Maintworld Magazine 1/2021
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1/<strong>2021</strong> www.maintworld.com<br />
maintenance & asset management<br />
Five Key Benefits of Improving<br />
Operations with Modern p 6<br />
Wireless Vibration Monitoring<br />
THE DAY AFTER TOMORROW IN ASSET PERFORMANCE PG 10 PRECISION BELT ALIGNMENT AND WHAT IT ENTAILS PG 22 MONETIZING DATA IN MAINTENANCE PG 48
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EDITORIAL<br />
Release the<br />
power of data<br />
AFTER OVER 20 YEARS working<br />
with customers within maintenance,<br />
I still do not see much focus<br />
on the output of the CMMS:s. I see<br />
two actions all companies should<br />
take here. First, set the analysis<br />
tools free for all users and bring on<br />
the creativity!<br />
Put effort in providing a userfriendly,<br />
neat, and really attractive<br />
tool for users. Let them be amazed<br />
and baffled by the nice charts and<br />
turning tables of data. Let them<br />
twist the filters like there is no tomorrow.<br />
Throwing the figures around<br />
gets creativity going. Finding new<br />
insights and possibilities you never knew of. More results and more good decisions<br />
will come. New intrapreneurs will step forward.<br />
I am a big fan of securing good data and having valid models of analysis. Users<br />
not used to this will fall into easy traps and might present bad data charts…<br />
there is always a learning curve.<br />
When we within maintenance talk about KPIs and the importance to measure<br />
and benchmark, we absolutely need secured data and valid models. Often<br />
the data tools are built around that, with terrible static reports, printable, for<br />
a few users. I have also seen some pretty good intentions – but very little in 20<br />
years.<br />
So, the second action needed is to set a good maintenance strategy with<br />
defined goals and find needed data-points to measure. The more defined, the<br />
easier to find out your measures. Here you set a few important KPI:s (Key Performance<br />
Indexes) controlling your process. For the every-day running of business<br />
there needs to be another bunch of measures. In order to know what to do<br />
now, how to prioritise the day and week.<br />
We call it to be Data-Driven. Knowing where to put effort, by fact. No estimates,<br />
no fiction, but real data from all that hard work we have put into our<br />
CMMS:s 24-seven for years. All those years... is the data at all in good quality? –<br />
you will not know until you start looking.<br />
At Trivalo we talk about Data-Driven Maintenance in the means of making<br />
both strategic and operational decisions based on good data. No matter<br />
on what level and how manual or automated. It is important that both the<br />
long-term KPI:s and the operational measures are defined, communicated and<br />
visual for all to act upon.<br />
But, I am just saying. While setting your business goals and creating your<br />
dashboards. Do not forget to release the data for all to play with. Analysis is a<br />
free-form art of insights, fuelled by your creativity, and only limited by the tools<br />
provided. Start playing with your data and learn how to move forward.<br />
With love,<br />
4 maintworld 1/<strong>2021</strong><br />
Mia Ilkko<br />
Senior Consultant Data-Driven Maintenance at Trivalo AB,<br />
B.Sc.; Cert. European Expert in Maintenance Management<br />
24<br />
The auto lubricant devices<br />
have evolved to become<br />
smarter. Many of them not<br />
only dispense the lubricant<br />
but can also set alarms based<br />
on excessive feedback and<br />
low lubricant.
IN THIS ISSUE 1/<strong>2021</strong><br />
32<br />
Digitalisation<br />
in the field<br />
of capital goods cannot be<br />
viewed as an isolated trend,<br />
but must be embedded in<br />
key current trends.<br />
=<br />
38<br />
Keeping<br />
the Lights On<br />
and Preventing Failures.<br />
SPI Inspections provides<br />
customers with topnotch<br />
utility system and<br />
infrastructure inspections.<br />
6<br />
Five Key Benefits of Improving<br />
Operations with Modern Wireless<br />
Vibration Monitoring<br />
10<br />
14<br />
18<br />
The Day After Tomorrow in Asset<br />
Performance<br />
Next Level Energy and Alarm<br />
Management in ICONICS’ Latest Release<br />
We Succeeded, what is Next?<br />
22<br />
Precision Belt Alignment and what it<br />
Entails / Easy<br />
24<br />
Bearing Lubrication Reimagined:<br />
Remote and Real Time Friction<br />
Monitoring and Lubrication<br />
26<br />
Safe Operation of Software-<br />
Controlled Lifts<br />
30<br />
OPC UA including Ethernet TSN<br />
and Ethernet APL for the field: An<br />
intermediate goal has been achieved<br />
32<br />
Digitalisation of Production Systems:<br />
getting smart while keeping out of<br />
harm’s way?<br />
38<br />
42<br />
46<br />
Keeping the Lights On and Preventing<br />
Failures<br />
Cui Solution for Aging Plants.<br />
Maintaining Production During Critical<br />
Maintenance<br />
Creativity Was – and Still Is – Needed in<br />
Teaching and R&D Projects during the<br />
Pandemic Time<br />
48<br />
Monetizing Data in Maintenance: Datadriven<br />
Spare Parts Management –<br />
Part 2<br />
Issued by Promaint (Finnish Maintenance Society), Messuaukio 1, 00520 Helsinki, Finland tel. +358 29 007 4570 Publisher Omnipress Oy,<br />
Väritehtaankatu 8, 4. kerros, 01300 Vantaa, tel. +358 20 6100, www.omnipress.fi Editor-in-chief Nina Garlo-Melkas tel. +358 50 36 46 491,<br />
nina.garlo@media.fi, Advertisements Kai Portman, Sales Director, tel. +358 358 44 763 2573, ads@maintworld.com Layout Menu Meedia,<br />
www.menuk.ee Subscriptions and Change of Address members toimisto@kunnossapito.fi, non-members tilaajapalvelu@media.fi<br />
Printed by Reusner, www.reusner.ee Frequency 4 issues per year, ISSN L 1798-7024, ISSN 1798-7024 (print), ISSN 1799-8670 (online).<br />
1/<strong>2021</strong> maintworld 5
ASSET MANAGEMENT<br />
Five key benefits of improving<br />
operations with modern<br />
wireless vibration monitoring<br />
BY JOSE VERDUGO, vibration portables and wireless product manager, Emerson<br />
As many manufacturing<br />
organisations today move<br />
toward wireless monitoring<br />
technology, they<br />
have more choices than<br />
ever before. Users have<br />
found tremendous savings<br />
through monitoring technology<br />
and yet have had<br />
to guard against drowning<br />
in data or merely looking<br />
at the big picture rather<br />
than details. Either condition<br />
has meant potentially<br />
overlooking issues that can<br />
cause shutdowns.<br />
RECENT EVOLUTIONS IN VIBRATION<br />
MONITORING technology will bring users<br />
beyond their previous successes<br />
and assist with data digestion through<br />
organised and understandable views<br />
of conditions. With new technology in<br />
hand, users can now more easily find<br />
and address the root causes of machinery<br />
issues.<br />
It is important to bear in mind clear<br />
guidelines while matching personnel<br />
abilities and available time to the newly<br />
evolved wireless monitoring technologies.<br />
Manufacturers around the globe<br />
who are choosing wireless monitoring<br />
technology have found success by focusing<br />
on key elements such as improved<br />
safety, cost of implementation, decisionmaking<br />
support, intuitive operation, and<br />
overall return on investment.<br />
6 maintworld 1/<strong>2021</strong>
ASSET MANAGEMENT<br />
Improved Safety<br />
Monitoring for vibration in field equipment<br />
is critical because it can signal bearing wear,<br />
poor lubrication, and more – precursors to<br />
hazardous conditions. But because safety is<br />
the number-one priority in manufacturing<br />
facilities, it is out of the question to send<br />
personnel for route-based monitoring into<br />
areas where a potential safety situation may<br />
arise. However, monitoring must continue.<br />
Recently at a UK processing plant, vibration<br />
on an asset indicated impending failure.<br />
Rather than expose personnel to risk<br />
by performing manual vibration readings,<br />
the facility chose to implement a wireless<br />
vibration monitoring solution. Not only did<br />
the technology enable technicians to make<br />
fewer visits to a potentially hazardous site,<br />
the monitor increased visibility to the condition<br />
before it posed additional risks. Data<br />
was delivered remotely away from the risk<br />
to personnel and the facility team obtained<br />
enough data to trend and find solutions.<br />
Evolving with the technology, this company<br />
could continue to improve their solution<br />
by shifting to a technology that enables<br />
them to move the vibration monitor to<br />
different assets for temporary monitoring.<br />
In addition, they could install a wireless device<br />
– such as Emerson’s AMS Asset Monitor<br />
– that could monitor up to 12 assets<br />
simultaneously. When fewer devices are<br />
required to monitor more assets, the team<br />
needs fewer trips to the field and gains better<br />
visibility.<br />
Cost of Implementation<br />
Cabling and equipment costs can prohibit<br />
continuous, hard-wired online vibration<br />
monitoring. In these cases, organisations<br />
have typically substituted manual measurements<br />
taken via handheld units. But<br />
quite often, manual readings do not enable<br />
the organisation to attain adequate<br />
analysis and trending because the manual<br />
readings require time and expertise. In addition,<br />
to achieve the most accurate picture<br />
of conditions, a facility might need a greater<br />
variety of sensor input options such as<br />
accelerometer placements.<br />
One power producer moved to a wireless<br />
solution that was versatile enough in<br />
its configuration and installation to deliver<br />
savings during implementation. The<br />
organisation needed to monitor a motor<br />
housed in a gas turbine auxiliary compartment<br />
where a cabled monitor would not be<br />
cost effective. Because the compartment<br />
acted as a Faraday cage, they needed easy,<br />
robust wireless connectivity. In addition,<br />
they wanted to measure other rotating<br />
equipment as required without overextending<br />
maintenance personnel.<br />
The solution they found included wireless<br />
transmission and no need for expensive<br />
cabling. It also included a wireless<br />
vibration transmitter that instantly connected<br />
to their network with no additional<br />
wireless infrastructure, such as a repeater.<br />
The transmitter and connected sensors<br />
could be moved as needed and the accelerometer<br />
configuration was flexible enough<br />
to be easily adapted to the situation.<br />
By embracing the next generation of<br />
wireless vibration monitoring – for example<br />
Emerson’s AMS Wireless Vibration<br />
Monitor – the ease and speed in which<br />
the power producer could implement<br />
monitoring of additional equipment could<br />
be increased greatly. With a standalone<br />
device, which includes both transmitter<br />
and sensor, installation and configuration<br />
becomes extremely easy. These devices,<br />
which can be preconfigured or configured<br />
onsite using a wireless gateway or handheld<br />
device, enable the company to place<br />
at any location in the facility immediately<br />
without needing to install and connect<br />
separate sensors to the transmitter. This<br />
gives almost instant access to readings<br />
and complete visibility of the health of that<br />
equipment.In addition, a longer battery<br />
life and field-replaceable batteries means<br />
1/<strong>2021</strong> maintworld 7
ASSET MANAGEMENT<br />
the user can plan for less maintenance and<br />
fewer trips to the asset being monitored. All<br />
these capabilities mean faster deployment,<br />
less engineering, and quicker return on<br />
investment.<br />
Decision-Making Support<br />
Effective decision making relies on many<br />
factors. For example, if operators receive<br />
unfocused alerts or alerts presented in a<br />
confusing format, they can become distracted.<br />
To remain focused on the correct<br />
problems and find ways to solve them, personnel<br />
should have effective tools such as<br />
online vibration monitoring.<br />
Online vibration monitoring can help<br />
predict when a failure will occur and alert<br />
maintenance to prevent unexpected shutdown.<br />
When personnel receive alerts via<br />
wireless, they can more simply make the<br />
right decisions because they have the information<br />
at their fingertips.<br />
In addition, wireless technology is an<br />
enabler to help focus personnel’s attention<br />
on the most important tasks to enable efficiency.<br />
Solutions have offered alerts delivered<br />
as intuitive health values that many<br />
plant personnel can quickly interpret.<br />
As users evolve with the wireless vibration<br />
monitoring technology, they will be<br />
able to receive alerts and interpret great<br />
amounts of data from a variety of platforms.<br />
In fact, the latest monitoring advances<br />
make it possible for users, through Emerson’s<br />
PeakVue Plus analytics, to immediately<br />
determine the root cause of the defect<br />
on a given machine. This power can provide<br />
them a more sophisticated look at asset<br />
health, including overall values, analysis parameter<br />
trends, spectrums, and waveforms.<br />
Intuitive Operation<br />
Without intuitive operation, vibration<br />
monitors might provide data without<br />
follow-up from the facility team – ease of<br />
use is key for follow-up action. Recently, another<br />
UK end user needed their operators<br />
to have information available easily and<br />
quickly, so they chose to implement a solution<br />
where vibration data was transmitted<br />
directly from equipment to the control<br />
system.<br />
More than simply data, their solution<br />
involved an intuitive health score through<br />
Emerson’s PeakVue technology. The data<br />
could be trended to determine when the<br />
equipment was going to fail. This solution<br />
enabled improvement of maintenance<br />
scheduling while avoided taking equipment<br />
offline when failure was not imminent. And<br />
because the information was continuous<br />
EVOLUTIONS IN VIBRATION<br />
MONITORING HAVE PROVIDED<br />
AN ALTERNATIVE TO ROUTE-<br />
BASED AND CONTINUOUS<br />
MONITORING USING HARD-<br />
WIRED DEVICES.<br />
and always available, personnel did not<br />
need to wait for collection or its subsequent<br />
analysis.<br />
As wireless vibration monitoring<br />
evolves, the users of PeakVue technology<br />
can choose monitoring devices that are<br />
supported through embedded prescriptive<br />
analytics powered by technology such as<br />
PeakVue Plus. The embedded intelligence<br />
enables teams quickly and easily to differentiate<br />
between mechanical problems<br />
– such as rolling element bearing defects<br />
– and root-cause issues such as insufficient<br />
lubrication.<br />
Return on Investment<br />
Assets that are monitored using wireless<br />
vibration can significantly impact the plant.<br />
Facilities find that they incur reduced impact<br />
when make repairs are made during<br />
scheduled rather than unscheduled downtime.<br />
Return on investment is often found<br />
by avoiding total asset failure, which can often<br />
cause irreparable damage and requires<br />
costly replacements of entire assets.<br />
A recent case proved the point at a power<br />
company that relied on a primary motor<br />
for continued operation. A shut down for a<br />
total overhaul would have reduced output<br />
capacity by 200MW and cost as much as<br />
£50,000 in lost revenue. Using a wireless<br />
vibration transmitter, the facility optimised<br />
their time and fixed the motor when market<br />
conditions minimised financial impact,<br />
and ran throughout the interim with<br />
wireless vibration monitoring continuing<br />
through the overhaul. The data that was<br />
sent to the control system in that interval<br />
freed up maintenance to do other jobs and<br />
keep their maintenance schedule.<br />
The next step for the company could be<br />
to choose a wireless monitor that can be<br />
immediately placed on the equipment to be<br />
monitored without the need for any wiring.<br />
This less complicated and less costly solution<br />
helps to speeds the return on investment<br />
for the user.<br />
Conclusion<br />
In general, evolutions in vibration monitoring<br />
have provided a true alternative to<br />
route-based and continuous monitoring<br />
using hard-wired devices. Users now can<br />
choose a solution that provides the raw<br />
data for deep-diving in tandem with the<br />
prescriptive analytics and tools to diagnose<br />
the underlying problems. Wireless has built<br />
a foundation for strong benefits discussed<br />
here and has expanded so much in recent<br />
years that users can take those benefits to<br />
new heights by updating and expanding<br />
their wireless technology.<br />
8 maintworld 1/<strong>2021</strong>
ASSET MANAGEMENT & TECHNOLOGY<br />
The Day After Tomorrow<br />
in Asset Performance<br />
Peter Hinssen is an entrepreneur, focused on start-ups for almost 20 years. He is a<br />
technologist at heart. About eight years ago, he decided to spend more time on telling<br />
the story about technology. He started teaching at MIT in Boston and London Business<br />
School (UK), and wrote a few books on how technology is changing the world.<br />
PETER HINSSEN BIOGRAPHY<br />
Peter Hissen is a serial entrepreneur, advisor,<br />
keynote speaker and author, Peter lectures<br />
at various business schools such as<br />
the London Business School (UK) and MIT<br />
in Boston. Peter has founded nexxworks to<br />
help organizations become fluid, innovate<br />
and thrive in 'The Day After Tomorrow'.<br />
10 maintworld 1/<strong>2021</strong>
ASSET MANAGEMENT & TECHNOLOGY<br />
Peter will be talking at the Asset Performance<br />
Awards about how companies<br />
and technical services can prepare for<br />
the future. How can you help your company<br />
in staying relevant The Day After<br />
Tomorrow?<br />
Peter, you will be present as a<br />
keynote speaker at the Asset<br />
Performance Awards. Can you<br />
explain where your interest in the<br />
industry comes from?<br />
It is a little bit personal because my father<br />
worked in the oil and gas industry<br />
his entire life, specifically Maintenance<br />
and everything that deals with process<br />
control. So, when I was a kid, it was all I<br />
heard from my dad coming home. And I<br />
think the evolution that you see in this<br />
industry is fascinating. New technologies<br />
are changing, in my opinion, tremendously:<br />
dealing with assets, managing<br />
performance, and thinking about prediction<br />
is going to change tremendously. So,<br />
I'm very excited to be part of this.<br />
Can you give some examples of<br />
technologies that will impact our<br />
world?<br />
Big Data. I mean, this is an industry that<br />
has always been interested in information.<br />
But now Big Data is becoming<br />
abundant. We have technologies to deal<br />
with that. We have machine learning,<br />
artificial intelligence, all these mechanisms<br />
of connectivity. I think if you put<br />
it all together, it's piling up technology<br />
after technology that is fundamentally<br />
changing how we think about how to<br />
deal with data. And I think it will have a<br />
tremendous impact on this industry.<br />
What do you think the main<br />
challenge of the industry today is?<br />
We're currently in a disruptive era. I<br />
use this word carefully, but it indicates<br />
a constant acceleration and the need to<br />
follow that speed. Lots of companies see<br />
a huge conflict between possibilities and<br />
reality. So this gap and tension between<br />
what is possible and what you do day to<br />
day is a big challenge. We need to take a<br />
huge leap in skills and technology. This<br />
is also an opportunity to become more<br />
critical of your company. Performance<br />
plays an important rule. And the reason<br />
why your company exists is absolutely<br />
core. But be careful what you wish for.<br />
Because once you enter the spotlight,<br />
you've got to deliver. Take up your role<br />
and realise it.<br />
What makes it so difficult to take up<br />
this role?<br />
Being able to tell the story and carry it<br />
out. Storytelling is key. IT people should<br />
be rock stars, but most of the time<br />
they're not so communicative. That's<br />
because they don't have the skills to tell<br />
their story. If you go from predictive<br />
maintenance to Asset Performance in a<br />
connected world, then you have so many<br />
touchpoints, that you have to broaden<br />
your gaze. You need more skills and<br />
competences. Your suppliers change.<br />
Your partners change. And everything<br />
becomes more fluid.<br />
In your book ‘The Day After<br />
Tomorrow’, you're talking about<br />
what is going wrong in companies<br />
today. What is your vision?<br />
Well, I have a very simple idea of how<br />
much time companies spend on today,<br />
tomorrow, the day after tomorrow. Most<br />
companies are very busy with today.<br />
And when they look at the future, they<br />
often extrapolate today, they think that<br />
tomorrow is approximately the same.<br />
But we're now facing so many different<br />
changes that there might be changes in<br />
business models or in technologies or<br />
new players coming onto the market.<br />
We have to think about this disruption,<br />
'this is the day after tomorrow', and how<br />
you deal with that. When I talk about<br />
today, tomorrow, the after tomorrow,<br />
many people say they dedicate 70-20-10<br />
percent of their time on it. The reality<br />
is we spend 93 percent of our time today,<br />
maybe 7 percent thinking about<br />
tomorrow and virtually none in the day<br />
after tomorrow. And I think in many<br />
industries, this was okay and in the 20th<br />
century. But we're now fully in the 21st<br />
century. That doesn't work anymore. We<br />
have to be much more flexible and agile.<br />
And that's why the day after tomorrow is<br />
more important than ever before.<br />
You will also talk about two<br />
interesting concepts: staying<br />
essential and staying relevant. How<br />
can we achieve that?<br />
Of course, you want to be essential. You<br />
want to do something that makes sense.<br />
If you do predictive maintenance, that<br />
is essential. If you work for customers,<br />
you're hoping that you are vital for<br />
that customer. But the other question<br />
1/<strong>2021</strong> maintworld 11
ASSET MANAGEMENT & TECHNOLOGY<br />
is, how relevant are you? And I think<br />
there's a very clear difference between<br />
essential and relevant. And I think an<br />
exampleis the telecoms industry. If you<br />
look at telecoms 10 years ago, a telecom<br />
operator was essential. You needed a<br />
SIM card, and they were relevant, they<br />
gave you added value. In today’s world,<br />
they are still essential, because you still<br />
need that SIM card. But the relevance<br />
has dropped. And therefore, if whatever<br />
capacity you have in an organization,<br />
whatever position you have in dealing<br />
with the outside world, that is the core<br />
question, are you essential? I hope you<br />
are. But how can you make sure that<br />
your relevance doesn't go down?<br />
And that brings us to the maintenance<br />
and quality department. They<br />
don't add value directly to the product.<br />
The customer doesn't pay for<br />
maintenance that was necessary to<br />
produce his product. But it is essential.<br />
So, what would your tip be to<br />
staying relevant?<br />
Well, I think it's because we're in an age<br />
where everything is interconnected. So,<br />
if you look at an organization, they are<br />
not silos anymore. We're in this network<br />
age, everything is connected to everything.<br />
So, when you say that your customer<br />
doesn't pay for the maintenance<br />
directly, that's true, but your customer<br />
will feel, see, and understand whether<br />
this is something which is integral in<br />
terms of quality thinking or performance<br />
management. And in the end, if<br />
your company wants to be flexible and<br />
fast and agile, you have to incorporate<br />
that into every part of the organization.<br />
Every fibre, every node, every element<br />
has to understand that you are part of a<br />
bigger picture, and you have to keep reinventing<br />
itself to be both essential and<br />
relevant for the outside world.<br />
On the other hand, in our industry,<br />
there are a lot of service providers.<br />
They are companies that perform<br />
maintenance activities and make<br />
services. How is this new and how<br />
will they need to evolve?<br />
We're more and more in this age of networks,<br />
thinking about ecosystems, the<br />
role that they play is different. We're<br />
beginning to see the old "I supply a<br />
product and that's it" is over. It's more<br />
and more a service type of activity. And<br />
what you see is, instead of the traditional<br />
boundaries, we get fluidity, we have<br />
more and more of that network and ecosystem<br />
type thinking. And that means<br />
that you're going to have new players<br />
entering the market very, very quickly.<br />
You're going to have traditional players<br />
who must reinvent themselves. And you<br />
have different types of partnerships and<br />
agreements that we need to figure out.<br />
And I think figuring out what your role<br />
is, as an external provider in this sea of<br />
fluidity in a connected world is going to<br />
be very fascinating.<br />
This connectivity is entering a lot of<br />
factories. They are experimenting,<br />
but we see some reluctance and<br />
difficulties to scale up. How can you<br />
solve that?<br />
Well, I think we're in a phase where a lot<br />
of the technologies are emerging. Take<br />
something like AI or machine learning<br />
that's relatively new. Most people don't<br />
understand it very well, there is a huge<br />
skill gap that we need to fill, because<br />
we need to train and prepare people for<br />
that. But a lot of things are just trying<br />
out, companies are experimenting and<br />
figuring out how to apply this, but it's a<br />
very early game.<br />
If you compare that to the PC industry,<br />
this was the time where we had<br />
Commodores and Ataris, and not the<br />
established industry like we have today.<br />
We're going through that phase. And if<br />
you're too early, you're going to burn a<br />
lot of money and not get a lot of results.<br />
But if you wait too long, you probably<br />
run the risk of becoming completely<br />
obsolete. I think it's making sure that<br />
you're constantly in tune that you're<br />
constantly alert that you follow this as<br />
closely as possible and make the right<br />
move at the right time. But you can only<br />
do that if you are prepared.<br />
How can people prepare for this skill<br />
challenge?<br />
I think they have to make time for it.<br />
Time is the biggest issue. To put your<br />
day-to-day work at the side is difficult,<br />
but you really must invest in these skills.<br />
Experiment at first, like tinkering with a<br />
fuse until something blows up. There are<br />
so many possibilities, also online, to test<br />
and try out different stuff. Everybody<br />
talks about life- long learning, but most<br />
managers don't do it themselves.<br />
Why should people attend your<br />
keynote at the Asset Performance<br />
4.0 Conference?<br />
I think this is one of the most fascinating<br />
industries that for a long time, has<br />
already worked with data. But it's now<br />
making a quantum leap. I'd love to talk<br />
about how I see that evolving, I hope to<br />
inspire you to maybe even do more than<br />
what you're doing today. But above all,<br />
to prepare us for, I think, a very disruptive<br />
wave that is going to affect everyone.<br />
And I think if we understand this,<br />
we can all actually come out even better<br />
as a result.<br />
INFORMATION<br />
CHECK OUT more information<br />
on the Asset Performance 4.0 Hybrid<br />
Conference & Exhibition <strong>2021</strong> via<br />
www.assetperformance.eu/<strong>2021</strong><br />
12 maintworld 1/<strong>2021</strong>
Scan me<br />
Hybrid Conference & Exhibition<br />
October 26-28, <strong>2021</strong><br />
Antwerp, Belgium<br />
The 4th Industrial revolution, IoT and predictive<br />
analytics are bringing unseen possibilities in<br />
maintenance, reliability and condition monitoring.<br />
The Asset Performance 4.0 Conference & Exhibition offers a<br />
unique opportunity to learn how new 4.0 technologies and<br />
fundamentals in operations, maintenance and asset<br />
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Keynote by Peter Hinssen (entrepreneur & MIT lecturer).<br />
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Powered by<br />
www.assetperformance.eu/<strong>2021</strong>
PARTNER ARTICLE<br />
Next Level Energy and<br />
Alarm Management in<br />
ICONICS’ Latest Release<br />
ICONICS is a global automation software provider of advanced industry 4.0 Webenabled<br />
OPC UA and BACnet certified visualization, analytics, and mobile software<br />
solutions for any energy, manufacturing, industrial, or building automation application.<br />
This year marks a few milestones. Within <strong>2021</strong>, ICONICS will mark its 35th year of<br />
operations, doing so within its first full year as a group company of Mitsubishi Electric<br />
Corporation, itself celebrating the 100th anniversary of its establishment.<br />
THIS YEAR also marks the release of<br />
the latest version of ICONICS Suite:<br />
version 10.97. With this latest release,<br />
ICONICS has addressed a wide variety<br />
of customer challenges through innovative<br />
technological solutions and<br />
enhancements across its automation<br />
MELISSA TOPP,<br />
Senior Director of<br />
Global Marketing,<br />
ICONICS,<br />
melissa@iconics.com<br />
software lineup of data visualization,<br />
archiving/rapid retrieval, analytics,<br />
mobile apps, and edge to cloud connectivity.<br />
Some of the new additions<br />
include ICONICS’ connected field service<br />
software, CFSWorX’, integration<br />
with Maximo, ServiceNow, and Azure<br />
14 maintworld 1/<strong>2021</strong>
PARTNER ARTICLE<br />
ICONICS SUITE VERSION 10.97 CONTAINS MULTIPLE DATA VISUALIZATION,<br />
ANALYTICS, HISTORIAN, MOBILITY, AND CLOUD CONNECTIVITY SOLUTIONS.<br />
Active Directory and support for load<br />
balancing. The Data Exporter within<br />
ICONICS’ high-speed data historian,<br />
Hyper Historian, now supports Azure<br />
Data Lake Generation 2 and other scalable<br />
cloud storage services. Also newly<br />
added are Sankey Diagram controls,<br />
available for use across any of ICON-<br />
ICS’ visualization environments on any<br />
desktop, laptop, web browser, or smart<br />
device.<br />
This issue of <strong>Maintworld</strong> highlights<br />
energy management and condition<br />
monitoring in maintenance applications.<br />
Solutions for both of these requirements<br />
are included within version<br />
10.97 of ICONICS Suite, as well.<br />
Energy AnalytiX® for Energy<br />
Management<br />
Energy management systems help to<br />
deliver rich platform and browserindependent<br />
real-time visualization<br />
of energy use. Such software can address<br />
any size application, from a single<br />
building to an entire campus or multisite<br />
enterprise. Energy management<br />
system software also involves monitoring,<br />
analyzing, and improving organizational<br />
assets. It helps to optimize en-<br />
ergy usage of buildings and equipment<br />
and can help identify energy-related efficiency<br />
issues in production processes.<br />
It also helps to simplify workflow for<br />
maintenance personnel and field operatives.<br />
With such software tools, users<br />
can create IT firewall-friendly, secure<br />
custom energy dashboards and kiosks<br />
to view reports for analysis of energy<br />
consumption patterns, resource usage,<br />
and progress on sustainability efforts.<br />
Maintenance personnel, site managers,<br />
and building engineers can quickly<br />
and intuitively navigate energy-related<br />
data and discover opportunities for improvement.<br />
ICONICS’ energy management system<br />
software, Energy AnalytiX®, provides<br />
open universal data connectivity<br />
and enterprise integration to a wide variety<br />
of building management systems<br />
(BMS), SCADA, enterprise resource<br />
planning (ERP), and control systems.<br />
Managers of commercial or government<br />
buildings, university campuses,<br />
and industrial plants can use this revolutionary<br />
smart energy software solution<br />
to configure, customize, operate,<br />
and improve. Energy AnalytiX includes<br />
1/<strong>2021</strong> maintworld 15
PARTNER ARTICLE<br />
built-in calculations, KPIs, analytics,<br />
data historian, reporting, and the rich<br />
visualization needed to take decisive<br />
action to reduce and manage utility<br />
costs and consumption.<br />
Energy AnalytiX can be deployed<br />
quickly in order to more swiftly<br />
achieve return on investment. Integration<br />
with a wide variety of existing<br />
meters, coupled with preconfigured<br />
charts, helps to reduce the engineering<br />
time involved. It can also help<br />
realize cost savings through informed<br />
decision-making, as organizations<br />
frequently seek ways to reduce consumption,<br />
monitor conditions, lower<br />
energy costs, and minimize carbon<br />
emissions. Energy AnalytiX provides<br />
in-depth comparison and visualization<br />
of energy costs.<br />
16 maintworld 1/<strong>2021</strong><br />
ENERGY ANALYTIX NOW<br />
UTILIZES INFORMATIVE SANKEY<br />
DIAGRAMS TO HIGHLIGHT<br />
INFORMATION FLOW.<br />
ICONICS energy management software<br />
comes with the ability to provide<br />
standard cost, consumption, and carbon<br />
reports. Charts can include consumption<br />
(electric, wind, solar, steam, gas,<br />
water, and/or cogen), costs (electricity,<br />
steam, water, and/or gas), conditions<br />
(occupants, equipment runtime, sun, air<br />
handling unit, zone footage, outside air<br />
temperature [OAT], and/or component<br />
count), and carbon (carbon dioxide and/<br />
or methane). Energy AnalytiX can also<br />
integrate with a wide array of meter<br />
types, featuring compatibility with manufacturers<br />
in multiple energy-related<br />
categories (electric, wind, solar, steam,<br />
gas, water, and/or cogen), which helps<br />
toward quicker configuration and ROI.<br />
With Energy AnalytiX, users are able<br />
to drill down into the causes of abnormal<br />
energy use. Asset-based management<br />
provides setup and configuration<br />
to any level of aggregation. Users can<br />
drill down to specific sources of energy<br />
efficiencies and locate suspected consumption<br />
offenders. The software is also<br />
widely scalable, from a single building<br />
to a large campus to a global enterprise<br />
location portfolio to even an entire city.<br />
In the latest version 10.97 release,
PARTNER ARTICLE<br />
FREE TRIAL DOWN-<br />
LOAD OF ICONICS SUITE<br />
VERSION 10.97<br />
Visit https://iconics.com/Downloads/<br />
Download-ICONICS-Suite to download<br />
a trial copy of the latest version<br />
of ICONICS Suite, including both<br />
Energy AnalytiX and the new Hyper<br />
Alarm Server.<br />
Energy AnalytiX’ data model and sample<br />
dashboards have been updated to<br />
utilize the previously mentioned Sankey<br />
Diagram control. Sankey diagrams help<br />
illustrate information flow between<br />
different sources and destinations.<br />
The Sankey diagram expects a dataset<br />
with three columns: a source, a destination,<br />
and a weight. In runtime, the diagram<br />
intelligently draws the correctly<br />
weighted lines between each source and<br />
destination. Optionally, gains and losses<br />
can also be visualized, while the colors<br />
and shapes of the nodes and links can be<br />
extensively customized, if desired.<br />
Condition Monitoring and<br />
Improved Alarm Management<br />
ICONICS provides multiple software<br />
tools capable of condition monitoring,<br />
VERSION 10.97 INTRODUCES<br />
HYPER ALARM SERVER, THE<br />
NEXT GENERATION OF ALARM<br />
MANAGEMENT.<br />
as well as remote systems management.<br />
One aspect of condition monitoring that<br />
ICONICS has advanced, specifically for<br />
its version 10.97 release, is alarm management,<br />
with the result being its new<br />
Hyper Alarm Server product. Hyper<br />
Alarm Server offers ISA 18.2-compliant<br />
and redundant alarming using all new<br />
technology, allowing for better performance,<br />
more control, native integration<br />
with ICONICS product communications,<br />
and easy, intuitive configuration<br />
via ICONICS’ asset-based management<br />
system, AssetWorX.<br />
ICONICS Suite version 10.97 still<br />
includes the existing AlarmWorX64<br />
Server solution, but users are encouraged<br />
to experience the added benefits of<br />
Hyper Alarm Server. One such feature<br />
enables access to historical data for each<br />
tag, making it even easier to configure<br />
rate-of-change or similar alarm types.<br />
Another allows for unlimited related<br />
values, empowering users to analyze<br />
alarm information from a creative array<br />
of new angles. ICONICS believes Hyper<br />
Alarm Server represents the future of<br />
advanced SCADA systems for its unparalleled<br />
performance and extensive<br />
functionality.<br />
Also new in the Hyper Alarm<br />
Server, users are able to define alarm<br />
types, which act as a template or class<br />
for alarm tags. The type defines the<br />
core logic behind an alarm, its states<br />
or conditions, when it is evaluated,<br />
and more. The sample Hyper Alarm<br />
Server configuration includes several<br />
of the most common alarm types. In<br />
comparison, AlarmWorX64 Server<br />
had a set of hard-coded alarm types –<br />
such as digital or limit – that worked<br />
in very specific ways. Users with specific<br />
needs could not always get the<br />
alarm behavior they needed. Hyper<br />
Alarm Server alarm types give users<br />
the freedom to customize the way<br />
alarms work without having to implement<br />
counterintuitive workarounds<br />
or request product enhancements.<br />
Hyper Alarm Server is also available<br />
for edge devices running ICONICS’<br />
Internet of Things compatibility software,<br />
IoTWorX.<br />
1/<strong>2021</strong> maintworld 17
PARTNER ARTICLE<br />
We succeeded,<br />
what is next?<br />
Back in the fourth quarter of 2019, SDT<br />
team assisted LUBExpert implementation<br />
(parallel to Condition Monitoring<br />
implementation) in wastewater facility<br />
in SE Europe, with the primary target of<br />
improving lubrication practice on 180<br />
assets (more or less 700 bearings).<br />
THIS TASK MIGHT sound simple and straightforward, still it<br />
highly depended on many real condition facts. A relatively<br />
small team was working on several improvements at the same<br />
time: Condition Monitoring (CM) and Lubrication. A small<br />
team, in this case, means: two technicians engaged in CM activities,<br />
one grease technician and the maintenance manager<br />
playing the role of reliability engineer, lube manager, CM engineer<br />
as well as many others. Certainly, it was not an easy task<br />
for the team, and certainly it was not as it should have been, but<br />
that was the reality and what was approved by decision makers.<br />
Obviously, that was one of those situations when management<br />
gives you less than you need to succeed, promising to give<br />
you more once you succeed. Catch-22, but it is something we<br />
face often, making the process more challenging and rewarding.<br />
To make it happen, our grease technician was trained to the<br />
level of LUBExpert Strategist, understanding Why job needs<br />
to be done, What needs to be done and How, and being able to<br />
perform entire setup, execution and reporting. Proper selection<br />
of lubricants, controlled purchase process, proper storage,<br />
cleanliness… all was included in the process, of course. Once<br />
started, the gained experience resulted in growing confidence,<br />
increased work efficiency, well organized work orders and<br />
smooth execution. Once grease guy, now LUBExpert Strategist.<br />
However, there was another aspect of implementation that<br />
was highly important for the success of the entire program. Do<br />
more than required with less than needed.<br />
Critical point of implementation was the proper positioning<br />
of each department (CM and Lube) and interdepartmental cooperation,<br />
considering available resources. The approach applied<br />
(knowing LUBExpert’s capabilities) was to erase departmental<br />
fences and silos and set it more like an army formation:<br />
• first line of defence – grease bearings right and eliminate<br />
mayor cause of failures;<br />
• scouting – frequent data collection and trending, share data<br />
and locate anomalies;<br />
• light calvary – collect dynamic (TWF, FFT) data for analytic<br />
purposes;<br />
• heavy artillery – deeper analysis, problem definition, root<br />
cause definition (and elimination).<br />
Lots of work and lots of tasks<br />
for a small team.<br />
As usual, Pareto’s 80:20, fits in from all angles. 80 percent of<br />
problems come from 20 percent of activities, 20 percent of<br />
problems require 80 percent of available time to be analysed …<br />
and so on.<br />
Although it may sound ambitious, we assigned first two tasks<br />
to our Lube team/technician:<br />
• First line of defence – Lubrication department job, for sure<br />
• Scouting – CM job, normally<br />
Some call it a burden too big, some think it is impossible, we<br />
consider it an integral part of LUBExpert strategy. Whoever<br />
is taking care of Lubrication, has his hands-on assets more<br />
18 maintworld 1/<strong>2021</strong>
frequently than anyone else in the Reliability team, and has<br />
the most interactive relationship with the asset. LUBExpert<br />
Specialist (in this case also Strategist) is collecting data for<br />
Lubrication purposes, has an opportunity to monitor and<br />
trend data before and after replenishment condition, possess<br />
the data collected and analysed during replenishment.<br />
Knowing that, LUBExpert Strategy easily takes care of<br />
the first two tasks, bringing huge benefits to the CM team by<br />
giving them the most valuable data, and consequently time!<br />
More available time for deeper analysis, problem definition,<br />
root cause search.<br />
At the end of the first year of the LUBExpert program implementation:<br />
• Lube technician took care of 35 – 40 bearings per day (per shift)<br />
• That includes work task preparation, data collection,<br />
on-site analysis based on triggered alarms, LUBExpert<br />
guided grease replenishment, data overview and possible<br />
strategy corrections, and reporting.<br />
• All bearings showed an excellent response (as one in<br />
the picture 1 below), operating at minimum friction and<br />
wear level:<br />
• Process statistics (as shown in picture 2 below) showed<br />
high level of performance, correct lubrication practice and<br />
strategy settings, as well as additional observations and condition<br />
assessments:<br />
• Q4 2020 compared to Q4 2019 shows significant decrease<br />
of bearings related failures in rotating assets;<br />
• Q4 2020 shows no Lubrication related failures, except<br />
ones inherited from previous period;<br />
• Full traceability and detailed data about each process<br />
achieved;<br />
• Data shows that most of the previously used interval and<br />
quantity plans were incorrect;
PARTNER ARTICLE<br />
• LUBExpert Strategy was successfully implemented.<br />
In addition:<br />
• Lube technician delivered 12.500 Ultrasound readings to<br />
CM team, including static trend graphs, triggered alarms, before<br />
and after grease replenishment values, all relevant events, all<br />
taken actions;<br />
• Lube technician delivered 18 “Suspected bearing failure”<br />
warnings to CM team;<br />
• Lube technician delivered 10 “Safety risk” warnings to everyone’s<br />
attention.<br />
First year of the implemented program can now be safely declared<br />
as successful. As usual, once you succeed, there comes the question:<br />
“What’s next?”<br />
For the Lube team, “next” equals expanding the program to the<br />
entire plant and sustaining top performance.<br />
For the CM team, “next” equals covering more assets, covering<br />
more failure modes, digging deeper into analysis to define a root<br />
cause, suggesting corrections to remove root cause, and suggesting<br />
improvements.<br />
So, first, we need to look at the accomplished results and assigned<br />
tasks, once again emphasising the necessity to remove departmental<br />
division and silos mindset and conclude that both tasks<br />
are actually one. The question that we really needed to answer was:<br />
“How can the Lube team further assist the CM team to accomplish<br />
more with less or the same resources?”<br />
Again, more work on Lube tech shoulders?<br />
Not really, the answer is: LUBExpert Dynamic.<br />
LUBExpert Dynamic is equipped with an additional feature:<br />
collects Dynamic data (TWF, FFT) while performing usual LUBExpert<br />
work. No additional time needed, no additional training<br />
needed, no additional efforts, only additional benefits. Those benefits<br />
are exactly what the CM team needs to accomplish.<br />
Now, out of four army style operating segments, we can add<br />
one more to Lube team without creating any additional stress on<br />
our Lube tech, but freeing huge amount of time for our CM team:<br />
• First line of defence – Lubrication department job, for sure<br />
• Scouting – CM job, normally<br />
• Light calvary – collect dynamic (TWF, FFT) data for analytic<br />
purposes<br />
What does it mean for Lube tech during his daily work? Absolutely<br />
nothing.<br />
• Dynamic data is collected in the background.<br />
• Remember this from above?<br />
• Lube technician delivered 12.500 Ultrasound readings to<br />
the CM team, including static trend graphs, triggered alarms,<br />
before and after grease replenishment values, all relevant<br />
events, all actions taken.<br />
Now add the same amount of Time Waveform and Spectra, that<br />
normally requires the work of an additional technician.<br />
One more task off the shoulders of the CM team and a huge<br />
opportunity for them to increase coverage, dig deeper and have<br />
more time for analysis and problem solving.<br />
Each Condition Monitoring team knows exactly how big this<br />
benefit is and how it improves CM efficiency.<br />
Here is how it looks like in the first week of implementation.<br />
Bearing successfully greased with declared condition as “Suspected<br />
bearing failure”, TWF and Spectra collected before and<br />
after grease replenishment (picture 3):<br />
Before grease replenishment<br />
After grease replenishment<br />
Lubrication as part of Condition Monitoring? Well, shouldn’t it be that way? The first line of defence has just become a Maginot line.<br />
20 maintworld 1/<strong>2021</strong>
LUBExpert<br />
Grease Bearings Right<br />
DOUBLE DATA COLLECTION<br />
NO ADDITIONAL ATTENTION<br />
NO ADDITIONAL RESOURCES<br />
NO ADDITIONAL TIME<br />
The LUBExpert Dynamic Option delivers advanced analysis of bearing condition.<br />
During grease replenishment, dynamic data is captured in the background.<br />
These outcomes are fed to the condition monitoring team<br />
to help assess real-time bearing condition.<br />
sdtultrasound.com
PARTNER ARTICLE<br />
Precision belt alignment<br />
and what it entails.<br />
JOHN LAMBERT, Benchmark PDM.<br />
John has a lifetime of experience measuring and<br />
aligning machines. He is also a contributor to the ANSI/<br />
ASA standard for rotating machinery. BENCHMARK<br />
PDM Inc. provides the industry with instruments for<br />
reliable machinery installation and maintenance.<br />
The term Precision Maintenance is<br />
popular in today's maintenance world.<br />
What it means in a simplistic way, is<br />
to work to a known set of tolerances.<br />
FOR EXAMPLE, when we overhaul a machine<br />
– say a gearbox or pump – precision<br />
maintenance promotes that we measure<br />
the bearing bores not only for the diameter<br />
but also the ovality, how round it is.<br />
This is to ensure good bearing fits and<br />
there is a known tolerance for this work.<br />
Unfortunately, many may take that care<br />
during an overhaul but then they install<br />
that machine back onto a base that is not<br />
flat and now the machine's casing that<br />
they have measured precisely is distorted<br />
because of the base. There is also a known<br />
standard for base flatness however, many<br />
do not know this or have the capability of<br />
measuring it. The point about precision<br />
maintenance is that the precision needs<br />
to be all inclusive from start to finish.<br />
Precision Maintenance includes the<br />
overhaul and the installation, and it is the<br />
22 maintworld 1/<strong>2021</strong><br />
key factor in machine (asset) reliability.<br />
Fortunately, we have known standards<br />
that we can use for shaft-to-shaft<br />
driven machines (ANSI standard) but<br />
not belt driven machines. Have you<br />
ever conceded how imprecise belt<br />
driven machines are installed? And<br />
that it is a fact that the maintenance<br />
industry spends millions each year<br />
replacing sheaves, pulleys, and belts?<br />
Most of these installations are done<br />
well before their full life expectancy is<br />
reached.<br />
A major reason for this is that we do<br />
not install these drives to a standard<br />
tolerance as there does not appear to<br />
be any for belt alignment – one published<br />
from a recognized organisation<br />
like ISO or ANSI. If you search the internet<br />
you will find Guidelines such as<br />
the one below which comes from Ludeca<br />
who’s a known expert company in<br />
the field of alignment and this is one of<br />
the only ones we currently use.
PARTNER ARTICLE<br />
Surprisingly, we do not see too much information from<br />
the belt manufacturers and what we do see is not particularly<br />
good. From one large North American manufacturer, in their<br />
Technical Information Library, they provide a paper showing<br />
the right and wrong way to use a string to align two sheaves.<br />
This is a major reason why we have premature belt failure. By<br />
promoting the use of string or even a straightedge, prompts<br />
the belief that close enough is good enough.<br />
The company also says that a general rule of thumb is to get<br />
the alignment within 0.5 degrees for V-belts. Can you imagine<br />
a tradesman using string and trying to get a tolerance of 0.5<br />
degrees? You would think the days of using a string or for that<br />
matter a straightedge are in the past, but they are not unfortunately.<br />
At a minimum you should be using a visual Laser based<br />
alignment system or better still, a digital laser belt alignment<br />
system.<br />
Belt drives systems have changed. It is rare to see a single<br />
(strand) belt drive system, most are multiple (strand) belts. We<br />
also have flatback (banded) V belts (as on the main picture) as<br />
well as timing belts which are much more common. This means<br />
these belt drives are much more susceptible to misalignment. To<br />
align these belts requires a great degree of accuracy. Rather 0.1<br />
degree than 0.5. We still need to measure the same parameters<br />
which are explained in the picture below.<br />
Angular misalignment in<br />
vertical plane<br />
Angular misalignment in the<br />
horizontal plane (aka Toe-out<br />
and toe-in)<br />
Parallel / Offset misalignment<br />
in the axial plane<br />
A combination of misalignments<br />
is probably most common<br />
Notice that in the graphic above, in each form of misalignment<br />
the belt runs against the wall of the sheave groove. Obviously,<br />
this is the cause of the belts drying out becoming hard<br />
and then brittle due to the increased friction. It is the reason<br />
why the hardened belt wears out the sheave. It is also the reason<br />
why sheave grooves do not wear evenly, and therefore we do not<br />
recommend that you use them to align the sheave. Just a small<br />
amount of sheave wear might cause an angular deviation when<br />
aligning. For example, 0.1° equals almost 70 thou (1.8 mm) offset<br />
at 40 inches (1 meter). If you are using a laser system, we recommend<br />
that you use the walls of the sheaves and align them.<br />
The reason why is that it is a large flat (machined) surface area<br />
that we can attach to and have the laser beam be parallel to this<br />
surface, it is the reference point from which we measure. Your<br />
target or detector is mounted on the other sheave wall surface.<br />
Now let me tell you what the most ignored issue in belt<br />
alignment is. It is the fact that many sheave walls (faces) are<br />
mismatched, meaning not the same width. When we used string,<br />
straightedges and even some models of visual laser system, we<br />
never aligned them correctly because we never compensated<br />
for this variable offset. And just like belt drives have changed, so<br />
have the tools we can use to align them. If you are using a digital<br />
laser system you can quite easily input the sheave wall dimensions<br />
and the laser system will automatically compensate for<br />
you. If you want precision alignment you will need a digital laser<br />
alignment system for this reason alone.<br />
Different sheave wall (face)<br />
width will cause problem if<br />
not taken into consideration.<br />
Left picture, As Found. Right picture, As Left. With a digital tool this can be documented.<br />
Another reason is that if you are trying to use Precision<br />
Maintenance Techniques you will want documentation. And<br />
a digital laser can give a quantifiable, measurable result, a<br />
numeric value. If we are using string, straightedge or even<br />
visual lasers, there is no quantifiable result. But more than<br />
this, it will give you a documented result including an As<br />
Found and an As Left result. It will also tell you whether the<br />
sheave wall has been compensated for. This is important<br />
because along precision maintenance, asset reliability goes<br />
hand in hand and if you did have to do breakdown analysis<br />
on this machine without documentation, you would only be<br />
guessing as to what happened during the installation.<br />
1/<strong>2021</strong> maintworld 23
PARTNER ARTICLE<br />
Bearing Lubrication Reimagined:<br />
Remote and Real Time Friction<br />
Monitoring and Lubrication<br />
What if we could lubricate our bearings remotely, from any device, making sure<br />
that the right amount and right lubricant are always used – and even better, based<br />
on bearing condition? Then we would address the 3 main lubrication issues which<br />
cause most of early bearing failures. Today this is already possible. Using ultrasonic<br />
sensors and single point lubrication devices, all connected to a central system, we<br />
can now bring lubrication practices to a whole new level!<br />
Prevention in place of<br />
monitoring<br />
We have a serious problem with bearing<br />
condition monitoring! Technology is<br />
making it easier and more cost-effective<br />
to monitor our bearings in real-time and<br />
as a result, we are seeing sensors and<br />
systems being installed on equipment at<br />
an exponential rate.<br />
There is a race from these monitoring<br />
systems to detect the onset of failure<br />
(Point P on the P-F curve) at the earliest<br />
possible point. And this race to detect<br />
a failure is a serious problem. We are<br />
spending more money and extra TIME<br />
to detect a failure when we should be<br />
preventing that failure in the first place.<br />
Addressing lubrication<br />
issues – the root of most<br />
bearing failures<br />
It is no secret that over 80% of<br />
premature bearings failures can be<br />
traced back to lubrication related<br />
issues. These issues can be put into<br />
three general categories: inadequate<br />
lubrication (over or under lubricated),<br />
wrong lubricant, and contamination.<br />
When it comes to addressing<br />
premature bearing failure, reducing<br />
the impact on just one of these issues<br />
can have a large impact on the bearing<br />
life. But when we start to address<br />
all three, then we can reach excellence<br />
in our lubrication programs.<br />
It’s all about the friction levels<br />
A lot of expertise needs to be designed into<br />
the bearing selection and lubrication requirements,<br />
no technology will likely ever<br />
replace the need for trained and experienced<br />
lubrication experts. But when it boils<br />
down to it, it is all about friction - that’s why<br />
they are called anti-friction bearings.<br />
Once the correct bearing is installed<br />
properly and the right lubricant is chosen,<br />
it comes down to managing that friction in<br />
the bearing by using the correct regreasing<br />
volume and frequency. Simple to understand<br />
but often difficult to put into practice.<br />
24 maintworld 1/<strong>2021</strong>
PARTNER ARTICLE<br />
Time based lubrication<br />
vs condition-based: using<br />
ultrasound to avoid under and<br />
over-lubrication<br />
One technique is to use time-based lubrication.<br />
In this case, regreasing is done based<br />
on time, with a predetermined amount of<br />
grease. This method is often based on an<br />
ideal calculation that is not reflective of the<br />
real-life condition that influences the friction<br />
in the bearing. This often leads to under<br />
greasing or over greasing the bearing.<br />
A step-change in lubrication practices<br />
came with condition-based lubrication.<br />
Using ultrasound to measure the friction<br />
in real-time to determine exactly when<br />
lubrication (and how much) is required to<br />
bring the friction back to or near the ideal<br />
level. Moving to ultrasound-assisted lubrication<br />
will ensure we do not over or under<br />
lubricate but has still not addressed the two<br />
other lubrication related issues: using the<br />
correct lubricant, and contamination.<br />
What about automatic<br />
lubricators?<br />
To address these two other lubrication<br />
issues many have turned to automatic lubrication<br />
devices or auto lubers. Automatic<br />
WHAT IF WE WERE ABLE<br />
TO COMBINE THE PROVEN<br />
PRECISION AND BEST<br />
PRACTICE OF CONDITION-<br />
BASED LUBRICATION USING<br />
ULTRASOUND WITH THE<br />
CONVENIENCE, SAFETY, AND<br />
ACCURACY OF AUTOMATIC<br />
LUBRICATION DEVICES?<br />
lubrication provides a safer and more convenient<br />
method of supplying the precise<br />
amount of lubricant into the bearings on a<br />
more frequent basis.<br />
These devices ensure we always use the<br />
correct grease stored in the device but also<br />
reduce or eliminate the possibility of contamination<br />
caused by the operational environment.<br />
These devices are time-based and<br />
set to dispense lubricant on a set frequency<br />
or run time.<br />
The auto lubricant devices have evolved<br />
to become smarter. Many of them not only<br />
dispense the lubricant but can also set<br />
alarms based on excessive feedback and low<br />
lubricant.<br />
The best of two worlds:<br />
SmartLube – single point<br />
lubricator, remotely operated,<br />
based on friction levels<br />
We have two solutions addressing the different<br />
aspects of the common lubrication<br />
issues. On one side we have ultrasoundassisted<br />
lubrication, using friction to determine<br />
when and how much lubrication is<br />
required. Combined with good lubrication<br />
practices, it will provide benefits but still<br />
requires an investment in time and training<br />
to ensure the proper lubricant is used to reduce<br />
the potential of contamination.<br />
On the other side, we have automatic lubrication<br />
devices ensuring the correct, contaminant-free<br />
lubricant but still based on<br />
time or running hours versus the condition<br />
or friction in the bearing, often still leading<br />
to not optimizing lubrication frequency.<br />
What if we were able to combine the<br />
proven precision and best practice of condition-based<br />
lubrication using ultrasound<br />
with the convenience, safety, and accuracy<br />
of automatic lubrication devices? We would<br />
then have a solution that allows us to lubricate<br />
our bearings only when required by<br />
measuring friction and ensuring we always<br />
use the correct, contaminant-free lubricant<br />
every time. That’s exactly what the Smart-<br />
Lube from UE Systems does.<br />
Lubricate based on friction,<br />
from any device, anywhere<br />
When we use technology to make all this<br />
remotely operated, we can now monitor<br />
the real-time friction of our bearings and,<br />
when needed, remotely dispense the correct<br />
lubricant. All this with the confidence<br />
that the lubricant is getting to the bearing<br />
with real-time alerts and notifications from<br />
any internet-connected device, anywhere<br />
in the world!<br />
The OnTrak SmartLube by UE Systems<br />
has the power of real-time bearing<br />
friction monitoring and the convenience,<br />
safety, and accuracy of single-point bearing<br />
lubricators. Lubrication experts can now<br />
lubricate remotely with confidence from<br />
anywhere, anytime, on any device.<br />
How does it work?<br />
This disruptive device works with a simple<br />
concept: ultrasonic sensors are permanently<br />
mounted on the bearings to monitor<br />
friction levels. All this data is sent to a<br />
central processing unit – the OnTrak – and<br />
can be viewed in dashboards using any internet-connected<br />
device. The OnTrak then<br />
is also connected to single point lubrication<br />
devices. Based on the friction levels and on<br />
setup alarms, we now have the possibility to<br />
tell the OnTrak that a certain bearing needs<br />
lubricant. The OnTrak will then instruct<br />
the SmartLube – single point lubricator – to<br />
dispense lubricant, just the right amount.<br />
And the best part: all can be done remotely,<br />
anywhere, anytime.<br />
1/<strong>2021</strong> maintworld 25
LIFT SAFETY<br />
Safe operation<br />
of softwarecontrolled<br />
lifts<br />
Is this lift safe to use until its next periodic inspection?<br />
Lift experts and maintenance personnel are expected<br />
to answer this question clearly and unambiguously –<br />
potentially challenging in practice, as safety functions<br />
in modern lifts are software-monitored and digitally<br />
controlled. The solution is based on effective and<br />
continuous verification of the firmware’s product<br />
safety and its safety in use.<br />
TEXT and PHOTOS: DR. ROLF ZÖLLNER, TÜV SÜD Industrie Service GmbH<br />
TO ENSURE LIFT SAFETY even in the<br />
presence of faults, demands on lift safety<br />
components such as safety gears have<br />
always been subject to high demands.<br />
In Germany the same as in the rest of<br />
Europe, lifts may only use safety components<br />
that have passed type examination<br />
(assessing design, construction, material,<br />
workmanship, load limits, etc.) and<br />
proved that they always fulfil their safety<br />
functions reliably.<br />
Type examined for safety<br />
functions<br />
As technological change leaps forward,<br />
many safety functions that used to be<br />
mechanical are now embedded systems,<br />
monitored and controlled by hardware<br />
and software (HW/SW) systems. Modern<br />
lifts contain safety circuits, with a<br />
typical architecture including sensors,<br />
logic units and actuators (hardware),<br />
that digitally generate, process, evaluate<br />
data (software) and trigger actuators.<br />
Lift shaft information systems, for<br />
example, identify safety-relevant faults<br />
in the dynamic behaviour of the lift and<br />
reliably place the lift in a safe operational<br />
state. In regular operation they monitor<br />
the lift’s position whilst travelling as well<br />
as its levelling accuracy, and allow the<br />
precise measurement of other dynamic<br />
parameters such as acceleration and<br />
speed.<br />
The qualified data provided by these<br />
systems can be used to identify safetyrelevant<br />
faults and initiate effective<br />
countermeasures. In this context the<br />
HW/SW system must reliably identify<br />
all hazardous operational states and<br />
process them correctly, the detection of<br />
overspeed travelling being one example.<br />
On the other hand, however, the system<br />
shall also minimise “false positives”,<br />
such as triggering the safety gear unnecessary<br />
in regular safe operation.<br />
Stickers raise questions<br />
Inspectors often find control units<br />
bearing only a sticker with the version<br />
number of the installed software version<br />
(SW) but no indication of when the<br />
26 maintworld 1/<strong>2021</strong>
LIFT SAFETY<br />
SW TESTING AND<br />
QUALIFICATION ARE ESSENTIAL<br />
PARTS OF TYPE EXAMINATION.<br />
sticker was affixed or whether the information<br />
is still up-to-date and correct.<br />
Has the SW been updated meanwhile,<br />
or perhaps even a new version installed?<br />
If so, is the update qualified and suitable<br />
for the HW-setup, who performed the<br />
update or installation and why, and does<br />
it impact on the safety functions? When<br />
the lift is connected to the Internet, is<br />
manipulation by unauthorised parties<br />
excluded? Can the company rule out unauthorised<br />
or unintentional manipulation<br />
by, say, a service technician?<br />
In periodic inspections, these questions<br />
are often hard to answer. The<br />
inspectors must search for evidence,<br />
review documentation and access authorisations<br />
and, in particular, check test<br />
results and information from the original<br />
type examination, which informs<br />
about the system configuration and the<br />
SW installed in the examined type that<br />
was approved for use in a safety function<br />
… and of course qualified SW-updates. If<br />
the experts cannot determine without<br />
doubt that the control unit SW is still the<br />
same as in type examination, they cannot<br />
confirm that its use will be safe.<br />
Working together:<br />
Hard- and software<br />
SW testing and qualification are thus<br />
clearly essential parts of type examination<br />
as they ensure the functional safety<br />
of the lift system in case of a fault.<br />
While SW updates may be executed<br />
and new versions developed and installed,<br />
the important principles of the<br />
safety life cycle of SW development must<br />
be complied with in the same way as it is<br />
done with HW. Yet, this is not always sufficiently<br />
guaranteed.<br />
The methods and qualities for ensuring<br />
the reliability and effectiveness of<br />
safety-related functions required in SW<br />
development differ from those required<br />
for hardware components. That is because<br />
SW is subject to systematic and<br />
IEC 61508 “Functional Safety of Electrical/<br />
Electronic/Programmable Electronic<br />
Safety-related Systems (E/E/PE)”<br />
1/<strong>2021</strong> maintworld 27
LIFT SAFETY<br />
Directive 2014/33/EC of<br />
the European Parliament<br />
and of the Council of 26<br />
February 2014 on the<br />
approximation of the laws<br />
of the Member States<br />
relating to lifts and safety<br />
components for lifts<br />
DIN EN ISO 9001 “Quality Management Systems – Requirements”<br />
intended errors only – failure rates and<br />
reliability data cannot be calculated as<br />
it is common practice in HW qualifications.<br />
All professional methods are characterised<br />
by typical quality assurance<br />
activities as clear goals, instructions,<br />
responsibilities, and authorities. Feedback,<br />
meetings, test environments and<br />
simulations keep developers informed of<br />
important findings about shortcomings,<br />
incompatibilities, programming errors<br />
or malfunctions, while milestones in<br />
important project phases ensure sourcecode<br />
verification and SW validation. In<br />
this context, experts rely on traceability,<br />
the four-eye principle (two-man rule)<br />
and other proven and tested quality assurance<br />
measures to prevent systematic<br />
faults.<br />
Unlike HW, SW is not subject to wear<br />
and tear, i.e. there are no random faults.<br />
Causes of systematic faults include inadequate<br />
implementation of the requirements<br />
in SW specifications, unsystematic<br />
use of anchor links and variables or<br />
insufficient test coverage. These faults<br />
must be excluded through efficient quality<br />
assurance.<br />
28 maintworld 1/<strong>2021</strong>
LIFT SAFETY<br />
Functional safety<br />
requirements<br />
Safety-related electrical, electronic and<br />
programmable electronic systems (E/E/<br />
PE systems) are considered to achieve<br />
the intended risk reduction if they fulfil<br />
the requirements of the IEC 61508 series<br />
of standards [1]. Part 3 of this series<br />
specifies the requirements regarding<br />
safety-related software. This part defines<br />
safety life cycle, tools to be used and<br />
the documentation quality. It is thus<br />
particularly relevant for software and<br />
applies to all PESSRAL (=Programmable<br />
Electronic Systems in Safety-Related<br />
Applications for Lifts) in the scope of Directive<br />
2014/33/EU [2] in the EU.<br />
In addition to special software-related<br />
requirements, IEC 61508 also addresses<br />
general requirements for safety<br />
functions realised as HW/SW systems<br />
which ensure reliable achievement of<br />
the necessary Safety Integrity Level<br />
(SIL) which indicates the expected risk<br />
reduction to be achieved through the<br />
specific PESSRAL.<br />
A functional safety management system<br />
according to IEC 61508 is critical in<br />
this context. Like the ISO 9001 standard<br />
FEEDBACK, MEETINGS, TEST EN-<br />
VIRONMENTS AND SIMULATIONS<br />
KEEP DEVELOPERS INFORMED OF<br />
IMPORTANT FINDINGS ABOUT<br />
SHORTCOMINGS, INCOMPATIBILI-<br />
TIES, PROGRAMMING ERRORS OR<br />
MALFUNCTIONS.<br />
[3], it establishes quality assurance along<br />
the supply chain, demanding that HW<br />
and SW suppliers, but also inspection<br />
organisations establish functional safety<br />
and apply it correctly.<br />
Furnishing proof of<br />
safe lift use<br />
The existing system configuration must<br />
thus be documented in an equally thorough<br />
and traceable manner as every<br />
safety-related change to the lift system<br />
(e.g. sensor replacement, firmware<br />
update). Compliance with this requirement<br />
is generally ensured in the form<br />
of a suitable configuration management<br />
system.<br />
In periodic inspection, a sticker or note<br />
with a QR code is often found in the lift<br />
documentation. By scanning the code and<br />
entering the correct password, the expert<br />
can access the entire documentation of<br />
the lift. The digital file includes all relevant<br />
information at a glance. In case of remote<br />
software updates, the expert verifies the<br />
integrity of data transmission.<br />
Further evidence and certificates by<br />
accredited bodies then prove that cybersecurity<br />
measures correspond to the state<br />
of the art and that the lift control unit is<br />
protected against software manipulation<br />
and malware. Information on these aspects<br />
can be found in the IEC 62443 series of<br />
standards [4].<br />
This type of documentation answers all<br />
questions on IT security and functional<br />
safety, enabling experts to confirm that use<br />
of the lift will be safe until the next periodic<br />
inspection. This “futuristic” form of verification<br />
has already become reality as all<br />
stakeholders have realised that it supports<br />
easy and continuous verification of lift<br />
safety, which benefits everybody – and lift<br />
users in particular.<br />
Reveal Your Potential<br />
Get a Reliability and Maintenance Assessment<br />
Call us +1 919-847-8764
PARTNER ARTICLE<br />
OPC UA including Ethernet TSN<br />
and Ethernet APL for the field:<br />
AN INTERMEDIATE GOAL<br />
HAS BEEN ACHIEVED!<br />
At SPS 2018, in Nuremberg, Germany the FLC initiative was founded<br />
under the umbrella of the OPC Foundation. A total of 27 companies,<br />
including the largest automation manufacturers in the world, have joined the<br />
initiative's Steering Committee, supporting it financially as well as with man-power<br />
and technical know-how.<br />
PETER LUTZ, OPC Foundation, peter.lutz@opcfoundation.org<br />
THE COMMON GOAL is to expand the scope<br />
of OPC UA down to the field level and to<br />
establish OPC UA as a uniform and consistent<br />
communication standard in factory<br />
and process automation. In the technical<br />
working groups, which are open to all<br />
members of the OPC Foundation, a total of<br />
over 320 experts from more than 65 companies<br />
are currently working to develop<br />
appropriate concepts and specifications.<br />
OPC UA at the field level - the<br />
system architecture<br />
The extensions specified by the FLC Initiative<br />
are based on the OPC UA Framework<br />
(IEC 62541), which enables a secure and<br />
reliable, manufacturer and platformindependent<br />
information exchange. Controllers<br />
and field devices support both, the<br />
connection-oriented client/server communication<br />
model and the publish/subscribe<br />
extensions, which are indispensable for<br />
communication at the field level due to the<br />
corresponding requirements for flexibility,<br />
efficiency and determinism. The security<br />
mechanisms specified in OPC UA are also<br />
used, which, among other things, support<br />
authentication, signing and encryption of<br />
the data to be transported and can be used<br />
for both client/server and publish/subscribe<br />
communication relationships.<br />
The initial release candidate of the FLC<br />
30 maintworld 1/<strong>2021</strong><br />
Initiative, completed in November 2020,<br />
consists of four specification parts (OPC<br />
UA Parts 80-83) and focuses on C2C communication<br />
(controller-to-controller) for<br />
the exchange of process and configuration<br />
data by means of peer-to peer-connections<br />
and a basic diagnosis.<br />
Work on the safety solution for OPC UA<br />
(OPC UA Safety) is also very advanced. A<br />
first OPC UA Safety specification, which is<br />
based on client-server mechanisms which<br />
arose from a Joint Working Group with<br />
Profibus & Profinet International (PI), was<br />
already adopted in November 2019 (Part<br />
15, OPC 10000-15). A revision of the OPC<br />
UA Safety specification will be available<br />
shortly, which describes the extensions for<br />
OPC UA publish / subscribe and the parameterization<br />
of safety participants. The<br />
special thing about the safety concept for<br />
OPC UA is, among other things, that safe<br />
participants can be dynamically integrated<br />
into the communication, with a unique<br />
identification, even while a machine or system<br />
is in operation.<br />
Progress can also be reported with<br />
regard to motion. A working group has<br />
been developing an OPC UA-based motion<br />
solution since mid-2020. OPC UA Motion<br />
comprises the specification of motion control<br />
functions for various types of motion<br />
devices such as controllers, standard drives,<br />
frequency converters and servo drives. The<br />
FLC Steering Committee has agreed to<br />
base the work on the CIP Motion and Sercos<br />
specifications and to adapt them to the<br />
OPC UA information modeling and system<br />
architecture, taking into account the relevant<br />
Industry 4.0 use cases. The fact that, as<br />
with safety, existing concepts and specifications<br />
are being used, the specification work<br />
can be significantly accelerated.<br />
The combination with TSN, APL<br />
and 5G<br />
The OPC UA Framework is fundamentally<br />
transport-agnostic and can therefore be<br />
flexibly used with various underlying communication<br />
protocols and transmission<br />
physics. Ethernet Time-Sensitive Networking<br />
(Ethernet TSN) and the Ethernet Advanced<br />
Physical Layer (Ethernet APL) are<br />
considered by the OPC Foundation as important<br />
elements of the strategy to expand<br />
OPC UA to all use cases and requirements<br />
in factory and process automation and the<br />
vision to create a completely scalable, industrial<br />
interoperability solution.<br />
The combination with TSN<br />
By using Ethernet TSN, deterministic<br />
data transmission via OPC UA is facilitated,<br />
which is particularly indispensable for<br />
demanding automation applications. In<br />
addition, TSN allows different applications
PARTNER ARTICLE<br />
the supply of energy and data via a common,<br />
twisted 2-wire cable, and protective measures<br />
for safe use in hazardous areas. This makes<br />
Ethernet APL the enabling technology for<br />
the use of OPC UA and other Ethernet-based<br />
protocols in the process industry. Due to the<br />
special importance of this technology, the<br />
OPC Foundation joined the Advanced Physical<br />
Layer (APL) project group in June 2020<br />
to develop and promote APL together with<br />
other non-profit organizations and various<br />
industrial partners.<br />
The combination with 5G<br />
Data exchange via OPC UA is not limited to<br />
wired or wireless Ethernet communication.<br />
Support for the 5G mobile communications<br />
standard is also on the OPC Foundation's<br />
development horizon. The mapping to 5G<br />
will be seamlessly integrated into the existing<br />
OPC UA architecture, so that all protocol and<br />
profile extensions of the FLC initiative can be<br />
used, not only via Ethernet and Ethernet TSN,<br />
but also via 5G in the future.<br />
and protocols to be operated using standardized<br />
hardware and a common network<br />
infrastructure. This enables convergent<br />
industrial automation networks to be<br />
implemented in which various IT and OT<br />
protocols can coexist. A Working Group of<br />
the FLC Initiative is currently working out<br />
which TSN sub-standards shall be mandatory<br />
for OPC UA-based end devices and<br />
infrastructure components to meet the<br />
specified requirements for performance,<br />
flexibility and ease-of-use. The OPC Foundation<br />
has given a clear commitment to the<br />
TSN-IA (Industrial Automation) profile,<br />
which is being developed by the IEC/IEEE<br />
60802 working group. For this reason, the<br />
OPC Foundation has entered into liaison<br />
agreements with the standardization bodies<br />
IEC SC65C and IEEE 802.1.<br />
The combination with APL<br />
Ethernet APL describes a physical layer<br />
for Ethernet that was specially developed<br />
for the requirements of the process industry.<br />
Ethernet APL enables data transmission<br />
at high speeds over long distances,<br />
Figure: Semantic interoperability with OPC UA from the sensor to the cloud<br />
Summary<br />
The OPC UA (IEC 62541) framework, with<br />
extensions for the field level, specified by the<br />
FLC Initiative, in combination with underlying<br />
communication standards such as APL,<br />
TSN, and, in the future, 5G, offers a complete,<br />
open, standardized and interoperable solution.<br />
It not only fulfills the requirements of<br />
industrial communication, but, at the same<br />
time, enables consistency and semantic interoperability<br />
from the field level to the cloud<br />
and vice versa (Fig. 5). With this approach - in<br />
combination with the various companion<br />
specifications - information is made available<br />
with a standardized semantics directly at the<br />
data source.<br />
Use cases to consider: A flow meter offers<br />
directly standardized "OPC UA flow<br />
measuring data" the moment the APL cable<br />
is plugged in. And analogously, servo drives<br />
directly process standardized "OPC UA<br />
drive setpoints” and provide standardized<br />
“OPC UA actual drive values” as soon as<br />
they are integrated into a machine network<br />
with Ethernet TSN.<br />
FURTHER INFORMATION<br />
AND DOWNLOADS:<br />
• FLC Initiative Technical Paper<br />
• APL White Paper<br />
• FLC webinar presentations /<br />
recordings<br />
WWW.OPCFOUNDATION.ORG/FLC<br />
1/<strong>2021</strong> maintworld 31
DIGITALISATION<br />
Figure 1: Digitalisation of production systems<br />
Digitalisation of production<br />
systems: getting smart while<br />
keeping out of harm’s way?<br />
When embarking on their digitalisation / IIot course, machine and plant manufacturers<br />
are often unsure how to approach things, which steps come first, which can wait<br />
and which may be entirely superfluous. This article sums up the current experiences<br />
of mechanical engineering customers of the HARTING Technology Group and shows<br />
how this important but also tremendously multifaceted topic can be mastered.<br />
THE TOPICS OF DIGITALISATION / IIOT of<br />
production systems are omnipresent<br />
in the general reporting media, as well<br />
as featuring heavily in the specialist<br />
media. More and more new keywords<br />
are emerging in the process. Companies<br />
such as Amazon, Uber & Co. are often<br />
cited as examples, demonstrating to the<br />
whole world how digitalisation strategies<br />
can be used to achieve economic success<br />
through the consistent digitalisation of<br />
JAKOB DÜCK,<br />
DIPL.-ING.<br />
Global Industry<br />
Segment Manager<br />
online trade and logistics (Amazon) or<br />
through the digitally mediated use of<br />
existing resources (Uber). Consequently,<br />
OEMs of capital goods are also asking<br />
themselves: Can we achieve similarly<br />
rapid success with digitalisation, and if<br />
so, how?<br />
First of all, the topics of digitalisation<br />
/ IIoT (Industrial Internet of Things)<br />
for production systems need to be further<br />
narrowed down. We will consider<br />
possible digitalisation steps along the<br />
typical machine lifecycle (VDMA [1]),<br />
or more precisely: only those measures<br />
32 maintworld 1/<strong>2021</strong>
DIGITALISATION<br />
that relate to products, services or other<br />
performances that can be offered to an<br />
end user. We will not consider entirely<br />
new technologies and business models<br />
which are technically conceivable, but<br />
currently have no legal framework (such<br />
as "Machine-to-Machine Order & Payment",<br />
for example).<br />
One fundamental aspect should be<br />
mentioned in advance. Some experts<br />
question whether digitalisation and IIoT<br />
technologies in mechanical and plant<br />
engineering have any potential at all to<br />
bring about fundamental or even disruptive<br />
changes in existing business models.<br />
As the author, business angel and former<br />
CTO of IBM, Dr. Gunter Dueck, comments<br />
in this context [2]: "When the<br />
Deluge comes, build ships, not dikes ... Are<br />
we building ships to set sail to the digital<br />
future continent? That would mean that<br />
we are looking for digital innovations that<br />
would shape our new age”. The study<br />
"Digitalisation in Mechanical Engineering"<br />
by the Hans Böckler Foundation in<br />
2018 [3] sizes things up in more concrete<br />
terms and quotes an expert from a German<br />
company: "We will definitely remain<br />
mechanical engineers and not become a<br />
software house. But we need software and<br />
networking to sell our machines better<br />
and make sure that they remain attractive.<br />
Based on digitalisation, we want to<br />
help customers to solve their problems better.<br />
Above all, we want to leverage the digital<br />
potentials to ensure that no one comes<br />
between us and our customers. This is a<br />
forward strategy, coupled with a hedging<br />
strategy, so that no disruptor - Amazon,<br />
Google, Microsoft or similar players - ends<br />
up alienating us from our customers". In<br />
the final instance, competitive pressure<br />
leaves OEMs for capital goods no other<br />
option: they must face up to the emerging<br />
digitalisation!<br />
So it is not a question of whether, but<br />
how. The current state of digitalisation<br />
and the necessary priorities in mechanical<br />
and plant engineering, however, are<br />
assessed quite differently by the parties<br />
involved. The IMPULS Foundation of<br />
the VDMA, for example, summarised<br />
the state of affairs in the foreword to a<br />
2016 study [4] as follows: "Industry 4.0<br />
has arrived in German mechanical and<br />
plant engineering. Companies are taking<br />
a leading role, especially as providers of<br />
digitally networked technologies and services<br />
... For customers around the world,<br />
additional added value is being created”.<br />
Gunther Kegel, Chairman of the<br />
Board of Pepperl+Fuchs and current<br />
ZVEI President commented as follows<br />
in an interview in June 2018 [5]: "However,<br />
I do think that ... our pace moving<br />
forward is rather slow. The possibilities<br />
are so diverse that we have to choose very<br />
consciously for which of the many promises<br />
resources are used, degrees of freedom<br />
are allowed and perhaps something new<br />
will be established. It has to be weighed up<br />
what has to be implemented and what not<br />
yet, because it still seems too far away."<br />
The statements show how differently<br />
the situation in mechanical engineering<br />
is assessed by the actors themselves. At<br />
the end of 2019 [6], Commerzbank AG<br />
attempted a quantitative assessment of<br />
Figure 2: Modularity and scalability<br />
as exemplified by HARTING Ethernet<br />
interfaces.<br />
1/<strong>2021</strong> maintworld 33
DIGITALISATION<br />
digitalisation in the German mechanical<br />
engineering industry: "A decisive development<br />
towards the digital company is the<br />
integration of platform solutions, both at<br />
the process and service levels as well as at<br />
the sales level. In the meantime, three out<br />
of four companies in the sector state that<br />
such IIoT platforms are important for<br />
them, and almost 30 percent are already<br />
using corresponding solutions". This<br />
means that more than half of the German<br />
machine and plant manufacturers<br />
had not yet taken any action on the topic<br />
of digitalisation / IIoT. The situation is<br />
similar in other countries with a comparable<br />
mechanical engineering industry.<br />
But what success patterns can be observed<br />
among mechanical engineering<br />
customers of the HARTING Technology<br />
Group and what concrete steps can be<br />
recommended?<br />
As an OEM for production systems, it is<br />
important to identify the most important<br />
players in the field of digitalisation /<br />
IIoT in the industry - and consider their<br />
role, capabilities and interests (see also<br />
VDI/VDE Status Report [9]):<br />
• OEMs - providers of individual machine<br />
modules or complex machines<br />
/ systems - have the know-how to<br />
offer machine users the key functions<br />
as the most important differentiating<br />
feature in an economically<br />
successful manner, and to expand<br />
these functions to include digital<br />
IIoT components and services;<br />
• Suppliers of automation components<br />
- suppliers of PLC, CNC,<br />
Figure 3: HARTING T1 Ethernet<br />
connector for SPE technology in<br />
Ethernet interfaces.<br />
DIGITALISATION IN<br />
THE FIELD OF CAPITAL GOODS<br />
CANNOT BE VIEWED AS<br />
AN ISOLATED TREND.<br />
industrial PC, HMI, drive systems,<br />
measurement technology, sensors<br />
etc. - have been mainly producing<br />
digital controller-based systems;<br />
these use digital signals and information<br />
for the direct control of machines<br />
and processes and can also<br />
easily aggregate these further;<br />
• Software providers for production<br />
control at the factory/enterprise<br />
level - providers of ERP, MES<br />
and similar management software<br />
systems - command an extremely<br />
high level of expertise in the control<br />
of business processes and handling<br />
of large data volumes; however, they<br />
rarely have direct access to machine-<br />
and process-related data;<br />
• Platform providers for new<br />
business models - still poorly represented<br />
in the capital goods sector<br />
- are well-known names in the B2C<br />
sector, e.g. Amazon & Co. But there<br />
is also activity in B2B, as the growing<br />
demand for subscription models<br />
("Pay per Use", "Pay per Month",<br />
"Pay per Unit" etc.) is raising hopes<br />
among these providers of being able<br />
to establish themselves in the mar-<br />
ket with benefit and service-oriented<br />
models;<br />
• Associations and co-operations<br />
for digitalisation and IIoT - strategic<br />
alliances between mechanical<br />
engineering and software companies<br />
– are frequently pursuing the goal<br />
of creating an open, manufacturerneutral<br />
IIoT environment and corresponding<br />
standards based on leading<br />
software and communication<br />
technologies (e.g. Open Industry 4.0<br />
Alliance: Endress + Hauser, KUKA,<br />
MULTIVAC, Pepperl + Fuchs, SAP,<br />
SVA, Voith et al.; Open Manufacturing<br />
Platform: BMW and Microsoft,<br />
umati: machine tools, etc.).<br />
• Users/operators of machines<br />
and plants - on the one hand hold<br />
the greatest expert knowledge in<br />
the everyday use of machines and<br />
plants and the associated technologies;<br />
they also know the most about<br />
the problems in the background;<br />
on the other hand, they are also the<br />
strongest "beneficiaries" of ongoing<br />
technical development, including<br />
digitalisation in all its facets.<br />
Moreover, digitalisation in the field of<br />
capital goods cannot be viewed as an<br />
isolated trend, but must be embedded in<br />
key current trends. The most important<br />
ones are:<br />
• "Industry 4.0 / industrial production<br />
of individual products" - End users<br />
expect an increasingly high variability<br />
of manufacturing systems: it<br />
must be possible to manufacture the<br />
widest possible range of products in<br />
small to medium quantities harnessing<br />
the same system;<br />
• Production plants must be scalable<br />
and offer options for cost-effective<br />
subsequent expansion of existing<br />
systems in terms of capacity and<br />
output;<br />
• Declining OEM margins on new installations<br />
combined with high end<br />
user expectations for maintenance<br />
and service make the expansion of<br />
LCC-based business models (LCC<br />
= Life Cycle Costs [1]) with new<br />
business concepts (including maintenance,<br />
service, retrofit services,<br />
e.g. "Predictive Maintenance") more<br />
and more economical for OEMs as<br />
well, and therefore more meaningful;<br />
• Users' expectations of the interoperability<br />
of machine modules and<br />
sub-systems are constantly on the<br />
34 maintworld 1/<strong>2021</strong>
YOUR PARTNER IN<br />
ULTRASOUND<br />
INSTRUMENTS<br />
Leak Detection<br />
Bearing Condition Monitoring<br />
Bearing Lubrication<br />
Steam Traps & Valves<br />
Electrical Inspection<br />
TRAINING<br />
CAT & CAT II Ultrasound Training<br />
Onsite Implementation Training<br />
Application Specific Training<br />
CONTINUOUS SUPPORT<br />
Free support & license-free software<br />
Online Courses<br />
Free access to our Learning Center<br />
(webinars, articles, tutorials)<br />
UE SYSTEMS<br />
www.uesystems.com<br />
info@uesystems.com<br />
CONTACT US FOR AN<br />
ONSITE DEMONSTRATION
DIGITALISATION<br />
rise; machines and machine modules<br />
from different suppliers should be<br />
as easy as possible to combine in a<br />
single production line. This results<br />
in greater comparability and tougher<br />
competition for OEMs.<br />
All these requirements can only be reconciled<br />
very efficiently in machine and<br />
plant construction, both in technical and<br />
economical terms, if production systems<br />
are consistently modularised, scalable in<br />
various stages of expansion and, in the final<br />
instance, also networkable. Only with<br />
modular networked machines will<br />
one be economically successful in the<br />
long term - more details are described in<br />
the HARTING article on modularisation<br />
"How granular can production technology<br />
be?" [8]. So it is precisely the modularity<br />
and the possibilities of scalability and<br />
expandability of existing systems - a "state<br />
of the art" of "hardware" in modern mechanical<br />
engineering - which from today's<br />
point of view is the key to the success of<br />
digitalisation (IIoT)!<br />
This is also illustrated by two examples<br />
from "related" areas:<br />
• The modularisation of today's<br />
industrial PLC, CNC and HMI systems<br />
is proverbial. The respective<br />
hardware and the development environment<br />
involved here is designed for<br />
each concrete application according<br />
to the principle of "only as much as<br />
necessary"; but if necessary, these can<br />
also be designed for subsequent upgrades,<br />
which applies in particular to<br />
the data interfaces; in this case, subsequent<br />
expansion, the "growth" of<br />
control software in delivered systems<br />
is in principle no problem - and only<br />
limited by the know-how of the given<br />
OEM supplier;<br />
• The scalability of high-performance<br />
drive systems consisting of a<br />
servo-inverter and a servo-motor is<br />
nowadays very often not realised by<br />
the manufacturer via the hardware,<br />
but only through the software (similar<br />
to the "chip tuning" of combustion<br />
engines). Consequently, the hardware<br />
is identical for simple and "high-end"<br />
products, and only the software determines<br />
the functionality and performance<br />
of a concrete system at the<br />
customer's site.<br />
Since the economic success of digitalisation<br />
in the mechanical engineering industry<br />
can vary greatly from segment to segment,<br />
and depends among other things on<br />
company focus and business models, we<br />
Figures 4 and 5: HARTING PushPull RJ45 and M12 X-coded - typical high-performance<br />
data interface in mechanical and plant engineering.<br />
will not make any recommendations here.<br />
In answering these questions, you<br />
should refer to current studies: e.g. "Industrie<br />
4.0 Barometer / Summary 2019"<br />
by MHP [9], the "Market study industrial<br />
communication / Industry 4.0” (“Marktstudie<br />
Industrielle Kommunikation /<br />
Industrie 4.0") by VDMA / M. Rothhöft<br />
[10] or the very recent study “Customer<br />
centricity as opportunity for the digital<br />
breakthrough" (“Kundenzentrierung als<br />
Chance für den digitalen Durchbruch") by<br />
VDMA / McKinsey & Company [11].<br />
How can digitalisation<br />
be shaped and designed<br />
successfully for an OEM?<br />
Evaluating the experience of HARTING<br />
customers in different sub-segments of<br />
the mechanical engineering industry and in<br />
different countries, three aspects must first<br />
be considered:<br />
1. The functions and existing software elements<br />
of the basic, initial system must be<br />
prioritised:<br />
• Key functions that reflect the core competence<br />
of the OEM;<br />
• Basic functions that apply across the<br />
entire system, but do not impact on the<br />
core know-how;<br />
• Add-on or auxiliary functions that are<br />
secondary for the OEM and the end<br />
user, and are usually purchased as<br />
sub-systems;<br />
2. In the next step, collect the expert<br />
knowledge of the end users (customers)<br />
and own experts relevant to possible digitalisation<br />
projects and give preference to<br />
36 maintworld 1/<strong>2021</strong>
DIGITALISATION<br />
Figure 6: Han-Modular:<br />
established hybrid power and<br />
data interface for sophisticated<br />
and demanding industrial<br />
applications.<br />
high-priority functions and software elements.<br />
Possibly compare with the knowhow<br />
of competitors and develop a list of<br />
requirements. This list must be modular<br />
throughout and as specific as possible in<br />
terms of prioritised functions and software<br />
elements;<br />
3. Now it is necessary to assess the feasibility<br />
of digitalisation for individual<br />
functional modules; in this step it is advisable<br />
to involve all in-house OEM experts<br />
along the performance and service<br />
provision chain - development & design,<br />
project planning & sales, production &<br />
assembly, documentation, service & aftersales<br />
services. Moreover, assessments<br />
can be obtained from external specialists<br />
and any specifications or standards that<br />
have already been drawn up can serve as<br />
a template (e.g. by umati). Remember the<br />
sentence: "We will definitely remain mechanical<br />
engineers and will not become a<br />
software house".<br />
The biggest challenges for OEMs in<br />
these steps are:<br />
• The contradiction between the diverse<br />
individual requirements of the<br />
customers on the machines and the<br />
economic necessity to keep the number<br />
of modules / processes required<br />
for this (especially for key functions)<br />
small. OEMs are already solving<br />
this problem today by consistently<br />
"breaking down" their systems into<br />
logical units and pursuing modularisation<br />
- in order to act economically<br />
when digitalising here, the following<br />
should be considered.<br />
AS MUCH EXISTING technological and<br />
machine-related data as possible should<br />
be used and aggregated at the "lowest"<br />
modular level for future digitalisation<br />
INTERFACES PLAY AN<br />
IMPORTANT ROLE IN MODULAR<br />
NETWORKED PRODUCTION<br />
SYSTEMS.<br />
projects, i.e. utilising existing sources, data<br />
and machine and process models that are<br />
already in place. Particular attention should<br />
be paid to the previously unused or little<br />
used "intelligence" of the automation components,<br />
such as drives, sensors for machine<br />
or process states, etc.<br />
AT ALL HIGHER levels (edge and above) the<br />
most open, future-oriented standards possible<br />
for physical interfaces should be relied<br />
on, as well as the latest software and communication<br />
protocols.<br />
• Too broadly designed and not very<br />
concretely elaborated targets in combination<br />
with unduly high expectations<br />
regarding the economic effects of<br />
digitalisation will result in frustration.<br />
On the one hand, relevant projects are<br />
often overloaded with expectations<br />
on the part of the OEM management,<br />
while on the other hand, they are also<br />
insufficiently equipped with resources.<br />
For the development, implementation<br />
and ongoing support of digitalisation<br />
projects, it is therefore advisable not<br />
to want to achieve everything right<br />
away. Rather, the following should be<br />
considered:<br />
SUB-PROJECTS should be defined in terms<br />
of modules and focus on high-priority key<br />
functions;<br />
THE DESIGN of the interfaces on the<br />
physical level as well as on the data level<br />
should always correspond to the latest<br />
state of the art and be open for subsequent<br />
software updates and extensions<br />
(especially for end users);<br />
THE PARTICIPANTS should be divided<br />
into interdisciplinary project groups, so<br />
that on the one hand a constant dynamic<br />
exchange of information can take place,<br />
while on the other hand, access to the<br />
management level of the OEM is possible<br />
at any time at short notice for the purpose<br />
of correcting objectives and targets;<br />
Consequently, the overriding rule is<br />
as follows: If the modularity of digitalisation<br />
projects (the "software") follows<br />
the modularity of machines and systems<br />
(the "hardware") and features the latest<br />
physical and data interfaces, as an OEM,<br />
you will then be providing an economically<br />
and technically optimal system for<br />
the current customer requirements.<br />
Such systems are also best equipped<br />
to cope with the constantly growing and<br />
partly still unknown future requirements!<br />
Interfaces play an important role<br />
in modular networked production<br />
systems: they are the "lifelines, nerve<br />
pathways and synapses" and create the<br />
necessary infrastructure for the module<br />
and machine transitions, the edge area,<br />
the factory and other superordinate levels.<br />
The HARTING Technology Group<br />
provides solutions for all interfaces<br />
that are essential in modern and future<br />
control, drive, HMI and communication<br />
technology for production systems, in<br />
order to implement and advance digitalisation<br />
in this area without functional<br />
restrictions.<br />
1/<strong>2021</strong> maintworld 37
ASSET MANAGEMENT<br />
Keeping the Lights On and Preventing<br />
Failures with the FLIR Si124<br />
SPI Inspections provides their customers with top-notch utility system and<br />
infrastructure inspections, relying on their extensive experience in the field and<br />
advanced inspection technology. The team uses UAVs, FLIR thermal cameras, and<br />
other high-tech equipment to deliver qualified inspection services and independent<br />
verification of construction standards and monitoring of power systems.<br />
RECENTLY, the team at SPI Inspections<br />
test-ran the new FLIR Si124 acoustic<br />
imaging camera. Built with 124 microphones,<br />
the Si124 produces a precise<br />
acoustic image that visually displays<br />
ultrasonic information in real time on<br />
top of a digital camera picture. This allows<br />
the user to visually pinpoint the<br />
source of the sound.<br />
The founders of SPI Inspections<br />
have more than 100 years of combined<br />
experience working with utility systems,<br />
from building power lines to<br />
inspecting substations. “We’ve been<br />
around the block a few times,” says Elton<br />
Hunter, Field Manager at SPI. “Our<br />
background is basically power, from<br />
where it's made in the generating facility<br />
to where the meter is—either the<br />
The FLIR Si124 is a lightweight, one-handed<br />
solution that can identify issues up to 10<br />
times faster than with traditional methods.<br />
meter on your home or the meter on<br />
your business.”<br />
“We've really assisted our customers,”<br />
says Hunter. “Our goal is to make their<br />
systems work better, safer, and be more<br />
reliable.” The team at SPI Inspections<br />
found the FLIR Si124 to be an invaluable<br />
asset in detecting partial discharge, a<br />
sign of approaching or imminent failure<br />
in power infrastructure.<br />
The Tools of Inspection<br />
The journey of electricity from power<br />
plant to lightbulb in your home presents<br />
plenty of opportunities for failure if infrastructure<br />
isn’t properly maintained.<br />
SPI uses their extensive experience to<br />
recognize when an element needs maintenance,<br />
aided by advanced technology.<br />
38 maintworld 1/<strong>2021</strong>
ASSET MANAGEMENT<br />
The FLIR GF77 offers both radiometric temperature measurement and the ability to<br />
detect a wide range of gases by simply changing lenses.<br />
SPI Inspections that their tools are ready<br />
for the job. “It's very user friendly,” says<br />
Hunter about the Si124. “Within a halfdozen<br />
hours, we were very confident<br />
working with it.”<br />
“The camera has wonderful clarity<br />
for us in the field,” Hunter continues.<br />
He said his team appreciated the quality<br />
of the images, ease of download to a<br />
laptop or the cloud, and the functionality<br />
of the user interface. “We're guys that<br />
have been in construction for 40-plus<br />
years—we've got arthritis and big swollen<br />
fat hands hitting hammers and stuff.<br />
The user interfaces—the keys, the touch<br />
boards—are very user friendly. We found<br />
them very easy to work with.”<br />
IT IS IMPORTANT TO THE TEAM<br />
AT SPI INSPECTIONS THAT THEIR<br />
TOOLS ARE READY FOR THE JOB.<br />
“We bring a lot of technological tools to<br />
the trade,” says Hunter. Among the tools<br />
in their arsenal is the FLIR GF77 gas<br />
detection camera, which allows them to<br />
spot sulfur hexafluoride (SF6) leaks in<br />
electrical installations as well as detect<br />
hot spots. The GF77 is a multi-use camera<br />
that can detect a range of gases just<br />
by changing out the lens. When equipped<br />
with an HR Lens, the camera can visualize<br />
sulfur hexafluoride, while an LR<br />
Lens allows the camera to see methane,<br />
ethylene, ammonia, and other gas emissions.<br />
The camera is also calibrated for<br />
temperature, so it functions as a standard<br />
thermography camera use to reveal a<br />
wide range of utility issues.<br />
Having relied on FLIR gas detection<br />
cameras for previous inspections, the<br />
SPI team was excited to get their hands<br />
on the Si124 and see what it could do.<br />
Though acoustic imaging cameras are<br />
often used to locate pressurized leaks in<br />
compressed air systems, the Si124 is also<br />
a very effective tool for detecting partial<br />
discharge from high-voltage systems.<br />
Partial discharge—caused by a breakdown<br />
in electrical insulation—can be<br />
detected when the air around the breakdown<br />
becomes ionized, creating a phenomenon<br />
called “corona.” Corona can<br />
be quickly detected by acoustic imaging,<br />
identified by a “meatball” of sound in the<br />
image. “For us, that's invaluable,” says<br />
Hunter.<br />
Almost invisible electrical utility issues are quickly detected with the Si124.<br />
The team had previously been using<br />
ultraviolet technology to detect corona<br />
and were pleased to find that the Si124<br />
achieved about the same result for a fifth<br />
of the price. “The Si124 basically does<br />
the same job and it's very easy to use,”<br />
explains Brett Fleming, Corporate Manager<br />
at SPI Inspections.<br />
Intuitive and Accessible<br />
Features<br />
Because so much of their work is done<br />
in the field, it’s important to the team at<br />
The Si124 made it much easier to<br />
spot failures from the ground. During<br />
their test run of the camera, they found<br />
a failure on a power line 220 feet up in<br />
the air, a difficult issue to detect. “With<br />
our drones we could, but we would have<br />
known where to look,” says Hunter. “Because<br />
of our field experience we were<br />
able to pick it out and zoom in on it,<br />
then we knew that there was a bit of a<br />
problem up there.”<br />
“That's a 25-million-dollar failure<br />
on a line that's only five years old,” he<br />
1/<strong>2021</strong> maintworld 39
ASSET MANAGEMENT<br />
The Si124 can detect issues up to 100<br />
m (328 ft) away, keeping inspectors<br />
on the ground and out of danger.<br />
remarks. With the Si124 they were able<br />
to catch the problem early, before the<br />
cost to fix it became nearly that high.<br />
Safely Accessing<br />
Dangerous Areas<br />
Electrical substations and other utility<br />
infrastructure present numerous<br />
hazards for workers and inspectors.<br />
When the team confronted a particularly<br />
dangerous area inside the substation<br />
where a capacitor bank had come<br />
down, they were required to stay outside<br />
the chain-link fence enclosing the<br />
area. They were pleased to find that<br />
the Si124 could look through the fence<br />
to assess the situation.<br />
“We were able to walk right up, and<br />
we could look right through the chainlink<br />
fence. Because there's 124 microphones<br />
on the front of the camera and<br />
then one little tiny camera,” Hunter<br />
explains, “that camera was able to<br />
look right through that two by two<br />
inch square and keep our people safe,<br />
which is a huge advantage for us being<br />
in the field.”<br />
Catching Problems Before<br />
They Become Catastrophes<br />
SPI’s goal during inspections is to catch<br />
issues before they’re allowed to escalate<br />
too far. Spotting partial discharge and corona<br />
early with tools like the Si124 helps<br />
them anticipate failures and keep the<br />
lights on for their clients. “It allows us to<br />
preemptively prognosticate what's happening<br />
in our power line,” says Hunter.<br />
“So instead of there being a catastrophic<br />
failure and then an outage and a repair,<br />
we can go in ahead of time and we can tell<br />
them, ‘hey, you're going to have a problem<br />
with this if you don't fix it’.”<br />
Unplanned outages can be prevented<br />
with regular inspection and maintenance.<br />
“If we do our jobs right, nobody<br />
ever knows we're out there. The customer<br />
doesn't know we're there; we go<br />
do our job, we make recommendations,<br />
and then through planned outages or<br />
regular maintenance they can repair<br />
something.”<br />
SPI Inspections operates in Canada<br />
and China—learn more about the services<br />
they offer here: www.spiinspections.<br />
com/, and learn more about the FLIR<br />
Si124: www.flir.com/products/si124/<br />
ABOUT FLIR SYSTEMS, INC.<br />
FOUNDED IN 1978, FLIR SYSTEMS<br />
is a world-leading industrial technology<br />
company focused on intelligent<br />
sensing solutions for defense,<br />
industrial, and commercial applications.<br />
FLIR Systems’ vision is to be<br />
“The World’s Sixth Sense, creating<br />
technologies to help professionals<br />
make more informed decisions that<br />
save lives and livelihoods. For more<br />
information, please visit www.flir.<br />
com and follow @flir.<br />
40 maintworld 1/<strong>2021</strong>
ASSET MANAGEMENT<br />
IGS Technician Applying<br />
HVTS (High Velocity Thermal<br />
Spray) Alloy Cladding<br />
Cui Solution for Aging Plants<br />
Maintaining Production During<br />
Critical Maintenance<br />
BO ANDERSEN,<br />
bo.andersen@integratedglobal.com<br />
TSA (Thermal Sprayed<br />
Aluminium) provides lasting<br />
(>20 years) protection<br />
of carbon steel equipment.<br />
It acts as a barrier<br />
coating, passivating the<br />
surface and galvanically<br />
protecting it against atmospheric<br />
and immersion<br />
corrosion mechanisms,<br />
such as CUI (corrosion<br />
under insulation).<br />
IN THE PAST, TSA applications were<br />
performed during turnarounds, disrupting<br />
schedules and other activities due to<br />
noise, possible TSA fumes, and abrasive<br />
blasting. Plant operators were forced to<br />
make tradeoffs between turnaround duration<br />
and asset integrity as the amount<br />
and location of surfaces protected by<br />
TSA in turnarounds are limited.<br />
Aging Plants Require Work<br />
between Turnarounds<br />
There has been a higher demand for<br />
prolonged TSA application outside<br />
of the turnarounds in the past years.<br />
Equipment within many refineries, petrochemical<br />
plants, and other facilities<br />
is now a lot older. Pipes, vessels, and other<br />
process equipment face rapid deterioration<br />
of their original non-optimal corrosion<br />
protection.<br />
How to Increase the Speed of<br />
Maintenance and Maintain Production<br />
Capacity?<br />
Maintenance and Operations Managers<br />
are under pressure to increase the maintenance<br />
speed not to lose many production<br />
facilities or at least the production capacity.<br />
Thus, they look at doing the critical maintenance<br />
while the plant is online – in other<br />
words, without shutting it down. That way,<br />
they will be able to reach their maintenance<br />
goal and maintain uptime simultaneously.<br />
42 maintworld 1/<strong>2021</strong>
ASSET MANAGEMENT<br />
What about Safety?<br />
There are concerns about “hot-work”<br />
such as welding, abrasive blasting, and<br />
the open flame of TSA application in<br />
many locations around the world. Temperature<br />
and humidity also need to be<br />
controlled to reach the optimal environment<br />
for the TSA application. These<br />
concerns apply to both colder areas,<br />
such as Canada, Alaska, The North Sea,<br />
Northern Russia, and high temperature/<br />
humidity areas like the Middle East, Singapore,<br />
and West Africa.<br />
Hot-work that may produce sparks<br />
or open flames can be dangerous due<br />
to the risk of explosion, fire, and the<br />
release of poisonous gasses. It can be<br />
hazardous for personnel, equipment,<br />
and the entire plant.<br />
Developing IGS TUFFss<br />
Online TSA Solution<br />
Large national and international petrochemical<br />
companies have been actively<br />
looking for a safer TSA solution, which<br />
can be applied while the plant is in operation.<br />
Royal Dutch Shell, a British-Dutch<br />
multinational oil and gas company, has<br />
initiated a project with TUFFss to develop<br />
a safer online TSA solution.<br />
TUFFss has since been acquired<br />
by Integrated Global Services (IGS), a<br />
global turnkey thermal spray cladding<br />
provider. IGS was chosen to join this<br />
project due to their lasting experience in<br />
the field of thermal spray. IGS is the sole<br />
provider of a proprietary HVTS (High<br />
Velocity Thermal Spray) alloy cladding<br />
technology, specifically designed<br />
for the protection of mission-critical<br />
equipment, including pressure vessels<br />
and boilers. Furthermore, IGS HVTS is<br />
applied in situ, whereas the majority of<br />
thermal spray applications take place in<br />
CUI on Piping is Common<br />
in Aging Facilities<br />
IGS TUFFss Online TSA Meets<br />
Highest Industry Standards<br />
workshops. To enable the HVTS application<br />
in the field, IGS have successfully<br />
optimized their materials, conveyancing<br />
technology, and application procedures.<br />
Could the same be done for TSA?<br />
IGS TUFFss Online TSA Meets<br />
Highest Industry Standards<br />
For TSA to be safely applied online, several<br />
issues would need to be resolved,<br />
including process-specific safety procedures,<br />
temperature, and humidity.<br />
Following two years of intensive R&D<br />
work, a safer online TSA solution was<br />
introduced. –<br />
– The solution included enhanced<br />
TSA application processes and procedures,<br />
sealed safety enclosures, humidity<br />
and temperature control, (negative) environmental<br />
pressure control, and a fully<br />
automated safety shutdown system for<br />
the TSA and abrasive blasting processes.<br />
Everything was custom-made and combined<br />
in ways unheard of, meeting the<br />
highest standards in the industry, Bo<br />
Andersen, who has been instrumental in<br />
the development of this new technology,<br />
said.<br />
Safety! Safety! Safety First!<br />
The IGS IGS TUFFSS ONLINE TSA<br />
solution is a safe way to handle online<br />
maintenance with blasting, TSA, or other<br />
coatings. This is made possible with a<br />
proprietary Automatic Shutdown System.<br />
This emergency shutdown system<br />
continuously monitors the entire work<br />
area and surroundings. The system will<br />
give digital, audible, and visual warnings<br />
in case of leak of gasses, pressure loss, or<br />
any other parameter deviation.<br />
This, in turn, enables almost instantaneously<br />
automatic termination of any<br />
work and equipment inside or outside<br />
the habitat, including, but not limited to,<br />
welding, grinding, power, grit/sandblasting,<br />
TSA, HVAC, dust collection, etc. All<br />
equipment is controlled through the<br />
use of electrical connections, solenoid<br />
valves, and pneumatic connections.<br />
Pilot Project at a Liquefied<br />
Natural Gas-Producing Plant<br />
Established in 1989, NLNG, an LNG facility<br />
in Nigeria, currently has 6 Trains.<br />
The plant has a total production capacity<br />
of 22 Million Tons Per Annum (mtpa) of<br />
LNG and 5mtpa of Natural Gas Liquids<br />
(NGLs), which equals 6% of the global<br />
market.<br />
1/<strong>2021</strong> maintworld 43
ASSET MANAGEMENT<br />
Hot and Humid<br />
Located in a hot, humid, and very salty<br />
environment, piping at this facility is<br />
prone to corrosion. Various kinds of<br />
paint and insulation have initially been<br />
used for corrosion protection. After 20<br />
years in service, Corrosion Under Insulation<br />
(CUI) has turned into a significant<br />
problem with many pipes about to burst.<br />
Ignoring the problem or an insufficient<br />
solution could result in fire, explosion,<br />
environmental damage, loss of life, loss<br />
of profit, or production loss.<br />
CUI Problem: Evaluating<br />
Alternatives<br />
One option was to repaint the piping<br />
with the same or similar paints and coatings<br />
that have already failed once. Some<br />
new technology paints and coatings<br />
were also being considered. These paints<br />
would still need to be inspected and usually<br />
reapplied every 5-10 years. Thermal<br />
Spray Aluminium (TSA) was an optimum<br />
solution due to its long inspection<br />
cycle, >20 years, and proven reliability.<br />
IGS TUFFss Online TSA Pilot<br />
Application<br />
TSA coatings applied in traditional ways<br />
without environmental controls would<br />
not be practical in this case. The scale of<br />
the work in total exceeded 360,000m2.<br />
Applied during turnarounds, it would<br />
have taken over 30 years to protect all corroded<br />
piping. The plant would not have<br />
lasted 30 years in its present condition!<br />
The plant needed a solution that could be<br />
applied while the plant is live. The application<br />
would need to be climate-controlled<br />
during surface preparation and TSA application,<br />
with all grit and dust contained.<br />
The IGS TUFFSS ONLINE TSA pilot<br />
project was first completed on train 1.<br />
The scope included a 50-meter (160 foot)<br />
column and a two-level platform with two<br />
heat exchangers/reboilers. IGS TUFFSS<br />
ONLINE TSA was applied to a total area<br />
of 700m2 on cold and hot surfaces.<br />
This onsite project began on October 1st<br />
2016, and concluded in January 2018.<br />
The project was carried out in adverse<br />
weather conditions, including heavy<br />
rain, thunder, sandstorms, high temperature,<br />
and high humidity.<br />
One Train Done, Six to Go<br />
This project succeeded in meeting and<br />
exceeding objectives by rigidly following<br />
all safety guidelines. The project utilized<br />
specially designed Habitats to enable<br />
IGS IGS TUFFSS ONLINE TSA Project at a Liquefied Natural Gas-Producing Plant<br />
CUI Problem Area on Piping<br />
weather protection, climate, humidity, and<br />
pressure control. It was now confirmed<br />
without a doubt that it is possible to do the<br />
encapsulated TSA maintenance in a live<br />
environment, which will be of great importance<br />
to NLNG in the future as the work<br />
continues on the remaining six trains.<br />
IGS TUFFSS ONLINE TSA –<br />
In Summary<br />
As equipment within refineries, petrochemical<br />
plants, and other facilities<br />
continues to age, the demand for maintenance<br />
solutions that can be applied all<br />
year round is growing. Plant operators<br />
are looking to companies like IGS to<br />
utilize their global footprint and experience<br />
to deliver innovative solutions<br />
safely and efficiently. Preventing shutdowns<br />
and providing the work outside of<br />
turnarounds eases the pressure off the<br />
maintenance and operations teams, who<br />
can continue production while crucial<br />
maintenance work is being simultaneously<br />
carried out. Further IGS TUFFSS<br />
ONLINE TSA projects are now being<br />
commissioned within refineries and<br />
petrochemical sites, paving the way for<br />
more uptime in aging facilities.<br />
GOOD TO KNOW<br />
INTEGRATED GLOBAL SERVICES, Inc.<br />
(IGS) is an international provider of<br />
surface protection solutions headquartered<br />
in Virginia, USA. IGS operates<br />
operational hubs, subsidiaries, and<br />
sales offices around the world to service<br />
global asset owners and operators.<br />
The company has 40 years of experience<br />
helping customers solve metal<br />
wastage and reliability problems in<br />
mission critical equipment and is an<br />
industry leader in the development<br />
and application of solutions to corrosion<br />
and erosion problems in challenging<br />
operating environments.<br />
44 maintworld 1/<strong>2021</strong>
Registration:<br />
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IT meets Automation<br />
JUN 08 – 10, <strong>2021</strong><br />
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EACH DAY: 2H CONFERENCE – 1H Q&A<br />
DIGITAL EVENT<br />
Join this digital event free of charge<br />
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Listen to infl uencers on technology, security and solutions:<br />
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©royyimzy – stock.adobe.com
TRAINING & EDUCATION<br />
Creativity Was<br />
– and Still Is –<br />
Needed in Teaching and R&D Projects<br />
during the Pandemic Time<br />
The Corona virus outbreak shut<br />
down all of Häme University<br />
of applied sciences (HAMK)<br />
campuses, just as it did in other<br />
Universities. Teaching was<br />
transferred to the internet. But<br />
how were research activities<br />
continued with the tight<br />
movement restriction in place?<br />
LEA MUSTONEN, Senior Lecturer (Communications), School of Technology, Häme University of Applied Sciences (HAMK),<br />
SUSAN HEIKKILÄ, Senior Lecturer, Electrical and Automation Engineering study programme, Häme University of Applied Sciences (HAMK)<br />
THE SHIFT TO REMOTE TEACHING happened<br />
in a few hours. On Friday 13.3.2020<br />
regular classroom teaching was being<br />
implemented as usual, but with the<br />
recent corona outbreak on everyone’s’<br />
minds. But at the same day all the contact<br />
lessons were cancelled to the end of the<br />
semester. Classrooms became deserted.<br />
The jump to pure virtual-based teaching<br />
was not painless, but the staff had strong<br />
experience of teaching diverse students<br />
who studied and worked at that time.<br />
Some students used to traditional<br />
classroom teaching and university facilities<br />
had problems with software and<br />
internet connections. Luckily many of<br />
the software developers had a “We are all<br />
in the same boat” -mentality. At the start,<br />
teachers often had to think what software<br />
would likely work for teaching virtually,<br />
but a lot of the software used got quick updates<br />
within the first few weeks. In addition<br />
to students, the teaching staff moved<br />
to a virtual environment with no major<br />
problems. So, there were some problems<br />
with teaching, but the goal was in sight.<br />
Digital twin as a solution<br />
Staff of universities does not only include<br />
teaching staff. The radical change also<br />
meant rethinking the means of success<br />
for research activities. To further<br />
research during these restrictions, the<br />
digital twin was taken in use in our project,<br />
Low Carbon Energy Efficiency with<br />
Micro-CHP-technology (later called as<br />
VEneCT).<br />
The term “digital twin” tells it’s meaning<br />
quite well: a digital copy is made of a<br />
physical thing. The copy is made to simulate<br />
the parameters and components<br />
essential for its functionality as close as<br />
possible in the development environment.<br />
Digital twin is a simulation that<br />
makes it possible to test how a change<br />
to an existing one or a new functionality<br />
would affect the original.<br />
The goal of the VEneCT-project is low<br />
carbon usage, as it is a goal in all of the research<br />
projects conducted by HAMK that<br />
involve energy efficiency. The basis of the<br />
research is that its results benefit companies<br />
and teaching in the future.<br />
The purpose of the project is to resolve<br />
how electricity can be produced on a small<br />
scale with waste energy including the possibility<br />
of utilizing the waste energy produced<br />
by burning process. The research<br />
is conducted using a physical construct<br />
that utilizes a “hybrid module” of generating<br />
and storing energy. Different types of<br />
energy-generating possibilities are tested.<br />
The construct has been installed with a<br />
control system that determines what energy<br />
source is the most cost efficient. The<br />
possible energy sources are solar heating,<br />
solar panels and heating bio-boiler. Different<br />
storage methods of heat energy are<br />
also being explored. Testing is being done<br />
on different phase change materials in addition<br />
to water to enable larger amounts<br />
of heat energy storage. In addition to the<br />
hybrid module creating data, the construct<br />
itself could be an energy source.<br />
Corona virus sped up the<br />
development process<br />
When teaching moved to a virtual environment<br />
with a fast pace, the research<br />
46 maintworld 1/<strong>2021</strong>
TRAINING & EDUCATION<br />
Picture 1. The digital twin’s interface<br />
It is also possible to delve deeper into the data, for example, if some sudden<br />
change or outcome draws attention. Picture 2 shows an example of a report.<br />
Picture 2. Boiler water temperature<br />
The advantage is that different data can be combined and later we can<br />
return to a certain time period to inspect it. It is also beneficial to be able to<br />
monitor individual status changes in real time, allowing for a quick response<br />
to the situation. “The novelty is that the reporting view and process control<br />
are combined”, sums up the project engineer Ari Lindgren.<br />
personnel also started working from<br />
home as much as possible. The continuation<br />
of the VEneCT-research project<br />
with a great start became a challenge.<br />
The hybrid module is controlled with<br />
touch-screen control panel, which is<br />
situated inside the building. Remote<br />
access to collected data has been a goal<br />
from the very start, but remote control<br />
of the system was not part of the written<br />
down objectives of the project. The idea<br />
had been brought up at the start of the<br />
year before the pandemic, but there had<br />
not been any active development on it.<br />
Closing of the campus changed the situation<br />
totally.<br />
The size of the hybrid module building<br />
is 18 square meters. Tight pandemic<br />
security measures allow for only one<br />
person to enter the building. Because<br />
of the complicity of its interior design,<br />
even careful cleaning practices cannot<br />
guarantee the safety off the staff. Staff<br />
access was limited so that there had to<br />
be a three-day gap between access of different<br />
staff members. So, the research<br />
activities could not be continued in a<br />
realistic way.<br />
Special attention to data<br />
security<br />
When designing the remote control,<br />
special attention had to be paid to data<br />
security, emphasizes research assistant<br />
Duong Truong. Control cannot be performed<br />
from home computers or home<br />
network connections; it can only take<br />
place in a secure network of HAMK.<br />
Thus, the researchers had to physically<br />
come to campus, but since there was no<br />
contact teaching, there was plenty of<br />
room on campus to operate without any<br />
kind of close contact.<br />
A digital twin was built for the control<br />
system of the hybrid module. It is now<br />
possible to both monitor and control activities<br />
remotely. A key part of the digital<br />
twin’s operations is reporting. The digital<br />
twin’s interface (picture 1) provides realtime<br />
information on process status and,<br />
for example, temperature changes, water<br />
flows, and electricity production.<br />
Digital twin came to stay<br />
The digital twin changed the way to operate<br />
and came to stay. It will be used in the<br />
future, when physical presence requiring<br />
burn tests are not being performed. Everything<br />
else can be done virtually.<br />
At the moment, virtual learning and<br />
work will continue. Changing circumstances<br />
forced – and will force - us to<br />
search new solutions in teaching and research;<br />
the digital twin is a good example<br />
of this. Ending research and development<br />
cannot be afforded.<br />
PROJECT INFORMATION:<br />
VEneCT i.e. Low Carbon Energy Efficiency<br />
using Micro-CHP-technology.<br />
An EU project funded by the Pirkanmaa<br />
Association integrates electricity<br />
generation using waste heat from the<br />
combustion process. (CHP, combined<br />
heat and power)<br />
1/<strong>2021</strong> maintworld 47
ASSET MANAGEMENT<br />
Monetizing Data<br />
in Maintenance:<br />
Data-driven Spare Parts<br />
Management – Part 2<br />
TOMÁŠ HLADÍK,<br />
Principal Consultant,<br />
Logio S.R.O.<br />
Today, digitization, Industry 4.0 and Maintenance<br />
4.0 bring about vast volumes of data. Technologies<br />
such as IoT or IIoT allow large sets of devices to<br />
connect to data networks and send complex data<br />
continuously.<br />
Organizations today maintain huge amounts of data, structured<br />
or unstructured. However, from research of renowned<br />
organizations like Gartner, we know that industrial firms today<br />
are not able to use 70—90 percent of data that are collected<br />
and stored. This paradox is described in the paper, and various<br />
generic models of big data monetization are proposed. Some of<br />
these models are shown in examples from spare parts management.<br />
Spare parts inventory can lock in significant amounts of<br />
working capital. This article summarizes recommendations<br />
for effective spare parts inventory management and spare<br />
parts optimization using various sets of data and statistical<br />
analytical methods.<br />
The management of spare parts and other materials needed<br />
for realization of maintenance processes is one of the key functions<br />
in physical asset management. Especially in power generation,<br />
oil and gas and heavy chemical industries, spare parts<br />
inventories can easily add up to tens of thousands of various<br />
items, at a value of hundreds of millions of euros.<br />
It is obvious that efficient spare parts inventory management<br />
can have significant impact on the financial performance<br />
of the company. Better spare parts management can lead to<br />
improvement of financial performance of the company.<br />
In previous research we discussed several recommendations<br />
for spare parts inventory management. Using these<br />
recommendations, companies can achieve better financial<br />
performance in different parts of the spare parts lifecycle.<br />
In some of these recommended practices, various data can<br />
be employed and analysed – especially in areas like portfolio<br />
segmentation, criticality assessment, forecasting, improving<br />
spare parts naming and identification, or cleaning and rectifying<br />
master data.<br />
Eight Rules of Good Spare Parts Management<br />
In our previous research, we refined the following eight rules –<br />
best practices – for good spare parts management:<br />
• Focus on preventative maintenance – for preventative<br />
maintenance no inventories of spare parts need to be<br />
held.<br />
• Solve problems in spare parts processes.<br />
• Segment your spare parts portfolio.<br />
• Analyse spare part’s criticality.<br />
• Use suitable forecasting methods and verify their accuracy<br />
and reliability.<br />
• Use special methods for intermittent demand items.<br />
• Consider the whole lifecycle of your assets while mak-<br />
48 maintworld 1/<strong>2021</strong>
ASSET MANAGEMENT<br />
ing decisions related to spare parts.<br />
• Implement a good information system for spare parts<br />
management so all above stated rules are supported<br />
and/or automated.<br />
In this issue of <strong>Maintworld</strong> we will describe in more detail the<br />
importance of analysing spare parts critically and the need to<br />
use suitable forecasting methods and verify their accuracy and<br />
reliability.<br />
Analyse Spare Part’s Criticality<br />
In large organizations operating large production systems, the<br />
size of spares portfolio amounts to tens or hundreds of thousands<br />
of items. It is therefore essential to be able to distinguish<br />
the important ones from the others. Criticality of spare parts is<br />
after all the ultimate measure of spare parts’ importance.<br />
The level of a spare part’s criticality is inevitably related to<br />
the criticality of the production equipment it is used for (so<br />
having an RCM analysis done will certainly help in assessing<br />
the criticality of spares). However, we need to keep in mind<br />
that criticality of spare parts is not equal to criticality of the<br />
device the spares are used for.<br />
When analysing criticality, we need to collect and look at<br />
various areas of data linked with the item: cost of inventory<br />
holding, failure probability, impacts of spare part unavailability,<br />
lead-time and other parameters – as shown in Fig. 4.<br />
Based on the level of item’s criticality, appropriate service level<br />
targets should be set.<br />
In practice, costs of inventory holding, and costs of spare<br />
parts unavailability should be carefully balanced. Costs can be<br />
compared using the following equation:<br />
Cinv=Cun*LT*f (1)<br />
Figure 4: Spare parts criticality analysis areas<br />
Where Cinv are costs of inventory holding per one year and<br />
Cun are costs of unavailability of spare part in case of need<br />
calculated per one day. LT is lead time calculated in days and<br />
f is frequency or probability of failure (need for spare part) as<br />
occurrences per year.<br />
If all data for the equation is available, criticality can be<br />
calculated directly – and easily. But in practice typically some<br />
the variables in the equation are not known at all or are uncertain,<br />
blurred and inaccurate. This is where advanced analysis<br />
Figure 5: Equation of criticality calculation – example<br />
1/<strong>2021</strong> maintworld 49
ASSET MANAGEMENT<br />
of available data comes to question. From our experience, in<br />
industrial organizations a number of interesting sets of data can<br />
be utilized to evaluate (or support evaluation) of spare parts’<br />
importance (criticalness or criticality).<br />
In the following diagram (Figure 6), a 2-level evaluation of<br />
criticality (or identification of critical items – materials or spare<br />
parts) is described. This 2-level approach allows for the “clever”,<br />
efficient process of evaluation of large numbers of items. Using<br />
various data sources like spare parts master data, history of<br />
spare parts transactions, RCM data, data from previous assessments<br />
of critical items, bills of materials etc., a preliminary separation<br />
of clearly non-critical items vs. suspicious (potentially<br />
critical) items can be done by means of data analysis without<br />
human interaction. After this preliminary evaluation, we can<br />
spot the relatively small group of potentially critical items and<br />
focus further evaluation on them. In this way the preliminary<br />
evaluation can save a lot of work and time otherwise required<br />
from maintenance technicians to assess each item individually.<br />
In the second step, potentially critical items are scrutinized<br />
thoroughly to find out their level (score) of criticalness. This can<br />
be done either in a quantitative way (if required data is available)<br />
or qualitative way (data must be collected by means of questionnaires<br />
filled-in by maintenance technicians or engineers).<br />
If it is less than 0 we should not – this spare part is not critical.<br />
Weights should be tested on selected parts with known (or<br />
agreed) criticality. A pilot mix of spare parts should include<br />
some parts which are critical for sure, some which are not, and<br />
some which are in between.<br />
It is essential to include maintenance engineers in both<br />
selecting questions for the questionnaire and in selecting<br />
weights for answers. This helps to create a better understanding<br />
of the questions and the whole purpose of the criticality<br />
assessment. A maintenance engineer should be able to fill the<br />
questionnaire in an average time of 2-10 minutes, so that the<br />
criticality assessment will not consume much of working time.<br />
Although assessment can be done on paper or in Excel, today<br />
it makes more sense to use available services like Google<br />
Forms or SurveyMonkey or others, that can be used to collect<br />
needed data and minimize the work with collecting, processing<br />
and analysing the data.<br />
Spare Parts Management Starts with Good<br />
Forecasting<br />
The next step in the specification of optimum spare parts<br />
inventory management regime is the prediction of future<br />
demand (consumption) for the items in stock. The forecast is<br />
always based on transactional data from information systems<br />
GOOD FORECASTING IS ALWAYS A BALANCED<br />
COMBINATION OF QUANTITATIVE METHODS<br />
AND HUMAN INTELLIGENCE. MATHEMATICS<br />
AND AI CAN WORK FOR US AUTOMATICALLY,<br />
BUT STILL WE NEED TO ENSURE QUICK AND<br />
EFFICIENT INPUT FROM PEOPLE.<br />
Figure 6: 2-level evaluation of spare parts criticality.<br />
If data for quantitative calculation is not available, we need to<br />
rely on information from maintenance engineers or technicians. To<br />
objectivize their subjective view on spare parts (maintenance engineers<br />
are often strongly biased towards keeping excessive inventory,<br />
“just to be safe”), we have proposed a structured questionnaire.<br />
Questions about spare parts realisability, probability of failure,<br />
and impact of unavailability, lead time, etc. should be designed<br />
to fit specific conditions of the organization (industry, technology/production<br />
equipment used etc.). The equation (1) should<br />
be taken into logarithm, so we can change variables for indices<br />
which can be added and subtracted instead of multiplicated. Answers<br />
should be given weights, and the questionnaire should be<br />
balanced so that we can have sums for each area (index) as shown<br />
in the following equation:<br />
IP-Iun-ILT-If=0 (2)<br />
This allows for summing weights for answers in each area<br />
into a single index. If the left side of the equation is greater<br />
than 0, we should keep at least one item of spare part in stock.<br />
– history of spare parts consumptions, which must be representative<br />
(meaning sufficiently long). In the case of spare parts,<br />
we usually work with a history of three to ten years (depending<br />
on industry). Three years of recorded history seems to be the<br />
minimum for intermittent items. A general rule here applies:<br />
the longer the history, the better and more reliable the forecast.<br />
When analysing historical consumption, we need to carefully<br />
distinguish between material consumed for planned<br />
maintenance (planned shutdowns, turnarounds, preventive<br />
maintenance) and spare parts issued for unplanned (corrective)<br />
maintenance – repairs. In forecasting, we must adjust the<br />
history for planned maintenance.<br />
In the forecasting process, items should be treated individually,<br />
according to the character of their consumption. Items<br />
with common demand patterns (high runners – fast moving<br />
items like fasteners, etc.) can be forecast using a number of<br />
standard statistical methods normally used in inventory management<br />
(moving average, exponential smoothing, Holt’s exponential<br />
smoothing, trends, seasonal indexes, Winter’s method,<br />
etc.). Items with intermittent demand require a special<br />
suitable method to be applied. The use of standard methods of<br />
prediction and inventory management in case of intermittent<br />
items results often in a substantial overestimate of future consumption<br />
and therefore excessive inventory level.<br />
50 maintworld 1/<strong>2021</strong>
VIBRATION ANALYSIS<br />
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