Maintworld Magazine 4/2023

4/2023 maintworld.com 

maintenance & asset management 

Maintaining the Future: 

Industry 5.0 

Triumphs Over 

Industry 4.0’s 

Challenges 

Preventative 

Maintenance in 

Construction 

p 26 

The Impact of 

Corrosion on Heavy 

Equipment 

p 30 

Best Practices 

for Storing 

Electric Motors 

p 44

EDITORIAL 

I 

had the opportunity to visit Iceland a 

few weeks ago as part of the EFNMS 

General Assembly meeting. The 

Icelandic Maintenance Association 

hosted our visit, during which we also 

had the chance to explore hydro- and geothermal 

power plants. It was fascinating 

to learn that 75% of Iceland's electrical 

energy is generated through hydro power, 

while 25% is produced using geothermal 

energy. Additionally, geothermal energy 

plays an important role in heating both 

urban areas and remote houses, making 

Iceland a prime example of sustainable 

energy utilization. 

In Europe, we have been struggling with energy challenges, particularly 

concerning gas delivery, which has prompted a renewed focus on innovation 

and investments in alternative energy sources. Energy issues affect us all, and 

some political analysts argue that energy is a central factor behind many of 

the global crises we are witnessing today. 

Regarding energy field maintenance, one of the presenters in Iceland 

informed us that in the event of a sudden hot lava eruption, they have only a 

few hours to evacuate the site. The next step would be a total new investment 

of the site – I guess. 

In the energy industry, effective asset management is crucial, as the initial 

investment is often substantial 

compared to the expected lifetime 

costs when machinery operates 

smoothly during the operational 

phase. From an investor's perspective, 

it is prudent to meticulously 

evaluate and calculate the 

types of devices and solutions 

needed to ensure optimal equipment 

operation throughout its 

operational lifespan to optimize the return on invested capital. 

Wind power is already a known area with enough competence and understanding 

of the maintenance needs. New areas of energy such as large-scale 

solar power, hydrogen and small nuclear power plants will most probably 

create new needs for maintenance competencies. Nevertheless, the demand 

for environmentally friendly and domestically controllable energy sources is 

increasing, placing significant pressure on the development of such technologies. 

In this edition of Maintworld magazine, you'll find an article from the German 

certification organization, TÜV SÜD, which provides insights into the 

maintenance of photovoltaic systems, commonly known as solar power. TÜV 

SÜD estimates that there are approximately 2.6 million photovoltaic systems 

generating solar power on rooftops and sites in Germany. Additionally, 

Associate Professor Mirka Kans from Chalmers University of Technology 

in Sweden emphasizes the significance of maintenance in a circular economy 

environment in her article. 

Furthermore, in this magazine you can learn what steps should be taken to 

simplify the transition in organisations toward robot-assisted work environments. 

While automation is often essential for improving productivity and 

cost-effectiveness, it may not always be met with enthusiasm by employees. 

In this magazine, we share strategies to introduce new technology in a way 

that positively impacts your workforce. 

Jaakko Tennilä 

Editor-in-Chief, Maintworld magazine 

In the energy 

industry, effective asset 

management is crucial, 

as the initial investment 

is often substantial. 

40 

Maintenance 

plays a 

huge role in achieving a 

high level of circularity. 

4 maintworld 4/2023

IN THIS ISSUE 4/2023 

26 

In 

the construction industry, 

preventative maintenance 

stands out as a pivotal practice, 

underpinning the operational 

longevity and efficiency of 

critical machinery. 

24 

Casing 

distortion is not only 

one of the biggest problems 

for rotating machinery but is 

also a very common one. 

4 Editorial 

6 News 

12 

16 

18 

Maintaining the Future: Industry 5.0 

triumphs over Industry 4.0’s challenges 

Bearing Lubrication 4.0: Autonomous and 

smart lubrication assisted by ultrasound 

Make gas detection a pillar of 

your ESG strategy 

22 

24 

26 

Mastering Ultrasound Monitoring with 

the CONMONSense Sensor Range 

Understanding casing distortion 

From Breakdowns to Breakthroughs: 

The transformative impact of 

preventative maintenance in 

construction 

30 

The impact of corrosion on heavy 

equipment 

34 

38 

40 

44 

48 

What biocatalysis has to offer for 

green industries and city planning? 

Simplifying the transition to a 

robot-assisted work environment 

Maintenance – A crucial factor for 

achieving circularity 

Best practices for storing electric motors 

Photovoltaic systems in the limelight 

Issued by Promaint (Finnish Maintenance Society), Messuaukio 1, 00520 Helsinki, Finland, tel. +358 29 007 4570. Editor-in-chief Jaakko 

Tennilä, Promaint. Publisher Avone Oy, avone.fi, executive producer Vaula Aunola, editor@maintworld.com, producer Nina Garlo-Melkas. 

Advertisements Kai Portman, Sales Director, tel. +358 358 44 763 2573, kai@maintworld.com. Layout Avone. Subscriptions and Change of 

Address: toimisto@kunnossapito.fi. Printed by Savion Kirjapaino Oy Frequency 4 issues per year, ISSN L 1798-7024, ISSN 1798-7024 (print), 

ISSN 1799-8670 (online). 

4/2023 maintworld 5

In Short 

Wind Turbine Services Market in Europe 

to increase by USD 2.88 billion from 

2023 to 2028; ABB Ltd., Acciona SA, B9 

Energy Ltd. and more among key companies. 

Source: Technavio 

ABB and Imperial College extend carbon 

capture collaboration to support future 

workforce and energy transition 

ABB AND IMPERIAL COLLEGE LONDON signed a 10-year 

contract to continue their carbon capture technology partnership. 

Following the agreement, ABB – a technology leader in 

electrification and automation – aims to prepare current students 

for future industrial processes, showcasing how advanced 

technology can optimize plant performance and enhance safety 

in real-life applications. 

The collaboration with Imperial College grants the university 

access to cutting-edge control and instrumentation technology. 

– Extending the partnership with Imperial College allows us to 

offer students practical training to prepare them for a career in 

industry, said Simon Wynne, Head of Energy Industries, ABB UK & 

Ireland. 

The plant, which is spread over four floors, uses ABB Ability 

System 800xA® for distributed process control and over 250 

instruments, measuring temperature, pressure, carbon dioxide 

and flow. System 800xA automatically controls and coordinates 

all aspects of the plant process, which is then visualized on displays 

in the ABB Control Room where students can monitor and 

intervene if necessary. 

ABB’s Ability Verification for measurement devices and new 

Ability SmartMaster verification and condition monitoring platform 

are also being used to equip students with the skills needed to optimize 

instrument performance through predictive maintenance. 

– When we started the partnership with ABB, the aim was to 

encourage more people to go into and stay in chemical engineering, 

said Dr Colin Hale, Senior Teaching Fellow at Imperial College 

London. 

– One of the ways to do this was to set up this carbon capture 

plant so we could enthuse students to follow through on the 

environmental topics they have learnt previously. ABB shares 

this collective vision. 

– During my time in the carbon capture pilot plant, I have 

actively participated in the operation of the process, gaining a 

deeper understanding of the development and application of the 

technology, said Yiheng Shao, fourth year undergraduate student 

at Imperial College London. 

According to a report by S&P Global, carbon capture and storage 

(CCS) can help decarbonize industry, reduce emissions and reach 

net zero, while the Global CCS Institute said in 2022 there was a 

44 percent increase in the number of CCS facilities around the world 

compared with the previous year. 

Earlier this year, the UK Government outlined its Powering 

Up Britain policy. This series of net-zero pledges, including £20 

billion of funding to unlock private investment and jobs in CCS, 

aims to deliver an energy system with cleaner, more affordable 

energy sources. 

Metal Forging Market 

to grow by USD 33.29 

billion from 2023 to 

2028 – Technavio 

HIGH DEMAND for advanced materials and alloys is a key factor driving 

market growth. Advanced alloys, which are being developed and used 

to fuel the evolution of performance materials with increased strength, 

durability, and corrosion resistance, are also becoming increasingly 

in demand. In addition, components with exceptionally high strength, 

longevity, and resistance to extreme conditions must be used in industries 

such as aircraft, automobiles, or energy. 


6.39% 

The 

wind turbine gearbox market size is estimated 

to grow at a CAGR of 6.39% between 

2022 and 2027. The market size is forecast to 

increase by USD 4,232.96 million. 

Smart buildings market 

size is estimated to 

increase by USD 46.12 

billion from 2022 to 2027 

THE SMART BUILDINGS market's growth momentum will progress 

at a CAGR of 9.73% during the forecast period. An emerging trend in 

the smart buildings market is the growing concept of BIoT. BIoT is the 

new vision of making the building intelligent to take insights from 

the information and react automatically. 

Smart building is the integration of all standalone automated systems 

with additional support features such as cloud integration. The 

cloud infrastructure connects the sensors and actuators to exchange 

information among themselves and improve the working conditions. 

In addition, BIoT enables the integration of handheld devices such 

as mobile phones and tablets with building control to manage the 

process remotely. Moreover, the analytical reports help managers to 

optimize energy efficiency and the working environment further. 

Vendors are also making continuous efforts to integrate smart 

buildings with cyber security and connected buildings technology. 

Thus, the rising adoption of BIoT in smart building solutions will 

drive the growth of the market in focus during the forecast period. 

Source: Technavio 

EU unveils plans to 

boost energy sector 

THE EUROPEAN COMMISSION has unveiled plans aimed at bolstering 

the European Union's wind energy sector while addressing various 

challenges, including permitting delays, workforce shortages, and 

limited access to raw materials. The initiative is primarily designed 

to shield the EU's wind industry from unfair global competition and 

safeguard its energy security. 

The action plan also aims to enhance cybersecurity in the wind energy 

sector. Wind farms' growth in Europe presents security risks, and 

the plan suggests redesigning auctions that allow countries to procure 

clean power, with a focus on assessing cybersecurity risks. The EU aims 

to increase wind capacity from 204 GW in 2022 to more than 500 GW 

by 2030 to meet its renewable energy targets. This will involve speeding 

up permitting processes, expanding the workforce, and improving 

access to finance. 

The EU's wind industry expansion is driven by the revised Renewable 

Energy Directive, which sets a target of 42.5% for wind, solar, 

and biomass in the EU's energy mix by 2030, requiring a significant 

increase in wind capacity. Source: Research and Markets 

Recycled Plastics Market 

to grow by 18.37 million 

tons from 2022 to 2027 – 

Technavio 

THE RECYCLED PLASTICS market size is 

estimated to grow by USD 18.37 million 

tons from 2022 to 2027, according to 

Technavio. The market is estimated 

to rise at a CAGR of 4.75%. The use of 

recycled plastics in the industries such as 

automotive, textile, and construction drives 

the growth of the regional market. 


In Short 

The Medical Device Contract Manufacturing 

Market to grow at a CAGR of 11.19% from 

2021 to 2026|The impact of Industry 

4.0 on the medical device industry drives 

market growth. Source: Technavio 

EU-OSHA AND THE FUTURE OF WORK: 

CHAMPIONING SAFETY AND HEALTH 

IN THE DIGITAL ERA 

and Healthy Work 

in the Digital Age" is the 

title of the new edition 

of EU-OSHA's Healthy 

‘Safe 

Workplaces Campaign, 

which commenced in October. The 

campaign's objectives are to increase 

awareness, encourage collaboration, 

and establish a future where occupational 

safety and health continue to be 

a top priority alongside technological 

advancement. 

With 93% of workers in large companies 

and 85% in micro companies using 

digital devices, this campaign addresses 

the evolving dynamics of work, emphasising 

the imperative of ensuring safety 

and health in a human-centred digital 

transformation. 

As Artificial Intelligence (AI), cloud 

computing, and collaborative robots 

become integral to work processes, the 

very nature of work is transforming. 

The campaign recognises the potential 

for improved occupational safety 

and health (OSH) while confronting 

emerging risks in this rapidly evolving 

environment, EU-OSHA says in a statement. 

– The world of work has seen a huge 

transformation in recent years, with the 

rise of digital technologies, algorithmic 

management and remote working. It 

is essential to strike the right balance: 

as we reap the benefits of the digital 

age, we must also make sure we don’t 

compromise on the human-cantered 

approach, Nicolas Schmit, European 

Commissioner for Jobs and Social 

Rights, declared. 

The campaign will explore five priority 

areas over the next two years: digital 

platform work, automation of tasks, 

remote and hybrid work, worker management 

through Artificial Intelligence 

and smart digital systems. 

– This campaign will help drive a 

digital transformation of the world of 

work that is fair and leaves no one behind, 

spreading knowledge about digital 

solutions that represent opportunities 

for companies and workers, Joaquín 

Pérez Rey, interim secretary of State 

for Employment and Social Economy 

of Spain and representing the Spanish 

Presidency of the EU Council, added. 

This edition seeks to enhance awareness 

of the impact of digital transformation 

on OSH and encourage a safe and 

productive use of digital technologies 

across diverse sectors and workplaces. 

It also aims to foster collaboration 

among stakeholders, providing resources 

and promoting proactive risk assessment 

for a secure and efficient digital 

transformation of work. 

– As Europe’s digital transformation 

steams ahead, its impact on businesses 

and workers is far from being fully 

understood. There’s an urgent need to 

grasp the opportunities and identify 

the risks of digitalisation to maximise 

the benefits of these new technologies 

for safe, healthy and productive workplaces, 

William Cockburn Salazar, 

Executive Director of the European 

Agency for Safety and Health at Work 

(EU-OSHA), said. 


Google Cloud 

Cybersecurity 

Forecast for 

2024 now 

published 

GIS 

Next 

Generation 

EAM 

PdM 

Mobile 

AIP 

BI 

PPM 

WHAT WILL CYBERSECURITY look like in 2024? Google 

Cloud Global Cybersecurity Forecast found that generative 

AI can help attackers and defenders and urged security 

personnel to look out for nation-state backed attacks and 

more. 

— While new technologies will aid security teams, they 

can also expand the cyber-attack surface, a recently published 

Google Cloud Cybersecurity Forecast 2024 report 

predicts. In 2024, the rapidly evolving world of gen AI will 

provide attackers with new ways to conduct convincing 

phishing campaigns and information operations at scale. 

However, defenders will use the same technologies to 

strengthen detection, response, and attribution of adversaries. 

According to the report, in 2024, continued activity by 

The Big Four—China, Russia, North Korea, and Iran—can be 

expected as they conduct espionage, cybercrime, information 

operations, and other campaigns to achieve their individual 

goals. With many organisations becoming better at 

security, many of these attacks will involve techniques to 

evade detection, including use of zero-day vulnerabilities 

and the targeting of edge devices, the report reveals. 

– Everyone should be prepared for global activity 

around the myriad major events held throughout 2024, 

including the U.S., European Parliament, and other elections, 

as well as the Summer Olympics in Paris, the report warns. 

– Additionally, as major global conflicts continue into 

next year, be prepared for an uptick in disruptive hacktivism, 

it adds. 

BIM 

AI 

APM 

Many companies use their Enterprise Asset Management 

(EAM) system mainly as an electronic card index or a 

digital work order system, unaware of the possibilities it 

has for Asset Management. EAM Systems like Maximo, 

IFS Ultimo, HxGN EAM and SAP EAM have evolved 

tremendously. They now offer functionalities for Asset 

Investment Planning, Project Portfolio Management, 

Asset Performance Management, Business Intelligence 

and Predictive Maintenance. Major steps have also been 

taken in the field of Mobile, GIS and BIM integration. 

Are you ready for Next Generation EAM? 

Our VDM XL experts can assist you with further 

professionalisation and automation of your Maintenance 

& Asset Management organisation. 

www.mainnovation.com

In Short 

Lithium-ion battery demand soars, projected 

to reach 4.7 TWh by 2030 boosted 

by a shift toward green energy and electric 

mobility. Research and Markets 

Finnish cleantech company 

SpinDrive raises €3.8M to cut 

industrial energy waste and pollution 

with magnetic levitation bearings 

Finnish cleantech company 

SpinDrive has secured €3.8 

million in Series A funding 

led by Rhapsody Venture 

Partners, with participation 

from existing investors Innovestor and 

Born2Grow. The funds will support 

global expansion and the development 

of new Active Magnetic Bearings. 

SpinDrive aims to enhance global 

industrial machinery efficiency by providing 

affordable, frictionless magnetic 

levitation bearings as an alternative to 

traditional, high-maintenance options. 

SpinDrive's technology offers smaller, 

more energy-efficient bearings with 

up to 20 years of maintenance-free 

operation, reducing downtime and 

costs. Additionally, the lubricant-free 

operation helps eliminate pollution, 

contributing to cutting 500Mt of CO2 

annually by 2050. The company has 

raised a total of €8 million to date and 

has a global presence with offices in 

Finland and Germany. 

Meanwhile, traditional ball bearings 

in industrial high-speed applications 

have a 12-18 month maintenance cycle, 

requiring bearing replacement. Spin- 

Drive's bearings also provide condition 

monitoring and predictive maintenance 

of the whole machine, removing 

the need to install external sensors to 

monitor system health and reducing 

overall equipment maintenance costs 

by over 80%, the company says in a 

statement. 

– We have seen increasing international 

demand for more energy 

efficiency and cleaner solutions in 

industrial production, and we are excited 

to build SpinDrive to meet those 

customer needs with our active magnetic 

bearing systems and controllers. 

With its specialization in industrial 

Traditional ball 

bearings in industrial 

high-speed applications 

have a 12-18 month 

maintenance cycle. 

technologies and global reach into industrial 

companies, Rhapsody Venture 

Partners is an ideal partner for us, and 

we're thrilled to be working with them, 

says Nikita Uzhegov, COO and Cofounder 

of SpinDrive. 

– Climate change is the biggest 

challenge of our time, but we often 

get stuck thinking about technologies 

like carbon capture when it comes to 

CO2 emissions. Industrial production 

is a massive part of the world's energy 

consumption and climate emissions, 

so we must create energy-efficient 

and clean components to turn this 

tide. By improving the energy efficiency 

in existing and new machinery, 

we tackle the problem in a massive 

area and provide a significant impact, 

adds Janne Heikkinen, CEO and Cofounder 

of SpinDrive. 


CONMONSense 

Standalone, Permanent Mount, Ultrasound Sensors 

Enhance your remote condition monitoring 

capabilities with the CONMONSense range. 

Ultrasound sensors designed for easy integration 

into a variety of acquisition systems to suit 

your specific application needs. 

The CONMONSense range includes standalone sensors 

with both 4-20mA and 0-10V standard output. 

Contact 

Airborne open 

Airborne enclosed 

Ultrasound Soluons

CONSTRUCTION INDUSTRY 

Text: Prof. DIEGO GALAR / Prof. RAMIN KARIM / Prof. UDAY KUMAR Images: STOCKPHOTO, DIEGO GALAR 

Maintaining the Future: 

Industry 5.0 Triumphs Over 

Industry 4.0’s Challenges 

THE CONCEPT OF INDUSTRY 5.0 

The concept of Industry 4.0, while initially 

promising, encountered various 

challenges and limitations that ultimately 

led to its partial failure. Despite 

its emphasis on automation, data 

exchange, and manufacturing technologies, 

it often overlooked the human 

element, neglecting the crucial role of 

workers in the production process. Concerns 

also arose about its environmental 

sustainability and societal impact, highlighting 

the need for a more holistic approach 

to industrial development. 

The emerging concept of Industry 

5.0 represents a significant departure 

from traditional industrial models, emphasizing 

a holistic approach to production 

that prioritizes human-centricity, 

sustainability, and resilience. While 

the exact implications and disruptions 

of Industry 5.0 remain uncertain, recognition 

of its potential to bridge the 

gap between the physical and virtual 

worlds is growing. In this context, Industry 

5.0 embodies a broader purpose 

that extends beyond profit generation. 

It underscores the need for industrial 

practices to align with societal and environmental 

considerations, emphasizing 

responsible innovation that benefits all 

stakeholders, including investors, workers, 

consumers, and the environment. 

A key facet of Industry 5.0 is its 

human-centric approach, which places 

human needs and interests at the 

forefront of the production process. 

This approach leverages technology 

to accommodate the requirements 

of workers, ensuring their well-being 

and fundamental rights are upheld. 

Sustainability is another critical tenet, 

necessitating the implementation of circular 

processes and resource-efficient 

technologies to reduce waste and environmental 

impact. Resilience also plays 

a vital role in Industry 5.0, advocating 

for the development of robust industrial 

systems that can withstand disruptions 

and support critical infrastructure, particularly 

in times of crisis. The concept 

promotes the establishment of adaptable 

production capacities and flexible 

business processes, fostering a resilient 

and crisis-ready industrial landscape. 

Ultimately, Industry 5.0 is defined by 

its commitment to societal goals, prior- 



itizing the well-being of industry workers 

and ensuring environmentally sustainable 

production practices that align with 

the planet's natural boundaries. The transition 

to Industry 5.0 promises a wealth of 

benefits not only for companies but also 

for workers. Benefits span the spectrum 

from enhanced talent attraction and 

retention to improved energy efficiency 

and heightened overall resilience. 

There are some possible dangers 

inherent to the shift. Industry needs to 

ensure sustained competitiveness and 

relevance by adapting to evolving global 

markets and societal shifts. While there 

might be a short-term risk of temporarily 

losing competitiveness to those not 

yet embracing Industry 5.0, strategic 

timing and coordinated investments can 

help mitigate this potential setback. The 

most significant peril is the failure to engage 

with the broader societal transition 

towards sustainability, human-centricity, 

and resilience, risking competitiveness 

in the long run. 

HUMAN-CENTRIC 

Industry 5.0 represents a paradigm shift 

that addresses the concerns and challenges 

associated with the concept of the 

‘dark factory’, one where humans are 

not needed. By prioritizing the humancentric 

approach, Industry 5.0 integrates 

advanced technologies to enhance the 

capabilities and well-being of workers, 

thereby dispelling the notion of a dark, 

automated workplace devoid of human 

presence. This shift towards Industry 5.0 

represents a profound transformation 

in perspective, with a notable shift from 

a technology-driven to a human-centric 

approach. This necessitates the incorporation 

of societal constraints, ensuring 

no one is left behind. Consequently, the 

industrial sector must establish a secure 

and empowering work environment, respect 

human rights, and develop specific 

skill sets for workers. 

Withing the framework of Industry 

5.0, the industry worker assumes a significantly 

elevated position, viewed not 

as an expense but as an investment in 

the company's growth. This reorientation 

necessitates a commitment to 

the advancement of employee skills, 

capabilities, and well-being, signalling a 

departure from the traditional practice 

of balancing worker costs with financial 

revenues. Moreover, it underscores the 

critical role of technology in serving the 

diverse needs of industry workers, empowering 

them and fostering an inclusive 

work environment. Addressing workplace 

safety and inclusivity, Industry 5.0 

leverages advancements in robotics and 

AI to mitigate physical risks and streamline 

complex tasks, thereby reducing 

workplace accidents. Technologies like 

AI, virtual and augmented reality, and 

wearables also contribute to safeguarding 

workers' mental health, emphasizing 

the importance of maintaining a balance 

between work and well-being. 

A key area where Industry 5.0 yields 

significant benefits is in attracting and 

retaining skilled talent. Given the challenges 

of filling positions that demand 

digital and multi-disciplinary skills, the 

focus on accommodating the preferences 

and values of the millennial workforce 

is crucial. Research has found the millennial 

generation is more inclined towards 

socially responsible and environmentally 

conscious companies, prioritizing 

workplace environments that align with 

their values and offer a sense of purpose. 

Companies need to adapt their practices, 

fostering a culture of social responsibility 

and sustainability to remain competitive 

in the hiring market. 

SUSTAINABILITY 

The 5.0 concept involves leveraging 

innovative green technologies, driven 

not only by environmental concerns 

but also by the potential for enhanced 

corporate image and cost savings on 

energy and materials. While industrial 

production often demands more energy 

and contributes to increased carbon 

emissions, innovations and smarter 

production planning can reverse this 

trend. Despite notable improvements in 

From Steam to Smart: Tracing the Evolution from Industry 1.0 to 5.0 and the Synergy 

of Human Expertise with Intelligent Machines. 

Maintenance 5.0, within the context of Industry 5.0, is characterized by three pillars: 

sustainability, human-centricity, and resilience. These pillars redefine maintenance 

practices to integrate environmental responsibility, empower human expertise through 

advanced technologies, and ensure adaptability in the face of disruptions. 



energy efficiency across various sectors, 

the pace of progress in energy-intensive 

industries has recently slowed, necessitating 

more targeted research and innovation 

efforts in this domain. 

RESILIENCE 

Industry 5.0 champions increased resilience 

in the face of disruptive changes, 

both geopolitical and environmental. 

By fostering adaptive strategies at various 

levels of value chains and industrial 

systems, industry players can manage 

vulnerabilities and minimize the 

impacts of unforeseen circumstances. 

Leveraging digital technologies, such as 

real-time risk monitoring and cybersecurity 

measures, can bolster industry 

resilience, ensuring smooth operations 

even in the face of technical disruptions 

and cyber threats. The emphasis on resilience 

is growing, particularly in light 

of the disruptions caused by the pandemic 

and the intensifying frequency 

of extreme weather events attributed to 

climate change. 

MAINTENANCE 5.0 

The shift from Maintenance 4.0 to 

Maintenance 5.0 mirrors the broader 

transition occurring in the industrial 

landscape. Maintenance 4.0 focuses on 

the integration of digital technologies, 

such as the Internet of Things (IoT), 

data analytics, and predictive maintenance, 

to optimize industrial maintenance 

processes. It emphasizes the use 

of advanced data-driven techniques 

and automation to enhance equipment 

reliability and reduce downtime. Maintenance 

5.0 takes this a step farther by 

incorporating a more human-centric 

approach, aligning with the principles 

of Industry 5.0. Maintenance 5.0 also 

prioritizes sustainability and resilience 

in maintenance operations. This shift is 

critical in the face of the dual challenges 

posed by the COVID-19 pandemic and 

the escalating impact of climate change. 

As Maintenance 5.0 increasingly aligns 

with sustainable and resilient principles, 

it will become a cornerstone for ensuring 

the long-term viability and adaptability 

of industrial processes, mitigating 

the adverse impacts of global crises 

on operational efficiency and overall 

productivity. 

HUMAN-CENTRIC ORIENTATION 

Maintenance 5.0 goes beyond the 

traditional focus on machines and processes 

to prioritize the well-being and 

involvement of maintenance workers. 

This approach acknowledges the critical 

role of human expertise in maintaining 

industrial systems and promotes the 

integration of workers into the digitalized 

maintenance ecosystem. It aims to 

empower workers through the use of 

innovative technologies, offering them 

opportunities for skill development, 

greater autonomy, and involvement in 

the decision-making process. It also ensures 

a safe and inclusive work environment, 

utilizing technologies to mitigate 

workplace risks and prioritize workers' 

physical and mental well-being. 

SUSTAINABILITY 

Maintenance 5.0, as an evolution of the 

maintenance paradigm, emphasizes the 

integration of sustainability principles 

within its framework. It recognizes that 

maintenance practices play a vital role 

in achieving sustainable development 

goals, aligning with the broader efforts 

to minimize environmental impact, 

conserve resources, and promote social 

well-being. The concept of sustainability 

within Maintenance 5.0 underscores 

the adoption of sustainable practices, 

such as resource-efficient maintenance 

processes and circular economy principles, 

to optimize resource utilization 

and minimize environmental impact. By 

implementing predictive and preventive 

maintenance strategies, industries can 

reduce unnecessary waste and conserve 

energy, thereby contributing to the 

global efforts towards sustainable development. 

The sustainability dimension of 

Maintenance 5.0 encompasses the following 

key aspects: 

• Environmental impact reduction: 

Maintenance 5.0 emphasizes the adoption 

of eco-friendly practices to reduce 

the environmental footprint of industrial 

processes. This includes the efficient 

use of resources, waste reduction, 

and the implementation of sustainable 

technologies that contribute to a circular 

economy. 

• Energy efficiency: Sustainable maintenance 

practices focus on optimizing 

energy consumption and minimizing 

the carbon footprint of industrial 

operations. This involves the use of 

energy-efficient technologies, the adoption 

of renewable energy sources, and 

the implementation of energy manage- 



ment systems to reduce overall energy 

consumption. 

• Lifecycle management: Maintenance 

5.0 promotes the concept of lifecycle 

management, which involves considering 

the entire lifecycle of assets and 

equipment. This approach integrates 

sustainable practices throughout the 

asset lifecycle, from design and production 

to operation, maintenance, and 

eventual decommissioning or recycling. 

• Circular economy integration: 

Maintenance 5.0 actively supports the 

integration of circular economy principles 

within industrial maintenance 

processes. This involves extending the 

life of assets through effective maintenance, 

refurbishment, and reuse, as well 

as promoting the recycling and repurposing 

of materials and components to 

minimize waste and resource depletion. 

By incorporating these sustainability dimensions, 

Maintenance 5.0 not only enhances 

operational efficiency and asset 

performance but also contributes to the 

overall sustainability goals of organizations, 

aligning with global efforts to promote 

environmentally responsible and 

socially conscious industrial practices. 

RESILIENCE 

There is a clear need for resilient maintenance 

strategies that can swiftly adapt 

to changing circumstances and address 

disruptions in the industrial landscape, 

thus ensuring the continuous and reliable 

operation of critical infrastructure, 

even during unforeseen crises. Simply 

stated, resilience in Maintenance 5.0 refers 

to the ability of industrial organizations 

to anticipate, adapt to, and recover 

from various disruptions and challenges 

that may arise within their operational 

environment. It emphasizes the implementation 

of proactive strategies and 

advanced technologies to ensure the 

continuous and efficient functioning 

of critical assets, even in the face of unexpected 

events or adverse conditions. 

Resilience is crucial to maintain operational 

stability, minimize downtime, and 

sustain productivity, thereby enabling 

organizations to remain competitive 

and sustainable in the long run. 

Some key aspects related to resilience 

in Maintenance 5.0 are the following: 

• Predictive and preventive maintenance: 

By integrating predictive 

maintenance techniques, such as condition 

monitoring, data analytics, and 

real-time asset performance tracking, 

organizations can proactively identify 

potential equipment failures or 

operational inefficiencies before they 

escalate into significant disruptions. 

Implementing preventive maintenance 

protocols based on predictive insights 

allows companies to address issues 

early, minimizing the risk of costly 

downtime and ensuring the uninterrupted 

operation of critical assets. 

• Risk management and contingency 

planning: Effective risk management 

is a fundamental component of resilient 

maintenance practices. Organizations 

need to identify potential vulnerabilities 

within their operational processes 

and develop comprehensive contingency 

plans to mitigate the impact of 

unforeseen events, such as natural 

disasters, supply chain disruptions, or 

technological failures. By establishing 

robust risk assessment frameworks 

and implementing adaptive strategies, 

companies can enhance their ability to 

respond to and recover from various 

operational challenges while maintaining 

overall system resilience. 

Maintenance 5.0 

emphasizes the adoption 

of eco-friendly 

practices to reduce 

the environmental 

footprint of industrial 

processes. 

• Data-driven decision-making: By 

leveraging advanced data analytics and 

intelligent automation, Maintenance 5.0 

enables organizations to make informed 

and data-driven decisions regarding 

asset management and maintenance 

strategies. By harnessing the power of 

Big Data and AI-driven insights, companies 

can optimize maintenance schedules, 

streamline repair processes, and 

prioritize resource allocation, thereby 

enhancing the overall resilience of their 

maintenance operations. Data-driven 

decision-making empowers organizations 

to respond swiftly to changing 

operational conditions and proactively 

address emerging maintenance needs. 

• Adaptive and flexible maintenance 

processes: Resilience in Maintenance 

5.0 emphasizes the development of 

adaptive and flexible maintenance processes 

that can accommodate evolving 

operational requirements and changing 

environmental conditions. By fostering a 

culture of continuous improvement and 

agility, organizations can optimize their 

maintenance strategies in response to 

dynamic market demands, technological 

advancements, and regulatory changes. 

Implementing agile maintenance methodologies 

enables companies to swiftly 

adapt to new challenges and opportunities, 

ensuring the efficient and sustainable 

operation of their assets. 

• Technology integration for 

enhanced resilience: Leveraging 

advanced technologies, such as IoT 

devices, digital twins, and cloud-based 

monitoring systems, enables organizations 

to build resilient maintenance 

frameworks that facilitate real-time 

asset tracking, remote diagnostics, and 

predictive maintenance scheduling. 

Integrating smart sensors and interconnected 

systems within industrial 

facilities enhances the overall visibility 

and control of critical assets, enabling 

organizations to proactively identify 

potential issues and swiftly address 

them, thereby minimizing the risk of 

operational disruptions and ensuring 

continuous asset reliability. 

By incorporating these key aspects, 

organizations can strengthen their resilience 

in Maintenance 5.0, fostering a robust 

operational framework capable of 

withstanding challenges and uncertainties 

while ensuring the sustainable and 

efficient functioning of critical assets. 

CONCLUSION 

Overall, the shift from Maintenance 4.0 

to Maintenance 5.0 represents a transformational 

journey from data-driven 

and automated maintenance practices 

to a more holistic approach that 

integrates the well-being of workers, 

sustainability, and resilience into the 

core of maintenance operations. By embracing 

Maintenance 5.0, industries can 

ensure the optimal performance of their 

equipment and the empowerment and 

safety of their maintenance workforce, 

while contributing to a more sustainable 

and adaptable industrial ecosystem. In 

essence, the comprehensive adoption of 

Industry 5.0 principles in Maintenance 

5.0 can pave the way for a sustainable 

and adaptive industrial landscape, not 

only providing economic benefits but also 

promoting environmental consciousness 

and societal well-being. 


PARTNER ARTICLE 

Text: PETER BOON, Product Specialist, UE Systems Images: UE SYSTEMS 

Bearing Lubrication 4.0: 

Autonomous and Smart lubrication 

assisted by ultrasound 

It is estimated that 60-80% of bearing failures are related to lubrication. Bearing failures very 

often lead to unplanned downtime, which often has a significant impact on production and related 

equipment. This downtime is maby times very costly. Although the costs vary according to the 

severity of the incident and the industry in question, they do add up to production costs. 

Example of a lubrication monitoring dashboard - UE Insights Platform 

from UESystems. 

The most frequent cause of bearing 

failure is directly linked to lubrication, 

so this is a real probme. Its impact on 

the reliability of industrial equipment is 

well established! The facts show that, for 

many years, the lubrication of bearings 

has been treated more randomly than in 

a methodical and controlled way. 

Many technicians have resorted 

to 'preventive' lubrication based on 

time: lubricating at a fixed period 

of time without any physical measurement 

of the bearing in order to 

determine whether or not lubricating 

is required! Every X months, a grease 

gun appears in front of the bearing 

to be lubricated and the bearings are 

lubricated in this way. 

Manual lubrication, based solely on 

the manufacturer's lubrication interval 

data, gives rise to at least the following 

two risks: 

• The risk of under-lubrication 

increases the mechanical constraints 

of rotation and can be the cause of 

failures leading to equipment breakdowns 

and stoppages, as well as 

costly corrective maintenance. 

• The risk of over-lubrication, which 

has been identified by a large number 

of studies as the main cause of 

premature bearing failure. 

Principle of Ultrasound 

technology applied in 

lubrication : 

Ultrasonic technology uses specially 

designed sensors to detect and monitor the 

level of friction in bearings. 

In the case of lubrication, the ultrasonic 

level detected by a sensor in contact 

with the bearing is directly linked to the 

friction level of the bearings. From this 

point onwards, the maintenance engineer 

responsible for lubricating bearings has 

two choices: 

• Manual lubrication, using a simple 

hand-held tool to listen to the bearings 

during the lubrication operation; 



• The installation of an autonomous, 

ultrasonic-assisted lubrication 

system to carry out this operation 

safely, efficiently and without human 

intervention. 

Lubrication 4.0: autonomous, 

ultrasound-assisted lubrication 

A fully autonomous lubrication system 

completely replaces human intervention 

for lubrication operations. It is an intelligent 

lubrication and monitoring system, 

reducing bearing failures caused by poor 

lubrication practices by 80%. 

How does it work? 

Using ultrasound, this system measures 

bearing friction levels in real 

time. It enables lubrication problems 

and requirements to be detected at an 

early stage, well before the bearings 

are damaged. 

By using bearing friction as a guide, 

the system enables bearings that 

require lubrication to be precisely lubricated 

with the right amount of lubricant, 

avoiding over- and under-lubrication. 

As the friction level is measured 

continuously and in real time, even 

during lubrication, the system will stop 

lubricating on its own as soon as the 

friction level has dropped to its reference 

value. 

This totally autonomous system 

means that only the bearings that need 

lubrication will be lubricated, when 

they need it and with the right amount 

of lubricant. 

Ultrasonic technology for intelligent 

lubrication offers a number of 

advantages: 

• Know precisely when to lubricate 

• Know precisely how much lubricant 

to apply 

• Always use the right type of lubricant 

• Eliminate the risk of lubricant contamination 

• Reduce lubricating time and resources 

Example of bearing lubrication using a 

manual hand-held tool. 

Example of autonomous lubricators 

controlled by ultrasound 

Example of remote autonomous single 

point lubricators controlled by ultrasound 

A fully autonomous 

lubrication system completely 

replaces human 

intervention for lubrication 

operations. 

• Reduce lubricating time 

• Reduce lubricating resources 

• Reduce lubricant consumption 

• Reduce failure rates 

Finally, it should be noted that such a solution 

will provide software-based, permanent, 

real-time monitoring of lubrication 

practices. For example, for the OnTrak, we 

have the UE Insights: a Cloud platform for 

storing and monitoring remote data. This 

fully customisable platform stores all data 

relating to the condition and lubrication of 

bearings. It can be used to create monitoring 

dashboards and set alarm levels. Users 

can choose to use pre-configured dashboards 

and widgets, or create their own 

indicators. This is a web-based platform 

that requires no software installation and 

can be consulted from any type of device 

connected to the internet: desktop PC, laptop, 

tablet, smartphone, etc. 

Conclusion 

From a time-based periodic lubrication 

perspective, it is assumed that bearings 

need to be lubricated at regular, fixed time 

intervals. The question then becomes: how 

can these time intervals be established? 

This is often a combination of manufacturer's 

data, valid for general cases, or for 

bearings mounted on manufacturer's test 

benches, and approximations based on 

empirical experience of the same type of 

equipment. 

By using ultrasonic technology, lubrication 

technicians will be able to know which 

bearings to lubricate, when to lubricate them 

and how much lubricant to use. 

These three pieces of information, 

especially if delivered in real time and for 

each bearing to be lubricated, will make it 

possible to considerably improve lubrication 

practices, reduce lubrication times 

and the ammount of lubricant consumed, 

as well as drastically reducing bearing 

breakdown rates. 

The benefits of an Ultrasound 

Assisted Lubrication 4.0 

solution 

• Easy to install and use 

• Multiple connection capabilities: 

Ethernet, Wi-Fi, 4G,5G 

• Compatibility with existing systems 

and software 

• Identify lubricating needs early on 

• Lubricate as required 

• Drastically improve bearing life 

• Avoid over- and under-lubricating 

A condition-based lubrication approach will keep bearing friction at minimum levels. 


HSE 

Make gas detection 

a pillar of your 

ESG strategy 

Robust environmental, social and governance (ESG) policies have become integral to day-to-day 

operations. Functioning as more than just a risk management exercise, ESG is not something 

that modern companies can afford to neglect. From investors using ESG strategies to evaluate 

potential investments to assuring the public that they are acting responsibly, companies that 

prioritise their ESG goals demonstrate that they care about their people and the planet and 

may also enjoy greater profits, as data shows that those with long-established ESG policies 

have outperformed their competitors. [1] 

Text: MARK NAPLES, General Manager, Umicore Coating Services Images: STOCKPHOTO 


HSE 

Understandably given the 

current international 

focus on sustainability, 

the environmental part of 

ESG policies can at times 

feel like it has received the lion's share 

of attention. With more sustainable 

business operations increasingly under 

the spotlight, controlling greenhouse 

gases and other harmful emissions 

represents an eye-catching way for 

companies to show that they are making 

a difference, and a wide range of 

technologies have been developed to 

help achieve these goals. 

But it is important to remember that 

environmentalism is just one pillar of 

any effective ESG strategy. While requirements 

like workplace safety may 

not get the same attention in the media, 

they are just as important for demonstrating 

ESG credentials. Any company 

operating today needs measures in 

place for protecting their employees – 

and this starts with achieving a healthy 

working environment. 

A BREATH OF FRESH AIR 

Air pollution is one of those issues 

where it can be difficult to see the consequences 

until it is too late. Air quality 

is one of the leading causes of death 

worldwide and is linked to conditions 

like lung cancer and dementia. In the 

UK alone, up to 36,000 deaths are attributed 

to long-term exposure to air 

pollution each year. [2] 

From industrial gases to harmful 

particles like black carbon, ammonia, 

nitrates, and sulphates, the list of pollutants 

that workers may be exposed to 

through accidental leaks is extensive. 

When such a leak occurs, the ensuing 

threat to wellbeing requires immediate 

action to prevent catastrophe. 

Not only can leaks cause death or 

other long-term health conditions, 

businesses that are seen to be complacent 

in this area risk regulatory penalties 

and reputational damage. What's 

more, they may end up losing ground 

in a competitive market. Investors frequently 

use ESG compliance to evaluate 

potential investments, and companies 

that are seen as uncaring about the 

environment or employee health and 

wellbeing could become a PR disaster, 

and so represent a risky investment. 

However, addressing this problem 

can be easier said than done. Gas leaks 

are by nature accidental, and many of 

ESG. Three small 

letters that have major 

implications for any 

business. 

these substances are colourless and 

odourless, rendering them impossible 

to detect without specialist equipment. 

Taking pollutants out of the air 

therefore requires companies to start 

improving their data. 

Information is the key to identifying 

and addressing problems before they 

become a serious threat to employee 

health and wellbeing. Early detection 

can enable companies to address leaks 

before the threat becomes severe, 

informing preventative maintenance 

strategies, safeguarding employee 

health, and protecting a business's 

reputation. Actively monitoring for 

dangerous gases should therefore be 

the first step towards mitigating the risk 

that is posed. 

Collecting this information requires 

companies to have access to intelligent 

sensing technology. Without these systems 

in place, businesses lack the data 

they need to inform their ESG policies, 

preventing them from effectively protecting 

their people. 

The case here is clear: in today's 

workplace, gas detection systems are no 

longer just 'nice to have'. This technology 

is essential for protecting employee 

health and should form a core part of 

any worthwhile ESG strategy. 

MAKING THE RIGHT CHOICE 

OF EQUIPMENT 

Thankfully, modern sensor technology 

means industry professionals have access 

to a broader range of gas detection 

systems than ever. These technologies, 

once limited to specialist applications, 

are becoming increasingly affordable 

and accessible, and are bringing connected 

gas detection to a wide range of 

sectors. 

This range of choices means that 

when selecting a gas detector, organisations 

must consider what is right for 

their business. Fixed detectors may 

be more appropriate in environments 

where the threat from gas is serious and 

ongoing. In more fast-paced industries, 

personal or handheld devices may be 

more appropriate, enabling staff to 

identify dangerous gas concentrations 

during spot checks. However, these 


HSE 

The focus 

on ESG compliance 

is not going away 

any time soon. 

must be balanced against the fact that 

they rely on individuals using them correctly 

at the required time, risking introducing 

human error into the process. 

Another avenue for gas detection 

is presented by laser absorption spectroscopy. 

Offering high sensitivity, reliability, 

and fast response times, laserbased 

sensing is becoming increasingly 

popular for gas detection and analysis 

applications. 

This popularity is due to the unique 

properties of infrared (IR) light for gas 

detection applications. IR wavelengths 

are particularly well suited for gas detection 

and analysis due to how they 

interact with gas samples. Different 

gases have different absorption profiles, 

meaning that they absorb wavelengths 

of light in varying amounts. 

This information can be used to create 

a unique chemical fingerprint 

enabling gases to be identified. Many 

gases are particularly absorbent to IR 

wavelengths, making it easy to create 

detection devices that can identify gas 

with a sensitivity that extends to parts 

per billion. 

In laser absorption spectroscopy, 

an IR laser beam is passed through gas 

samples before reaching a sensor that 

converts the light into electrical signals. 

Monitoring the changes between the 

laser beam and the light that reaches the 

sensor can help to demonstrate the presence 

of a particular gas. These systems 

are also capable of continually monitoring 

for combustible gases and vapours 

within the lower explosive limit and provide 

alarm indications where necessary. 

Investing in systems like these can 

provide the pillar that a solid ESG 

strategy is built around. By enabling 

companies to quickly and accurately 

determine where leaks are occurring, 

preventative action can be taken that 

reduces the risk to staff and the environment 

alike. 

FOCUS FOR THE FUTURE 

The focus on ESG compliance is not 

going away any time soon. To remain 

competitive, companies must actively 

demonstrate their commitment to 

wellbeing and the environment, by taking 

action to reduce their impact on 

the planet and protecting their people. 

These ESG programmes must be authentic 

and achievable, reflecting companies' 

own market positions, and be 

supported with a workplace culture that 

ensures safety is treated as a priority. 

Training and education are essential 

in ensuring workers can identify 

potential hazards and begin the process 

of addressing them. Staff must be 

coached and supported by a management 

team that genuinely cares about 

safety and is committed to ensuring 

gas detection data is collected and 

acted upon. Crucially, these cultures 

must be supported by state-of-the-art 

gas detection systems that make data 

accessible and enable appropriate precautionary 

actions. With a combined 

approach to air quality such as this, it 

is easier than ever to get on the path to 

delivering excellence in ESG. 



Text: GAUTHIER GHISLAIN, Marketing and Communication Assistant, SDT Ultrasound Solutions 

Images: SDT ULTRASOUND SOLUTIONS 

Mastering Ultrasound Monitoring with 

the CONMONSense Sensor Range: 

A Breakthrough in Asset Reliability 

For industrial maintenance and condition monitoring practitioners, precision and 

reliability are paramount. The SDT CONMONSense range of sensors is a game-changing 

solution, opening up a new era of ultrasound monitoring. With advanced technology and 

unparalleled features, these sensors provide a consistent, robust, and cost-effective means 

of tracking the health of your critical assets. 

THE POWER OF ULTRASOUND 

IN YOUR HANDS 

The CONMONSense sensors are 

part of the SDT Ultrasound Solutions 

product family, introducing a set of 

heterodyned ultrasound sensors with a 

unique capability to detect vibroacoustic 

phenomena in the air or through 

solid mediums. What sets these sensors 

apart is their ability to provide direct 

audible signals, eliminating the need 

for specialized SDT handheld devices 

with higher sampling rates. This simplifies 

the monitoring process, making 

it more efficient and readily implementable 

in your organization. 

Embedded with analog electronics, 

the CONMONSense sensors perform 

the heterodyne process within the sensor 

itself. This design not only ensures 

compatibility with existing acquisition systems 

(with standard outputs) but also finetunes 

the sensor's response, making it easier 

to connect and integrate into your monitoring 

infrastructure. 

With a typical band-pass frequency range 

between 250 Hz to 4kHz, these sensors convert 

ultrasound signals into audible form, 

optimizing them for the human ear. The 

standardized analog outputs are easily interfaced 

with a wide range of acquisition systems, 

including the SDT VIGILANT, offering 

users the flexibility to choose between AC 

(signal) and DC (RMS only) modes, tailored 

to their specific applications. 

VERSATILE DESIGNS FOR DIVERSE 

ENVIRONMENTS 

The CONMONSense sensors come in contact 

and airborne designs, each addressing 

specific measurement needs. Their robust 

build ensures they can be installed in the 

most challenging environments, boosting 



reliability while reducing downtime and 

maintenance costs. The contact sensors 

are ideal for continuous monitoring 

of critical assets like bearings, valves, 

steam traps, and hydraulic systems. 

In contrast, the airborne sensors, 

with varying IP ratings (IP65 and IP40), 

are tailored to accommodate the constraints 

of your specific environment, 

including inspecting electrical systems. 

In other words, they can be employed 

for monitoring assets suffering from abnormal 

friction, impact, and turbulence, 

which are telltale signs of distress or 

product quality issues. Whether you're 

monitoring the health of valves, steam 

traps, hydraulic systems, or even deploying 

ultrasound-driven lubrication, these 

sensors are your go-to solution. 

But the real beauty of CONMON- 

Sense sensors is their ability to be permanently 

installed on your most critical 

assets. For example, you can use CON- 

MONSense Airborne sensors to monitor 

potential partial discharge in electrical 

cabinets, adding a layer of safety and 

security to your operations. 

EXCEPTIONAL SIGNAL 

MEASUREMENT CAPABILITIES 

While the CONMONSense sensors 

share similarities with the SDT handheld 

device-compatible sensors, they 

stand out in terms of their signal measurement 

capabilities. The embedded 

electronics in the CONMONSense range 

enable advanced compatibility but have 

certain limitations when measuring 

weak signals. In cases where you need to 

acquire faint signals, sensors dedicated 

to SDT handheld instruments might be 

preferable, as they offer more capabilities 

in measuring weak signals. 

DISCOVER THE POWER OF 

ANALOG SENSORS 

Analog sensors are pivotal in industrial 

applications, as they capture and transmit 

information in the form of electrical 

signals. The CONMONSense sensors 

offer a range of popular analog outputs, 

including 4-20 mA, 0-10 V, and IEPE. 

These outputs are compatible with acquisition 

systems equipped with voltage 

and/or current channels, making them 

highly versatile and cost-effective. 

In industrial applications, electrical 

noise can be a significant concern. The 

4-20 mA output standard, embraced 

by the CONMONSense sensors, excels 

in such scenarios. Its high immunity to 

electrical noise ensures accurate and 

consistent readings over long distances, 

even in harsh industrial environments 

where other signal types may falter. 

TWO DISTINCT OUTPUT MODES: 

DYNAMIC (AC) AND STATIC (DC) 

CONMONSense sensors are designed 

to provide both dynamic (AC) and 

static (DC) output modes. The dynamic 

mode delivers a continuous signal 

that oscillates around a bias voltage 

(in the case of voltage output) or bias 

current (in the case of current output). 

This signal, sampled at a minimum 

rate of 10 kHz, can be further postprocessed 

and analyzed to extract 

valuable information about the health 

of the asset being monitored. Spectral 

transformation techniques such as 

FFT or envelope FFT can highlight the 

most prominent frequencies and their 

amplitudes in a signal. On the other 

hand, statistical indicators like RMS 

(Root Mean Square), Peak Value, and 

Crest Factor are employed for tracking 

trends and triggering alarms. 

In the static mode (DC output), 

CONMONSense sensors provide RMS 

values representing ultrasound energy 

in the band-pass frequency. While this 

mode doesn't offer the same level of 

detailed information as the dynamic 

mode, it is valuable for tracking changes 

and trends over an extended period, 

making it an excellent tool for proactive 

maintenance. 

SELECTING THE RIGHT SENSOR 

The choice between dynamic and 

static modes largely depends on your 

acquisition system's specifications and 

capabilities. A minimum sampling rate 

of 10 kHz is essential to avoid aliasing 

phenomenon and loss of information in 

the dynamic mode. 

THE BENEFITS OF THE CON- 

MONSENSE SENSORS RANGE 

They are numerous: 

• Ultrasound Measurement Simplified: 

Experience the easiest way to measure 

ultrasound signals, converted into 

audible form, and compatible with 

conventional acquisition systems. 

• Enhanced Efficiency: Real-time and 

accurate data provided by CON- 

MONSense sensors allow businesses 

to optimize processes, reduce waste, 

and enhance productivity. 

• Cost Savings: With affordability and 

extended compatibility, these sensors 

help organizations reduce operational 

costs and increase profitability. 

• Data-Driven Decision Making: These 

sensors provide valuable insights for 

informed decision-making and proactive 

maintenance strategies. 

• Scalability: With a complete range of 

options, CONMONSense sensors can 

easily integrate into existing systems, 

enabling scalable deployment across 

different industries and applications. 

• Simplified Implementation: Userfriendly 

interfaces and comprehensive 

documentation make installation 

and configuration a breeze, giving a 

"sixth sense" to your installations. 

In conclusion, SDT CONMONSense 

sensors are a technological marvel in the 

world of condition monitoring. Their advanced 

features, versatile design, and easy 

integration with existing systems make 

them a vital asset for organizations aiming 

to improve asset performance, reduce 

maintenance costs, and enhance reliability. 

The precision and consistency offered 

by these sensors empower you to take 

control of your assets' health and ensure 

the continued success of your operations. 

Download the CONMONSense Brochure 

by scanning the QR code below. 


EQUIPMENT MAINTENANCE 

Understanding 

casing distortion 

One of the most critical issues 

affecting rotating machines is 

casing distortion. This article 

delves into what casing distortion 

means, how it impacts machine 

performance, and why it is 

essential to address it in order to 

achieve reliable operation. 

Text: ROMAN MEGELA, Senior Reliability Engineer, Easy-Laser AB 

Images: EASY-LASER AB 

Casing distortion is not only one 

of the biggest problems for rotating 

machinery, but is also a very 

common one. But what does it 

actually mean? To explain it, we 

can use the famous analogy of a rocking table 

in the restaurant. This is a situation everybody 

can relate to. Due to an uneven floor or 

bad construction of the table, there is space 



When it comes 

to rotating equipment, 

precision is a necessity. 

under one leg which makes the whole table 

rock from one side to another. It is a problem 

that is easy to solve, just use a few napkins 

and the table will stay still. 

The same happens when placing rotating 

machinery on a foundation that is not flat. 

Most rotating equipment is designed to be 

installed on a flat surface. At the manufacturer 

site, all machine feet are milled to be 

in a perfectly flat plane. When placing the 

equipment on a non-flat foundation or uneven 

sole plates, it will reproduce that rocking 

situation we just mentioned. That is what we 

call “soft foot”. 

operate under designed loads. When casing 

distortion occurs, the shafts are put under 

strain and their positions change. That will 

affect the bearings by changing their designed 

load, and the rolling elements inside the 

bearing will move from designated race way. 

This is something that will seriously affect 

lubrication. The rolling elements of the bearing 

will push away the lubrication since there 

will be no space for it. Heat will build up and 

produce more thermal expansion of internal 

components, which will gradually reduce 

their gap until, inevitably, failure occurs. 

(Changing the designed loads in the bearings 

will reduce bearing life by as much as 50%.) 

Ensuring proper installation can make the 

difference between smooth operation and 

unexpected failure. As we have seen, all it 

takes is a minor gap to throw your machinery 

off balance. When it comes to rotating equipment, 

precision is a necessity. 

TINY CLEARANCES, BIG IMPACT 

Rotating equipment consists of many parts: 

rotors, shafts, bearings, mechanical seals, 

impellers in compression chambers, just 

to mention a few. And these all have very 

small internal clearances. If a machine is 

bolted down on an uneven surface, the forces 

applied on the machine feet will change the 

casing geometry. As a result, these clearances 

will quickly change. 

To fix a soft foot condition, is necessary 

to compensate everything above 0.05 mm. 

That is not much, if you consider the fact 

that the thickness of a human hair is between 

0.06 mm to 0.08 mm! This is how little it 

takes to convert our new or newly overhauled 

machine into a victim of casing distortion. 

PIPE CONNECTION ISSUES 

Another possible cause for casing distortion 

is pipe strain. Pipe strain can occur when the 

pipes are wrongly fabricated, and the connection 

flanges are not aligned. It can also 

be that the pipe supports are too high or too 

low, which creates large gaps between the 

connections. A common solution for this is to 

force them together, which will result in what 

we call nozzle load. This too will put a lot of 

stress on the machine casing. (The OEM will 

specify the allowed nozzle load on the equipment.) 

THE LONG-TERM CONSEQUENCES 

So what kinds of problems can you run into if 

casing distortion occurs? Previously we mentioned 

the internal parts of rotating machinery, 

such as shafts. How do they get affected? 

Well, shafts have mounted bearings to 

carry the rotating motion, and these bearings 

Forces occur at the machine 

inlet and discharge flanges. 



Text: CHARLIE GREEN, Senior Research Analyst at Comparesoft Images: STOCKPHOTO 

From Breakdowns to Breakthroughs: 

THE TRANSFORMATIVE IMPACT OF 

PREVENTATIVE MAINTENANCE IN 

CONSTRUCTION 

The construction industry is the backbone of infrastructural development, and the machinery and 

equipment used in this sector play a pivotal role in ensuring projects are completed efficiently 

and on time. However, one of the most significant pain points in the construction industry is the 

frequent breakdown and inefficiency of equipment. These breakdowns not only lead to project 

delays but also escalate costs. Enter preventative maintenance – a proactive approach that 

addresses these challenges head-on, ensuring the longevity and efficiency of machinery. 

WHAT IS PREVENTATIVE 

MAINTENANCE IN 

CONSTRUCTION? 

In the intricate tapestry of the construction 

industry, preventative maintenance 

stands out as a pivotal practice, 

underpinning the operational longevity 

and efficiency of critical machinery. It 

encompasses a systematic regimen of 

inspection, detection, rectification, and 

proactive measures to stave off potential 

equipment failures before they burgeon 

into tangible issues. This methodology 

transcends the rudimentary act 

of merely repairing a malfunctioning 

machine; it delves into a rigorous, routine-based 

examination and servicing 

paradigm, ensuring machinery remains 

in pristine working condition, thereby 

preventing unforeseen breakdowns. 

Take, for example, a towering crane, 

an indispensable asset in a construction 

site's arsenal. Rather than adopting a 

reactive stance and awaiting an inevitable 

malfunction, preventative maintenance 

adopts a proactive approach. 

This involves meticulous scrutiny of its 

The construction 

industry is the backbone 

of infrastructural 

development. 



these benefits 

is the consistent 

operational 

efficiency that 

well-maintained 

equipment guarantees. 

The Construction 

Industry 

Institute 

underscores this, 

highlighting that 

machinery under 

a rigorous preventative maintenance 

regimen retains a vast majority of its 

operational prowess throughout its lifecycle. 

This directly translates to projects 

adhering to their timelines, fortifying a 

company's reputation for reliability and 

punctuality. 

Additionally, the stability offered 

by equipment longevity, courtesy of 

preventative maintenance, means that 

operators gain in-depth familiarity 

with their machinery. This continuity 

ensures that operators master their 

equipment, leading to optimized perintricate 

components, including cables, 

pulleys, and hydraulic systems. 

Activities such as lubrication, calibration 

of loose parts, replacement of 

components exhibiting wear and tear, 

and periodic software updates (if the 

machinery is digitally integrated) are 

integral to this regimen. According to 

a study by the Construction Equipment 

Management Program, regular 

preventative maintenance can enhance 

equipment life by up to 60%. Such a 

methodical and sophisticated approach 

not only ensures that the crane operates 

at its zenith of capacity but also significantly 

diminishes the probability of 

unanticipated operational downtimes, 

which can have cascading repercussions 

on project timelines and costs. 

lays associated with equipment replacement. 

Research from the Construction 

Industry Institute underscores this, 

suggesting that machinery under a preventative 

maintenance umbrella can see 

its operational life extended by 20-40%. 

This elongation represents not just a 

delay in replacement costs but also 

ensures that the equipment operates 

at peak efficiency, leading to reduced 

operational costs. 

In summation, the financial wisdom 

of preventative maintenance in the 

construction sector is evident. While 

there's an upfront cost, the long-term 

savings, both direct and indirect, make 

it an indispensable strategy for firms 

aiming for fiscal prudence and project 

success. 

THE BENEFITS OF USING 

PREVENTATIVE MAINTENANCE 

IN CONSTRUCTION 

1 

Significant Cost Savings 

in Many Areas of The 

Business 

In the intricate world of construction, 

where financial margins are 

often razor-thin, the role of preventative 

maintenance stands out as a beacon of 

fiscal responsibility. At first glance, the 

outlay for regular equipment upkeep 

might appear as an added expenditure. 

However, delving 

deeper into the 

financial matrix 

reveals a different 

narrative. 

Unplanned 

equipment breakdowns, 

often 

resulting from 

neglect, can lead to 

exorbitant repair 

costs. According 

to the National 

Research Council, the financial implications 

of such reactive maintenance 

can be up to nine times more than a 

well-planned preventative approach. 

Beyond the direct repair expenses, the 

ripple effects of these breakdowns, such 

as project delays and potential contractual 

penalties, further strain project 

budgets. 

Moreover, the longevity of machinery 

is intrinsically tied to its maintenance 

regimen. By investing in preventative 

care, construction firms can 

significantly defer the hefty capital out- 

Preventative 

maintenance stands out 

as a pivotal practice, 

underpinning the 

operational longevity 

and efficiency of critical 

machinery. 

2 

The Role of Preventative 

Maintenance in Ensuring 

Equipment Longevity 

in Construction 

In the construction realm, equipment 

longevity is not just a financial asset 

but a cornerstone for seamless operations 

and sustained business growth. 

At the heart of this longevity lies preventative 

maintenance—a proactive 

approach that ensures machinery not 

only endures but operates at its zenith, 

bringing manifold strategic benefits to 

construction entities. 

Central to 



formance and minimizing errors—a 

crucial edge in an industry where precision 

is non-negotiable. 

Lastly, preventative maintenance 

not only ensures the equipment's operational 

longevity but also preserves 

its intrinsic value. When the juncture 

arises to upgrade or divest, equipment 

that has been consistently maintained 

through preventative measures commands 

a premium in the secondary 

market, testifying to the enduring 

value of preventative care in the construction 

sector. 

3 

Enhanced Safety as 

a Result of Well-Maintained 

Assets 

In the construction sector, where the 

interplay of machinery and manpower 

is constant, safety remains paramount. 

Preventative maintenance emerges as a 

critical strategy to address the inherent 

Equipment 

longevity is not just 

a financial asset but 

a cornerstone for 

seamless operations 

and sustained 

business growth. 

risks, ensuring that equipment functions 

optimally and safely, thereby safeguarding 

the workforce. 

The Occupational Safety and Health 

Administration (OSHA) has highlighted 

equipment-related incidents as a significant 

contributor to on-site injuries. 

However, the proactive approach of 

preventative maintenance can mitigate 

these risks. A study by the National 

Safety Council underscores this, revealing 

that up to 70% of machinery-related 

accidents could be averted through 

timely inspections and consistent 

maintenance. This proactive approach 

ensures that potential equipment malfunctions 

are identified and rectified 

before they escalate into safety hazards. 

Moreover, the Bureau of Labour 

Statistics notes that the construction 

domain experiences a higher rate of 

fatal work injuries than many other sectors. 

Equipment malfunctions, unfortunately, 

play a pivotal role in these 

statistics. By integrating preventative 

maintenance into their operational 

protocols, construction firms can substantially 

diminish these incidents. This 

not only protects the workforce but also 

reinforces the company's commitment 

to safety. 

By proactively ensuring the health 

and efficiency of equipment, construction 

companies can create a safer envi- 



ronment for their employees, reduce 

potential liabilities, and deliver projects 

that stand as testaments to both quality 

and safety. 

4 

Environmental Benefits 

The construction industry, 

with its heavy reliance on 

machinery and equipment, 

has a significant environmental footprint. 

However, preventative maintenance 

emerges as a potent tool in mitigating 

these environmental impacts, 

offering benefits that extend beyond 

mere operational efficiency. 

• Reduced Fuel Consumption: 

Machinery that undergoes regular 

preventative maintenance operates 

at its peak efficiency. According to 

the U.S. Department of Energy, wellmaintained 

equipment can reduce 

fuel consumption by up to 10-15%. 

This not only translates to cost savings 

but also means fewer fossil fuels 

are burned, leading to a reduction in 

greenhouse gas emissions. 

• Decreased Emissions: Emissions 

from construction equipment, 

particularly older models, can be 

a significant source of air pollution. 

The Environmental Protection 

Agency (EPA) notes that preventative 

maintenance, including timely 

oil changes, filter replacements, and 

engine tune-ups, can reduce emissions 

by up to 40%. This plays a 

crucial role in improving air quality, 

especially in urban areas where construction 

activities are frequent. 

• Waste Reduction: Preventative 

maintenance also means fewer parts 

replacements and less waste. A 

study by the Construction Industry 

Research Board found that regular 

equipment checks can reduce waste 

from worn-out parts by up to 50%. 

This not only conserves resources 

but also reduces the burden on landfills. 

• Resource Conservation: Efficient 

machinery requires fewer resources, 

from lubricants to replacement 

parts. The International Journal of 

Construction Management highlights 

that preventative maintenance 

can lead to a 20% reduction in the 

use of ancillary materials, further 

diminishing the industry's environmental 

impact. 

• Noise Pollution: Well-maintained 

equipment tends to operate more 

quietly, reducing noise pollution—a 

significant concern in urban construction 

sites. The World Health 

Organization has identified noise 

pollution as a major environmental 

health risk, and by ensuring equipment 

operates smoothly through 

preventative maintenance, construction 

companies can contribute to 

quieter, more liveable urban environments. 

PREVENTATIVE MAINTENANCE 

AS PART OF A COMPREHENSIVE 

MAINTENANCE STRATEGY 

While preventative maintenance offers 

numerous benefits, it should not be 

viewed in isolation. Instead, it should 

be a part of a comprehensive maintenance 

strategy that also includes 

corrective maintenance (fixing things 

when they break down) and predictive 

maintenance (using data analytics to 

predict when a machine might break 

down). By integrating preventative 

maintenance into a broader strategy, 

construction companies can ensure that 

their equipment is always in the best 

possible condition, leading to efficient 

operations and successful project completions. 

IN CONCLUSION 

The integration of preventative maintenance 

into a holistic maintenance strategy, 

encompassing both corrective and 

predictive maintenance, is emblematic 

of a forward-thinking, responsible, and 

sustainable approach to construction. 

Such a comprehensive strategy not only 

ensures the optimal performance of 

equipment but also safeguards the wellbeing 

of workers, the environment, and 

the broader community. 

In the ever evolving and competitive 

arena of construction, companies that 

prioritize and invest in preventative 

maintenance position themselves at the 

forefront, setting industry standards 

and paving the way for a safer, more 

efficient, and environmentally conscious 

future. In essence, preventative maintenance 

is not merely an operational 

choice but a defining pillar for construction 

entities aspiring for excellence, sustainability, 

and enduring success. 



Text: ALGHAITHAN, ABDULLAH K, Saudi Aramco Mobility and Logistics Services Department 

Images: SAUDI ARAMCO MOBILITY AND LOGISTICS SERVICES DEPARTMENT 

The Impact of Corrosion 

on Heavy Equipment 

It is self-evident that cranes 

and heavy equipment 

are indispensable in 

various industries such 

as construction, mining, 

rigging, and notably in 

hydrocarbon sectors. 

Consequently, property 

owners and contractors are 

required to adhere to high 

standards of maintenance, 

in accordance with OSHA 

guidelines, to ensure a safe 

working environment for all 

employees. 

Leading maintenance operations 

on a financial scale 

poses a potential challenge for 

any maintenance organization 

managing their assets, 

which could be valued at millions, if not 

billions, of dollars. Corrosion, defined 

as the gradual deterioration of metal 

components due to environmental factors 

like high temperature, humidity, 

and chemical exposure, presents a significant 

challenge to cranes and heavy 

industrial equipment. This corrosion 

severely compromises the functionality 

of cranes and heavy industrial equipment, 

resulting in substantial economic 

losses, environmental pollution, and 

Data preprocessing 

Failure 

Prediction 

Industrial 

Sensors 

Data 

De-noising 

Training 

Anomaly 

Detection 

Acquisition 

Examples of Economic Loss by Corrosion. 

Dimensionality 

Reduction 

(optional) 

Remaining 

Useful Life 



Corrosion control aims 

at ensuring the efficient 

operation and upkeep of 

physical assets. 

even loss of life. A comprehensive corrosion 

control policy is crucial to attain 

and sustain the requisite levels of quality, 

safety, and reliability within the 

maintenance organization. 

Effects of corrosion on Cranes 

and Heavy Equipment: 

The neglect of corrosion control measures 

in industrial settings has led to tragic 

outcomes, including loss of life, injuries, 

significant economic losses, and severe 

environmental damage. Corrosion has 

been linked to numerous injuries and fatalities. 

For instance, on March 15, 2009, a 

50-ton hydraulic crane accident at a construction 

site in New York City resulted 

in the death of seven individuals. The hydraulic 

crane, while hoisting a heavy load, 

suddenly collapsed. 

Investigations revealed that the 

crane's right lifting cylinder had been 

inadequately maintained, and corrosion 

had weakened the lifting cylinders. Various 

national studies conducted in several 

countries over the past fifty years 

have consistently estimated the costs 

of corrosion to be around 3% to 4% of 

each nation's Gross Domestic Product 

(GDP). Considering a global GDP figure 

of 3.4% (as of 2013), the estimated 

worldwide cost of corrosion is a staggering 

US$2.5 trillion. Another study, conducted 

from 1949 to 1994, summarized 

the economic losses resulting from corrosion 

in the subsequent table. 

Maintenance Solutions for 

Corrosion Control: 

Maintenance solutions aimed at controlling 

corrosion are a crucial aspect of 

industrial operations, ensuring the longevity, 

safety, reliability, and efficiency 

of heavy equipment and infrastructure. 

By adopting effective corrosion 

control practices, it is estimated that 

significant savings, ranging from 15% 

to 35% of corrosion-related expenses, 

could be realized. This translates to 

annual global savings of approximately 

US$375 to $875 billion. These solutions 

encompass a variety of strategies, from 

protective coatings to predictive maintenance, 

all aimed at mitigating the 

destructive effects of corrosion. Implementing 

effective maintenance solutions 

not only protects valuable assets 

but also minimizes economic losses, 

environmental impacts, and potential 

safety hazards. Below are the best industry 

practices for maintenance solutions 

against corrosion. 

INTERNATIONAL STANDARDS 

International standards are instrumental 

in guiding corrosion control 

and maintenance solutions for heavy 

industrial equipment, providing a 

universally recognized framework 

that emphasizes consistency, quality, 

and safety in practice. Below are 



Corrosion specific Management system elements 

Policy 

Strategy 

Objectives 

Enablers, controls 

and measures 

Plans 

Procedures and working practices 

• Organizations 

• Contractors 

• Resources 

• Communications 

• Risk management 

• Management of change 

Corrosion Management System Pyramid. 

• Training & competency 

• Incident investigation 

• Documentation 

• Assurance 

• Management review 

• Continuous improvement 

• Based on corrosion type, life cyde, return 

on investment (ROI), asset criticality, 

regulations, and mitigation options 

• Implementation approach 

• Verification / inspection 

• Mitigation procedures 

some of the standards pertinent to 

corrosion control for cranes and industrial 

equipment: 

1. **ISO 12944**: This standard 

outlines guidelines for protective 

coatings, covering aspects such as 

types of coatings, application methodologies, 

and inspection criteria. 

By adhering to these standards, a 

standardized approach to combating 

corrosion across various industrial 

settings, including those involving 

cranes and industrial equipment, is 

ensured. 

2. **ISO 8502**: This standard 

addresses the preparation of steel 

substrates before the application 

of paints and related products. It 

includes tests for assessing surface 

cleanliness and evaluating dust on 

steel surfaces prepared for painting. 

This standard is applicable to cranes 

and heavy equipment constructed 

with steel structures. 

Advanced Maintenance 

Methods and Technologies 

Beyond adherence to international 

standards, numerous advanced methods 

and innovative approaches exist 

for maintenance solutions in corrosion 

control. When integrated into 

corrosion control practices, these 

advanced methods and technologies 

enhance corrosion mitigation. 

Predictive maintenance, facilitated 

by condition-based monitoring, 



leverages the power of artificial intelligence 

(AI) and predictive analytics 

to forecast corrosion rates and refine 

maintenance schedules. Through the 

seamless integration of a multitude 

of sensors and cutting-edge technologies, 

condition-based monitoring 

programs continuously assess the 

health of equipment, collect and process 

data, and accurately detect any 

anomalies. Advanced cathodic protection 

systems, such as Impressed 

Current Cathodic Protection (ICCP), 

offer more precise control over corrosion 

inhibition. This proactive 

strategy not only minimizes downtime 

but also optimizes maintenance 

efforts, ensuring that resources are 

deployed precisely when needed to 

combat corrosion effectively. 

Furthermore, a Corrosion Management 

System (CMS) should be 

incorporated into the corporate management 

system. Effective integra- 

tion of corrosion management within 

an organization entails more than 

just technology; it necessitates the 

incorporation of corrosion decisions 

and practices within the organization’s 

management system. This 

integration extends from specific 

corrosion procedures to overarching 

organizational policies and strategies, 

encompassing all levels of the 

management system. 

To maximize the benefits of corrosion 

management, it's crucial to articulate 

traditional corrosion practices 

within the language and context of 

organizational policies, ensuring commitment 

to the corrosion management 

system across all organizational levels. 

This approach aids in managing corrosion 

processes throughout all stages 

of asset integrity management, as depicted 

in the subsequent figure. 

Providing methods and solutions 

on how to measure and improve the 

quality of maintenance is a key consideration 

for any maintenance organization. 

While corrosion control presents 

significant challenges and risks, proper 

maintenance processes and procedures 

can mitigate the detrimental effects. 

Corrosion control aims at ensuring 

the efficient operation and upkeep 

of physical assets, be it a maintenance 

facility, a commercial building, or a 

fleet of vehicles. By adhering to maintenance 

guidelines and referencing 

international standards, any maintenance 

organization can enhance the 

safety, reliability, and longevity of their 

cranes and heavy equipment. 


BIOCATALYSIS 

Fig 1. Our modern life is increasingly characterized by a more or 

less organised effort of human societies to achieve balance with the 

global ecosystem and provide reasonable living standards for all. 

With the means and tools of biocatalysis, these goals are achievable 

without a zero-sum game. 


BIOCATALYSIS 

What biocatalysis 

has to offer for 

green industries 

and city planning? 

In our world, anything nearly perfect tends to be stamped as fantasy. 

Does this kind of statement imply the character of human endeavour, 

its very essence? On the contrary, nature represents purity and clarity. 

Text and images: ELIAS HAKALEHTO AND TARMO HUMPPI 

ABOUT THE AUTHORS: 

• Elias Hakalehto, PhD, Adjunct 

Professor in the Universities of 

Helsinki and Eastern Finland, 

Microbiologist and Biotechnologist, 

CEO of Finnoflag Oy, Vice President 

of the International Society of 

Environmental Indicators. 

• Tarmo Humppi, PhD, Principal 

Scientist, Chemist, Retired from the 

Finnish Defence Research Agency. 

All of us have been staring at 

the starry night. The organisation 

of the macrocosm can 

equally well be seen in the 

microscopic world. There, 

the microorganisms make the wheels of 

the microcosmic universe turn around. 

Together with plants and animals, they 

comprise the constituents of the biosphere. 

Why, then, do human industries get contented 

with anything less? Microbes and 

their enzymes could make the wheels turn 

around in future industries. 

Recently, it has become increasingly 

evident that heavy and fast industrialization 

not only elevated our standard of living but 

has also led us to the brink of abysmal ecocatastrophes. 

Fortunately, we have the vast 

resources of molecular universes in our use 

to avoid their aftermath or repair the damages. 

Sadly, we have wasted those resources 

for a long time. 

"There is plenty of room at the bottom". 

The saying of physicist Richard 

Feynman in 1959 gives us many leads. 

It has actualized in the IT revolution of 

our times. This has enabled giant steps 

in industrial control and maintenance 

of machinery, steering and adjustments 

of processes, flow of information, and, 

last but not least, ecological efficiency. 

We have eventually come closer to 

the ways of functioning of biological 

entities, ecosystems, and the cells and 

Fig 2. Food production around and in the cities can happen in a cleaned-up environment of biocatalytically furnished soil, water and air. 

Bioprocesses are developed for the removal of recalcitrant substances, pollutants and eutrophication. The past burdens can be converted 

into novel products by biocatalysis. 


BIOCATALYSIS 

Fig 3. Biohydrogen is an example of the immense metabolic capabilities of micro-organisms, which could be utilized, besides energy 

production, for the future traffic solutions, as well as for the manufacturing of complementary bulk or commodity chemicals for the 

petrochemical and other industries as well as for precious specialty chemicals, not forgetting the organic fertilizers. The latter are 

increasingly available and effective facilitators of food and feed production, horticulture, hydroponics and forestry. 

microbes in particular. The miniaturisation 

of technical solutions has brought 

us nearer the scale of microbes, molecules, 

atoms and their structures, which, 

indeed, have a lot of space for variation 

and production. 

POWER OF BIOCATALYSIS 

Biocatalysis in Nature could be described 

as allowing low reaction energies 

in the microscale. This is the secret 

of all the incredible effectiveness of 

organismal life around us. This built-in 

energy network of living cells and their 

enzymes facilitates our lives and that 

of plants, animals and microorganisms. 

Why could we not exploit it in our industries 

more intensively than so far? 

The low-energy route could decisively 

help us avoid the often predicted loss 

of natural resources. It could also lower 

the emissions of manufacturing, agriculture, 

energy production and all sectors 

of our economy (Fig. 1). 

Moreover, as integrated with human 

or AI intelligence, this nature-born enormous 

efficiency could ultimately boost 

future endeavours for investigating, innovating 

and developing novel disruptive 

technologies for our use. This technology 

platform is by far more sustainable than 

any other imaginable solution. Using 

it effectively, we could also harness the 

biological multitudes and reactions for 

cleaning up our polluted and intoxicated 

planet Earth. 

DREAMS AND REALITY 

OF THE FUTURE INDUSTRIAL 

BIO-REVOLUTION 

In natural ecosystems, energy flows, and 

materials circulate. This could also be 

achievable in the industrial ecosystems. Ten 

years ago, we, Member of the Swedish Royal 

Academy of Engineering and Chairman of 

the Scandinavian Simulation and Modelling 

Society, Professor Erik Dahlquist, 

and Professor Semida Silveira, the current 

Professor in Practise in the Systems 

Engineering Program at Cornell University, 

Ithaca, New York, and one of the authors of 

this article, microbiologist Elias Hakalehto, 

published a calculation that the annual 

biomass increase could provide twice the 

energies needed globally. Also, the various 

petrochemical goods could be produced in 

complementary biorefineries based on organic 

sources. A citation of our chapter 

"Concluding remarks and perspectives on 

the future of energy systems using biomass" 

in the book edited by E. Dahlquist, "Biomass 

as Energy Source. Resources, Systems and 

Applications", published in 2013 by CRC 

Press, Taylor & Francis Group, Boca Raton: 

"In the chapter on global biomass resources, 

we have seen that biomass can 

fulfil most of the energy resources as well 

as for replacement of fossil fuels for the 

production of plastics and similar. What 

we still have to do is to use all materials 

and resources in an efficient system, where 

the same fibres, for instance, are used 

many times for different purposes before 

they eventually are combusted, instead of 

combusting stem wood directly. What is 

considered waste should instead be seen as 

a valuable resource." 

This valuable principle and method for 

global survival have been applied in practical 

experiments of the ABOWE European 

Union Baltic Sea Region biorefinery project, 

ending in 2014. In the "Zero Waste from Zero 

Fiber '' project in Tampere, funded by the 

Finnish Government in 2018-19, the ecosystem 

engineering of massive past industrial 

lake bottom sediments into valuable chemicals, 

energy gases and organic fertilisers was 

accomplished in an economically feasible 

way. These projects are referred to in the 

Maintworld magazine 3/2023 and before, as 

well as in the recent lectures at the European 

Geosciences Union (EGU) general assembly 

in 2022 and 2023. Indeed, we could see the 

shoots of true ecodevelopment emerging and 

potentially growing into "sheaves in the field 

of progress", as the statement made a century 

ago by the first Finnish president, 

K.J. Ståhlberg, could be modified. 

We need today the political will as it was 

summed up in our 2013 book chapter (see 

above): "Only facts are not enough. Good examples 

are also significant, and these have 

to be presented in a convincing way. Then 

both regulatory frameworks and interest 

from investors could be achieved. Thereby 

system development can take place." - Furthermore, 

a citation from the same source: 

"In fact, it could be much better to treat 

and recycle the wastes in a sustainable way 


BIOCATALYSIS 

including the microbiological and biotechnological 

solutions, than by just discharging 

the organic loads into the water and maritime 

ecosystems, or to the atmosphere." 

This principle could be equally applicable 

in the "cradle of Finnish industries" in Tampere, 

as well as globally in any place where 

forest or other biomass industries will be 

developed into true circulation economics 

(see above). 

BIOHYDROGEN SOURCE 

In 1874, French writer Jules Verne predicted 

in his book "Mysterious Island" the 

future we aim for and head toward. This 

old reasoning and imagination of one of the 

most eminent early science fiction authors 

illustrates the roots of an essential and potential 

avenue for future development: biohydrogen. 

Its implementation could now 

lead to sustainable planning of cities, their 

food production and traffic, and societies in 

general too. See Fig. 2. 

Quotations of the "Mysterious Island" 

(1874) by Jules Verne: 

• "...I believe that water will one day be 

employed as fuel, that hydrogen and 

oxygen which constitute it, used singly 

or together, will furnish an inexhaustible 

source of heat and light of an 

intensity of which coal is not capable." 

• "Some day the coalrooms of steamers 

and the tenders of locomotives will, 

instead of coal, be stored with these 

condensed gases, which will burn in 

the furnaces with enormous calorific 

power..." 

• "...there will be no want of either light 

or heat as long as the productions of 

the vegetable, mineral or animal kingdoms 

do not fail us. I believe, then, 

that when the deposits of coal are 

exhausted, we shall heat and warm 

ourselves with water. Water will be 

the coal of the future." 

In the previous Maintworld article (in volume 

3/2023), Elias Hakalehto took up the 

potential of biologically produced hydrogen, 

or biohydrogen, in solving global and local 

energy needs. It could be made using anaerobic 

bacteria or other microbes to split the 

water in renewable energy sources into Hydrogen 

and Oxygen (Fig. 3). These microbes 

could be photosynthetic ones, such as algae 

or cyanobacteria, or the fermentative anaerobic 

bacteria using their enzymes to split 

the water molecule. Then, the various steps 

for utilising the bio-catalytically liberated 

energies could also include their capture, 

purification, storage and use in the fuel cells 

or elsewhere. Such motors could power future 

flying vehicles, for instance. 

Biohydrogen could be converted and 

reacted into other gaseous fuels, such as 

methanol or ammonia. Besides in the aviation 

industries, they could be applied for 

maritime, industrial fuels, etc. Hydrogen 

gas can be coupled with biogas methane, 

thus forming hythane. If Carbon dioxide is 

simultaneously emitted in this reaction, it 

could be separated from biohydrogen and 

used for greenhouses, where it is a precious 

raw material for plant growth. 

RETURN TO THE ROOTS OF 

INDUSTRIAL BIOTECHNOLOGY 

In 1904, one of the founders of the industrial 

fermentation, Chaim Weizmann, 

became a lecturer at the University of 

Manchester. His method for the microbiological 

production of acetone was piloted 

in London in 1915. He used Clostridium 

acetobutylicum (the Weizmann organism) 

to produce acetone, butanol, ethanol 

and hydrogen gas (Fig. 4). Later on, in 

1939, in Helsinki, a Dutch microbiologist, 

A.J. Kluyver took for the first time up the 

potential of microorganisms to assimilate 

Carbon dioxide. - What an opportunity 

for climate-friendly bio-based production 

and sequestration of carbon-containing 

molecules, substances, polymers, etc.! - 

We have also proven that the generation 

of Carbon dioxide significantly boosts the 

onset of microbiological or bioprocess 

reactions (Hakalehto and Hänninen 2012, 

Gaseous CO2 signal initiate growth of 

butyric acid producing Clostridium butyricum 

both in pure culture and in mixed 

cultures with Lactobacillus brevis, in the 

Canadian Journal of Microbiology). The 

same phenomenon was also documented 

for the Weizmann bacterium (Hakalehto 

2015, Enhanced microbial process in the 

sustainable fuel production. In: Jinyue, 

Y (ed.), Handbook of clean energy systems, 

by JR Wiley & Sons). 

Fig 4. A simplified scheme of the central metabolism of Clostridium acetobutylicum 

bacterium. Acetone, butanol and ethanol are the liquid end-products of the solvetogenic 

reactions. Hydrogen gas is generated as a function of ferredoxin enzymes. The starting 

molecule of the cascade is glucose, which usually results from the hydrolysis of organic, 

plant-derived macromolecules such as cellulose or starch. The by-product Carbon dioxide 

is readily usable in greenhouses or algal ponds. 

UPSTREAM AND DOWNSTREAM 

IN BIOTECHNOLOGY 

The former term designates in microbial 

biotechnology the production of valuable 

chemicals or gases by biological organisms, 

whereas downstreaming means the collection, 

purification and concentration of 

these biorefinery products into applicable 

forms. This is a well-studied field nowadays, 

but more research and development is always 

needed to boost the applications. And, 

as Professor Malcolm D. Lilly often stated 

during his most excellent bioengineering 

lectures in 1984-5 at the University College 

London: "Downstream processing is a losing 

game", meaning that it is impossible to 

reach perfection or complete recovery of 

the produced bio-based (or other) products 

in the industries. On the contrary, there are 

some losses at every step of that effort. But 

as developers, both scientific and societal, 

we should ensure that we could end up as 

victorious as possible. 


AUTOMATION AND ROBOTICS 

Text and images: MOBILE INDUSTRIAL ROBOTS 

Simplifying the transition to a 

robot-assisted work environment 

The rapid advance of automation and robotics means that some work tasks can now be done by 

machines and robots – from production to material handling processes. Even though automation 

is often necessary for enterprises to increase productivity and keep costs down, these advances 

are not always welcome by employees. 


AUTOMATION AND ROBOTICS 

There is no denying that 

the word automation can 

evoke images of robots 

taking over jobs, and breed 

apprehension in employees. 

But automation can be a great 

tool for businesses, freeing employees 

from dirty, dull and dangerous 

tasks while boosting team effectiveness 

and creativity. The challenge for 

employers is often to communicate 

the benefits of automation and show 

people how it can change the future 

of work for the better. 

Here we share some ideas on how 

to introduce new technology with 

positive impact on your workforce. 

1 

Communicate your 

automation plans in 

good time. 

It is very important that you communicate 

what is going to happen to your employees. 

If you do not explain the process, 

this can create feelings of uncertainty 

amongst staff members. If you describe 

the process and leave room for questions, 

employees are less likely to feel threatened 

or fearful about the change but 

instead engaged and interested 

2 

Involve your employees 

in the process. 

Making your employees 

part of the process is the best way to 

smoothening your upcoming path to 

automation. It is important that you 

listen to the workforce’s concerns and 

reluctance, so you can explain and 

correct misguided information. It is 

also crucial that you give them space 

to give ideas and make proposals. They 

are the people working daily with 

both current and future systems at 

the facility and therefore, they are the 

ones who can best identify points of 

interest within the space which could 

benefit from additional help and relief 

through automation. Information 

gathered from employees is an excellent 

resource for deploying the robots 

most effectively. 

3 

Make the process enjoyable 

for your employees. 

MiR AMRs take the most 

repetitive and heavy tasks, allowing 

your employees to focus on high-value 

activities. Help them to see that the 

robots are a tool for them to perform 

even better in their jobs. Rather than 

thinking that robots are being installed 

to take over their jobs, employees 

can see automation processes as 

something to work alongside. 

Let your employees know that the future 

of work is not robots that are here 

to replace them, but rather that they 

will help and work alongside people, increasing 

efficiency but also safety. E.g., 

MiR AMRs take over manual tasks that 

are usually met with high absences due 

to work injuries. Show your employees 

that the robots will help them have better 

health and better job results. 

DENSO, a leading mobility supplier, 

deployed six MiR250 robots in its 

800,000-square foot powertrain component 

production facility in Athens, 

Tennessee. A pilot program between 

its warehouse and production areas 

delivered results within six months, 

freeing six workers from pushing carts 

and allowing them to move to valueadded 

roles. 

After installing six MiR 250 robots, 

Travis Olinger, logistics and automation 

engineer in DENSO’s Total 

Industrial Engineering (TIE) group, 

explains: “Overall employee morale has 

improved, with employees recognizing 

DENSO as an innovative company that 

wants to make employees’ jobs easier 

and that the company cares about the 

ergonomic aspect of the job.” 

4 

Train your employees to 

work with the robot. 

Nobody likes something 

they do not understand, and automation 

does not work on its own. Training 

your employees with the robot 

will help them to understand the 

robots and processes better. It will 

also give them new and valuable skills 

in their career. MiR AMRs are easy to 

program and learn, and we also offer 

our free online learning platform MiR 

Academy, which can help your staff 

ease into working with robots and the 

new workflows surrounding them. 

MiR Academy has learning programs 

for all levels. 

“The MiR interface is really user 

friendly, the way of building mission is 

very easy made through building blocks 

instead of code lines. Thus, it is understandable 

enough even for people without 

previous programming experience,” 

Benjamin Paillusson, PC&L Improvement 

Leader in Faurecia Clean Mobility 

Písek, Forvia. 

5 

Make your employees familiar 

with the robot. 

There are different ways 

of making your employees perceive 

robots as part of the staff instead of a 

threat. Autonomous mobile robots are 

collaborative and therefore it is easy 

to “personalize” the robots for higher 

engagement of the employees. For example, 

asking your employees to name 

the robots is an excellent way to add 

fun and familiarity into the upcoming 

changes. Creating events around the 

robot, where the employees feel part of 

the integration process, can help them 

feel part of the change and be more proactive 

towards automation. 


CIRCULAR ECONOMY 

MAINTENANCE – 

a crucial factor 

for achieving circularity 



Let us start with defining circular economy, 

or circularity as it is also commonly 

referred as. Circular economy is 

all about reducing waste and prolonging 

the lifespan of products, components, 

and materials. It is contrasted to the linear 

economy where raw materials are processed into 

products that are consumed and then disposed. 

Instead of a linear lifecycle, the products, components, 

and materials are given one or more 

life cycles when they reach the end of life. The 

ecosystem perspective is prominent; circular 

economy is not achieved by a single company – it 

is a joint effort seen in the entire value chain and 

on societal level. Moreover, circular economy is 

a way to achieve sustainable development, i.e., 

a development that meets the needs of today 

without compromising the possibility to meet 

the needs of future generations. Therefore, we 

must apply a now-centred perspective as well 

as a future-centred perspective on circularity. 

All these perspectives are distinguishable in the 

definition of circular economy given by Krichherr 

et al. (2017, p. 229) 1 : 

Maintenance plays 

a huge role in achieving high 

level of circularity. 

Circular economy is a buzz word today, but what does 

circular economy mean and how is the term connected 

with maintenance? In the following, we will try to shed 

some light on the concept and explain how maintenance 

acts as a facilitator for achieving circular strategies. 

Text: MIRKA KANS, Associate professor (docent), Chalmers University of Technology 

Images: STOCKPHOTO 

“…an economic system that replaces the ‘end-oflife’ 

concept with reducing, alternatively reusing, 

recycling and recovering materials in production/distribution 

and consumption processes. It 

operates at the micro level (products, companies, 

consumers), meso level (eco-industrial parks) and 

macro level (city, region, nation and beyond), with 

the aim to accomplish sustainable development, 

thus simultaneously creating environmental quality, 

economic prosperity and social equity, to the 

benefit of current and future generations”. 

How to assess the “circularity” of e.g., a company 

or a nation? For businesses, the Science 

Based Target Initiative (SBTi) allows for formulating 

environmental targets that comply with 

the Paris agreement of not exceeding a global 

warming of 1.5°C. Thousands of businesses have 

started using science-based targets aiming at 

net zero emissions by 2050. SBTi reports that 

the global emissions increased by over 3% from 

energy and industry between 2015 and 2019, but 

also that the emissions in the SBTi companies 

decreased by 25% in the same period. Circularity 

is an important aspect for achieving the sustainability 

development goals, or Agenda 2030, 

agreed upon by the United Nations in 2015 2 . The 

level of goal fulfilment spans from 39% to 87%, 

with Finland, Sweden, and Denmark being 

the top three countries 3 . If we measure global 



circularity in terms of virgin material 

use, the trend is rather discouraging. 

According to the recently 

launched Circularity Gap Report 4 

the world is 7.5% circular, which 

could be compared with 9.1% in 2018 

and 8.6% in 2020. 

Very disappointing reading, you 

may think. On the upside, there is 

an immense potential in applying 

circularity on all levels to reach the 

set targets. Several circular strategies 

exist that could be applied to reduce 

virgin material use and prolong the 

lifespan of products, components, 

and materials. The 10R model 5 is 

commonly used to describe circular 

strategies from less circular to highly 

circular (see Figure 1). On the bottom 

(R9 and R8), we find strategies to recover 

some value from material, such 

as using biomaterial waste as fuel in 

heating plants or making toilet paper 

out of scrapped books. The next five 

strategies (R7-R3) aim to prolong the 

lifespan of a product. Repurposing and 

remanufacturing are strategies for 

giving the product or its components 

a new life cycle either by restoring 

or altering the functionality while 

refurbish, repair, and reuse are strategies 

aiming at prolonging the existent 

life cycle and functionality of the 

product. An old school bus could for 

instance be sold on the second-hand 

market, undergo maintenance, or be 

repurposed as a mobile home. The 

final three strategies (R2-R0) aim to 

reduce the resources in production 

and consumption. Reduced resources 

in the production may address energy 

consumption or material by increasing 

the availability and quality rate or 

reducing performance losses. Reducing 

resources in consumption may 

be achieved by offering a product as a 

service or by offering performance instead 

of a product. The latter could for 

instance be in form of renting or leasing 

a car instead of buying and owning 

one as a consumer, or by arranging 

the transportation need in other ways 

such as train or bus services. 

Maintenance plays a huge role in 

achieving high level of circularity. 

Let us start by looking at the rethink 

and reduce strategies. Rethinking 

strategies rely on companies acting 

as service providers rather than 

producers and sellers of products. 

The ownership of the product that 

creates the customer value is kept 

by the provider, who benefits in an 

asset management strategy for these 

Figure 1. Circular strategies and the role of maintenance as a facilitator 



products. The longer the lifespan of 

the asset providing value, the higher 

life cycle profit might be achieved. 

From a production perspective, it is 

well known that efficient asset management 

in the form of preventive 

maintenance strategies has significant 

impact on the production processes 

in terms of higher availability, 

dependability, and quality output. 

For the strategy reuse, maintenance 

plays an indirect role. The 

main idea is to resell the product 

on the second-hand market. For 

products in bad shape, maintenance 

in the form of cleaning, repair, or 

The longer the 

lifespan of the asset 

providing value, the 

higherlife cycle profit 

might be achieved. 

the similar is necessary. This could 

be conducted by the second-hand 

dealer or by a specialised contractor 

offering maintenance services. If 

maintenance is not done before the 

sales, the new owner might need to 

buy maintenance services instead. 

Maintenance is a direct activity 

in repair and refurbish. For fulfilling 

these circular strategies, maintenance 

services are offered to the 

owner of the product. Maintenance 

is, from this perspective, a business 

model rather than an operations 

strategy. In this context, refurbishing 

is the same thing as doing 

maintenance in the end-of-life of 

the product. We can assume that the 

product has a partial or complete 

functional failure, and that corrective 

and preventive maintenance is 

needed. The maintenance need is, 

thus, higher for this product than for 

a product in need of repair. 

Lastly, we have the remanufacturing 

and repurposing strategies. 

Cleaning and repair, i.e., common 

maintenance activities, are necessary 

sub-activities in the remanufacturing 

or repurposing process. Remanufacturing 

is defined as ”returning 

a used product to at least its original 

performance with a warranty 

that is equivalent or better than that 

of the newly manufactured product” 

6 . If we scrutinize the definition 

of remanufacturing, it is obvious 

that maintenance plays a larger role, 

as remanufacturing aims at regaining 

the function of a product to at 

least its original performance. Based 

on this reasoning, remanufacturing 

could be viewed as a maintenance 

activity on the industrial scale. 

In conclusion, we see that maintenance 

is a crucial factor for achieving 

circular strategies both within the 

company and throughout the full life 

span of the product. Maintenance 

allows for reduction of virgin raw 

material by making the products and 

production more efficient. It prolongs 

the lifespan of products and 

components by appropriate services 

for individual users and businesses, 

and by centralized and industrialized 

maintenance of products at the 

end-of-life. 

REFERENCES 

[1] Kirchherr, J., Reike, D., & Hekkert, M. (2017). Conceptualizing the circular economy: An analysis of 114 definitions. Resources, conservation and 

recycling, 127, 221-232. 

[2] https://unstats.un.org/sdgs/report/2023/ 

[3] https://dashboards.sdgindex.org/rankings 

[4] https://www.circularity-gap.world/ 

[5] http://www.pbl.nl/sites/default/files/cms/publicaties/pbl-2016-circular-economy-measuring-innovation-in-product-chains-2544.pdf 

[6] British Standard Institute, 2009. BS 8887-2:2009 Design for manufacture, assembly, disassembly, and end-of-life processing (MADE) Terms and definitions. 


ELECTRIC MOTOR STORAGE 

Best practices for storing 

ELECTRIC MOTORS 

Storing an electric motor for more than a few weeks involves several steps to ensure it will 

operate properly when needed. For practical reasons, these are governed by the motor’s size and 

how long it will be out of service. Factors like the temperature, humidity and ambient vibration in 

the storage area also influence the choice of storage methods–some of which may be impractical 

for smaller machines or need to be reversed before the motor goes into service. With these things 

in mind, here are some common recommendations for storing motors. 

Text: CHUCK YUNG, senior technical support specialist at EASA, Inc., St. Louis, MO USA 

Images: EASA, STOCKPHOTO 

Good, readily available 

records are essential for 

any motor storage program. 

One method is to 

attach a form like that in 

Figure 1 to each motor to document the 

storage dates, maintenance procedures 

completed, and the results of all tests 

performed during the storage period. 

For motors in long-term storage, a good 

practice is to replace the form annually 

(or at other designated intervals). Store 

electronic copies of the previous forms for 

future reference, or simply keep them in 

an envelope attached to the motor. 

Figure 1: Motor storage tag. 

STORAGE CONDITIONS 

Short-term storage. Motors that 

will be in storage for just a few weeks 

primarily require protection from the 

weather (see “Indoor storage” and 

“Outdoor storage” below) and ambient 

vibration (more on this later). 

Long-term storage. Motors slated 

for several weeks to several years 

in storage and all above-NEMA size 

machines require additional preparations 

to protect their machined surfaces, 

bearings and windings. 

Indoor storage. If possible, store 

motors indoors in a clean, dry area. 

Place horizontal machines in a horizontal 

position and vertical motors in 

a stable vertical position. 

Unless the storage area is climate 

controlled, prevent condensation 

from forming inside the motor by 

energizing the space heaters (if supplied) 

to keep the windings 5-10°C


(10-20°F) above the ambient temperature. 

(For other ways to prevent condensation, 

see “Special care for windings” 

below.) 

Outdoor storage. Don’t! Seriously, 

if a motor is too large to store indoors, it 

is likely to be a very expensive machine. 

It’s worth the cost to construct an enclosed 

storage facility. When outdoor 

storage is absolutely necessary, protect 

the motor with a waterproof cover (e.g., 

a tarp), allowing a breathing space at 

the bottom. Wrapping it tightly in plastic 

and placing it outdoors will cause 

condensation to form inside the motor 

due to the temperature extremes and 

humidity. 

Outdoor storage also requires preventive 

measures to keep out rodents, 

snakes, birds or other small animals 

that can damage the winding insulation. 

If insects are prevalent, keep them from 

blocking ventilation and drain openings 

by loosely wrapping the motor and covering 

all openings. 

Shafts and machined surfaces 

Apply a viscous rust/corrosion inhibitor 

(e.g., LPS2, Techtyl 502C or RustVeto) 

to exposed machined surfaces and 

sleeve bearings, allowing it to remain 

intact throughout the storage period. In 

humid and rainy/snowy environments, 

have the service center paint as much of 

the motor’s interior surface as practical, 

and coat the windings with a topical 

fungicide in tropical environments. 

(Note: Disassemble the machine and inspect 

the sleeve bearings before placing 

it into service.) 

BEARING PROTECTION 

Grease-lubricated motors. For longterm 

storage, completely fill the bearing 

cavities with compatible grease to prevent 

rust and corrosion staining that 

can occur if moisture collects between 

the balls and races. 

Oil-lubricated motors. Do not ship 

or move these motors with oil in the 

reservoir. After placing the motor in 

storage, fill the reservoir with enough 

oil to cover the bearings but without 

overflowing the stand tube or labyrinth 

seal. Fill sleeve bearing machines to just 

below the labyrinth seal and vertical 

motors to the “max fill” line. 

The oil should contain a rust and corrosion 

inhibitor and be moisture free. 

Check it every three months by drawing 

a sample from the drain. Since water 

Figure 2: False brinelling. 

weighs more than oil, any moisture will 

be evident. 

Ambient vibration. This can damage 

motors, even when they are not 

rotating. Proximity to rail lines, busy 

roads, and/or production floors can all 

contribute to the ambient vibration. 

Even low-magnitude vibration, over 

time, can damage bearings while they 

are stationary–e.g., false brinelling (see 

Figure 2). Solutions vary. For example, 

one mill that had ambient vibration 

from nearby machinery stored its motors 

on scrapped conveyor belting. 

False brinelling damages the bearing 

race at uniform intervals matching the 

spacing of the rolling elements. Although 

the damage initially may appear 

slight or even invisible to the naked eye, 

it often progresses rapidly once the motor 

is in service. 

Shaft rotation. Turning the motor’s 

shaft at least monthly during long-term 

storage redistributes lubricant on machined 

surfaces to inhibit corrosion. 

Motors with ball or roller bearings also 

benefit from monthly rotation, since 

the rolling elements stop in different 

positions each time. Larger, 2-pole machines 

require more frequent attention 

than smaller (NEMA-frame) machines. 

Motors with spring-loaded spherical 

bearings are more difficult to turn, but 

they still require manual rotation to 

coat the bearings with oil. With sliding 

plate (i.e., Kingsbury) bearings, lift the 

shaft before rotating it–from below 

with a short jack and a bearing ball 

centered on the shaft, or from above 

with an overhead crane and eyebolts. To 

avoid bearing damage, be careful not to 

lift the shaft more than a few mils. 

Machines with heavy rotors and 

long frames in ratings of about 2000 

hp (1500 kW) and larger sometimes 

require more frequent (weekly) rotation 

to prevent shaft bowing caused 

by the weight of the rotor. As an extreme 

example, power plants often 

keep large turbine generators rotating 

slowly all the time to prevent sag. 

While it is uncommon, removing and 

vertically suspending the rotors of 

very large critical machines also can 

prevent sagging. 

SPECIAL CARE FOR MOTOR 

WINDINGS 

Methods for preventing condensation. 

Motor windings must stay clean 

and dry to keep the insulation from 

degrading. Unless the storage area is 

climate controlled, condensation can 

form in the motor if the temperature of 

the winding dips below the dew point. 

As mentioned earlier, the usual way 

of avoiding this is to keep the winding 

5-10°C (10-20°F) above ambient temperature. 

If the motor has space heaters, 

energize them while it is in storage; if 

not, add them. Another option is to use 

the windings as a resistance heater by 

supplying low-voltage DC current (approximately 

8-12% of rated amperage). 

An energy-saving alternative is to lower 

the dewpoint of the storage room with a 

dehumidifier. 



Figure 3: Insulation 

resistance (IR) tests 

can be performed with 

a megohmmeter or 

motor analyzer. 

Insulation resistance (IR) tests. Measure and 

record the IR of the winding(s) before storing a motor 

even a few weeks, and again just before putting it 

in service (see Figure 3). Correct all IR readings to a 

standard temperature and address any decrease in IR 

before installing the motor. If a motor will be in storage 

for a long time, take IR readings annually. 

Polarization index (PI) and dielectric absorption 

ratio (DAR) tests. For form coil windings, 

conduct a PI test in addition to the IR test. The PI 

test variables skew results for windings with lots of 

exposed conductor surface area, so use the DA ratio 

test for random windings and DC armatures (see 

Tables 1 and 2). 

Table 1: Dielectric absorption ratio recommendation 

Table 2: Dielectric absorption ratio (DAR) assessment 

Type of winding 

Minimum insulation resistance 

60:30 seconds Condition 

Form-wound coils (PI) 

P1= 

10-minute IR (to ground) 

1-minute IR 

≥ 2.0 

< 1.1 Poor 

1.1 to 1.24 Questionable 

1.25 to 1.3 Fair 

Random-wound coils (DA) 

DA= 

1-minute IR 

30-seconds IR 

> 1.25 

1.4 to 1.6 Good 

> 1.6 Excellent 



If the windings need to be cleaned and dried, measure the 

IR again. If it is greater than 5000 megohms, disregard the PI 

(see IEEE 43); otherwise, recalculate the PI. 

CARBON BRUSHES 

DC machines, wound-rotor motors and some synchronous 

machines have carbon brushes. For long-term storage, lift the 

brushes away from the commutator/slip rings to prevent a 

chemical reaction (sometimes called “photographing”) that 

can discolor the underlying commutator or slip ring. When 

practical, store the springs in the relaxed state to prevent a 

gradual loss of spring pressure. 

Putting the motor into service 

To ensure proper operation when removing a motor from 

storage and putting it into service, perform the following: 

• Use compressed air to clean the outside of the motor, and 

visually inspect it. 

• Assess the condition of the insulation system by measuring 

the IR with a megohmmeter. 

• Oil-lubricated motors: 

• Drain the oil before moving the motor to the 

installation site. 

• If there is water in the oil, check for and replace any 

rusty bearings. 

• If sleeve bearings received a protective coating, 

disassemble the machine and clean the bearings with 

an appropriate solvent before putting the motor into 

service. 

• Fill the oil reservoir to the correct running level after 

installing the motor. 

• Grease-lubricated motors: 

• Moisture in the grease usually indicates rust-damaged 

bearings that need replacement. 

• After several years in storage, the grease probably will 

be hard and the drainpipe will be plugged; usually it is 

best to disassemble the motor, remove the old grease 

and repack with fresh, compatible lubricant. 

• Run the motor 10-20 minutes without the drain plug to 

purge excess grease. 

• Vibration and alignment: 

• If the storage area has ambient vibration, inspect and 

replace damaged bearings before installing the motor. 

• After installing and aligning the motor, document the 

uncoupled baseline vibration levels; check the levels 

again after a week or two of service. 

• For motors with rolling element bearings, check for 

bearing fault frequencies in the vibration spectra. 

• On large machines that are susceptible to shaft sag, 

monitor the vibration levels during startup to avoid 

catastrophic damage. 

High-cost machines obviously justify more precautions than 

inexpensive, readily available motors. What is not always apparent 

is that some “smaller” motors are equally important to 

production and can have enormous consequences if they fail. 

TIPS FOR TRACKING IR TEST RESULTS 

Attach a card to each motor and record the IR, 

temperature and date of each test. 

TIPS FOR ROTATING THE SHAFT 

Rotating the shaft keyway position in 150-degree 

increments every month makes it easy to spot a 

neglected motor. If you visualize a clock face, each 

increment represents 5 hours: For example, if the 

keyway position for September is 12:00, October 

will be 5:00, November will be 10:00, and so on. 

This puts the rolling elements in a different position 

each time and avoids rocking the rotor back and 

forth between just two positions (see Figure 1). 

TIPS FOR OIL-LUBRICATED MOTORS 

Never move a motor with oil in the reservoir. If oil 

sloshes over the stand tube, it could contaminate 

the windings or even initiate capillary action that 

can siphon oil from the chamber. Before putting 

the motor into service, always drain the oil and 

replace it with compatible lubricant. (Drain it. Move 

it. Refill it.) 

REFERENCES 

IEEE Std. 43-2013: Recommended Practice for Testing Insulation Resistance of Electric Machinery. Institute of Electrical and Electronics Engineers, Inc. 

New York, NY, 2013. 


PHOTOVOLTAIC ENERGY 

Photovoltaic systems 

in the limelight 

Germany has around 2.6 million photovoltaic (PV) systems producing solar power on rooftops 

and sites. Demand for qualified installation companies in the country is high, resulting in 

time pressure during PV system installation. When it comes to ensuring the long-term safety 

and efficiency of PV systems, due diligence is a top priority. This applies in particular to 

commissioning of new PV systems and performance of modernisation measures. 

Text: MBA, B. ENG. STEFAN VEIT, Head of Product and Quality Management Electrical Engineering, Team Lead Electrical/ 

Building Technology, TÜV SÜD Industrie Service GmbH 

Images: TÜV SÜD 

Owning a PV system is 

becoming increasingly 

popular, with benefits 

including greater independence 

from the 

energy market, energy savings and climate 

protection. Large-scale producers, 

such as businesses, trades, and agricultural 

enterprises with a power output 

of 30 kWp or more, benefit particularly 

from good returns that make up for the 

high costs of installation. 

The German government is seeking 

to significantly speed up the expansion 

of solar power. Its PV Strategy aims at 

raising the proportion of PV in Germany’s 

power mix to over 30 per cent 

by 2035. 1 To reach this goal, PV systems 

must make full use of their maximum 

efficiency. However, this is not always 

the case at present. According to estimates 

by the German Insurance Association 

(GDV), around 400,000 of the 2 

million PV systems in Germany in 2020 

had been installed incorrectly, revealing 

not only technical defects, but also economic 

deficits. 



Possible causes alongside production 

faults or damage in transit also include 

errors in installation and planning. In 

addition, age-related wear, accumulation 

of dirt on the panels or weatherrelated 

damage can also result in 

impaired efficiency. When PV modules 

are connected in a string, one defective 

cell is all it takes to cause a significant 

reduction in output. 

Faults may reduce the system’s 

efficiency, the service life and, in a 

worst-case scenario, even cause a fire. 

Many of these defects can be easily 

remedied by, say, replacing defective 

modules or cleaning panel surfaces. 

Steps to prevent shading of the solar 

modules by roof structures should 

already be taken in the planning 

stage. During PV system operation, 

vegetation may have to be cut back 

regularly. 

TESTING AND INSPECTION – 

BEFORE DAMAGE OCCURS 

Early identification of deficiencies may 

eliminate high secondary costs, and 

even generate additional yield. Along 

with economic advantages, testing 

and inspection also serve to identify 

safety-relevant defects. For this reason, 

law and technical standards require 

periodic electrical safety tests of PV 

systems to be performed. In particular, 

the accident prevention regulation 

DGUV V3 and the standards EN 62446 

(VDE 0126-23), IEC 62548 and DIN 

VDE 0105-100/A1 do apply in Germany. 

Depending on the age of the system and 

other operating conditions, PV systems 

TÜV SÜD 

TÜV SÜD is a German certification 

and inspection organization. 

TÜV SÜD provides a wide range of 

testing, inspection, certification, 

and consulting services in various 

sectors, including automotive, 

industrial, energy, healthcare, 

and more. Their primary focus is 

on ensuring the safety, quality, 

and sustainability of products, 

processes, and systems. 

may have to be tested and inspected 

every one to four years. 

Experts frequently identify simple 

defects by means of visual testing performed 

to evaluate a system’s actual 

state of repair. Target-performance 

comparison can be carried out with the 

help of simulation software; it offers 

indications of defects that may also impact 

on the output of the PV systems. 

By applying the voltage-current 

characteristic, the software measures 

the actual performance of the system 

and compares it to the manufacturer’s 

specifications. In case of deviations, 

imaging processes are introduced to 

provide more detailed information. 

Defects increase electrical resistance, 

and thus build up more heat. 

The resulting hotspots are captured 

by thermal imaging cameras. Inactive 

modules, disconnected substrings and 

performance degradation caused by 

ageing, i. e. potential-induced degradation 

(PID), are further anomalies that 

can be identified using this method, 

provided an adequate level of current 

is produced by solar radiation. 

HIGHEST PRECISION 

ELIMINATES LOOPHOLES 

By contrast, inverse thermography, also 

known as reverse-current thermography, 

is weather- independent. It detects even 

the smallest defects at an early stage. In 

this “reversed” method, current is fed 

into the PV systems and the difference in 

temperature is measured when current 



flows through the cells. Drones can also 

be used to capture images. The only other 

method offering even greater detail is 

electroluminescence measurement (EL 

measurement). This method likewise 

involves feeding external current into the 

modules. Using special cameras at night, 

the experts then record the electromagnetic 

radiation at wavelengths of approximately 

1,150 nm. EL measurement 

thus enables the experts to look inside a 

solar cell and identify defective bypass 

diodes, failed cells, micro-cracks and 

even performance degradation caused by 

light and elevated temperature induced 

degradation (LETID). 


Photovoltaic energy, commonly known as solar energy, is a renewable and 

sustainable source of electricity generated by converting sunlight into 

electrical power using photovoltaic cells (solar panels). These cells contain 

semiconductor materials that absorb photons from the sun and release 

electrons, creating a flow of electricity. Solar energy is clean, environmentally 

friendly, and increasingly used to power homes, businesses, and more. 

It helps reduce greenhouse gas emissions and dependence on fossil fuels. 

Owning a PV system 

is becoming increasingly 

popular, with benefits 

including greater 

independence from the 

energy market, energy 

savings and climate 

protection. 

CONCLUSION 

Modern test methods such as thermography 

enable testing and inspection to be 

performed during operation or outside 

the system’s regular service hours. EL 

measurement, for example, is performed 

at night. In addition, modern test methods 

do not require modules to be dismantled. 

The use of drones reduces the need 

to set up cranes or lifting platforms. 

The longer a defect goes undetected, 

the higher the secondary costs it causes. 

In this case, planners and installation 

and maintenance companies benefit 

from the support provided by recognised 

testing, inspection, and certification 

(TIC) companies like TÜV SÜD. 

Drawing on their technical expertise 

and using ultramodern technical 

equipment, they track down safety- and 

efficiency-relevant defects and identify 

opportunities for improvement. 

Combining safety inspections with efficiency 

checks also pays off for smaller 

systems, particularly when they are still 

within the manufacturer’s or installation 

company’s warranty period. 

REFERENCES 

[1] PV Strategy, Federal Ministry for Economic Affairs and Climate Action: https://www.bmwk.de/Redaktion/DE/Publikationen/Energie/photovoltaik-stategie- 

2023.pdf?__blob=publicationFile&v=4 


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Maintworld Magazine 4/2023

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