />
• Message Replay<br />
• Profiling<br />
• Session Hijacking<br />
By implementing a security strategy for<br />
a site, an administrator can thwart the<br />
above threats and achieve the security<br />
objectives needed to protect critical infrastructure.<br />
Site Security<br />
Most sites will incorporate a Cyber Security<br />
Management System (CSMS) to<br />
address security-related requirements.<br />
These requirements may range from<br />
the adoption of security policies around<br />
physical and electronic boundaries, auditing,<br />
and preventative and response<br />
procedures. In order to address the<br />
threats discussed earlier, a security risk<br />
assessment will be initiated and appropriate<br />
security measures will be implemented.<br />
A good implementation will<br />
follow a “defense–in-depth” strategy,<br />
where there will be multiple layers of<br />
protection. This may include a combination<br />
of firewalls, intrusion detection/<br />
prevention systems (IDS/IPS), patchmanagement<br />
systems, and IT rules for<br />
what is allowed and what is not allowed<br />
within the context of the system.<br />
OPC UA can adapt to a site’s CSMS<br />
by allowing the administrator complete<br />
control on how communications are<br />
OPC UA Security Architecture<br />
To mitigate against security threats, OPC<br />
UA has a multi-tier design that consists<br />
of an application layer, communications<br />
layer, and a transport layer.<br />
The majority of OPC functionality is<br />
handled within the context of the application<br />
layer i.e. where clients and servers<br />
process UA information—operations like<br />
reading, writing, and browsing items. It<br />
is also where UA provides management<br />
for authentication and user authorization<br />
through the concept of a session between<br />
a client and server instances.<br />
The secure channel that makes up<br />
the communications layer provides the<br />
functionality that allows for application<br />
authentication, confidentiality, and integrity.<br />
It does this by utilizing an appropriate<br />
level of encryption and decryption<br />
to maintain confidentiality of communication<br />
messages, by signing messages<br />
INTEROPERABILITY ALLOWS FOR THE EXCHANGE OF<br />
INFORMATION THAT IS CRITICAL TO ANY INDUSTRIAL<br />
CONTROL SYSTEM.<br />
to ensure the integrity of data, and by<br />
utilizing digital certificates that provide<br />
application authentication. The resulting<br />
secured data is then passed on to the<br />
transport layer for further processing.<br />
The transport layer handles the actual<br />
sending and receiving of the data<br />
over a communications infrastructure.<br />
The transport mechanism used (such as<br />
OPC UA Binary or XML Web Services<br />
via HTTP) impacts the implementation<br />
of the secured channel managed by the<br />
communications layer.<br />
How It Works<br />
Every OPC UA application has a unique<br />
digital (X.509) certificate assigned to it<br />
per installation that is referred to as an<br />
application instance certificate. This<br />
certificate is comprised of a public key<br />
1/<strong>2017</strong> maintworld 17
INTERNET SECURITY<br />
Common ICS Security Threats<br />
#<br />
? @<br />
!<br />
Compromising User Credentials<br />
When an attacker assumes a user's identity<br />
by obtaining their credentials.<br />
Eavesdropping<br />
When an attacker intercepts confidential<br />
information for personal gain or to leverage<br />
in future attacks.<br />
Malformed Messages<br />
When abnormal communications are sent<br />
with the intent to limit or interrupt the<br />
receiver's availability to authorized users.<br />
Message Alteration/Spoofing<br />
When an attacker manipulates or forges a<br />
message in an effort to perform<br />
unauthorized tasks under an authorized<br />
user’s identity.<br />
Message Flooding<br />
When an attacker sends frequent and large<br />
amounts of communications with the goal<br />
of taking the receiver offline.<br />
Message Replay<br />
When authenticated messages are<br />
captured and re-sent later, allowing an<br />
attacker to perform valid operations at<br />
invalid times.<br />
Profiling<br />
When an attacker applies knowledge<br />
about a particular device or application’s<br />
security vulnerabilities.<br />
Session Hijacking<br />
When an attacker takes over a session from<br />
an authorized user.<br />
that can be shared with other trusted<br />
parties, as well as a private key that is<br />
only known to the application instance.<br />
These keys vary in size, where the longer<br />
the key, the harder it is for a third party<br />
to guess.<br />
When a client application connects<br />
to a server, it creates a secured channel.<br />
Only if an administrator has configured<br />
the client and server to trust each other’s<br />
certificates will the secured channel be<br />
established. This procedure provides application<br />
authentication.<br />
In order to provide the identity of<br />
the user of an application, the client will<br />
next create a session that leverages the<br />
secure channel for communications. Applications<br />
may utilize this user information<br />
to limit or restrict access to certain<br />
operations, thus providing a level of user<br />
authorization.<br />
From here on out, the client will encrypt<br />
all communications it sends to the<br />
server with the server’s public key, and<br />
will sign each message with its own private<br />
key. Upon receiving a message, the<br />
server will test the integrity of the message<br />
by validating the signature against<br />
the client’s public key and decrypt the<br />
message with its own private key. This<br />
ensures that all messages remain confidential<br />
and are not tampered with.<br />
THE MAJORITY OF OPC FUNCTIONALITY IS HANDLED<br />
WITHIN THE CONTEXT OF THE APPLICATION LAYER.<br />
Mitigation of Threats<br />
OPC UA’s secure channel/session model<br />
protects against potential threats in<br />
many ways. First of all OPC UA limits<br />
what actions a client can perform on a<br />
server before it is authenticated. Clients<br />
are limited to obtaining the security and<br />
connection requirements of a server<br />
and creating a secure channel. In the<br />
case of security and connection requirements,<br />
this information seldom changes<br />
after deployment and will require little<br />
processing time on the server. For the<br />
more processor-intensive secure channel<br />
creation, servers should monitor for<br />
repeated failed secure channel creation<br />
requests and intentionally delay the<br />
handling of future requests to minimize<br />
the impact of a potential attack. Servers<br />
should also allow administrators to<br />
limit the number of concurrent connections<br />
it will handle at any given time.<br />
These steps will prevent against message<br />
flooding. An additional benefit of limiting<br />
what an unauthenticated party can<br />
accomplish is that any known security<br />
vulnerabilities that could be compromised<br />
are limited, which minimizes the<br />
server profiling that could be done by an<br />
attacker.<br />
Each message that is exchanged contains<br />
a session ID, secure channel ID,<br />
request ID, timestamp, and sequence<br />
numbers. Since these messages are not<br />
modifiable, applications can validate<br />
these values to ensure that an attacker<br />
has not captured a message to replay at<br />
some point in the future. Clients and<br />
servers also validate each message to<br />
ensure it is of the proper form. Together,<br />
this eliminates the concerns around<br />
message replay and reception of malformed<br />
messages.<br />
Summary<br />
OPC UA provides the industry with interoperability<br />
between software-based applications<br />
and hardware appliances from<br />
various vendors. This interoperability<br />
allows for the exchange of information<br />
that is critical to any industrial control<br />
system, as well as for the overall business.<br />
In order to make optimal operating and<br />
business decisions, the ability to obtain<br />
information from anywhere in the world<br />
is pivotal. Since this will require data to<br />
be transmitted over public domains, it<br />
must be done securely in order to protect<br />
the authenticity, integrity, and confidentiality<br />
of information. OPC UA’s adoption<br />
of today’s widespread IT principles and<br />
techniques makes this possible.<br />
18 maintworld 1/<strong>2017</strong>
When things<br />
just work,<br />
work gets done.<br />
Kepware’s industrial connectivity software provides<br />
secure and reliable data from the shop floor to the top<br />
floor, so you can focus on productivity.<br />
Learn more at kepware.com/MW
INDUSTRIAL INTERNET<br />
The Mixed<br />
Reality of IIoT<br />
If I told you it was possible to use a mixed reality device to control a<br />
manufacturing robot using HMI/SCADA software for the Industrial Internet<br />
of Things (IIoT), would you believe me? Certainly there is a “wow” factor in<br />
being able to do so, but it is a reality today.<br />
TAKE A MOMENT to parse through that<br />
statement and you can appreciate the<br />
multiple technological advancements<br />
that have had to take place to lead to<br />
this opportunity. There is the evolution<br />
of HMI/SCADA and analysis software<br />
to take advantage of the Internet<br />
of Things. There are the continuous<br />
breakthroughs in operating systems, databases and<br />
business intelligence, as well as in augmented/mixed<br />
reality and wearable devices.<br />
This combination of technologies was not thrown together<br />
by coincidence either. It is based on real use cases<br />
from manufacturers who want to be able to leverage<br />
their investment in existing automation systems, while<br />
applying the latest breakthroughs in IoT and wearable<br />
device technology. Such an innovation will be on display<br />
at Hannover Messe <strong>2017</strong> in April, where global automation<br />
software provider ICONICS will demonstrate its<br />
IoT-integrated Holographic Machine Interface (HMI)<br />
and analytics solutions working in collaboration with<br />
Microsoft Azure and a Comau robot.<br />
Let’s take a step back and look at what it has taken to<br />
make this a (mixed) reality.<br />
IIoT Compatibility<br />
Companies looking to enhance their operations by<br />
connecting to the Industrial Internet of Things should<br />
know that there are off-the-shelf solutions available<br />
today. Adding IIoT connectivity helps organizations to<br />
scale operations when necessary, to ensure against IT<br />
hardware obsolescence, and to provide global access<br />
to connected systems. Plus, this can be done without<br />
20 maintworld 1/<strong>2017</strong><br />
MELISSA TOPP,<br />
Senior Director of<br />
Global Marketing,<br />
ICONICS, Inc.<br />
requiring any expensive<br />
retrofitting or costly new IT<br />
infrastructure.<br />
Combining low-cost,<br />
small footprint IoT gateways<br />
with proven HMI/<br />
SCADA, analytics, and mobile<br />
technology running in<br />
the cloud gives customers global visibility, scalability,<br />
and reliability. Those gateways connect companies’<br />
core equipment to their preferred cloud platform<br />
(e.g. Microsoft Azure), communicating via the most<br />
popular communication protocols, such as OPC UA,<br />
BACnet, SNMP, and Modbus. However, best-in-class<br />
IoT gateways should provide functionality beyond basic<br />
connectivity – a form of “connected intelligence”, so<br />
to speak. Users should look for included IoT gateway<br />
software that provides additional capabilities such as<br />
data collection, web-based visualization, edge analytics,<br />
alarm management, fault detection and diagnostics,<br />
and energy management to name a few. Such bi-directional<br />
control provides complete contextualization of<br />
an organization’s data, making the previously invisible<br />
knowledge points now visible.<br />
Some customers are not sure where to start, given<br />
the plethora of affordable gateway devices available on<br />
the market today. To assist with this, ICONICS recently<br />
initiated its own IoT Alliance Program for qualified<br />
hardware providers to complement its end-to-end<br />
IoTWorX solution. This alliance program is geared<br />
toward original device manufacturers (ODMs) and offers<br />
end users the ability to select from a number of pretested,<br />
approved devices from preferred providers.
INDUSTRIAL INTERNET<br />
1/<strong>2017</strong> maintworld 21
INDUSTRIAL INTERNET<br />
Microsoft Software/Hardware Integration<br />
Recently, some of the most interesting developments in cloud<br />
services, business intelligence, machine learning, and data<br />
analysis have come out of Redmond, Washington. Such new<br />
products and services add to Microsoft’s proven legacy of operating<br />
system, desktop productivity, database, and web connectivity<br />
solutions. Gartner has recognized Microsoft as a leader<br />
in its Magic Quadrant for Enterprise Application Platform as<br />
a Service (in 2016), as well as for Infrastructure as a Service (in<br />
2015), so manufacturers are now more readily embracing and<br />
investing in software solutions built on the Microsoft Azure<br />
cloud platform. IoTWorX leverages the Azure IoT Hub for<br />
rich connectivity to things, secure cloud communications, and<br />
built-in real-time visualization and analytics.<br />
COMPANIES LOOKING TO ENHANCE<br />
THEIR OPERATIONS SHOULD KNOW THAT<br />
THERE ARE OFF-THE-SHELF SOLUTIONS<br />
AVAILABLE TODAY.<br />
Another of Microsoft’s extraordinary technology breakthroughs<br />
is its HoloLens self-contained holographic computer.<br />
HoloLens is an evolution in user interfaces, allowing the<br />
wearer to see and interact with a “mixed reality” of 2D and 3D<br />
holograms superimposed over the real world environment.<br />
“HMI” has been redefined through ICONICS’ development of<br />
a Holographic Machine Interface, which uses HoloLens technology<br />
to perform remote monitoring, asset management, and<br />
predictive maintenance on production equipment.<br />
Robots … and Other Connected Machines<br />
As part of a working relationship with Comau, a business within<br />
the Fiat Chrysler Automotive (FCA) Group, a Comau Racer<br />
3 robot will be featured at Hannover Messe <strong>2017</strong> this spring.<br />
While visiting the Microsoft booth, attendees will be able to interact<br />
with the robot with associated data visualized, analyzed,<br />
and mobilized via high-tech software solutions.<br />
However, as cool as using a HoloLens with integrated HMI/<br />
analytical capabilities to monitor and control a robot over IoT<br />
seems, it is only partially representative of the multiple applications<br />
where these technological breakthroughs can be<br />
applied. Process, factory, and building automation applications<br />
can all benefit from the openness and standardization of IoTconnected<br />
visualization and control. Organizations now have<br />
their pick of easy-to-add IoT gateways with onboard software<br />
that includes energy, building and industrial protocols (including<br />
BACnet, OPC UA, Modbus and Web Services) with the latest<br />
in security measures and the ability to be configured from<br />
anywhere in the world.<br />
Those looking for the latest in HMI/SCADA and analytical<br />
software that integrates with cutting edge technology in a wide<br />
array of applications in multiple industries should pay close attention<br />
to what’s going on at Hannover Messe in April. Because<br />
there’s no denying the (mixed) reality of it all.<br />
22 maintworld 1/<strong>2017</strong>
ONE BUS FITS ALL<br />
Sercos = Real-Time + IoT.<br />
That‘s the Sercos ® world.<br />
www.sercos.org
CASE STUDY<br />
QR CODE<br />
Scan to read<br />
full version.<br />
Text: VIJAYA RAMA RAJU, Systems Architect, Yokogawa and Paul Hunkar, Consultant, DS Interoperabilityz<br />
Using Nodeset Files to Exchange<br />
Information: A Case in MDIS<br />
Any client that needs to work with an OPC UA Server has to understand the<br />
information model present in the server and discover the instance of the model<br />
to be able to wire up to the correct nodes and<br />
exchange data.<br />
MDIS Companion<br />
OPC UA Specification provides various<br />
ways for clients to get information.<br />
These include:<br />
a. Browsing the address space for the<br />
information required<br />
b. Server Developer and Client Developers<br />
agreeing upon the information<br />
model outside of OPC UA<br />
c. Server Developer providing excel<br />
files or text documents describing<br />
the instances.<br />
However, the methods described above<br />
have serious limitations in the context of<br />
MDIS. These are:<br />
1. The server might not be deployed<br />
by the time the client needs this<br />
information.<br />
2. The MDIS Standard defines Object<br />
Types. Vendors however, are<br />
allowed to, and often do define<br />
Object Types in order to extend or<br />
customize these objects.<br />
3. The instances of objects depend<br />
on each vendor or installation, and<br />
24 maintworld 1/<strong>2017</strong><br />
providing the instance information<br />
in excel or text files with different<br />
formats cause problematic data<br />
entry issues.<br />
An “Information Model XML Schema”<br />
describes a standard syntax that information<br />
model developers can use<br />
to define their information models in<br />
way a computer program can read. A<br />
file that uses the XML Schema is usually<br />
referred to as a NodesetFile. It is<br />
used extensively for defining industry<br />
standard models such as MDIS. There<br />
are also a number of modelling tools<br />
that generate information models and<br />
provide a description of each model as a<br />
NodesetFile. This method also applies<br />
to instance data, not just models. The<br />
XML Schema can easily be used to serialize<br />
information models directly from<br />
a server (i.e. Import/Export) and there<br />
are multiple ways this feature helps in<br />
the development of clients and servers,<br />
especially in MDIS.<br />
Modelling Tools<br />
Client<br />
Development<br />
Server<br />
Development<br />
Method 1 (Chart 1):<br />
Server vendors and client vendors<br />
implementing MDIS can agree upon<br />
an Information Model (extension and<br />
sub-typed Objects) and exchange this<br />
as an Xml File which can be version<br />
controlled. The server & client vendors<br />
can proceed to develop client and server<br />
extension or sub-types in parallel. When<br />
instance information is available, additional<br />
NodesetFiles can be generated<br />
representing all of the instance information.<br />
The client vendor can process and<br />
configure the client system based on<br />
these NodesetFiles.
CASE STUDY<br />
OPC UA Server<br />
Nodest Extraction<br />
Client Development<br />
Method 2 (Chart 2):<br />
If the Server is readily available, the<br />
actual configuration of the server can<br />
be extracted. Since OPC UA servers include<br />
type information, the extraction<br />
includes custom type information as<br />
well as any instance information. The<br />
generation of an extracted NodesetFile<br />
can be done with a standard third party<br />
tool. These tools can run on a separate<br />
machine and only need access to the UA<br />
Server. The client can use the exported<br />
NodesetFiles to generate any configuration,<br />
including all instance data.<br />
Client Configuration<br />
The nodeset format, since it is defined<br />
in the specification, allows the same tool<br />
to be used for importing configuration<br />
information from different server vendors.<br />
It allows for easy determination<br />
of changes in models. Tools can be built<br />
that actually provide detailed configuration<br />
for the client system. Yokogawa as<br />
part of the pilot project for MDIS built<br />
tools that include generating logic for<br />
interlock handling, mapping of MDIS<br />
types to existing Yokogawa Centum and<br />
UGS types, generation of Centum logic<br />
and assignment of standard faceplates<br />
to these types. These tools made use of<br />
Smart Parts, which is a standard feature<br />
in Centum systems.<br />
The tools allow for easy extension for<br />
new types, just by configuring the additional<br />
sub-type or extension in a configuration<br />
file; any additional logic could<br />
be generated. The tool only needs to be<br />
validated for a single instance of a custom<br />
type, i.e. that the configured logic is correct,<br />
and all instances will work correctly.<br />
Providing the Nodeset configuration and<br />
tools to import the industry standard format<br />
greatly reduced configuration time<br />
as well as testing time. The end user can<br />
be assured that no data entry errors exist,<br />
and that configuration errors do not<br />
exist. If the designed logic for the given<br />
type needs to be changed, a single change<br />
and a quick regeneration will correct it<br />
for all instances. Yokogawa saw that it<br />
took only a few minutes to generate a<br />
complete configuration for its UGS OPC<br />
UA Client including Centum logic.<br />
Conclusion<br />
The usage of Nodeset Files simplifies the<br />
exchange of information models and the<br />
configuration of clients and servers. It<br />
has the capability to decouple the development<br />
of client and server. It also has<br />
the ability to overcome the ever-present<br />
late changes and testing pressure that<br />
results from them in-server. End user<br />
can be assured that configuration is correct<br />
and it can minimize the testing of<br />
systems.<br />
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INDUSTRIAL COMMUNICATION<br />
INDUSTRIAL<br />
COMMUNICATION<br />
in the Context<br />
of Industry 4.0<br />
and IoT<br />
The blending of the digital world<br />
with the physical thanks to the<br />
Internet heralds the start of the<br />
intelligent factory era. Flexibility,<br />
efficient use of resources,<br />
improved ergonomics, and<br />
integrating customers and<br />
business partners into the<br />
business and value creation<br />
processes, are all features of<br />
this blending process.<br />
PETER LUTZ,<br />
Managing Director of<br />
Sercos International,<br />
p.lutz@sercos.de<br />
INFORMATION and communication<br />
technologies play a key role in implementing<br />
Industry 4.0 concepts.<br />
Cyber-physical systems such as sensors,<br />
actuators, embedded computers, smartphones<br />
and machines are connected<br />
to one another and exchange data both<br />
between themselves and outside of the<br />
factory work floor. Today’s automation<br />
networks and fieldbus systems<br />
26 maintworld 1/<strong>2017</strong><br />
must therefore not only guarantee that<br />
machines and facilities can carry out<br />
production with safety, precision and efficiency,<br />
but they must also help towards<br />
establishing a universal solution for<br />
integrating different IT systems on different<br />
rungs of the organizational ladder<br />
within a factory.<br />
The fourth industrial revolution will<br />
result in dramatic upheavals within<br />
the industry similar to those we have<br />
already experienced in the private sector<br />
when introducing the Internet and<br />
mobile communication. One can expect<br />
flexibility from Industry 4.0 in production<br />
processes that has never before<br />
been available. Processes will become<br />
more energy and resource efficient. The<br />
machines are therefore able to influence<br />
production/planning systems or stock<br />
management directly. It also means that<br />
manufacturers can be contacted directly<br />
when their products experience gradual<br />
wear and tear so that condition monitoring<br />
and preventative maintenance<br />
can be started, therefore minimizing<br />
dead time and optimizing productivity.<br />
When we have a closer look at today’s<br />
situation, we recognize that an increasing<br />
number of manufacturers are using<br />
Industrial Ethernet solutions to implement<br />
new machine concepts and to<br />
connect systems. The advantages over<br />
traditional fieldbus systems are obvious.<br />
There is sufficient bandwidth available<br />
to transmit safety-critical data as well as
INDUSTRIAL COMMUNICATION<br />
IT protocols via a common medium in<br />
addition to fast real-time data transmission.<br />
In addition, users and manufacturers<br />
benefit from the use of standardized<br />
Ethernet hardware, such as passive and<br />
active infrastructure components.<br />
However, a uniform standard remains<br />
a dream: There is a large number<br />
of competing communication<br />
solutions and although they all use the<br />
widespread Ethernet technology, they<br />
specify different protocols and profiles<br />
in the superimposed ISO/OSI layers.<br />
Thus, devices that support different<br />
Industrial Ethernet standards are not<br />
compatible or interoperable with each<br />
other. Moreover, most devices that<br />
support different real-time Ethernet<br />
protocols cannot coexist in a common<br />
network, thereby losing the advantages<br />
of a common network standard. Most<br />
real-time Ethernet solutions use the<br />
network on an exclusive basis, meaning<br />
that only devices of one’s “own” protocol<br />
can be operated on the network. Devices<br />
that support other real-time Ethernet<br />
protocols, as well as standard Ethernet<br />
protocols, can be connected only via<br />
gateways or special switches. Other<br />
protocols can only be transmitted over<br />
the network by tunnelling them over the<br />
underlying real-time protocol, which<br />
can significantly harm the functioning<br />
and performance of a system. The future<br />
Ethernet IEEE 802.1 TSN (Time Sensitive<br />
Networks) standard will eventually<br />
make time-controlled transmission of<br />
real-time critical messages via standard<br />
Ethernet components possible. Most<br />
likely, this Ethernet TSN technology will<br />
have a significant impact on improving<br />
the heterogeneous landscape of realtime<br />
Ethernet dialects.<br />
Important Role of OPC UA<br />
OPC UA plays a very important role in<br />
advancing the convergence of IT and automation<br />
technology, thus enabling the<br />
consistent exchange of information from<br />
the corporate level down to the control<br />
or field level. From a technical perspective,<br />
OPC UA is characterized by the fact<br />
that it contains both, mechanisms for<br />
data exchange and an information model<br />
which allows the structure and semantics<br />
of the information exchanged to be<br />
defined. This technology can not only be<br />
integrated into devices on any platform<br />
with various programming languages,<br />
but systems of any degree of complexity<br />
can be fully described with it. In addition,<br />
the OPC UA technology is standardized<br />
on an international basis and has<br />
very wide acceptance from manufacturers<br />
and users worldwide.<br />
However, although OPC UA is in fact<br />
a communication standard that extends<br />
from the enterprise level down to the<br />
control & field level, it has two key limitations.<br />
One is that OPC UA can use or<br />
replace existing fieldbus and Industrial<br />
Ethernet systems only where there are<br />
no specialized and sophisticated timeand<br />
deterministic-communication<br />
requirements. The other limitation is<br />
that OPC UA only defines how data are<br />
described and exchanged. The actual<br />
meaning of the data, which is generally<br />
understood and defined as semantics, is<br />
not defined.<br />
A very promising approach is therefore<br />
to combine and map the existing<br />
real-time Ethernet protocols and the<br />
respective profiles with OPC UA. In doing<br />
so, process and device data are made<br />
available not just locally via the respective<br />
real-time network but also via any<br />
superordinate network infrastructure,<br />
e.g. the Internet or Intranet, via OPC<br />
UA, in a uniform and cross-manufacturer<br />
manner. Thus, not only is data exchange<br />
between the machine periphery<br />
and superordinate IT systems simplified,<br />
but the requirements of Industry<br />
OPC UA PLAYS A VERY IMPORTANT ROLE IN ADVANCING THE<br />
CONVERGENCE OF IT AND AUTOMATION TECHNOLOGY.<br />
4.0 with respect to semantic interoperability<br />
are also supported.<br />
In this scenario, real-time capabilities<br />
of OPC UA are not required, as the<br />
real-time performance is guaranteed<br />
by the respective underlying real-time<br />
network. Of course, application scenarios<br />
are possible in which a real-time<br />
capability of OPC UA is necessary,<br />
for example in machine-to-machine<br />
communication or in the linking of<br />
process-related machine periphery via<br />
OPC UA. For this, the so-called OPC UA<br />
publisher-subscriber protocol extension<br />
in combination with the future Ethernet<br />
TSN standard is positioned.<br />
In order to apply OPC UA in a consistent<br />
way down to the field level, without<br />
affecting the performance and realtime<br />
characteristic of the underlying real-time<br />
network, the real-time networks<br />
need to be capable of supporting the<br />
multi-protocol capability, meaning that<br />
real-time protocols and IP based protocols<br />
can coexist and at the same time can<br />
run independent of each other.<br />
If these requirements are fulfilled,<br />
today’s bus systems in combination with<br />
technologies such as OPC UA and Ethernet<br />
TSN can make a significant contribution<br />
to the further convergence of<br />
information and automation technologies.<br />
Let’s make it happen.<br />
1/<strong>2017</strong> maintworld 27
Road Map to Operational<br />
Readiness and Asset<br />
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© <strong>2017</strong> Bentley Systems, Incorporated. Bentley, the “B” Bentley logo, and AssetWise are either registered or unregistered trademarks or service marks of Bentley<br />
Systems, Incorporated or one of its direct or indirect wholly owned subsidiaries. Other brands and product names are trademarks of their respective owners.
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CASE EXAMPLE<br />
CARDAN SHAFT MEASUREMENT –<br />
Working in Confined Spaces<br />
Winter Grün Markier-technologie GmbH produces, at their site in Wilnsdorf, machines<br />
specially designed for making road markings. In addition to this, trucks are fitted<br />
with special installations<br />
and equipped according to<br />
customer requirements.<br />
Text: MICHAEL STACHELHAUS,<br />
PRUFTECHNIK Condition Monitoring GmbH.<br />
ONE OF THE company’s special installations<br />
is a Unimog, which is fitted with<br />
a high-pressure water pump made by<br />
Hammelmann. With the help of highly<br />
specialized spraying tools, water pressure<br />
of up to 2500 bar generated by this<br />
pump is used to remove rubber abrasion<br />
from runways at airports, to establish a<br />
defined traction on roadway surfaces or<br />
to remove roadway markings.<br />
The image shows the output<br />
side of the gearbox for the<br />
auxiliary drive. The cramped<br />
conditions are clearly visible.<br />
A Cardan shaft is guided to the highpressure<br />
pump on the gearbox output<br />
side. This shaft then drives the highpressure<br />
pump at the required speed.<br />
Actually cardan shafts should not balance<br />
any angular offsets. If they do so,<br />
the offset has to take place in a narrowly<br />
limited angle range.<br />
Unimog platform with the driver's cab raised. The high pressure pump is visible at the rear.<br />
The deflection angle ß must be the same at<br />
both universal joints of the Cardan shaft.<br />
30 maintworld 1/<strong>2017</strong>
CASE EXAMPLE<br />
Objective of the alignment:<br />
Deflection angle ß1 = ß2<br />
There are two methods for measuring<br />
the Cardan shaft: one with the Cardan<br />
shaft disassembled and one with the<br />
Cardan shaft mounted.<br />
The first check measurements<br />
showed that measurement with the<br />
Cardan shaft mounted is not possible as<br />
the spatial conditions simply do not allow<br />
for the Cardan shaft rotation mechanism<br />
to be mounted and be rotated<br />
congruently.<br />
The measuring procedure with the<br />
Cardan shaft removed was thus the only<br />
option available. Removal of the Cardan<br />
shaft in this design is very quick. The<br />
possibility of straightforward disassembly<br />
of multiple components was taken<br />
into account during Werner-Grün’s development<br />
of this design.<br />
Laser set-up on the gearbox output<br />
shaft. The laser has already been set up<br />
to record the measurement values.<br />
Receiver on the high<br />
pressure pump. The<br />
sensor head is mounted<br />
on a rotation mechanism.<br />
Only the angular error is<br />
recorded.<br />
Principle schema of the design. Laser with<br />
holder and on the opposite side of the<br />
receiver, mounted on the motor shaft.<br />
The laser is now positioned centrally<br />
on the gearbox output side and set up.<br />
In this regard the laser must be placed<br />
exactly in the gap in the structure so<br />
that the laser can map out a measuring<br />
circuit of 90°. A smaller rotation range<br />
would indeed be possible but this would<br />
significantly impair the accuracy of the<br />
measurement.<br />
The “Intelli-Point” measuring procedure<br />
patented by PRUFTECHNIK is<br />
used to take the measurements. In this<br />
context, the lasers and receivers are positioned<br />
together at different points. An<br />
angle display with an additional pointer<br />
shows the congruence of the sensors<br />
and also checks whether the relative<br />
angular difference always remains the<br />
same.<br />
All measurements are repeated in<br />
order to rule out potential measurement<br />
errors. The measurement values are<br />
compared against each other using the<br />
“measurement table”. The measurement<br />
values are checked for potential discrepancies<br />
by means of quality analysis.<br />
Conclusion:<br />
Following the procedure explained<br />
above makes it very easy to measure potential<br />
errors or excessive strain on the<br />
body on-site and in a very straightforward<br />
manner. Subsequent corrections<br />
can also be carried out. The focus is now<br />
shifting towards even more demanding<br />
projects involving trucks. Moreover,<br />
some new features, which are also to be<br />
measured, will soon be available.<br />
Measurement results in the overall view. The maximum alignment error is 0.2°. The unit is within the specified tolerances.<br />
1/<strong>2017</strong> maintworld 31
CONDITION XXXXXX MONITORING<br />
LEVERAGING<br />
PLANNED OUTAGES<br />
AT POWER PLANTS<br />
Many of the world’s most efficient power plants are<br />
Combined Cycle Gas Turbine Plants (CCGT) incorporating<br />
gas and steam turbines. These turbines present<br />
demanding motion control challenges, which affect<br />
machine performance, safety, reliability and supply of<br />
power to customers.<br />
Gas valve-actuator assembly undergoes<br />
factory acceptance test.<br />
STEVE BEDDICK,<br />
Moog Inc.,<br />
sbeddick@moog.com<br />
POWER PLANT operators are looking for<br />
ways to keep turbines running at peak<br />
performance. Some of the most important<br />
ways to accomplish this in a power<br />
plant are to make the most of planned<br />
outages and reduce the risk of unplanned<br />
downtime. Many industries can<br />
benefit from some practical approaches<br />
to the strategic use of long-life upgrades,<br />
retrofits and exchange programmes.<br />
Why is motion control<br />
important?<br />
In the turbine system, the hydraulically<br />
actuated fuel gas control valve is the primary<br />
interface between a complex control<br />
system and the mechanical portion<br />
of the plant. From a safety perspective, it<br />
is vital to ensure a rapid closing time for<br />
the main valve actuator in the case of an<br />
emergency shutdown to avoid collateral<br />
damage to the turbine.<br />
The motion control system affects:<br />
• The power output of the turbine<br />
and the revenue stream<br />
• Energy efficiency that equates to<br />
profitability (i.e., 80 percent of the<br />
32 maintworld 1/<strong>2017</strong><br />
cost of running plants is fuel)<br />
• Emissions level, which is both a<br />
cost and compliance issue since<br />
improperly calibrated equipment<br />
can cause a plant to exceed its<br />
emission allowance<br />
• A safe, controlled shutdown, which<br />
protects human life and property<br />
The challenge for power plants is keeping<br />
motion control systems operating at<br />
a high level in spite of around-the-clock<br />
operations in rugged environments. Turbine<br />
OEMs have recommended planned<br />
maintenance schedules that help plant<br />
operators to minimize downtime and<br />
ensure optimized energy output. All repairs<br />
and maintenance of critical components,<br />
such as actuators and servo valves,<br />
need to be scheduled during an outage<br />
along with thousands of other maintenance<br />
tasks involving numerous vendors<br />
and complex scheduling.<br />
Maximizing maintenance<br />
budgets during plant outages<br />
As an original supplier of fuel control<br />
valves for General Electric (GE) 7FA turbines,<br />
Moog routinely works with power<br />
plants to ensure that the actuators and<br />
valves can be refurbished to “as new”<br />
condition during very tight outage windows.<br />
With experience in advanced material<br />
gleaned from many years of developing<br />
products for demanding environments<br />
ranging from aerospace to downhole<br />
oil exploration, Moog developed a<br />
long-life actuator as an upgrade offering.<br />
When GE introduced a new technology<br />
called Advanced Gas Path (AGP), the<br />
maintenance interval was extended from<br />
48,000 to 64,000 hours. Moog had the<br />
long-life product but needed to work<br />
closely with its partner Emerson to develop<br />
a process valve upgrade that is part<br />
of the gas valve assembly.<br />
Over the life of the equipment, an<br />
OEM will use data on the performance of<br />
products and capabilities, such as failure<br />
analysis, to understand how to increase<br />
reliability for a long service life. Engineers<br />
identified several key improvements<br />
to ensure that the gas valve actuator<br />
would operate reliably for 64,000<br />
hours, even in harsh conditions:<br />
• Low pressure dual elastomeric seal<br />
design to eliminate galling on the<br />
piston rod<br />
• New buffer seal for more durability<br />
• Harder rod surface through proprietary<br />
aerospace coating that replaces<br />
chrome plating for extended<br />
life<br />
• Hard, dense chrome coating added<br />
to cylinder bore surface<br />
Likewise, Emerson, which manufactures<br />
the EAB process valve, engineered<br />
a retrofit to extend scheduled maintenance<br />
intervals in two key areas:<br />
• The bonnet is machined to receive<br />
a Stellite alloy insert, eliminat-
CONDITION MONITORING<br />
Process valve tagged for shipment to<br />
Emerson IVS repair facility.<br />
ing the traditional coating that can<br />
degrade over time<br />
• A live-loaded packing system<br />
replaces the original manually<br />
adjustable configuration to ensure<br />
the integrity of the packing seal for<br />
extended operating periods<br />
Recently, Moog introduced a new Gas<br />
Control Valve Assembly 64 K Upgrade<br />
for General Electric 7FA turbines. It was<br />
the first offering able to extend the maintenance<br />
interval of gas control equipment<br />
from the typical 48,000 hours of<br />
operation to 64,000 hours.<br />
To complete the 64 K Upgrade package,<br />
the actuator and process valve are<br />
returned to “zero-hour” condition. The<br />
actuator receives a factory overhaul, and<br />
the process valve undergoes a Fisher<br />
Encore repair performed at an Emerson<br />
IVS repair facility. The integrated<br />
assembly overhaul is a 100 percent<br />
OEM repair. This process ensures the<br />
turbine’s valves are returned to as-new<br />
specifications and performance, resetting<br />
the inspection clock to hour zero.<br />
For turbine plants with the Advanced<br />
Gas Path Technology, the benefits of<br />
synchronizing major inspection periods<br />
means managers will never find themselves<br />
trying to overhaul gas valves when<br />
they have a much smaller outage window.<br />
Of course, many operators see the<br />
benefits of the extended life even if they<br />
have the 48,000 maintenance interval<br />
due to high confidence in the reliability<br />
of the assembly.<br />
Exchange programmes help<br />
leverage planned outage<br />
Risks during a scheduled outage are<br />
eliminated through the so-called Advanced<br />
Exchange Programme, which<br />
offers a turbine owner rebuilt gas control<br />
valves that arrive prior to the start<br />
date of an outage. This allows managers<br />
to remove the used valves and install<br />
the rebuilt valves in sequence, saving<br />
money and time. When considering the<br />
complexity of an outage and all of the<br />
tasks a maintenance manager must juggle,<br />
having a spare actuator assembly on<br />
hand when needed can help prevent the<br />
cost of an extended outage or unplanned<br />
downtime.<br />
One example of a power plant that<br />
effectively used its outage is a combined<br />
cycle power plant in the Southeastern<br />
U.S. that began planning for an extended<br />
outage months in advance.<br />
The plant’s managers had 21 days<br />
for the inspection of each combustion<br />
turbine and 18 days per steam turbine.<br />
Managers had to refurbish fuel gas and<br />
steam control valve assemblies during<br />
these outages. To maintain reliability,<br />
the plant had to return the equipment to<br />
as-new condition. The plant managers<br />
wanted OEM repairs and upgrades, and<br />
the timeframe to perform the repairs<br />
within the inspection window left no<br />
margin for error. If power was offline<br />
even for a single day, everyone knew the<br />
lost revenue would be significant. Moog<br />
service technicians proposed a service<br />
plan that included a combination of<br />
spares, repairs and exchange units to<br />
meet the plant’s inspection schedules.<br />
For the combustion turbine units,<br />
the plant purchased one spare set of<br />
actuators. These served dual roles as a<br />
rotatable set during planned outages and<br />
emergency spares during forced outages.<br />
Technicians used the power plant’s<br />
spares and a set of Moog’s exchange<br />
units complete with process valves. At<br />
the end of the preventative maintenance<br />
outage, technicians returned the plant’s<br />
spare set to the site and replaced the<br />
Moog set in the exchange pool inventory.<br />
The plant managers and service<br />
technicians determined that the steam<br />
turbines’ actuators and valves could be<br />
repaired within the allotted time, too.<br />
The plant’s managers coordinated the<br />
repair and removed the steam process<br />
valves from the actuators and sent the<br />
actuators to Moog for repair. After completing<br />
the actuator repairs, technicians<br />
conducted a final acceptance test and<br />
sent the actuators to the power station<br />
with a two-year warranty. The plant<br />
reassembled the valve to the actuator,<br />
installed the assembly, and tested it for<br />
commissioning.<br />
1/<strong>2017</strong> maintworld 33
TECHNOLOGY<br />
SMALL COST,<br />
BIG SAVINGS<br />
in Packaging and<br />
Bottling Industries<br />
Conveyors and assembly processes are widely used across many industries.<br />
As automation continues its upward trend, markets like PET bottling, food and<br />
beverage, and general packaging, which see many sudden stops and starts are<br />
seeing an increased need for shock absorbers to safely control and dampen the<br />
kinetic energy produced throughout the production line.<br />
DIETER KLAIBER,<br />
Project & Application<br />
Manager, ITT Endine<br />
Europe,<br />
dieter.klaiber@itt.com<br />
MOTION CONTROL technologies can<br />
be utilized in all areas of conveyance,<br />
whether linear or rotational motion. In<br />
facilities that use systems like diverter<br />
gates, conveyor stops, pick and place, and<br />
overhead pushers, shock absorbers are<br />
central to maintaining machine reliability<br />
by dissipating the energy and reducing<br />
wear. Shock absorbers are relatively lowcost<br />
components to purchase, install and<br />
maintain as compared to the equipment<br />
they protect, and they provide additional<br />
savings to a facility by preventing machine<br />
downtime, safety concerns and potential<br />
quality issues. Investing in shock<br />
absorbers that are engineered to your<br />
facility’s unique needs and equipment<br />
cycle counts—and maintaining the shock<br />
34 maintworld 1/<strong>2017</strong><br />
absorbers and surrounding equipment<br />
as suggested by the user manual—is a<br />
small overall cost and time commitment<br />
for a facility that results in huge overall<br />
savings.<br />
Small Cost, Big Savings<br />
Shock absorbers are key to maximizing<br />
a material handling system’s speed<br />
and load, making the machine more<br />
efficient and cost effective. A customengineered<br />
shock absorber can save the<br />
manufacturer valuable design time and<br />
solve multiple problems economically.<br />
In certain applications like the beverage<br />
bottling industry, conveyor systems are<br />
required to quickly bring a product to a<br />
stop at regular intervals along a conveyor<br />
line in order to be cleaned, filled, sorted<br />
and packaged. The high rate of speed of<br />
the conveyor transport, coupled with the<br />
rapid deceleration of a sudden stop could<br />
result in problems for the product and<br />
the conveyor equipment if the energy is<br />
not properly absorbed throughout. It is<br />
important to custom engineer the shock<br />
absorber to the specific industry, application,<br />
machinery load and product produced.<br />
If the initial design of machinery<br />
involves the implementation of shock<br />
absorbers, it can mean high reliability<br />
and cycle time for a facility, while ensuring<br />
quality.<br />
Maintaining the shock absorber on a<br />
regular interval ensures efficiency, avoids<br />
unexpected failures and reduces costs.<br />
Shock absorbers are adjustable based<br />
on the specific operating condition and<br />
maintaining, adjusting and replacing<br />
them accordingly is an additional step in<br />
the safe and optimal maintenance of your<br />
total assembly equipment. The shock<br />
absorber is a relatively cheap component<br />
within the larger, more expensive machine<br />
system. Lower impact forces from<br />
the motion, results in less bounce and<br />
more control over the motion. As shocks<br />
reduce the impact forces on equipment,<br />
replacing shock absorbers on schedule is<br />
an inexpensive step that will ultimately<br />
save significant long-term maintenance<br />
costs by preventing downtime and po-
TECHNOLOGY<br />
In PET bottle plants, shock absorbers<br />
are required to maintain the highest<br />
cycle rate possible while preventing<br />
damage to the bottle moulds.<br />
“A packaging systems manufacturer<br />
incorporated custom-engineered shock<br />
absorbers to minimize component failure and<br />
optimize cycle rates.”<br />
SHOCK ABSORBERS ARE KEY TO MAXIMIZING A MATERIAL<br />
HANDLING SYSTEM’S SPEED AND LOAD.<br />
tential quality issues. Dissipating the<br />
energy and force applied to equipment<br />
parts keeps machines reliable, ensures<br />
consistency, quality output and reduces<br />
overall wear on the equipment overtime.<br />
The installation and proper maintenance<br />
of a high-class but inexpensive hydraulic<br />
shock absorber can mean big savings in<br />
overall time and costs.<br />
Providing Added Safety<br />
Increased productivity demands are<br />
placed on everyone in the facility, the<br />
managers, machine operators and packagers.<br />
This increased demand on staff<br />
translates to increased demand on the<br />
equipment as packaging and bottling<br />
facilities operate their assembly processes<br />
above recommended speeds, with<br />
uneven loads and in harsh environments<br />
that the original equipment may not be<br />
designed to accommodate. This puts excess<br />
strain on equipment and conveyor<br />
systems and endangers the health and<br />
welfare of employees. As machines run<br />
faster and longer, the concern for safety<br />
and the need for emergency stops is<br />
critical.<br />
Packaging and bottling equipment<br />
manufacturers will often design equipment<br />
with shock absorption to the<br />
specifications that meet safety and<br />
industry requirements. However, when<br />
it comes to application, the end-user<br />
inevitably cranks up the speed because<br />
they want to run the machine faster to<br />
increase throughput. Shock absorbers<br />
manage the impact, or kinetic energy, of<br />
the pieces that are moving (KE = ½ m<br />
V2). Therefore, a small increase in speed<br />
means a significant increase in energy<br />
causing unplanned and unnecessary<br />
wear on the machinery and shock absorber.<br />
With the machine running faster<br />
than it should and the shocks calibrated<br />
to run at lower speeds, safety issues are<br />
presented for equipment operators. In<br />
some cases, shock absorbers aren’t designed<br />
into machinery in the first place,<br />
causing additional wear and equipment<br />
fatigue.<br />
Shock absorbers can, and often are<br />
a retrofit solution. Ideally though, they<br />
would be designed upfront to meet the<br />
requirements of the equipment and be<br />
installed before the original equipment<br />
is used, whilst working alongside the<br />
end-user to set realistic expectations for<br />
run-time, cycle and maintenance. Custom<br />
shock absorbers can help curb safety<br />
concerns by ensuring the extra daily<br />
force is being dissipated appropriately<br />
instead of being pushed through machine<br />
components, avoiding failures, and<br />
equipment can be slowed and stopped<br />
safely, if an emergency does happen.<br />
1/<strong>2017</strong> maintworld 35
TECHNOLOGY<br />
Shock absorbers maximize<br />
a material handling system’s<br />
speed and load, while increasing<br />
efficiency and cutting costs.<br />
Decreasing Downtime<br />
No Matter the Industry<br />
With today’s tight time constraints and<br />
ambitious production goals, shutting<br />
down a production line altogether can<br />
prove very expensive. For industries like<br />
packaging, food and beverage and PET<br />
bottling, machinery and its components<br />
also need to withstand environments<br />
like frequent wash down and high temperatures,<br />
while operating at a high cycle<br />
rate. As shock absorbers protect against<br />
excess force and prevent additional<br />
wear and tear, they can help minimize<br />
component failure and help machines<br />
operate at their highest capacity. Designing<br />
shock absorbers into the equipment<br />
is key in meeting unique requirements,<br />
whether a bottling facility requires specific<br />
location sensors or a food packaging<br />
plant needs components that operate<br />
in small spaces and unique wash-down<br />
environments. Downtime due to component<br />
failure is minimized, allowing<br />
equipment to operate at design conditions.<br />
For example, a packaging systems<br />
manufacturer produces a variety of machines<br />
that package food products such<br />
as deli and sausage products. One of<br />
these packaging machines was specifically<br />
used to package poultry products.<br />
During operation, this machine needs to<br />
withstand the wet and messy environment<br />
of poultry packaging, including<br />
frequent wash down. As a market leader,<br />
the company needed this machine to<br />
operate at the fastest cycle rate in the<br />
industry. This means that each machine<br />
36 maintworld 1/<strong>2017</strong><br />
must process 15 to 18 birds per minute.<br />
The machine was designed with shock<br />
absorbers installed at the end-of-stroke<br />
position on a pneumatic rodless cylinder<br />
used for a shuttle operation and<br />
at-the-end of cycle position as a positive<br />
stop for a pivot. Unfortunately, the<br />
pre-installed shock absorbers could not<br />
withstand the high cycle rate or harsh<br />
environment.<br />
ITT Enidine worked with the company<br />
to design a special shock absorber<br />
that would withstand the cycle rate,<br />
processing environment and frequent<br />
wash down. The solution was customengineered<br />
to have a substantially higher<br />
capacity and a smaller envelope than<br />
pre-installed, competing shock absorbers.<br />
With the new solution, downtime<br />
due to component failure was minimized<br />
and the packaging machines operated at<br />
optimal cycle rates. Because of this productivity<br />
increase, the company maintained<br />
its market position and increased<br />
sales annually. Packaging machines are<br />
excellent candidates for shock absorption<br />
technology, which control air cylinders<br />
and help machines operate at their<br />
highest capacity.<br />
Ensuring Quality and<br />
Reliability<br />
Shock absorbers can improve the overall<br />
quality of equipment by meeting the<br />
necessary environmental needs, like extreme<br />
heat or cold, production speed and<br />
uneven loading. Custom engineering of<br />
a shock absorber for each unique application<br />
will allow that shock absorber to<br />
work specific to that application. Regular<br />
equipment maintenance, including<br />
replacement of shock absorber, is key to<br />
keeping machinery running at its highest<br />
potential to ensure quality and reliability<br />
throughout the production process.<br />
In PET bottle plants, shock absorbers<br />
can create efficiencies and protect equipment<br />
in applications like blow moulding,<br />
case packing, carton forming or<br />
container labelling. The machines that<br />
are used to create today’s PET bottles—<br />
typically made of a high-gloss, crack<br />
resistant plastic known as Polyethylene<br />
Terephthalate (PET)—have the highest<br />
production rates in the industry and are<br />
referred to as blow moulding machines.<br />
The equipment consists of multiple<br />
“clam shell” moulds placed around a vertical<br />
axis, rotated in a horizontal plane.<br />
The rotated plane creates centrifugal<br />
force to move the plastic material within<br />
the mould cavity, creating the bottle<br />
shape. Shock absorbers are required to<br />
maintain the highest cycle rate possible<br />
while preventing damage to the opening<br />
and closing of the clamshell.<br />
In cases like PET bottle plants, shock<br />
absorbers are central to ensuring quality<br />
and reliability. By scheduling maintenance<br />
and proper replacement parts,<br />
facilities will see an increase in performance<br />
and durability in applications<br />
that encounter uneven loading, bending<br />
or harsh environments. Ultimately,<br />
this equipment protection results in<br />
increased safety, efficiency and product<br />
quality, while decreasing downtime and<br />
cost.
ASSET MANAGEMENT<br />
The parallel paths<br />
of maintenance<br />
and lubrication<br />
For maintenance programmes, the decades-long migration from Breakdown to<br />
Planned to Predictive strategies represents significant, albeit slow-paced, progress.<br />
It is interesting to note, however, that by comparison, this progress did not filter<br />
down equally to lubrication programmes. A look at the first two strategy phases<br />
- Breakdown and Planned – shows a close analogy between corresponding<br />
maintenance and lube processes.<br />
TOM MURPHY,<br />
CRL, SDT International,<br />
tom@sdthearmore.com<br />
OVER THE BETTER part of forty years,<br />
maintenance departments transitioned<br />
from a breakdown strategy to planned,<br />
task driven, interventions based on time<br />
in service. Replacing reactive firefighting<br />
with planned tasks reduced waste<br />
and extended life. Further evolution to<br />
a predictive model delivered even more<br />
value. This transition happened for<br />
maintenance in general, but did lubrication<br />
processes keep pace?<br />
Most lube programmes evolved beyond<br />
the reactive breakdown strategy<br />
phase, to employ a planned approach.<br />
Lubricating bearings on a prescribed<br />
schedule, dictated by time in service<br />
made more sense than waiting for<br />
failure to happen. A transition from<br />
Planned to Predictive rarely happens.<br />
Technology –<br />
A Catalyst for Change<br />
Technology breakthroughs often serve<br />
as a catalyst for change. This change is<br />
happening now in lubrication. The shift<br />
from Breakdown (grease that screaming<br />
bearing) to Planned Lubrication (grease<br />
with a set amount on a set date) to Predictive<br />
Lubrication, (lubrication on condition)<br />
is real, and driven by innovative<br />
ultrasound instruments that help lube<br />
techs grease bearings correctly.<br />
It is generally quoted that over 40<br />
percent of bearings (some say up to 80<br />
percent) are killed by inadequate lubrication.<br />
Logically this must lead to the<br />
conclusion that Breakdown and Planned<br />
lubrication processes sometimes fail.<br />
Advances in ultrasound technology<br />
now provide the maintenance world<br />
with an enhancement to the Planned<br />
strategy and an equivalent to Predictive<br />
strategies; namely, on-condition lubrication.<br />
There are three key problems with<br />
the existing planned strategy – we don’t<br />
know:<br />
1. when the bearing needs lubrication<br />
2. how much lubricant is needed<br />
3. that the lubricant we just injected<br />
did the job<br />
The current lube process is generally<br />
based upon a series of assumptions.<br />
First, the quantity of grease to inject<br />
into a bearing is approximated from its<br />
dimensions using this formula:<br />
Outer diameter (mm) x width (mm) x<br />
0.005 grams<br />
For example, a bearing with an outer<br />
diameter of 180mm and a width of<br />
40mm, has a theoretical grease quantity<br />
of 36 grams.<br />
REPLACING REACTIVE FIREFIGHTING WITH PLANNED TASKS<br />
REDUCES WASTE AND EXTENDS ASSET LIFE.<br />
The trickier part is to then derive a relubrication<br />
frequency. Once again, a series<br />
of approximations and calculations<br />
involving the operational conditions of<br />
the bearing, its size and rotational speed<br />
provide an estimate of this.<br />
The problem is to apply the correction<br />
factors to suit every operating condition<br />
that a bearing may find itself in. Applying<br />
the two extremes for a correction<br />
factor might produce on the one hand a<br />
38 maintworld 1/<strong>2017</strong>
!<br />
!<br />
!<br />
• Say what you’re going to do<br />
ASSET MANAGEMENT<br />
g to do<br />
relubrication interval of 5,333 hours and<br />
on the other hand 6 minutes! How can a<br />
machine manufacturer provide recommendations<br />
that account for every operating<br />
condition in the world?<br />
• Say what you’re going to do<br />
On-condition Lubrication<br />
Using Ultrasound<br />
Alternatively, on-condition lubrication<br />
using ultrasound provides data that<br />
eliminates these three problems by giving<br />
the lube tech<br />
1. A sound to assess<br />
2. Condition Indicators with alarms<br />
to measure<br />
3. A dynamic history of the health of<br />
every bearing in the programme<br />
In a Planned maintenance strategy,<br />
ultrasound will tell you when to stop<br />
injecting grease. In the Predictive strategy,<br />
an ultrasound measurement alerts<br />
the lube tech when and if lubrication is<br />
needed at all. The grease quantity and<br />
interval calculations become only guidelines.<br />
Measurement of friction using<br />
ultrasound is the driving and controlling<br />
parameter.<br />
Ultrasound “hears” friction, so the<br />
trained lube tech acquires valuable information<br />
on the frictional state of that<br />
bearing.<br />
As a rule, “to fail to prepare is to prepare<br />
to fail”. So many mistakes occur<br />
before the grease gun even reaches the<br />
lubrication point. Organizational tasks<br />
like lubrication management, storage,<br />
and contamination control are essential<br />
and their need cannot be over-emphasised.<br />
Likewise, the lubrication task<br />
itself must also be preceded by preparation.<br />
Preparation Information Essentials:<br />
1. Which lubricant do I use for this<br />
bearing?<br />
2. What is the calculated maximum<br />
amount?<br />
3. How frequently should we check<br />
this bearing?<br />
This task is best managed with software.<br />
Combining preparation with friction<br />
measurement software provides a<br />
smooth, seamless integration between<br />
the condition assessment and the lubrication<br />
function.<br />
A measurement and lubricant database<br />
is created for each bearing. The<br />
database controls the sensor type, the<br />
lubricant type and the calculated maximum<br />
quantity.<br />
How much grease does your grease<br />
gun dispense? If the answer is, “I don’t<br />
know”, then calibrate your grease guns.<br />
Minimise variables that cause errors.<br />
Ensure that the majority of grease guns<br />
used deliver the same amount.<br />
“Patience is a virtue” applies to lubrication.<br />
Build in a waiting time between<br />
each injection of grease to ensure that<br />
the impact of that injection is detectable.<br />
This prevents over-lubrication<br />
and allows you to spot failures such as<br />
blocked and broken grease tubes.<br />
A database Tree and Lube Surveys,<br />
similar to ones used for condition assessment,<br />
is now created. These surveys,<br />
loaded into your ultrasound data collector,<br />
guide you to a precise lubrication.<br />
In Survey Mode, the ultrasonic instrument<br />
guides the lube tech from point to<br />
point and measurement data is the reference<br />
to lubricate the bearing. With the<br />
reference stored, the detector prompts<br />
the technician to begin adding grease.<br />
After the waiting time, another measurement<br />
dictates the next action.<br />
• Say what you’re going to do<br />
Planned vs. Predictive<br />
Approach<br />
To assist the lube tech, the ultrasound<br />
meter’s built-in algorithms compare<br />
each successive reading and suggests the<br />
technician either add more grease at a<br />
controlled rate, or decides to stop.<br />
The integration of ultrasoundassisted<br />
lubrication can be deployed in<br />
either a Planned or Predictive strategy.<br />
In a Planned strategy, ultrasound guides<br />
the lube process, however the calendar<br />
still dictates the intervals between lube<br />
tasks. This time-based approach does<br />
not take full advantage of ultrasonic<br />
conditional data to trigger the lube<br />
process. Progressive lubrication programmes<br />
want to get to that stage.<br />
A successful migration from Planned<br />
to Predictive lube tasks is earmarked by<br />
message changes. “Inspect Bearings and<br />
Grease as Necessary” is replaced with<br />
“Take Ultrasound Readings and Grease<br />
ULTRASONICALLY Based on Need.”<br />
The result becomes a history for each<br />
1/<strong>2017</strong> maintworld 39
XXXXXX ASSET MANAGEMENT<br />
Maintenance<br />
Breakdown<br />
“Firefighting”<br />
Only fixing things when<br />
they break.<br />
Planned<br />
Scheduled maint. tasks on<br />
a calandar based system.<br />
Predictive<br />
Scheduled maint. tasks<br />
based on asset health.<br />
30 year<br />
timeline<br />
Lubrication<br />
Breakdown<br />
The method at this<br />
time was:<br />
“Grease it because<br />
it’s loud.”<br />
Planned<br />
“Grease it because<br />
it’s due.”<br />
Lubrication is based<br />
on a calendar<br />
schedule<br />
Predictive<br />
This graphic illustrates how maintenance processes continued to evolve from Planned to Predictive, while parallel evolution for<br />
lubrication stalled at the Planned stage.<br />
bearing with the latest bearing condition<br />
data always available to listen to or<br />
analyse for the presence of early-stage<br />
bearing defects.<br />
It is important to show that this new<br />
lubrication strategy is working. That<br />
means developing some performance<br />
indicators.<br />
The data collector records the number<br />
of shots of grease applied during the<br />
lube process and the database knows<br />
how much grease is in a shot. Calculating<br />
grease consumption therefore,<br />
becomes a simple task for this software;<br />
and the corresponding consumption reports<br />
are meaningful and useful. Showing<br />
a reduction in grease consumption<br />
along with a measurable improvement<br />
in machine reliability is a great way to<br />
prove that your programme is working.<br />
“None of this is particularly new,” you<br />
might say. To some this is old news. But<br />
for others, this is science fiction. One<br />
great success is documented from a<br />
mine in South Africa.<br />
Prior to implementing a Predictive ultrasound<br />
lubrication programme, they<br />
identified 945 grease points; all lubricated<br />
on a time-based schedule. After implementation,<br />
the number of bearings<br />
needing lubrication quickly reduced.<br />
They used to pump all 945 bearings full<br />
of grease, every month. This reduced on<br />
average to only 19 bearings each week.<br />
At the start of the programme, the<br />
plant purchased 22 18kg drums of<br />
grease each month. Within one month<br />
that dropped to 17 drums and within<br />
6 months, it was below 10 drums. The<br />
average amount of grease bought for<br />
the subsequent 6 months reduced to 6<br />
drums. Instead of wastefully pumping<br />
bearings full of grease, the technicians<br />
now devote their time to monitoring<br />
bearing condition. Furthermore, while<br />
huge savings accrued due to lower<br />
grease consumption, it is recognised<br />
that 95 percent of the bearings are operating<br />
at the lowest possible friction<br />
levels. This highly effective lube programme<br />
is delivering longer equipment<br />
life and reliability.<br />
There are very few organizations, if<br />
any, which benefit from a Breakdown<br />
maintenance strategy. Likewise, the concept<br />
of the squeaky bearing getting the<br />
grease is a dinosaur concept. If a bearing<br />
is greased because it is screaming, the<br />
damage is done; its lifecycle is already<br />
jeopardized. The migration from a Breakdown<br />
approach to a Planned approach<br />
represents beneficial evolution for both<br />
maintenance and lube processes.<br />
The next step forward, from Planned<br />
to Predictive, already happened for<br />
most maintenance departments. It<br />
was a competitive necessity. But lube<br />
programmes lagged, instead opting for<br />
antiquated OEM recommendations that<br />
insist lube tasks be triggered by timebased<br />
events rather than condition.<br />
The same competitive advantages<br />
enjoyed by maintenance, also exist for<br />
lubrication programmes. As they play<br />
catch up, more success stories like our<br />
South African mine will appear. These<br />
success stories will be driven by innovative<br />
technology advancements from<br />
progressive ultrasound manufacturers.<br />
Indeed, ultrasound-assisted lubrication<br />
is the driving force that will realign<br />
these two reliability strategies back to<br />
their parallel path.<br />
40 maintworld 1/<strong>2017</strong>
Be a LUBExpert<br />
®<br />
A COMPLETE ULTRASOUND SOLUTION TO MANAGE YOUR ACOUSTIC LUBRICATION PROGRAM<br />
Poor greasing practices are<br />
a leading cause of bearing failure.<br />
Many lube departments re-grease on a wasteful<br />
calendar-based schedule. This leads to over and<br />
under greased bearings that fail to deliver their<br />
engineered value.<br />
LUBExpert tells us when to grease...<br />
and when to stop.<br />
Grease reduces friction in bearings. Less friction<br />
means longer life. LUBExpert alerts you when<br />
friction levels increase, guides you during<br />
re-lubrication, and prevents over and under<br />
lubrication.<br />
Grease Bearings Right<br />
Right Lubricant<br />
Right Location<br />
Right Interval<br />
Right Quantity<br />
Right Indicators<br />
Ultrasound Soluons<br />
sdtultrasound.com/lubexpert
MAINTENANCE MANAGEMENT<br />
Reliability and Maintenance<br />
Management Beliefs<br />
Excellent leadership is an essential success factor for lasting results for any<br />
improvement initiative an organization undertakes. As a leader you need to<br />
create an organization of disciples that will follow you to make your vision,<br />
or future organization, a reality.<br />
CHRISTER<br />
IDHAMMAR,<br />
Founder and CEO of<br />
IDCON INC.,<br />
Raleigh NC, USA,<br />
info@idcon.com<br />
AS A LEADER it is very important to develop<br />
and communicate your beliefs to<br />
your organization. In this column I will<br />
share three beliefs that I hope can serve<br />
as a guideline to develop your own beliefs<br />
for the benefit of your organisation.<br />
The holistic system with its<br />
processes and elements can be<br />
supported by other tools and<br />
supporting processes.<br />
A holistic overview of the reliability and<br />
maintenance management system, processes,<br />
elements, tools and supporting<br />
processes can be described in the models<br />
below:<br />
The System<br />
The market drives the production plan,<br />
all maintenance work requiring shut<br />
down of equipment must be coordinated<br />
with the production plan for best time to<br />
be executed. When maintenance work<br />
is planned and then scheduled you have<br />
set the process that people work in correctly<br />
so they can execute work much<br />
more safely and more cost effectively. To<br />
plan work efficiently you must have access<br />
to an up to date technical database<br />
including Bills of Materials (BOM) and<br />
other information. After work is completed<br />
it should be recorded as to what<br />
was completed, parts and material used,<br />
update information to BOM and other<br />
valid information. The recorded information<br />
shall be used to continuously<br />
improve utilising Root Cause Problem<br />
Elimination (RCPE). However, most<br />
organizations do not work in this “Circle<br />
of Continuous Improvement” they work<br />
too much in the “Circle of Despair”. This<br />
means that they React to problems at<br />
short notice and bypass the planning and<br />
scheduling of work. Repairs made will<br />
therefore be of low quality. Because of<br />
this, failures will be Repeated and it will<br />
be necessary to Return to do the work<br />
again and the circle Repeats itself. To get<br />
out of this “Circle of Despair” you must<br />
set up the processes for Prevention,<br />
Condition Monitoring, Prioritization,<br />
Planning of work, and Scheduling of<br />
work, Execution of Work, Recording of<br />
executed work, and how to do RCPE.<br />
The Processes<br />
An example of a process is Planning and<br />
Scheduling, or the Work Management<br />
Process. It contains several steps and<br />
starts with Work Request then Priority<br />
of Request etc. as seen in the picture<br />
below.<br />
Within the process called Planning<br />
and Scheduling each step consists of a<br />
number of elements. E.g. the best practice<br />
within the work request process<br />
is that the request is not a work order<br />
and shall be done using the Computerized<br />
Maintenance Management System<br />
(CMMS), the requested priority shall<br />
be done according to a priority guideline<br />
agreed to between operations and<br />
maintenance. The object identity shall<br />
be clearly described verbally and with<br />
equipment number, etc. These elements<br />
are what we call the right things to do.<br />
The Tools and Supporting Processes<br />
The tools can be used to improve the<br />
processes in the holistic system. To avoid<br />
confusion and the “programme of the<br />
month ailment”, it is very important that<br />
tools are not mixed up with the holistic<br />
system. To be successful you must have<br />
a very well established holistic system<br />
including its processes. Tools such as 5S,<br />
Six Sigma, Reliability Centred Maintenance<br />
(RCM) etc. are good and very useful<br />
when used in the right environment.<br />
Implementation of only a tool will only<br />
result in temporary non-sustainable<br />
improvements. The holistic system and<br />
processes must be in place to support<br />
sustainability and continuous improvement.<br />
Always Explain What, Why<br />
and How<br />
People do not mind change, but they do<br />
not like to be changed. Any improvement<br />
initiative is a selling process. You<br />
need to have a clear vision of what the<br />
improvement initiative entails and why<br />
it is necessary to do it. You might have a<br />
clear idea of how it is going to be done,<br />
but after explaining the “what” and the<br />
“why” it is effective to ask people involved<br />
in the improvement initiative to<br />
come up with ideas on how they think<br />
it can be done. Focus first on getting an<br />
agreement on “The right things to do”<br />
then discuss how to do it. It is easier for<br />
people to agree on the right things to do<br />
than on how to do these things.<br />
Many organizations put too much<br />
emphasis on change management and<br />
make this more complicated than necessary.<br />
We often hear “We already do this”<br />
and this might be true. Most organizations<br />
do most of the elements of best reliability<br />
and maintenance practices, but<br />
most can do these elements much better.<br />
Of course there might be an element of<br />
change with some people, but as most<br />
42 maintworld 1/<strong>2017</strong>
MAINTENANCE MANAGEMENT<br />
of the improvements we talk about here<br />
are common sense and nothing new, the<br />
change management element should not<br />
be neglected but also not overdone.<br />
It can also help to describe, “What<br />
good looks like” and present a picture of<br />
what the future will look like. That is:<br />
• Production Reliability<br />
improved by 3 percent<br />
• Maintenance cost down by<br />
15 percent<br />
• Very few maintenance people<br />
on late shift (24/7 operation)<br />
• Majority of basic equipment<br />
done by trained operators<br />
• And so on<br />
Execution is Key to Success<br />
The elements of a maintenance management<br />
system have not changed much<br />
since the 1960s. Technology such as<br />
computerized maintenance management<br />
systems and predictive maintenance<br />
tools have changed dramatically<br />
and are today much better and much<br />
more affordable. Since the 1970s industries<br />
have moved away from fixed-time<br />
overhauls and replacements of equipment<br />
components to much more condition-based<br />
maintenance.<br />
It should be obvious that an improvement<br />
plan is executed, but many plans<br />
are never implemented to completion<br />
before a new initiative starts. I have seen<br />
so many excellent plans and Power Point<br />
presentations followed by no action.<br />
The time it takes to develop a best<br />
practices document, define roles for<br />
the team members involved to lead the<br />
project, educate the team members, and<br />
agree on a common repeatable assessment<br />
methodology and strategy documents<br />
might be 5 percent of the total<br />
effort. To get acceptance from those who<br />
are going to implement might be 10 percent<br />
of total effort, the remaining 85 percent<br />
is On-The-Job training and coaching.<br />
Often the time is spent more on<br />
development etc. and almost no time is<br />
spent on supporting execution through<br />
On-The-Job training and coaching.<br />
The only major difference I have seen<br />
between the best performers and the<br />
lagging organizations is that the best<br />
performers execute well-defined best<br />
practices. Most organizations know what<br />
they need to do, but they do not consistently<br />
execute the best practices better<br />
and better.<br />
1/<strong>2017</strong> maintworld 43
XXXXXX ASSET MANAGEMENT<br />
Text: NINA GARLO-MELKAS, <strong>Maintworld</strong>-magazine<br />
Extracting Maximum<br />
Economic Value from<br />
Ageing Assets<br />
More than 40 maintenance professionals<br />
from chemical production plants in<br />
Benelux joined Mainnovation last<br />
month to discuss challenges facing their<br />
industry. The key message of the event<br />
was straightforward: maintenance is an<br />
increasingly critical factor for industrial<br />
companies. More attention must,<br />
however, be devoted now to extending<br />
service life of ageing plants and to<br />
technological modernisation.<br />
44 maintworld 1/<strong>2017</strong>
ASSET MANAGEMENT<br />
Mark Haarman, Managing Partner of<br />
consultancy company Mainnovation N.V.<br />
THE KEY TOPIC of the special event was<br />
ageing assets. The subject is important<br />
because industry in the western countries<br />
is ageing rapidly. Not so much in<br />
terms of employees, but in terms of<br />
production assets. Moreover, the phenomena<br />
is not only facing the chemicals<br />
industry, but other industries as well,<br />
including the pharmaceutical and food<br />
and beverage sectors of western economies.<br />
– Many plants especially in the chemicals<br />
industry in western countries were<br />
built after World War II, and after 40-50<br />
years of operation they are now rapidly<br />
approaching the end of their service life.<br />
This is the new challenge faced by many<br />
modern-day maintenance managers,<br />
says Mark Haarman, Managing Partner<br />
of consultancy company Mainnovation<br />
N.V. of the Netherlands.<br />
Mainnovation specialises in Maintenance<br />
& Asset Management. The company<br />
has developed a so-called VDMXL<br />
methodology for Value Driven Maintenance<br />
and Asset Management, which<br />
explains how to extract maximum economic<br />
value from an existing plant, fleet<br />
or infrastructure using a professional<br />
management approach. Now, with the<br />
firm having successfully staged its first<br />
a sector-specific event with focus on the<br />
chemicals sector, it plans to organise similar<br />
happenings this autumn for professionals<br />
operating in the pharmaceutical<br />
and food and beverage industries as well.<br />
Learning from Good Examples<br />
Several case examples were introduced<br />
in the event’s presentations by representatives<br />
of major chemicals businesses.<br />
These included industry leader<br />
BASF from Germany, maintenance organisation<br />
Sitech from the Netherlands,<br />
and EVAL Europe N.V. – Belgium-based<br />
division of Japanese chemicals company<br />
Kuraray, which specialises in the production<br />
of various barrier materials. Each<br />
company presented examples of how<br />
they have themselves managed to compete<br />
against ageing assets in the highly<br />
competitive global chemicals market.<br />
– We started with chemicals companies<br />
because the challenges of ageing<br />
assets is quite notable in the industry.<br />
The event also marked a kick-off start<br />
to building a new maintenance network<br />
for the sector, which will give its companies<br />
the opportunity to learn from each<br />
Discover<br />
the hidden<br />
treasure in<br />
Maintenance<br />
Discover<br />
the hidden<br />
treasure in<br />
Maintenance<br />
There is value hidden in every maintenance organization. All companies have the potential to further improve, either by reducing<br />
costs, improve safety, work on the lifetime extension of machinery or by smart maintenance solutions that improves uptime. The<br />
question is where maintenance managers should be looking to fi nd these areas of improvement and where they need to start.<br />
You will fi nd the answer to this question at Mainnovation. With Value Driven Maintenance ® and the matching tools like the VDM<br />
Control Panel, the Process Map and our benchmark data base myVDM.com, we will help you to discover the hidden treasure in<br />
your company.<br />
Do you want to discover the hidden treasure in your maintenance organization?<br />
Go to www.mainnovation.com<br />
CONTROLLING MAINTENANCE, CREATING VALUE.
ASSET MANAGEMENT<br />
other, Haarman says.<br />
Haarman adds that the core message,<br />
which stood out from all presentations,<br />
was similar: to survive in the globalizing<br />
industry, we must increase the competitive<br />
strength of our ageing assets.<br />
– The challenge confirms that maintenance<br />
is an increasingly critical factor<br />
for industry. It also means that maintenance<br />
managers of industrial companies<br />
need to start replacing old technologies<br />
with modern solutions.<br />
Maintenance departments of the future<br />
must be drivers of improvement.<br />
This means that if a company is faced<br />
with ageing assets maintenance management<br />
is not enough – the company<br />
must also focus on asset management.<br />
– To stay competitive with ageing assets,<br />
chemical companies need to get<br />
more economic value from their existing<br />
plants. This can be done through<br />
uptime improvement, cost reduction,<br />
higher safety levels and/or lifetime extension,<br />
writer of the book “Value Driven<br />
Maintenance & Asset Management<br />
(VDMXL)”, Haarman, highlights.<br />
Evolution of Assets<br />
So what does the challenge of ageing<br />
assets mean in practice for a chemicals<br />
plant manager? Ultimately it brings out<br />
the need for a broader view on assets operated<br />
by chemical companies.<br />
Fig. 4.5<br />
– Maintenance managers need to<br />
change their business model. This requires<br />
another way of working, applying<br />
new best practices like asset portfolio<br />
management, brown field project management<br />
and predictive maintenance<br />
with big data. These best practices are<br />
incorporated in our VDMXL –model.<br />
TO SURVIVE IN THE<br />
GLOBALIZING INDUSTRY,<br />
WE MUST INCREASE THE<br />
COMPETITIVE STRENGTH<br />
OF OUR AGING ASSETS.<br />
Due to ageing assets the maintenance<br />
market in western countries is estimated<br />
to grow by as much as 20 percent in<br />
the coming years. This despite the swift<br />
increase of robotics and plant automatization,<br />
Industrial Internet of Things and<br />
digitalisation i.e. factors that have been<br />
viewed as potential threats to many industrial<br />
professions in the future.<br />
Haarman also specifies that the challenges<br />
related to ageing assets in industry<br />
are not only tied to technical aging but<br />
the commercial aging of plants as well.<br />
– Is the plant still producing a product<br />
that is in demand or does the company<br />
have to modernise the plant to be able<br />
to produce products that customers<br />
want to buy? The maintenance manager<br />
of tomorrow not only needs to look at<br />
technical ageing but also commercial<br />
and economic ageing.<br />
So what should the chemicals industry<br />
do to succeed better? Haarman<br />
notes that the first thing that chemical<br />
companies should start doing in to start<br />
measuring the performance of their<br />
Maintenance & Asset Management<br />
organisation. For this to be possible,<br />
Mainnovation is building on its already<br />
extensive database, which includes over<br />
1,000 industrial companies of which<br />
some 150 are chemical companies.<br />
– We have developed a VDMXL<br />
benchmarking platform with 12 Key<br />
Performance Indicators with which<br />
chemical companies can compare themselves<br />
with industry peers. By benchmarking<br />
the KPIs one sees directly how<br />
competitive the Maintenance & Asset<br />
Management organization is.<br />
Via the company’s new platform<br />
chemicals companies can obtain various<br />
data related to Maintenance & Asset<br />
Management. This includes information<br />
on technical availability, maintenance<br />
budgets, capital expenditures and<br />
planning compliances.<br />
VDMXL Competence Model<br />
46 maintworld 1/<strong>2017</strong><br />
© Mainnovation 2
CERTIFICATION TRAINING<br />
A Grease Caddy can be<br />
attached to a grease gun<br />
for easy lubrication.<br />
Building the Foundation for<br />
a Successful Ultrasound<br />
Programme<br />
Ultrasound is a key technology used by maintenance professionals all over the<br />
world. Its many applications and quick learning curve are adding to the popularity,<br />
but to get the maximum out of an ultrasonic inspection tool, companies need to invest<br />
in standardized Certification Training.<br />
48 maintworld 1/<strong>2017</strong>
CERTIFICATION TRAINING<br />
PETER BOON,<br />
European Training<br />
Manager, UE Systems<br />
Europe,<br />
peterb@uesystems.com<br />
THERE IS a lot one can do with an Ultrasonic<br />
inspection instrument. Leak detection<br />
is just one of its basic applications:<br />
listen to the leak, pinpoint it and fix it.<br />
Finding vacuum leaks, however, requires<br />
more experience and knowledge. The<br />
same goes for creating reports on detected<br />
and repaired leaks to include savings,<br />
costs, LPM losses and the carbon<br />
footprint.<br />
More recently, ultrasound has become<br />
the primary choice when it comes<br />
to optimizing a lubrication programme.<br />
UE Systems Grease Caddies are designed<br />
specifically to perform conditionbased<br />
lubrication. There is a lot more<br />
however: creating a lubrication programme<br />
using data management software<br />
like DMS or correctly setting up a<br />
dB baseline for bearings can make a huge<br />
difference in your asset’s lifetime.<br />
Maintenance professionals can also<br />
use ultrasound for an efficient steam<br />
traps & valves inspection, with the right<br />
accessories and procedures. Ultrasound<br />
can even pick up certain electrical failures<br />
- do you know you can identify a<br />
specific electrical failure by making a<br />
sound recording with the ultrasonic<br />
instrument, and analysing it on special<br />
sound analysis software such as Spectralyzer?<br />
There is a lot ultrasound can do for<br />
a maintenance programme. To get the<br />
ULTRASOUND TECHNOLOGY WILL PROVE ITS BENEFITS<br />
AND RESULTS IN SHORT TIME.<br />
maximum out of it, training is fundamental.<br />
Well-trained inspectors will<br />
be able to explore all of the potential of<br />
ultrasonic inspection instruments. And<br />
from a management perspective, having<br />
qualified engineers working with standard<br />
procedures is a safe road to success.<br />
Ultrasound<br />
Certification Training<br />
UE Systems offers two options for Ultrasound<br />
Certification Training – Level<br />
I and Level II – meeting the requirements<br />
of the American Society for Nondestructive<br />
Testing (ASNT) Recommended<br />
Practice, SNT-TC-1A and in accordance<br />
with ISO 18436-8, the standard<br />
for condition monitoring and diagnosis<br />
of machines. These are 32-hour courses,<br />
consisting on a mix of theory and handson<br />
practice, covering all application<br />
areas of ultrasound, operation, test procedures<br />
& how to use the software.<br />
Topics Covered<br />
These are the topics covered by a Level I<br />
Ultrasound Training course:<br />
EXTEND YOUR BEARINGS LIFE<br />
USING ULTRASOUND<br />
An Ultrasonic<br />
Instrument is<br />
the perfect tool<br />
to inspect<br />
and lubricate<br />
your bearings!<br />
ULTRAPROBE ® 15000<br />
For Inspection<br />
Detect early bearings failures<br />
Easily create a bearings route<br />
Trend your bearings condition<br />
Set alarms for early failures<br />
Make sound recordings of<br />
your bearings for analysis<br />
GREASE CADDY ® 401<br />
For Lubrication<br />
Listen to your bearings and<br />
know when to stop lubricating<br />
Avoid over-lubrication:<br />
the cause of over 60% of<br />
bearing failures<br />
Receive alarms when your<br />
bearings need lubrication<br />
Start a lubrication program<br />
Windmolen 20, 7609 NN Almelo, The Netherlands<br />
info@uesystems.eu | www.uesystems.eu | Tel. +31 546 725 125
CERTIFICATION TRAINING<br />
With the<br />
correct training,<br />
inspectors can<br />
create reports<br />
on identified<br />
compressed air<br />
leaks.<br />
Learning how to<br />
analyse sound<br />
spectrum will<br />
help inspectors<br />
detecting early<br />
failures.<br />
50 maintworld 1/<strong>2017</strong><br />
• All aspects of airborne/structure<br />
borne ultrasound technology<br />
• Effective mechanical analysis,<br />
leak detection and electrical inspections<br />
• Compressed air leak surveys, condition-based<br />
lubrication, steam<br />
trap inspections, bearing analysis<br />
and electrical inspections<br />
• How to improve asset availability<br />
and company profitability<br />
• How to enhance recording and<br />
reporting skills through a data<br />
management software and special<br />
analysis software<br />
• How to reduce and save on energy<br />
consumption<br />
Maintenance professionals who wish to<br />
take their ultrasound programme even<br />
further can attend a Level II course,<br />
which will give them deeper knowledge<br />
on inspection techniques and procedures:<br />
• Sound theory & ultrasound principles<br />
• Advanced leak detection: pressure<br />
leaks, vacuum leaks, reporting<br />
and costs analysis, developing a<br />
compressed air programme/procedures<br />
• Electrical inspection: inspection<br />
methods, spectral analysis, developing<br />
an electrical inspection<br />
programme<br />
• Valve inspection: configure instruments,<br />
software for ABCD<br />
record keeping and reporting,<br />
review of compressors<br />
• Steam traps: software for steam<br />
trap record keeping, data logging<br />
and steam cost analysis, review<br />
procedures<br />
• Bearings: monitoring, trending<br />
and lubrication, set up alarm<br />
groups and trend reports, developing<br />
a bearing detection / lubrication<br />
programme<br />
How to achieve Ultrasound<br />
Level I/Level II Certification<br />
Normally the training courses consist<br />
of open enrolment sessions, which are<br />
scheduled in advance. UE Systems has<br />
available trainings all over the world,<br />
in different languages, offering more<br />
than 80 annual courses worldwide.<br />
On-site Level I training is also a possibility;<br />
in case a company wishes to train a<br />
whole maintenance team at their own<br />
facility.<br />
In order to achieve the official certification,<br />
one must pass the general,<br />
specific and practical examinations with<br />
a score of 80 percent or more.<br />
Level II certification can only be obtained<br />
after getting the Level I certification.<br />
The complete agenda for the training<br />
sessions provided by UE Systems can be<br />
found at:<br />
United States:<br />
www.uesystems.com/training/<br />
Europe: (training sessions available<br />
in English, French, German, Spanish and<br />
Polish)<br />
www.uesystems.eu/training-agenda<br />
Application & Implementation<br />
Training<br />
Besides certification courses, UE Systems<br />
also provides other training solutions<br />
regarding the use of ultrasound in<br />
maintenance and reliability activities:<br />
On-site introduction training<br />
• Typically, ½ or 1-day course<br />
• Operation of the equipment &<br />
software<br />
• Where it can and where it cannot<br />
be used<br />
On-site implementation training<br />
• Typically, 2 or 2½ days (but can<br />
be customized)<br />
• Custom tailored training depending<br />
on the application interests<br />
• Hands-on orientated training to<br />
help setup a maintenance programme<br />
• Setup of test cases & evaluation<br />
MAINTENANCE<br />
PROFESSIONALS CAN<br />
CARRY OUT A VARIETY OF<br />
TASKS WITH ULTRASOUND<br />
TECHNOLOGY.<br />
Application specific training<br />
• Typically 1-day course<br />
• Application specific subjects:<br />
– Steam trap inspection courses<br />
– Leak auditing courses<br />
– Electrical inspection courses<br />
– Bearing inspection,<br />
optimizing lubrication pro<br />
gramme courses<br />
When companies want to achieve excellence<br />
in their maintenance programmes<br />
and get the maximum possible return on<br />
their investment, training their technicians<br />
is fundamental. A well-trained<br />
maintenance team will bring huge savings<br />
in money & energy spending and<br />
will keep the company’s assets always in<br />
top-condition, reducing downtimes and<br />
maintenance costs. Ultrasound technology<br />
together with training is a sure bet<br />
for any company and will prove its benefits<br />
and results in short time.
More Uptime.<br />
Better Returns.<br />
Strategy Management<br />
Zero tolerance for unexpected failures.<br />
Your assets are the value delivery engine of your business. Their most<br />
important function is to operate as engineered for their intended design<br />
life. With predictable performance and predictable results. Maximizing the<br />
return on your capital employed (ROCE), allowing you to bank more of your<br />
turnover. Being less sensitive to uncontrollable external factors such as<br />
commodity price fluctuations, macroeconomics, or monetary policies.<br />
Nexus Global Strategy Management implementations typically result<br />
in a 15%-40% reduction in operational costs with a 5%-10% increase in<br />
capacity utilization while maintaining or improving the risk tolerance of<br />
the business.<br />
Download our whitepaper and learn more at<br />
www.nexusglobal.com/bankonuptime<br />
+31.30.799.5050<br />
europe@nexusglobal.com
VIBRATION DIAGNOSTICS<br />
When VIBRATION DIAGNOSTICS<br />
Fails to Work<br />
In some cases the use of<br />
applied diagnostics fails<br />
to give you the expected<br />
end result. For instance,<br />
a company may buy<br />
a system for vibration<br />
diagnostics and offer<br />
proper training on the<br />
device to its staff, but<br />
still the anticipated results<br />
from it use, such as<br />
reduced costs and less<br />
unexpected shutdowns,<br />
are just not forthcoming.<br />
Why is this so?<br />
52 maintworld 1/<strong>2017</strong><br />
EVA GERDA BOJKO,<br />
Adash,<br />
eva.gerda@adash.cz<br />
THERE ARE a few factors, which may<br />
cause applied diagnostics to not be efficient.<br />
In this article we will have a look<br />
on what can go wrong.<br />
Vibration diagnostics needs<br />
proper knowledge<br />
The goal of vibration diagnostics is to<br />
receive the information about the current<br />
machine condition and decide if the<br />
condition is good, or if some repairs or<br />
adjustments need to be made.<br />
First of all, it is crucial to train the<br />
maintenance staff that uses the vibration<br />
diagnostics equipment. Vibration<br />
diagnostics is definitely a scientific discipline.<br />
However, this does not mean that<br />
the person using a vibration meter needs<br />
to have a deep knowledge of its theory!<br />
Obviously, when we train the maintenance<br />
staff that will be responsible for<br />
data collection and basic data trending,<br />
they don’t need knowledge of advanced<br />
data analysis such as orbits or similar issues.<br />
It is important to provide the appropriate<br />
level of knowledge and training.<br />
However, the person using an advanced<br />
vibration analyzer should have<br />
advanced knowledge. It is not enough to<br />
buy an expensive professional analyzer<br />
when we do not have anybody who can<br />
understand the measured data.<br />
Vibration evaluation is very similar<br />
to X-ray photo evaluation in medicine.
VIBRATION DIAGNOSTICS<br />
Some things are obvious and visible to<br />
almost anyone, but a more advanced<br />
evaluation depends on the doctor’s experience<br />
and knowledge.<br />
You can probably see that it would be<br />
not be wise to set up automatic standards<br />
for X-ray photo evaluation. With<br />
vibration diagnostics it is the same, the<br />
procedures and some limit values can be<br />
recommended, but the vibration diagnostician<br />
needs to make the final decision<br />
and evaluate the reading.<br />
Failing Communication<br />
between Maintenance Staff<br />
and the Diagnostic Team<br />
There are different organizational structures<br />
in different companies. The following<br />
scheme however, is common: vibration<br />
diagnosticians collect and evaluate<br />
the data and the mechanical maintenance<br />
staff take care of the repairs and other<br />
machine treatments. If the communication<br />
and data transmission between those<br />
two teams does not work properly, it unavoidably<br />
leads to poor results.<br />
maintenancenext<strong>2017</strong>-210x145-UK-hr.pdf 1 23-2-<strong>2017</strong> 15:04:46<br />
Whatever the structure in your company<br />
looks like, the communication and<br />
understanding of data is essential. If decision-makers<br />
do not have sufficient information,<br />
they obviously cannot make<br />
the right decision. Correct advanced<br />
vibration analysis is worthless if it just<br />
stays in the hands of those who cannot<br />
take any further steps or decisions.<br />
Moreover, the reports about machine<br />
condition should be accessible throughout<br />
the whole company for everybody<br />
who is responsible for the machines.<br />
Those reports should ideally include recommendations<br />
for further actions and<br />
deadlines when those actions need to be<br />
taken by.<br />
Proper Customer Service<br />
is Missing<br />
Customer service provided after purchasing<br />
the product is essential. When<br />
you buy an expensive professional analyzer<br />
it is necessary to be able to contact<br />
somebody who will answer your questions<br />
and provide you with sufficient<br />
information and training. Different<br />
systems have different functions and<br />
controls. It is important to know how the<br />
purchased system works and to be able<br />
to send questions directly to the producer<br />
and to get an answer. Unfortunately,<br />
contact details for the producer are not<br />
always available nowadays.<br />
The Human Factor<br />
The human factor is definitely one of<br />
the main influences on vibration diagnostics<br />
efficiency. The best situation is<br />
if when the person who is responsible<br />
for diagnostics is also the person who is<br />
interested in it. Vibration diagnostics is a<br />
fascinating field and a personal interest<br />
can fundamentally increase its efficiency.<br />
The more the person knows and cares<br />
about the machines, the better the diagnostics<br />
results are. If diagnostics tasks<br />
are given to a person who already has<br />
plenty of work under his or her responsibility<br />
(usually electricians) without<br />
increasing their salary, the results will be<br />
poor, or totally nonexistent.<br />
Register<br />
for a free visit<br />
PARTNERS IN PERFORMANCE<br />
Visit Maintenance NEXT in Rotterdam Ahoy from 11 to 13 April <strong>2017</strong>. The technology and<br />
maintenance expo in the Benelux, building on today’s and tomorrow’s maintenance industry.<br />
Go to www.maintenancenext.nl for an overview of all participants and the programme.<br />
@MaintenanceNEXT<br />
Strategic partners<br />
Organizer
VIBRATION DIAGNOSTICS<br />
Wrong System Purchased<br />
A top-quality, but inappropriate system<br />
is sometimes purchased by companies.<br />
When the decision of purchasing a new<br />
diagnostic product relies solely on the<br />
economic department, who only has<br />
the list of the required functions, the<br />
wrong decision may be made. Only a<br />
person with the appropriate knowledge<br />
can make a decision for the right solution.<br />
Moreover, you should consider the<br />
achievable skills of your staff properly<br />
before purchasing a system. You will not<br />
achieve expected results from purchasing<br />
an advanced system for somebody<br />
who will never learn how to use it.<br />
Wrong Application<br />
It is necessary to use the vibration measurement<br />
devices according to rules,<br />
which ensure correct signal transmission<br />
between the inspected machine<br />
and the measuring device. If not, we can<br />
get an incorrect reading; even an experienced<br />
diagnostician is unable to read<br />
the information that is simply not there.<br />
For example, measuring places are very<br />
important; we need to select the correct<br />
places and also prepare them properly.<br />
The best solution is to use measurement<br />
pads and glue them to the measuring<br />
points. This ensures good transmission<br />
of the signal and repeatability of the<br />
measurements.<br />
Insufficient Communication<br />
with External Service Provider<br />
All of the reasons above describe the<br />
situation when the company itself takes<br />
care of the diagnostics applied. The other<br />
option is to hire an external company<br />
providing diagnostic services. In some<br />
cases this could definitely be a good solution,<br />
especially in cases when we know<br />
we are not able to ensure all the factors,<br />
which are mentioned above. However,<br />
in this case all the issues are also not<br />
automatically solved. In this case the<br />
communication between the factory and<br />
diagnostics service company together<br />
with its correct interpretation are essential.<br />
Both groups needs to work as partners<br />
and discuss the finding and recommended<br />
solutions. Recommended steps<br />
by a service company should be taken,<br />
otherwise the services are worthless.<br />
There is one disadvantage when hiring<br />
an external service company, which cannot<br />
be reduced easily and that is the fact<br />
that they don’t know the machinery park<br />
as well as the employees of the company<br />
itself. The factory employees must say<br />
and report what they experience and see<br />
on their machinery to reduce this factor.<br />
A typical example of bad communication<br />
is a situation when the maintenance staff<br />
carried out a machine repair and nobody<br />
informed the external company about<br />
that repair. Then the external service<br />
company stares at the new measurement<br />
and vainly tries to find the reason<br />
for machine condition change.<br />
Conclusion<br />
You may think that all the reasons listed<br />
above sound quite obvious. However, in<br />
practice we see that it is not so easy to<br />
fulfill them all. Unfortunately, the listed<br />
mistakes can lead to the wrong judgment<br />
that the vibration diagnostics methods<br />
themselves are not working. The company<br />
may blame the method for not working<br />
as they imagined, but in this case the<br />
problem is only the bad application of<br />
the method. Correctly applied vibration<br />
diagnostics is definitely worth doing and<br />
it is a very effective part of a predictive<br />
maintenance programme.<br />
54 maintworld 3/2016 1/<strong>2017</strong>
PREDICTIVE MAINTENANCE 4.0<br />
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