Maintworld Magazine 4/2023
- maintenance & asset management
- maintenance & asset management
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4/<strong>2023</strong> maintworld.com<br />
maintenance & asset management<br />
Maintaining the Future:<br />
Industry 5.0<br />
Triumphs Over<br />
Industry 4.0’s<br />
Challenges<br />
Preventative<br />
Maintenance in<br />
Construction<br />
p 26<br />
The Impact of<br />
Corrosion on Heavy<br />
Equipment<br />
p 30<br />
Best Practices<br />
for Storing<br />
Electric Motors<br />
p 44
EDITORIAL<br />
I<br />
had the opportunity to visit Iceland a<br />
few weeks ago as part of the EFNMS<br />
General Assembly meeting. The<br />
Icelandic Maintenance Association<br />
hosted our visit, during which we also<br />
had the chance to explore hydro- and geothermal<br />
power plants. It was fascinating<br />
to learn that 75% of Iceland's electrical<br />
energy is generated through hydro power,<br />
while 25% is produced using geothermal<br />
energy. Additionally, geothermal energy<br />
plays an important role in heating both<br />
urban areas and remote houses, making<br />
Iceland a prime example of sustainable<br />
energy utilization.<br />
In Europe, we have been struggling with energy challenges, particularly<br />
concerning gas delivery, which has prompted a renewed focus on innovation<br />
and investments in alternative energy sources. Energy issues affect us all, and<br />
some political analysts argue that energy is a central factor behind many of<br />
the global crises we are witnessing today.<br />
Regarding energy field maintenance, one of the presenters in Iceland<br />
informed us that in the event of a sudden hot lava eruption, they have only a<br />
few hours to evacuate the site. The next step would be a total new investment<br />
of the site – I guess.<br />
In the energy industry, effective asset management is crucial, as the initial<br />
investment is often substantial<br />
compared to the expected lifetime<br />
costs when machinery operates<br />
smoothly during the operational<br />
phase. From an investor's perspective,<br />
it is prudent to meticulously<br />
evaluate and calculate the<br />
types of devices and solutions<br />
needed to ensure optimal equipment<br />
operation throughout its<br />
operational lifespan to optimize the return on invested capital.<br />
Wind power is already a known area with enough competence and understanding<br />
of the maintenance needs. New areas of energy such as large-scale<br />
solar power, hydrogen and small nuclear power plants will most probably<br />
create new needs for maintenance competencies. Nevertheless, the demand<br />
for environmentally friendly and domestically controllable energy sources is<br />
increasing, placing significant pressure on the development of such technologies.<br />
In this edition of <strong>Maintworld</strong> magazine, you'll find an article from the German<br />
certification organization, TÜV SÜD, which provides insights into the<br />
maintenance of photovoltaic systems, commonly known as solar power. TÜV<br />
SÜD estimates that there are approximately 2.6 million photovoltaic systems<br />
generating solar power on rooftops and sites in Germany. Additionally,<br />
Associate Professor Mirka Kans from Chalmers University of Technology<br />
in Sweden emphasizes the significance of maintenance in a circular economy<br />
environment in her article.<br />
Furthermore, in this magazine you can learn what steps should be taken to<br />
simplify the transition in organisations toward robot-assisted work environments.<br />
While automation is often essential for improving productivity and<br />
cost-effectiveness, it may not always be met with enthusiasm by employees.<br />
In this magazine, we share strategies to introduce new technology in a way<br />
that positively impacts your workforce.<br />
Jaakko Tennilä<br />
Editor-in-Chief, <strong>Maintworld</strong> magazine<br />
In the energy<br />
industry, effective asset<br />
management is crucial,<br />
as the initial investment<br />
is often substantial.<br />
40<br />
Maintenance<br />
plays a<br />
huge role in achieving a<br />
high level of circularity.<br />
4 maintworld 4/<strong>2023</strong>
IN THIS ISSUE 4/<strong>2023</strong><br />
26<br />
In<br />
the construction industry,<br />
preventative maintenance<br />
stands out as a pivotal practice,<br />
underpinning the operational<br />
longevity and efficiency of<br />
critical machinery.<br />
24<br />
Casing<br />
distortion is not only<br />
one of the biggest problems<br />
for rotating machinery but is<br />
also a very common one.<br />
4 Editorial<br />
6 News<br />
12<br />
16<br />
18<br />
Maintaining the Future: Industry 5.0<br />
triumphs over Industry 4.0’s challenges<br />
Bearing Lubrication 4.0: Autonomous and<br />
smart lubrication assisted by ultrasound<br />
Make gas detection a pillar of<br />
your ESG strategy<br />
22<br />
24<br />
26<br />
Mastering Ultrasound Monitoring with<br />
the CONMONSense Sensor Range<br />
Understanding casing distortion<br />
From Breakdowns to Breakthroughs:<br />
The transformative impact of<br />
preventative maintenance in<br />
construction<br />
30<br />
The impact of corrosion on heavy<br />
equipment<br />
34<br />
38<br />
40<br />
44<br />
48<br />
What biocatalysis has to offer for<br />
green industries and city planning?<br />
Simplifying the transition to a<br />
robot-assisted work environment<br />
Maintenance – A crucial factor for<br />
achieving circularity<br />
Best practices for storing electric motors<br />
Photovoltaic systems in the limelight<br />
Issued by Promaint (Finnish Maintenance Society), Messuaukio 1, 00520 Helsinki, Finland, tel. +358 29 007 4570. Editor-in-chief Jaakko<br />
Tennilä, Promaint. Publisher Avone Oy, avone.fi, executive producer Vaula Aunola, editor@maintworld.com, producer Nina Garlo-Melkas.<br />
Advertisements Kai Portman, Sales Director, tel. +358 358 44 763 2573, kai@maintworld.com. Layout Avone. Subscriptions and Change of<br />
Address: toimisto@kunnossapito.fi. Printed by Savion Kirjapaino Oy Frequency 4 issues per year, ISSN L 1798-7024, ISSN 1798-7024 (print),<br />
ISSN 1799-8670 (online).<br />
4/<strong>2023</strong> maintworld 5
In Short<br />
Wind Turbine Services Market in Europe<br />
to increase by USD 2.88 billion from<br />
<strong>2023</strong> to 2028; ABB Ltd., Acciona SA, B9<br />
Energy Ltd. and more among key companies.<br />
Source: Technavio<br />
ABB and Imperial College extend carbon<br />
capture collaboration to support future<br />
workforce and energy transition<br />
ABB AND IMPERIAL COLLEGE LONDON signed a 10-year<br />
contract to continue their carbon capture technology partnership.<br />
Following the agreement, ABB – a technology leader in<br />
electrification and automation – aims to prepare current students<br />
for future industrial processes, showcasing how advanced<br />
technology can optimize plant performance and enhance safety<br />
in real-life applications.<br />
The collaboration with Imperial College grants the university<br />
access to cutting-edge control and instrumentation technology.<br />
– Extending the partnership with Imperial College allows us to<br />
offer students practical training to prepare them for a career in<br />
industry, said Simon Wynne, Head of Energy Industries, ABB UK &<br />
Ireland.<br />
The plant, which is spread over four floors, uses ABB Ability<br />
System 800xA® for distributed process control and over 250<br />
instruments, measuring temperature, pressure, carbon dioxide<br />
and flow. System 800xA automatically controls and coordinates<br />
all aspects of the plant process, which is then visualized on displays<br />
in the ABB Control Room where students can monitor and<br />
intervene if necessary.<br />
ABB’s Ability Verification for measurement devices and new<br />
Ability SmartMaster verification and condition monitoring platform<br />
are also being used to equip students with the skills needed to optimize<br />
instrument performance through predictive maintenance.<br />
– When we started the partnership with ABB, the aim was to<br />
encourage more people to go into and stay in chemical engineering,<br />
said Dr Colin Hale, Senior Teaching Fellow at Imperial College<br />
London.<br />
– One of the ways to do this was to set up this carbon capture<br />
plant so we could enthuse students to follow through on the<br />
environmental topics they have learnt previously. ABB shares<br />
this collective vision.<br />
– During my time in the carbon capture pilot plant, I have<br />
actively participated in the operation of the process, gaining a<br />
deeper understanding of the development and application of the<br />
technology, said Yiheng Shao, fourth year undergraduate student<br />
at Imperial College London.<br />
According to a report by S&P Global, carbon capture and storage<br />
(CCS) can help decarbonize industry, reduce emissions and reach<br />
net zero, while the Global CCS Institute said in 2022 there was a<br />
44 percent increase in the number of CCS facilities around the world<br />
compared with the previous year.<br />
Earlier this year, the UK Government outlined its Powering<br />
Up Britain policy. This series of net-zero pledges, including £20<br />
billion of funding to unlock private investment and jobs in CCS,<br />
aims to deliver an energy system with cleaner, more affordable<br />
energy sources.<br />
Metal Forging Market<br />
to grow by USD 33.29<br />
billion from <strong>2023</strong> to<br />
2028 – Technavio<br />
HIGH DEMAND for advanced materials and alloys is a key factor driving<br />
market growth. Advanced alloys, which are being developed and used<br />
to fuel the evolution of performance materials with increased strength,<br />
durability, and corrosion resistance, are also becoming increasingly<br />
in demand. In addition, components with exceptionally high strength,<br />
longevity, and resistance to extreme conditions must be used in industries<br />
such as aircraft, automobiles, or energy.<br />
6 maintworld 4/<strong>2023</strong>
6.39%<br />
The<br />
wind turbine gearbox market size is estimated<br />
to grow at a CAGR of 6.39% between<br />
2022 and 2027. The market size is forecast to<br />
increase by USD 4,232.96 million.<br />
Smart buildings market<br />
size is estimated to<br />
increase by USD 46.12<br />
billion from 2022 to 2027<br />
THE SMART BUILDINGS market's growth momentum will progress<br />
at a CAGR of 9.73% during the forecast period. An emerging trend in<br />
the smart buildings market is the growing concept of BIoT. BIoT is the<br />
new vision of making the building intelligent to take insights from<br />
the information and react automatically.<br />
Smart building is the integration of all standalone automated systems<br />
with additional support features such as cloud integration. The<br />
cloud infrastructure connects the sensors and actuators to exchange<br />
information among themselves and improve the working conditions.<br />
In addition, BIoT enables the integration of handheld devices such<br />
as mobile phones and tablets with building control to manage the<br />
process remotely. Moreover, the analytical reports help managers to<br />
optimize energy efficiency and the working environment further.<br />
Vendors are also making continuous efforts to integrate smart<br />
buildings with cyber security and connected buildings technology.<br />
Thus, the rising adoption of BIoT in smart building solutions will<br />
drive the growth of the market in focus during the forecast period.<br />
Source: Technavio<br />
EU unveils plans to<br />
boost energy sector<br />
THE EUROPEAN COMMISSION has unveiled plans aimed at bolstering<br />
the European Union's wind energy sector while addressing various<br />
challenges, including permitting delays, workforce shortages, and<br />
limited access to raw materials. The initiative is primarily designed<br />
to shield the EU's wind industry from unfair global competition and<br />
safeguard its energy security.<br />
The action plan also aims to enhance cybersecurity in the wind energy<br />
sector. Wind farms' growth in Europe presents security risks, and<br />
the plan suggests redesigning auctions that allow countries to procure<br />
clean power, with a focus on assessing cybersecurity risks. The EU aims<br />
to increase wind capacity from 204 GW in 2022 to more than 500 GW<br />
by 2030 to meet its renewable energy targets. This will involve speeding<br />
up permitting processes, expanding the workforce, and improving<br />
access to finance.<br />
The EU's wind industry expansion is driven by the revised Renewable<br />
Energy Directive, which sets a target of 42.5% for wind, solar,<br />
and biomass in the EU's energy mix by 2030, requiring a significant<br />
increase in wind capacity. Source: Research and Markets<br />
Recycled Plastics Market<br />
to grow by 18.37 million<br />
tons from 2022 to 2027 –<br />
Technavio<br />
THE RECYCLED PLASTICS market size is<br />
estimated to grow by USD 18.37 million<br />
tons from 2022 to 2027, according to<br />
Technavio. The market is estimated<br />
to rise at a CAGR of 4.75%. The use of<br />
recycled plastics in the industries such as<br />
automotive, textile, and construction drives<br />
the growth of the regional market.<br />
4/<strong>2023</strong> maintworld 7
In Short<br />
The Medical Device Contract Manufacturing<br />
Market to grow at a CAGR of 11.19% from<br />
2021 to 2026|The impact of Industry<br />
4.0 on the medical device industry drives<br />
market growth. Source: Technavio<br />
EU-OSHA AND THE FUTURE OF WORK:<br />
CHAMPIONING SAFETY AND HEALTH<br />
IN THE DIGITAL ERA<br />
and Healthy Work<br />
in the Digital Age" is the<br />
title of the new edition<br />
of EU-OSHA's Healthy<br />
‘Safe<br />
Workplaces Campaign,<br />
which commenced in October. The<br />
campaign's objectives are to increase<br />
awareness, encourage collaboration,<br />
and establish a future where occupational<br />
safety and health continue to be<br />
a top priority alongside technological<br />
advancement.<br />
With 93% of workers in large companies<br />
and 85% in micro companies using<br />
digital devices, this campaign addresses<br />
the evolving dynamics of work, emphasising<br />
the imperative of ensuring safety<br />
and health in a human-centred digital<br />
transformation.<br />
As Artificial Intelligence (AI), cloud<br />
computing, and collaborative robots<br />
become integral to work processes, the<br />
very nature of work is transforming.<br />
The campaign recognises the potential<br />
for improved occupational safety<br />
and health (OSH) while confronting<br />
emerging risks in this rapidly evolving<br />
environment, EU-OSHA says in a statement.<br />
– The world of work has seen a huge<br />
transformation in recent years, with the<br />
rise of digital technologies, algorithmic<br />
management and remote working. It<br />
is essential to strike the right balance:<br />
as we reap the benefits of the digital<br />
age, we must also make sure we don’t<br />
compromise on the human-cantered<br />
approach, Nicolas Schmit, European<br />
Commissioner for Jobs and Social<br />
Rights, declared.<br />
The campaign will explore five priority<br />
areas over the next two years: digital<br />
platform work, automation of tasks,<br />
remote and hybrid work, worker management<br />
through Artificial Intelligence<br />
and smart digital systems.<br />
– This campaign will help drive a<br />
digital transformation of the world of<br />
work that is fair and leaves no one behind,<br />
spreading knowledge about digital<br />
solutions that represent opportunities<br />
for companies and workers, Joaquín<br />
Pérez Rey, interim secretary of State<br />
for Employment and Social Economy<br />
of Spain and representing the Spanish<br />
Presidency of the EU Council, added.<br />
This edition seeks to enhance awareness<br />
of the impact of digital transformation<br />
on OSH and encourage a safe and<br />
productive use of digital technologies<br />
across diverse sectors and workplaces.<br />
It also aims to foster collaboration<br />
among stakeholders, providing resources<br />
and promoting proactive risk assessment<br />
for a secure and efficient digital<br />
transformation of work.<br />
– As Europe’s digital transformation<br />
steams ahead, its impact on businesses<br />
and workers is far from being fully<br />
understood. There’s an urgent need to<br />
grasp the opportunities and identify<br />
the risks of digitalisation to maximise<br />
the benefits of these new technologies<br />
for safe, healthy and productive workplaces,<br />
William Cockburn Salazar,<br />
Executive Director of the European<br />
Agency for Safety and Health at Work<br />
(EU-OSHA), said.<br />
8 maintworld 4/<strong>2023</strong>
Google Cloud<br />
Cybersecurity<br />
Forecast for<br />
2024 now<br />
published<br />
GIS<br />
Next<br />
Generation<br />
EAM<br />
PdM<br />
Mobile<br />
AIP<br />
BI<br />
PPM<br />
WHAT WILL CYBERSECURITY look like in 2024? Google<br />
Cloud Global Cybersecurity Forecast found that generative<br />
AI can help attackers and defenders and urged security<br />
personnel to look out for nation-state backed attacks and<br />
more.<br />
— While new technologies will aid security teams, they<br />
can also expand the cyber-attack surface, a recently published<br />
Google Cloud Cybersecurity Forecast 2024 report<br />
predicts. In 2024, the rapidly evolving world of gen AI will<br />
provide attackers with new ways to conduct convincing<br />
phishing campaigns and information operations at scale.<br />
However, defenders will use the same technologies to<br />
strengthen detection, response, and attribution of adversaries.<br />
According to the report, in 2024, continued activity by<br />
The Big Four—China, Russia, North Korea, and Iran—can be<br />
expected as they conduct espionage, cybercrime, information<br />
operations, and other campaigns to achieve their individual<br />
goals. With many organisations becoming better at<br />
security, many of these attacks will involve techniques to<br />
evade detection, including use of zero-day vulnerabilities<br />
and the targeting of edge devices, the report reveals.<br />
– Everyone should be prepared for global activity<br />
around the myriad major events held throughout 2024,<br />
including the U.S., European Parliament, and other elections,<br />
as well as the Summer Olympics in Paris, the report warns.<br />
– Additionally, as major global conflicts continue into<br />
next year, be prepared for an uptick in disruptive hacktivism,<br />
it adds.<br />
BIM<br />
AI<br />
APM<br />
Many companies use their Enterprise Asset Management<br />
(EAM) system mainly as an electronic card index or a<br />
digital work order system, unaware of the possibilities it<br />
has for Asset Management. EAM Systems like Maximo,<br />
IFS Ultimo, HxGN EAM and SAP EAM have evolved<br />
tremendously. They now offer functionalities for Asset<br />
Investment Planning, Project Portfolio Management,<br />
Asset Performance Management, Business Intelligence<br />
and Predictive Maintenance. Major steps have also been<br />
taken in the field of Mobile, GIS and BIM integration.<br />
Are you ready for Next Generation EAM?<br />
Our VDM XL experts can assist you with further<br />
professionalisation and automation of your Maintenance<br />
& Asset Management organisation.<br />
www.mainnovation.com
In Short<br />
Lithium-ion battery demand soars, projected<br />
to reach 4.7 TWh by 2030 boosted<br />
by a shift toward green energy and electric<br />
mobility. Research and Markets<br />
Finnish cleantech company<br />
SpinDrive raises €3.8M to cut<br />
industrial energy waste and pollution<br />
with magnetic levitation bearings<br />
Finnish cleantech company<br />
SpinDrive has secured €3.8<br />
million in Series A funding<br />
led by Rhapsody Venture<br />
Partners, with participation<br />
from existing investors Innovestor and<br />
Born2Grow. The funds will support<br />
global expansion and the development<br />
of new Active Magnetic Bearings.<br />
SpinDrive aims to enhance global<br />
industrial machinery efficiency by providing<br />
affordable, frictionless magnetic<br />
levitation bearings as an alternative to<br />
traditional, high-maintenance options.<br />
SpinDrive's technology offers smaller,<br />
more energy-efficient bearings with<br />
up to 20 years of maintenance-free<br />
operation, reducing downtime and<br />
costs. Additionally, the lubricant-free<br />
operation helps eliminate pollution,<br />
contributing to cutting 500Mt of CO2<br />
annually by 2050. The company has<br />
raised a total of €8 million to date and<br />
has a global presence with offices in<br />
Finland and Germany.<br />
Meanwhile, traditional ball bearings<br />
in industrial high-speed applications<br />
have a 12-18 month maintenance cycle,<br />
requiring bearing replacement. Spin-<br />
Drive's bearings also provide condition<br />
monitoring and predictive maintenance<br />
of the whole machine, removing<br />
the need to install external sensors to<br />
monitor system health and reducing<br />
overall equipment maintenance costs<br />
by over 80%, the company says in a<br />
statement.<br />
– We have seen increasing international<br />
demand for more energy<br />
efficiency and cleaner solutions in<br />
industrial production, and we are excited<br />
to build SpinDrive to meet those<br />
customer needs with our active magnetic<br />
bearing systems and controllers.<br />
With its specialization in industrial<br />
Traditional ball<br />
bearings in industrial<br />
high-speed applications<br />
have a 12-18 month<br />
maintenance cycle.<br />
technologies and global reach into industrial<br />
companies, Rhapsody Venture<br />
Partners is an ideal partner for us, and<br />
we're thrilled to be working with them,<br />
says Nikita Uzhegov, COO and Cofounder<br />
of SpinDrive.<br />
– Climate change is the biggest<br />
challenge of our time, but we often<br />
get stuck thinking about technologies<br />
like carbon capture when it comes to<br />
CO2 emissions. Industrial production<br />
is a massive part of the world's energy<br />
consumption and climate emissions,<br />
so we must create energy-efficient<br />
and clean components to turn this<br />
tide. By improving the energy efficiency<br />
in existing and new machinery,<br />
we tackle the problem in a massive<br />
area and provide a significant impact,<br />
adds Janne Heikkinen, CEO and Cofounder<br />
of SpinDrive.<br />
10 maintworld 4/<strong>2023</strong>
CONMONSense<br />
Standalone, Permanent Mount, Ultrasound Sensors<br />
Enhance your remote condition monitoring<br />
capabilities with the CONMONSense range.<br />
Ultrasound sensors designed for easy integration<br />
into a variety of acquisition systems to suit<br />
your specific application needs.<br />
The CONMONSense range includes standalone sensors<br />
with both 4-20mA and 0-10V standard output.<br />
Contact<br />
Airborne open<br />
Airborne enclosed<br />
Ultrasound Soluons
CONSTRUCTION INDUSTRY<br />
Text: Prof. DIEGO GALAR / Prof. RAMIN KARIM / Prof. UDAY KUMAR Images: STOCKPHOTO, DIEGO GALAR<br />
Maintaining the Future:<br />
Industry 5.0 Triumphs Over<br />
Industry 4.0’s Challenges<br />
THE CONCEPT OF INDUSTRY 5.0<br />
The concept of Industry 4.0, while initially<br />
promising, encountered various<br />
challenges and limitations that ultimately<br />
led to its partial failure. Despite<br />
its emphasis on automation, data<br />
exchange, and manufacturing technologies,<br />
it often overlooked the human<br />
element, neglecting the crucial role of<br />
workers in the production process. Concerns<br />
also arose about its environmental<br />
sustainability and societal impact, highlighting<br />
the need for a more holistic approach<br />
to industrial development.<br />
The emerging concept of Industry<br />
5.0 represents a significant departure<br />
from traditional industrial models, emphasizing<br />
a holistic approach to production<br />
that prioritizes human-centricity,<br />
sustainability, and resilience. While<br />
the exact implications and disruptions<br />
of Industry 5.0 remain uncertain, recognition<br />
of its potential to bridge the<br />
gap between the physical and virtual<br />
worlds is growing. In this context, Industry<br />
5.0 embodies a broader purpose<br />
that extends beyond profit generation.<br />
It underscores the need for industrial<br />
practices to align with societal and environmental<br />
considerations, emphasizing<br />
responsible innovation that benefits all<br />
stakeholders, including investors, workers,<br />
consumers, and the environment.<br />
A key facet of Industry 5.0 is its<br />
human-centric approach, which places<br />
human needs and interests at the<br />
forefront of the production process.<br />
This approach leverages technology<br />
to accommodate the requirements<br />
of workers, ensuring their well-being<br />
and fundamental rights are upheld.<br />
Sustainability is another critical tenet,<br />
necessitating the implementation of circular<br />
processes and resource-efficient<br />
technologies to reduce waste and environmental<br />
impact. Resilience also plays<br />
a vital role in Industry 5.0, advocating<br />
for the development of robust industrial<br />
systems that can withstand disruptions<br />
and support critical infrastructure, particularly<br />
in times of crisis. The concept<br />
promotes the establishment of adaptable<br />
production capacities and flexible<br />
business processes, fostering a resilient<br />
and crisis-ready industrial landscape.<br />
Ultimately, Industry 5.0 is defined by<br />
its commitment to societal goals, prior-<br />
12 maintworld 4/<strong>2023</strong>
CONSTRUCTION INDUSTRY<br />
itizing the well-being of industry workers<br />
and ensuring environmentally sustainable<br />
production practices that align with<br />
the planet's natural boundaries. The transition<br />
to Industry 5.0 promises a wealth of<br />
benefits not only for companies but also<br />
for workers. Benefits span the spectrum<br />
from enhanced talent attraction and<br />
retention to improved energy efficiency<br />
and heightened overall resilience.<br />
There are some possible dangers<br />
inherent to the shift. Industry needs to<br />
ensure sustained competitiveness and<br />
relevance by adapting to evolving global<br />
markets and societal shifts. While there<br />
might be a short-term risk of temporarily<br />
losing competitiveness to those not<br />
yet embracing Industry 5.0, strategic<br />
timing and coordinated investments can<br />
help mitigate this potential setback. The<br />
most significant peril is the failure to engage<br />
with the broader societal transition<br />
towards sustainability, human-centricity,<br />
and resilience, risking competitiveness<br />
in the long run.<br />
HUMAN-CENTRIC<br />
Industry 5.0 represents a paradigm shift<br />
that addresses the concerns and challenges<br />
associated with the concept of the<br />
‘dark factory’, one where humans are<br />
not needed. By prioritizing the humancentric<br />
approach, Industry 5.0 integrates<br />
advanced technologies to enhance the<br />
capabilities and well-being of workers,<br />
thereby dispelling the notion of a dark,<br />
automated workplace devoid of human<br />
presence. This shift towards Industry 5.0<br />
represents a profound transformation<br />
in perspective, with a notable shift from<br />
a technology-driven to a human-centric<br />
approach. This necessitates the incorporation<br />
of societal constraints, ensuring<br />
no one is left behind. Consequently, the<br />
industrial sector must establish a secure<br />
and empowering work environment, respect<br />
human rights, and develop specific<br />
skill sets for workers.<br />
Withing the framework of Industry<br />
5.0, the industry worker assumes a significantly<br />
elevated position, viewed not<br />
as an expense but as an investment in<br />
the company's growth. This reorientation<br />
necessitates a commitment to<br />
the advancement of employee skills,<br />
capabilities, and well-being, signalling a<br />
departure from the traditional practice<br />
of balancing worker costs with financial<br />
revenues. Moreover, it underscores the<br />
critical role of technology in serving the<br />
diverse needs of industry workers, empowering<br />
them and fostering an inclusive<br />
work environment. Addressing workplace<br />
safety and inclusivity, Industry 5.0<br />
leverages advancements in robotics and<br />
AI to mitigate physical risks and streamline<br />
complex tasks, thereby reducing<br />
workplace accidents. Technologies like<br />
AI, virtual and augmented reality, and<br />
wearables also contribute to safeguarding<br />
workers' mental health, emphasizing<br />
the importance of maintaining a balance<br />
between work and well-being.<br />
A key area where Industry 5.0 yields<br />
significant benefits is in attracting and<br />
retaining skilled talent. Given the challenges<br />
of filling positions that demand<br />
digital and multi-disciplinary skills, the<br />
focus on accommodating the preferences<br />
and values of the millennial workforce<br />
is crucial. Research has found the millennial<br />
generation is more inclined towards<br />
socially responsible and environmentally<br />
conscious companies, prioritizing<br />
workplace environments that align with<br />
their values and offer a sense of purpose.<br />
Companies need to adapt their practices,<br />
fostering a culture of social responsibility<br />
and sustainability to remain competitive<br />
in the hiring market.<br />
SUSTAINABILITY<br />
The 5.0 concept involves leveraging<br />
innovative green technologies, driven<br />
not only by environmental concerns<br />
but also by the potential for enhanced<br />
corporate image and cost savings on<br />
energy and materials. While industrial<br />
production often demands more energy<br />
and contributes to increased carbon<br />
emissions, innovations and smarter<br />
production planning can reverse this<br />
trend. Despite notable improvements in<br />
From Steam to Smart: Tracing the Evolution from Industry 1.0 to 5.0 and the Synergy<br />
of Human Expertise with Intelligent Machines.<br />
Maintenance 5.0, within the context of Industry 5.0, is characterized by three pillars:<br />
sustainability, human-centricity, and resilience. These pillars redefine maintenance<br />
practices to integrate environmental responsibility, empower human expertise through<br />
advanced technologies, and ensure adaptability in the face of disruptions.<br />
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CONSTRUCTION INDUSTRY<br />
energy efficiency across various sectors,<br />
the pace of progress in energy-intensive<br />
industries has recently slowed, necessitating<br />
more targeted research and innovation<br />
efforts in this domain.<br />
RESILIENCE<br />
Industry 5.0 champions increased resilience<br />
in the face of disruptive changes,<br />
both geopolitical and environmental.<br />
By fostering adaptive strategies at various<br />
levels of value chains and industrial<br />
systems, industry players can manage<br />
vulnerabilities and minimize the<br />
impacts of unforeseen circumstances.<br />
Leveraging digital technologies, such as<br />
real-time risk monitoring and cybersecurity<br />
measures, can bolster industry<br />
resilience, ensuring smooth operations<br />
even in the face of technical disruptions<br />
and cyber threats. The emphasis on resilience<br />
is growing, particularly in light<br />
of the disruptions caused by the pandemic<br />
and the intensifying frequency<br />
of extreme weather events attributed to<br />
climate change.<br />
MAINTENANCE 5.0<br />
The shift from Maintenance 4.0 to<br />
Maintenance 5.0 mirrors the broader<br />
transition occurring in the industrial<br />
landscape. Maintenance 4.0 focuses on<br />
the integration of digital technologies,<br />
such as the Internet of Things (IoT),<br />
data analytics, and predictive maintenance,<br />
to optimize industrial maintenance<br />
processes. It emphasizes the use<br />
of advanced data-driven techniques<br />
and automation to enhance equipment<br />
reliability and reduce downtime. Maintenance<br />
5.0 takes this a step farther by<br />
incorporating a more human-centric<br />
approach, aligning with the principles<br />
of Industry 5.0. Maintenance 5.0 also<br />
prioritizes sustainability and resilience<br />
in maintenance operations. This shift is<br />
critical in the face of the dual challenges<br />
posed by the COVID-19 pandemic and<br />
the escalating impact of climate change.<br />
As Maintenance 5.0 increasingly aligns<br />
with sustainable and resilient principles,<br />
it will become a cornerstone for ensuring<br />
the long-term viability and adaptability<br />
of industrial processes, mitigating<br />
the adverse impacts of global crises<br />
on operational efficiency and overall<br />
productivity.<br />
HUMAN-CENTRIC ORIENTATION<br />
Maintenance 5.0 goes beyond the<br />
traditional focus on machines and processes<br />
to prioritize the well-being and<br />
involvement of maintenance workers.<br />
This approach acknowledges the critical<br />
role of human expertise in maintaining<br />
industrial systems and promotes the<br />
integration of workers into the digitalized<br />
maintenance ecosystem. It aims to<br />
empower workers through the use of<br />
innovative technologies, offering them<br />
opportunities for skill development,<br />
greater autonomy, and involvement in<br />
the decision-making process. It also ensures<br />
a safe and inclusive work environment,<br />
utilizing technologies to mitigate<br />
workplace risks and prioritize workers'<br />
physical and mental well-being.<br />
SUSTAINABILITY<br />
Maintenance 5.0, as an evolution of the<br />
maintenance paradigm, emphasizes the<br />
integration of sustainability principles<br />
within its framework. It recognizes that<br />
maintenance practices play a vital role<br />
in achieving sustainable development<br />
goals, aligning with the broader efforts<br />
to minimize environmental impact,<br />
conserve resources, and promote social<br />
well-being. The concept of sustainability<br />
within Maintenance 5.0 underscores<br />
the adoption of sustainable practices,<br />
such as resource-efficient maintenance<br />
processes and circular economy principles,<br />
to optimize resource utilization<br />
and minimize environmental impact. By<br />
implementing predictive and preventive<br />
maintenance strategies, industries can<br />
reduce unnecessary waste and conserve<br />
energy, thereby contributing to the<br />
global efforts towards sustainable development.<br />
The sustainability dimension of<br />
Maintenance 5.0 encompasses the following<br />
key aspects:<br />
• Environmental impact reduction:<br />
Maintenance 5.0 emphasizes the adoption<br />
of eco-friendly practices to reduce<br />
the environmental footprint of industrial<br />
processes. This includes the efficient<br />
use of resources, waste reduction,<br />
and the implementation of sustainable<br />
technologies that contribute to a circular<br />
economy.<br />
• Energy efficiency: Sustainable maintenance<br />
practices focus on optimizing<br />
energy consumption and minimizing<br />
the carbon footprint of industrial<br />
operations. This involves the use of<br />
energy-efficient technologies, the adoption<br />
of renewable energy sources, and<br />
the implementation of energy manage-<br />
14 maintworld 4/<strong>2023</strong>
CONSTRUCTION INDUSTRY<br />
ment systems to reduce overall energy<br />
consumption.<br />
• Lifecycle management: Maintenance<br />
5.0 promotes the concept of lifecycle<br />
management, which involves considering<br />
the entire lifecycle of assets and<br />
equipment. This approach integrates<br />
sustainable practices throughout the<br />
asset lifecycle, from design and production<br />
to operation, maintenance, and<br />
eventual decommissioning or recycling.<br />
• Circular economy integration:<br />
Maintenance 5.0 actively supports the<br />
integration of circular economy principles<br />
within industrial maintenance<br />
processes. This involves extending the<br />
life of assets through effective maintenance,<br />
refurbishment, and reuse, as well<br />
as promoting the recycling and repurposing<br />
of materials and components to<br />
minimize waste and resource depletion.<br />
By incorporating these sustainability dimensions,<br />
Maintenance 5.0 not only enhances<br />
operational efficiency and asset<br />
performance but also contributes to the<br />
overall sustainability goals of organizations,<br />
aligning with global efforts to promote<br />
environmentally responsible and<br />
socially conscious industrial practices.<br />
RESILIENCE<br />
There is a clear need for resilient maintenance<br />
strategies that can swiftly adapt<br />
to changing circumstances and address<br />
disruptions in the industrial landscape,<br />
thus ensuring the continuous and reliable<br />
operation of critical infrastructure,<br />
even during unforeseen crises. Simply<br />
stated, resilience in Maintenance 5.0 refers<br />
to the ability of industrial organizations<br />
to anticipate, adapt to, and recover<br />
from various disruptions and challenges<br />
that may arise within their operational<br />
environment. It emphasizes the implementation<br />
of proactive strategies and<br />
advanced technologies to ensure the<br />
continuous and efficient functioning<br />
of critical assets, even in the face of unexpected<br />
events or adverse conditions.<br />
Resilience is crucial to maintain operational<br />
stability, minimize downtime, and<br />
sustain productivity, thereby enabling<br />
organizations to remain competitive<br />
and sustainable in the long run.<br />
Some key aspects related to resilience<br />
in Maintenance 5.0 are the following:<br />
• Predictive and preventive maintenance:<br />
By integrating predictive<br />
maintenance techniques, such as condition<br />
monitoring, data analytics, and<br />
real-time asset performance tracking,<br />
organizations can proactively identify<br />
potential equipment failures or<br />
operational inefficiencies before they<br />
escalate into significant disruptions.<br />
Implementing preventive maintenance<br />
protocols based on predictive insights<br />
allows companies to address issues<br />
early, minimizing the risk of costly<br />
downtime and ensuring the uninterrupted<br />
operation of critical assets.<br />
• Risk management and contingency<br />
planning: Effective risk management<br />
is a fundamental component of resilient<br />
maintenance practices. Organizations<br />
need to identify potential vulnerabilities<br />
within their operational processes<br />
and develop comprehensive contingency<br />
plans to mitigate the impact of<br />
unforeseen events, such as natural<br />
disasters, supply chain disruptions, or<br />
technological failures. By establishing<br />
robust risk assessment frameworks<br />
and implementing adaptive strategies,<br />
companies can enhance their ability to<br />
respond to and recover from various<br />
operational challenges while maintaining<br />
overall system resilience.<br />
Maintenance 5.0<br />
emphasizes the adoption<br />
of eco-friendly<br />
practices to reduce<br />
the environmental<br />
footprint of industrial<br />
processes.<br />
• Data-driven decision-making: By<br />
leveraging advanced data analytics and<br />
intelligent automation, Maintenance 5.0<br />
enables organizations to make informed<br />
and data-driven decisions regarding<br />
asset management and maintenance<br />
strategies. By harnessing the power of<br />
Big Data and AI-driven insights, companies<br />
can optimize maintenance schedules,<br />
streamline repair processes, and<br />
prioritize resource allocation, thereby<br />
enhancing the overall resilience of their<br />
maintenance operations. Data-driven<br />
decision-making empowers organizations<br />
to respond swiftly to changing<br />
operational conditions and proactively<br />
address emerging maintenance needs.<br />
• Adaptive and flexible maintenance<br />
processes: Resilience in Maintenance<br />
5.0 emphasizes the development of<br />
adaptive and flexible maintenance processes<br />
that can accommodate evolving<br />
operational requirements and changing<br />
environmental conditions. By fostering a<br />
culture of continuous improvement and<br />
agility, organizations can optimize their<br />
maintenance strategies in response to<br />
dynamic market demands, technological<br />
advancements, and regulatory changes.<br />
Implementing agile maintenance methodologies<br />
enables companies to swiftly<br />
adapt to new challenges and opportunities,<br />
ensuring the efficient and sustainable<br />
operation of their assets.<br />
• Technology integration for<br />
enhanced resilience: Leveraging<br />
advanced technologies, such as IoT<br />
devices, digital twins, and cloud-based<br />
monitoring systems, enables organizations<br />
to build resilient maintenance<br />
frameworks that facilitate real-time<br />
asset tracking, remote diagnostics, and<br />
predictive maintenance scheduling.<br />
Integrating smart sensors and interconnected<br />
systems within industrial<br />
facilities enhances the overall visibility<br />
and control of critical assets, enabling<br />
organizations to proactively identify<br />
potential issues and swiftly address<br />
them, thereby minimizing the risk of<br />
operational disruptions and ensuring<br />
continuous asset reliability.<br />
By incorporating these key aspects,<br />
organizations can strengthen their resilience<br />
in Maintenance 5.0, fostering a robust<br />
operational framework capable of<br />
withstanding challenges and uncertainties<br />
while ensuring the sustainable and<br />
efficient functioning of critical assets.<br />
CONCLUSION<br />
Overall, the shift from Maintenance 4.0<br />
to Maintenance 5.0 represents a transformational<br />
journey from data-driven<br />
and automated maintenance practices<br />
to a more holistic approach that<br />
integrates the well-being of workers,<br />
sustainability, and resilience into the<br />
core of maintenance operations. By embracing<br />
Maintenance 5.0, industries can<br />
ensure the optimal performance of their<br />
equipment and the empowerment and<br />
safety of their maintenance workforce,<br />
while contributing to a more sustainable<br />
and adaptable industrial ecosystem. In<br />
essence, the comprehensive adoption of<br />
Industry 5.0 principles in Maintenance<br />
5.0 can pave the way for a sustainable<br />
and adaptive industrial landscape, not<br />
only providing economic benefits but also<br />
promoting environmental consciousness<br />
and societal well-being.<br />
4/<strong>2023</strong> maintworld 15
PARTNER ARTICLE<br />
Text: PETER BOON, Product Specialist, UE Systems Images: UE SYSTEMS<br />
Bearing Lubrication 4.0:<br />
Autonomous and Smart lubrication<br />
assisted by ultrasound<br />
It is estimated that 60-80% of bearing failures are related to lubrication. Bearing failures very<br />
often lead to unplanned downtime, which often has a significant impact on production and related<br />
equipment. This downtime is maby times very costly. Although the costs vary according to the<br />
severity of the incident and the industry in question, they do add up to production costs.<br />
Example of a lubrication monitoring dashboard - UE Insights Platform<br />
from UESystems.<br />
The most frequent cause of bearing<br />
failure is directly linked to lubrication,<br />
so this is a real probme. Its impact on<br />
the reliability of industrial equipment is<br />
well established! The facts show that, for<br />
many years, the lubrication of bearings<br />
has been treated more randomly than in<br />
a methodical and controlled way.<br />
Many technicians have resorted<br />
to 'preventive' lubrication based on<br />
time: lubricating at a fixed period<br />
of time without any physical measurement<br />
of the bearing in order to<br />
determine whether or not lubricating<br />
is required! Every X months, a grease<br />
gun appears in front of the bearing<br />
to be lubricated and the bearings are<br />
lubricated in this way.<br />
Manual lubrication, based solely on<br />
the manufacturer's lubrication interval<br />
data, gives rise to at least the following<br />
two risks:<br />
• The risk of under-lubrication<br />
increases the mechanical constraints<br />
of rotation and can be the cause of<br />
failures leading to equipment breakdowns<br />
and stoppages, as well as<br />
costly corrective maintenance.<br />
• The risk of over-lubrication, which<br />
has been identified by a large number<br />
of studies as the main cause of<br />
premature bearing failure.<br />
Principle of Ultrasound<br />
technology applied in<br />
lubrication :<br />
Ultrasonic technology uses specially<br />
designed sensors to detect and monitor the<br />
level of friction in bearings.<br />
In the case of lubrication, the ultrasonic<br />
level detected by a sensor in contact<br />
with the bearing is directly linked to the<br />
friction level of the bearings. From this<br />
point onwards, the maintenance engineer<br />
responsible for lubricating bearings has<br />
two choices:<br />
• Manual lubrication, using a simple<br />
hand-held tool to listen to the bearings<br />
during the lubrication operation;<br />
16 maintworld 4/<strong>2023</strong>
PARTNER ARTICLE<br />
• The installation of an autonomous,<br />
ultrasonic-assisted lubrication<br />
system to carry out this operation<br />
safely, efficiently and without human<br />
intervention.<br />
Lubrication 4.0: autonomous,<br />
ultrasound-assisted lubrication<br />
A fully autonomous lubrication system<br />
completely replaces human intervention<br />
for lubrication operations. It is an intelligent<br />
lubrication and monitoring system,<br />
reducing bearing failures caused by poor<br />
lubrication practices by 80%.<br />
How does it work?<br />
Using ultrasound, this system measures<br />
bearing friction levels in real<br />
time. It enables lubrication problems<br />
and requirements to be detected at an<br />
early stage, well before the bearings<br />
are damaged.<br />
By using bearing friction as a guide,<br />
the system enables bearings that<br />
require lubrication to be precisely lubricated<br />
with the right amount of lubricant,<br />
avoiding over- and under-lubrication.<br />
As the friction level is measured<br />
continuously and in real time, even<br />
during lubrication, the system will stop<br />
lubricating on its own as soon as the<br />
friction level has dropped to its reference<br />
value.<br />
This totally autonomous system<br />
means that only the bearings that need<br />
lubrication will be lubricated, when<br />
they need it and with the right amount<br />
of lubricant.<br />
Ultrasonic technology for intelligent<br />
lubrication offers a number of<br />
advantages:<br />
• Know precisely when to lubricate<br />
• Know precisely how much lubricant<br />
to apply<br />
• Always use the right type of lubricant<br />
• Eliminate the risk of lubricant contamination<br />
• Reduce lubricating time and resources<br />
Example of bearing lubrication using a<br />
manual hand-held tool.<br />
Example of autonomous lubricators<br />
controlled by ultrasound<br />
Example of remote autonomous single<br />
point lubricators controlled by ultrasound<br />
A fully autonomous<br />
lubrication system completely<br />
replaces human<br />
intervention for lubrication<br />
operations.<br />
• Reduce lubricating time<br />
• Reduce lubricating resources<br />
• Reduce lubricant consumption<br />
• Reduce failure rates<br />
Finally, it should be noted that such a solution<br />
will provide software-based, permanent,<br />
real-time monitoring of lubrication<br />
practices. For example, for the OnTrak, we<br />
have the UE Insights: a Cloud platform for<br />
storing and monitoring remote data. This<br />
fully customisable platform stores all data<br />
relating to the condition and lubrication of<br />
bearings. It can be used to create monitoring<br />
dashboards and set alarm levels. Users<br />
can choose to use pre-configured dashboards<br />
and widgets, or create their own<br />
indicators. This is a web-based platform<br />
that requires no software installation and<br />
can be consulted from any type of device<br />
connected to the internet: desktop PC, laptop,<br />
tablet, smartphone, etc.<br />
Conclusion<br />
From a time-based periodic lubrication<br />
perspective, it is assumed that bearings<br />
need to be lubricated at regular, fixed time<br />
intervals. The question then becomes: how<br />
can these time intervals be established?<br />
This is often a combination of manufacturer's<br />
data, valid for general cases, or for<br />
bearings mounted on manufacturer's test<br />
benches, and approximations based on<br />
empirical experience of the same type of<br />
equipment.<br />
By using ultrasonic technology, lubrication<br />
technicians will be able to know which<br />
bearings to lubricate, when to lubricate them<br />
and how much lubricant to use.<br />
These three pieces of information,<br />
especially if delivered in real time and for<br />
each bearing to be lubricated, will make it<br />
possible to considerably improve lubrication<br />
practices, reduce lubrication times<br />
and the ammount of lubricant consumed,<br />
as well as drastically reducing bearing<br />
breakdown rates.<br />
The benefits of an Ultrasound<br />
Assisted Lubrication 4.0<br />
solution<br />
• Easy to install and use<br />
• Multiple connection capabilities:<br />
Ethernet, Wi-Fi, 4G,5G<br />
• Compatibility with existing systems<br />
and software<br />
• Identify lubricating needs early on<br />
• Lubricate as required<br />
• Drastically improve bearing life<br />
• Avoid over- and under-lubricating<br />
A condition-based lubrication approach will keep bearing friction at minimum levels.<br />
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HSE<br />
Make gas detection<br />
a pillar of your<br />
ESG strategy<br />
Robust environmental, social and governance (ESG) policies have become integral to day-to-day<br />
operations. Functioning as more than just a risk management exercise, ESG is not something<br />
that modern companies can afford to neglect. From investors using ESG strategies to evaluate<br />
potential investments to assuring the public that they are acting responsibly, companies that<br />
prioritise their ESG goals demonstrate that they care about their people and the planet and<br />
may also enjoy greater profits, as data shows that those with long-established ESG policies<br />
have outperformed their competitors. [1]<br />
Text: MARK NAPLES, General Manager, Umicore Coating Services Images: STOCKPHOTO<br />
18 maintworld 4/<strong>2023</strong>
HSE<br />
Understandably given the<br />
current international<br />
focus on sustainability,<br />
the environmental part of<br />
ESG policies can at times<br />
feel like it has received the lion's share<br />
of attention. With more sustainable<br />
business operations increasingly under<br />
the spotlight, controlling greenhouse<br />
gases and other harmful emissions<br />
represents an eye-catching way for<br />
companies to show that they are making<br />
a difference, and a wide range of<br />
technologies have been developed to<br />
help achieve these goals.<br />
But it is important to remember that<br />
environmentalism is just one pillar of<br />
any effective ESG strategy. While requirements<br />
like workplace safety may<br />
not get the same attention in the media,<br />
they are just as important for demonstrating<br />
ESG credentials. Any company<br />
operating today needs measures in<br />
place for protecting their employees –<br />
and this starts with achieving a healthy<br />
working environment.<br />
A BREATH OF FRESH AIR<br />
Air pollution is one of those issues<br />
where it can be difficult to see the consequences<br />
until it is too late. Air quality<br />
is one of the leading causes of death<br />
worldwide and is linked to conditions<br />
like lung cancer and dementia. In the<br />
UK alone, up to 36,000 deaths are attributed<br />
to long-term exposure to air<br />
pollution each year. [2]<br />
From industrial gases to harmful<br />
particles like black carbon, ammonia,<br />
nitrates, and sulphates, the list of pollutants<br />
that workers may be exposed to<br />
through accidental leaks is extensive.<br />
When such a leak occurs, the ensuing<br />
threat to wellbeing requires immediate<br />
action to prevent catastrophe.<br />
Not only can leaks cause death or<br />
other long-term health conditions,<br />
businesses that are seen to be complacent<br />
in this area risk regulatory penalties<br />
and reputational damage. What's<br />
more, they may end up losing ground<br />
in a competitive market. Investors frequently<br />
use ESG compliance to evaluate<br />
potential investments, and companies<br />
that are seen as uncaring about the<br />
environment or employee health and<br />
wellbeing could become a PR disaster,<br />
and so represent a risky investment.<br />
However, addressing this problem<br />
can be easier said than done. Gas leaks<br />
are by nature accidental, and many of<br />
ESG. Three small<br />
letters that have major<br />
implications for any<br />
business.<br />
these substances are colourless and<br />
odourless, rendering them impossible<br />
to detect without specialist equipment.<br />
Taking pollutants out of the air<br />
therefore requires companies to start<br />
improving their data.<br />
Information is the key to identifying<br />
and addressing problems before they<br />
become a serious threat to employee<br />
health and wellbeing. Early detection<br />
can enable companies to address leaks<br />
before the threat becomes severe,<br />
informing preventative maintenance<br />
strategies, safeguarding employee<br />
health, and protecting a business's<br />
reputation. Actively monitoring for<br />
dangerous gases should therefore be<br />
the first step towards mitigating the risk<br />
that is posed.<br />
Collecting this information requires<br />
companies to have access to intelligent<br />
sensing technology. Without these systems<br />
in place, businesses lack the data<br />
they need to inform their ESG policies,<br />
preventing them from effectively protecting<br />
their people.<br />
The case here is clear: in today's<br />
workplace, gas detection systems are no<br />
longer just 'nice to have'. This technology<br />
is essential for protecting employee<br />
health and should form a core part of<br />
any worthwhile ESG strategy.<br />
MAKING THE RIGHT CHOICE<br />
OF EQUIPMENT<br />
Thankfully, modern sensor technology<br />
means industry professionals have access<br />
to a broader range of gas detection<br />
systems than ever. These technologies,<br />
once limited to specialist applications,<br />
are becoming increasingly affordable<br />
and accessible, and are bringing connected<br />
gas detection to a wide range of<br />
sectors.<br />
This range of choices means that<br />
when selecting a gas detector, organisations<br />
must consider what is right for<br />
their business. Fixed detectors may<br />
be more appropriate in environments<br />
where the threat from gas is serious and<br />
ongoing. In more fast-paced industries,<br />
personal or handheld devices may be<br />
more appropriate, enabling staff to<br />
identify dangerous gas concentrations<br />
during spot checks. However, these<br />
4/<strong>2023</strong> maintworld 19
HSE<br />
The focus<br />
on ESG compliance<br />
is not going away<br />
any time soon.<br />
must be balanced against the fact that<br />
they rely on individuals using them correctly<br />
at the required time, risking introducing<br />
human error into the process.<br />
Another avenue for gas detection<br />
is presented by laser absorption spectroscopy.<br />
Offering high sensitivity, reliability,<br />
and fast response times, laserbased<br />
sensing is becoming increasingly<br />
popular for gas detection and analysis<br />
applications.<br />
This popularity is due to the unique<br />
properties of infrared (IR) light for gas<br />
detection applications. IR wavelengths<br />
are particularly well suited for gas detection<br />
and analysis due to how they<br />
interact with gas samples. Different<br />
gases have different absorption profiles,<br />
meaning that they absorb wavelengths<br />
of light in varying amounts.<br />
This information can be used to create<br />
a unique chemical fingerprint<br />
enabling gases to be identified. Many<br />
gases are particularly absorbent to IR<br />
wavelengths, making it easy to create<br />
detection devices that can identify gas<br />
with a sensitivity that extends to parts<br />
per billion.<br />
In laser absorption spectroscopy,<br />
an IR laser beam is passed through gas<br />
samples before reaching a sensor that<br />
converts the light into electrical signals.<br />
Monitoring the changes between the<br />
laser beam and the light that reaches the<br />
sensor can help to demonstrate the presence<br />
of a particular gas. These systems<br />
are also capable of continually monitoring<br />
for combustible gases and vapours<br />
within the lower explosive limit and provide<br />
alarm indications where necessary.<br />
Investing in systems like these can<br />
provide the pillar that a solid ESG<br />
strategy is built around. By enabling<br />
companies to quickly and accurately<br />
determine where leaks are occurring,<br />
preventative action can be taken that<br />
reduces the risk to staff and the environment<br />
alike.<br />
FOCUS FOR THE FUTURE<br />
The focus on ESG compliance is not<br />
going away any time soon. To remain<br />
competitive, companies must actively<br />
demonstrate their commitment to<br />
wellbeing and the environment, by taking<br />
action to reduce their impact on<br />
the planet and protecting their people.<br />
These ESG programmes must be authentic<br />
and achievable, reflecting companies'<br />
own market positions, and be<br />
supported with a workplace culture that<br />
ensures safety is treated as a priority.<br />
Training and education are essential<br />
in ensuring workers can identify<br />
potential hazards and begin the process<br />
of addressing them. Staff must be<br />
coached and supported by a management<br />
team that genuinely cares about<br />
safety and is committed to ensuring<br />
gas detection data is collected and<br />
acted upon. Crucially, these cultures<br />
must be supported by state-of-the-art<br />
gas detection systems that make data<br />
accessible and enable appropriate precautionary<br />
actions. With a combined<br />
approach to air quality such as this, it<br />
is easier than ever to get on the path to<br />
delivering excellence in ESG.<br />
20 maintworld 4/<strong>2023</strong>
PARTNER ARTICLE<br />
Text: GAUTHIER GHISLAIN, Marketing and Communication Assistant, SDT Ultrasound Solutions<br />
Images: SDT ULTRASOUND SOLUTIONS<br />
Mastering Ultrasound Monitoring with<br />
the CONMONSense Sensor Range:<br />
A Breakthrough in Asset Reliability<br />
For industrial maintenance and condition monitoring practitioners, precision and<br />
reliability are paramount. The SDT CONMONSense range of sensors is a game-changing<br />
solution, opening up a new era of ultrasound monitoring. With advanced technology and<br />
unparalleled features, these sensors provide a consistent, robust, and cost-effective means<br />
of tracking the health of your critical assets.<br />
THE POWER OF ULTRASOUND<br />
IN YOUR HANDS<br />
The CONMONSense sensors are<br />
part of the SDT Ultrasound Solutions<br />
product family, introducing a set of<br />
heterodyned ultrasound sensors with a<br />
unique capability to detect vibroacoustic<br />
phenomena in the air or through<br />
solid mediums. What sets these sensors<br />
apart is their ability to provide direct<br />
audible signals, eliminating the need<br />
for specialized SDT handheld devices<br />
with higher sampling rates. This simplifies<br />
the monitoring process, making<br />
it more efficient and readily implementable<br />
in your organization.<br />
Embedded with analog electronics,<br />
the CONMONSense sensors perform<br />
the heterodyne process within the sensor<br />
itself. This design not only ensures<br />
compatibility with existing acquisition systems<br />
(with standard outputs) but also finetunes<br />
the sensor's response, making it easier<br />
to connect and integrate into your monitoring<br />
infrastructure.<br />
With a typical band-pass frequency range<br />
between 250 Hz to 4kHz, these sensors convert<br />
ultrasound signals into audible form,<br />
optimizing them for the human ear. The<br />
standardized analog outputs are easily interfaced<br />
with a wide range of acquisition systems,<br />
including the SDT VIGILANT, offering<br />
users the flexibility to choose between AC<br />
(signal) and DC (RMS only) modes, tailored<br />
to their specific applications.<br />
VERSATILE DESIGNS FOR DIVERSE<br />
ENVIRONMENTS<br />
The CONMONSense sensors come in contact<br />
and airborne designs, each addressing<br />
specific measurement needs. Their robust<br />
build ensures they can be installed in the<br />
most challenging environments, boosting<br />
22 maintworld 4/<strong>2023</strong>
PARTNER ARTICLE<br />
reliability while reducing downtime and<br />
maintenance costs. The contact sensors<br />
are ideal for continuous monitoring<br />
of critical assets like bearings, valves,<br />
steam traps, and hydraulic systems.<br />
In contrast, the airborne sensors,<br />
with varying IP ratings (IP65 and IP40),<br />
are tailored to accommodate the constraints<br />
of your specific environment,<br />
including inspecting electrical systems.<br />
In other words, they can be employed<br />
for monitoring assets suffering from abnormal<br />
friction, impact, and turbulence,<br />
which are telltale signs of distress or<br />
product quality issues. Whether you're<br />
monitoring the health of valves, steam<br />
traps, hydraulic systems, or even deploying<br />
ultrasound-driven lubrication, these<br />
sensors are your go-to solution.<br />
But the real beauty of CONMON-<br />
Sense sensors is their ability to be permanently<br />
installed on your most critical<br />
assets. For example, you can use CON-<br />
MONSense Airborne sensors to monitor<br />
potential partial discharge in electrical<br />
cabinets, adding a layer of safety and<br />
security to your operations.<br />
EXCEPTIONAL SIGNAL<br />
MEASUREMENT CAPABILITIES<br />
While the CONMONSense sensors<br />
share similarities with the SDT handheld<br />
device-compatible sensors, they<br />
stand out in terms of their signal measurement<br />
capabilities. The embedded<br />
electronics in the CONMONSense range<br />
enable advanced compatibility but have<br />
certain limitations when measuring<br />
weak signals. In cases where you need to<br />
acquire faint signals, sensors dedicated<br />
to SDT handheld instruments might be<br />
preferable, as they offer more capabilities<br />
in measuring weak signals.<br />
DISCOVER THE POWER OF<br />
ANALOG SENSORS<br />
Analog sensors are pivotal in industrial<br />
applications, as they capture and transmit<br />
information in the form of electrical<br />
signals. The CONMONSense sensors<br />
offer a range of popular analog outputs,<br />
including 4-20 mA, 0-10 V, and IEPE.<br />
These outputs are compatible with acquisition<br />
systems equipped with voltage<br />
and/or current channels, making them<br />
highly versatile and cost-effective.<br />
In industrial applications, electrical<br />
noise can be a significant concern. The<br />
4-20 mA output standard, embraced<br />
by the CONMONSense sensors, excels<br />
in such scenarios. Its high immunity to<br />
electrical noise ensures accurate and<br />
consistent readings over long distances,<br />
even in harsh industrial environments<br />
where other signal types may falter.<br />
TWO DISTINCT OUTPUT MODES:<br />
DYNAMIC (AC) AND STATIC (DC)<br />
CONMONSense sensors are designed<br />
to provide both dynamic (AC) and<br />
static (DC) output modes. The dynamic<br />
mode delivers a continuous signal<br />
that oscillates around a bias voltage<br />
(in the case of voltage output) or bias<br />
current (in the case of current output).<br />
This signal, sampled at a minimum<br />
rate of 10 kHz, can be further postprocessed<br />
and analyzed to extract<br />
valuable information about the health<br />
of the asset being monitored. Spectral<br />
transformation techniques such as<br />
FFT or envelope FFT can highlight the<br />
most prominent frequencies and their<br />
amplitudes in a signal. On the other<br />
hand, statistical indicators like RMS<br />
(Root Mean Square), Peak Value, and<br />
Crest Factor are employed for tracking<br />
trends and triggering alarms.<br />
In the static mode (DC output),<br />
CONMONSense sensors provide RMS<br />
values representing ultrasound energy<br />
in the band-pass frequency. While this<br />
mode doesn't offer the same level of<br />
detailed information as the dynamic<br />
mode, it is valuable for tracking changes<br />
and trends over an extended period,<br />
making it an excellent tool for proactive<br />
maintenance.<br />
SELECTING THE RIGHT SENSOR<br />
The choice between dynamic and<br />
static modes largely depends on your<br />
acquisition system's specifications and<br />
capabilities. A minimum sampling rate<br />
of 10 kHz is essential to avoid aliasing<br />
phenomenon and loss of information in<br />
the dynamic mode.<br />
THE BENEFITS OF THE CON-<br />
MONSENSE SENSORS RANGE<br />
They are numerous:<br />
• Ultrasound Measurement Simplified:<br />
Experience the easiest way to measure<br />
ultrasound signals, converted into<br />
audible form, and compatible with<br />
conventional acquisition systems.<br />
• Enhanced Efficiency: Real-time and<br />
accurate data provided by CON-<br />
MONSense sensors allow businesses<br />
to optimize processes, reduce waste,<br />
and enhance productivity.<br />
• Cost Savings: With affordability and<br />
extended compatibility, these sensors<br />
help organizations reduce operational<br />
costs and increase profitability.<br />
• Data-Driven Decision Making: These<br />
sensors provide valuable insights for<br />
informed decision-making and proactive<br />
maintenance strategies.<br />
• Scalability: With a complete range of<br />
options, CONMONSense sensors can<br />
easily integrate into existing systems,<br />
enabling scalable deployment across<br />
different industries and applications.<br />
• Simplified Implementation: Userfriendly<br />
interfaces and comprehensive<br />
documentation make installation<br />
and configuration a breeze, giving a<br />
"sixth sense" to your installations.<br />
In conclusion, SDT CONMONSense<br />
sensors are a technological marvel in the<br />
world of condition monitoring. Their advanced<br />
features, versatile design, and easy<br />
integration with existing systems make<br />
them a vital asset for organizations aiming<br />
to improve asset performance, reduce<br />
maintenance costs, and enhance reliability.<br />
The precision and consistency offered<br />
by these sensors empower you to take<br />
control of your assets' health and ensure<br />
the continued success of your operations.<br />
Download the CONMONSense Brochure<br />
by scanning the QR code below.<br />
4/<strong>2023</strong> maintworld 23
EQUIPMENT MAINTENANCE<br />
Understanding<br />
casing distortion<br />
One of the most critical issues<br />
affecting rotating machines is<br />
casing distortion. This article<br />
delves into what casing distortion<br />
means, how it impacts machine<br />
performance, and why it is<br />
essential to address it in order to<br />
achieve reliable operation.<br />
Text: ROMAN MEGELA, Senior Reliability Engineer, Easy-Laser AB<br />
Images: EASY-LASER AB<br />
Casing distortion is not only one<br />
of the biggest problems for rotating<br />
machinery, but is also a very<br />
common one. But what does it<br />
actually mean? To explain it, we<br />
can use the famous analogy of a rocking table<br />
in the restaurant. This is a situation everybody<br />
can relate to. Due to an uneven floor or<br />
bad construction of the table, there is space<br />
24 maintworld 4/<strong>2023</strong>
EQUIPMENT MAINTENANCE<br />
When it comes<br />
to rotating equipment,<br />
precision is a necessity.<br />
under one leg which makes the whole table<br />
rock from one side to another. It is a problem<br />
that is easy to solve, just use a few napkins<br />
and the table will stay still.<br />
The same happens when placing rotating<br />
machinery on a foundation that is not flat.<br />
Most rotating equipment is designed to be<br />
installed on a flat surface. At the manufacturer<br />
site, all machine feet are milled to be<br />
in a perfectly flat plane. When placing the<br />
equipment on a non-flat foundation or uneven<br />
sole plates, it will reproduce that rocking<br />
situation we just mentioned. That is what we<br />
call “soft foot”.<br />
operate under designed loads. When casing<br />
distortion occurs, the shafts are put under<br />
strain and their positions change. That will<br />
affect the bearings by changing their designed<br />
load, and the rolling elements inside the<br />
bearing will move from designated race way.<br />
This is something that will seriously affect<br />
lubrication. The rolling elements of the bearing<br />
will push away the lubrication since there<br />
will be no space for it. Heat will build up and<br />
produce more thermal expansion of internal<br />
components, which will gradually reduce<br />
their gap until, inevitably, failure occurs.<br />
(Changing the designed loads in the bearings<br />
will reduce bearing life by as much as 50%.)<br />
Ensuring proper installation can make the<br />
difference between smooth operation and<br />
unexpected failure. As we have seen, all it<br />
takes is a minor gap to throw your machinery<br />
off balance. When it comes to rotating equipment,<br />
precision is a necessity.<br />
TINY CLEARANCES, BIG IMPACT<br />
Rotating equipment consists of many parts:<br />
rotors, shafts, bearings, mechanical seals,<br />
impellers in compression chambers, just<br />
to mention a few. And these all have very<br />
small internal clearances. If a machine is<br />
bolted down on an uneven surface, the forces<br />
applied on the machine feet will change the<br />
casing geometry. As a result, these clearances<br />
will quickly change.<br />
To fix a soft foot condition, is necessary<br />
to compensate everything above 0.05 mm.<br />
That is not much, if you consider the fact<br />
that the thickness of a human hair is between<br />
0.06 mm to 0.08 mm! This is how little it<br />
takes to convert our new or newly overhauled<br />
machine into a victim of casing distortion.<br />
PIPE CONNECTION ISSUES<br />
Another possible cause for casing distortion<br />
is pipe strain. Pipe strain can occur when the<br />
pipes are wrongly fabricated, and the connection<br />
flanges are not aligned. It can also<br />
be that the pipe supports are too high or too<br />
low, which creates large gaps between the<br />
connections. A common solution for this is to<br />
force them together, which will result in what<br />
we call nozzle load. This too will put a lot of<br />
stress on the machine casing. (The OEM will<br />
specify the allowed nozzle load on the equipment.)<br />
THE LONG-TERM CONSEQUENCES<br />
So what kinds of problems can you run into if<br />
casing distortion occurs? Previously we mentioned<br />
the internal parts of rotating machinery,<br />
such as shafts. How do they get affected?<br />
Well, shafts have mounted bearings to<br />
carry the rotating motion, and these bearings<br />
Forces occur at the machine<br />
inlet and discharge flanges.<br />
4/<strong>2023</strong> maintworld 25
CONSTRUCTION INDUSTRY<br />
Text: CHARLIE GREEN, Senior Research Analyst at Comparesoft Images: STOCKPHOTO<br />
From Breakdowns to Breakthroughs:<br />
THE TRANSFORMATIVE IMPACT OF<br />
PREVENTATIVE MAINTENANCE IN<br />
CONSTRUCTION<br />
The construction industry is the backbone of infrastructural development, and the machinery and<br />
equipment used in this sector play a pivotal role in ensuring projects are completed efficiently<br />
and on time. However, one of the most significant pain points in the construction industry is the<br />
frequent breakdown and inefficiency of equipment. These breakdowns not only lead to project<br />
delays but also escalate costs. Enter preventative maintenance – a proactive approach that<br />
addresses these challenges head-on, ensuring the longevity and efficiency of machinery.<br />
WHAT IS PREVENTATIVE<br />
MAINTENANCE IN<br />
CONSTRUCTION?<br />
In the intricate tapestry of the construction<br />
industry, preventative maintenance<br />
stands out as a pivotal practice,<br />
underpinning the operational longevity<br />
and efficiency of critical machinery. It<br />
encompasses a systematic regimen of<br />
inspection, detection, rectification, and<br />
proactive measures to stave off potential<br />
equipment failures before they burgeon<br />
into tangible issues. This methodology<br />
transcends the rudimentary act<br />
of merely repairing a malfunctioning<br />
machine; it delves into a rigorous, routine-based<br />
examination and servicing<br />
paradigm, ensuring machinery remains<br />
in pristine working condition, thereby<br />
preventing unforeseen breakdowns.<br />
Take, for example, a towering crane,<br />
an indispensable asset in a construction<br />
site's arsenal. Rather than adopting a<br />
reactive stance and awaiting an inevitable<br />
malfunction, preventative maintenance<br />
adopts a proactive approach.<br />
This involves meticulous scrutiny of its<br />
The construction<br />
industry is the backbone<br />
of infrastructural<br />
development.<br />
26 maintworld 4/<strong>2023</strong>
CONSTRUCTION INDUSTRY<br />
these benefits<br />
is the consistent<br />
operational<br />
efficiency that<br />
well-maintained<br />
equipment guarantees.<br />
The Construction<br />
Industry<br />
Institute<br />
underscores this,<br />
highlighting that<br />
machinery under<br />
a rigorous preventative maintenance<br />
regimen retains a vast majority of its<br />
operational prowess throughout its lifecycle.<br />
This directly translates to projects<br />
adhering to their timelines, fortifying a<br />
company's reputation for reliability and<br />
punctuality.<br />
Additionally, the stability offered<br />
by equipment longevity, courtesy of<br />
preventative maintenance, means that<br />
operators gain in-depth familiarity<br />
with their machinery. This continuity<br />
ensures that operators master their<br />
equipment, leading to optimized perintricate<br />
components, including cables,<br />
pulleys, and hydraulic systems.<br />
Activities such as lubrication, calibration<br />
of loose parts, replacement of<br />
components exhibiting wear and tear,<br />
and periodic software updates (if the<br />
machinery is digitally integrated) are<br />
integral to this regimen. According to<br />
a study by the Construction Equipment<br />
Management Program, regular<br />
preventative maintenance can enhance<br />
equipment life by up to 60%. Such a<br />
methodical and sophisticated approach<br />
not only ensures that the crane operates<br />
at its zenith of capacity but also significantly<br />
diminishes the probability of<br />
unanticipated operational downtimes,<br />
which can have cascading repercussions<br />
on project timelines and costs.<br />
lays associated with equipment replacement.<br />
Research from the Construction<br />
Industry Institute underscores this,<br />
suggesting that machinery under a preventative<br />
maintenance umbrella can see<br />
its operational life extended by 20-40%.<br />
This elongation represents not just a<br />
delay in replacement costs but also<br />
ensures that the equipment operates<br />
at peak efficiency, leading to reduced<br />
operational costs.<br />
In summation, the financial wisdom<br />
of preventative maintenance in the<br />
construction sector is evident. While<br />
there's an upfront cost, the long-term<br />
savings, both direct and indirect, make<br />
it an indispensable strategy for firms<br />
aiming for fiscal prudence and project<br />
success.<br />
THE BENEFITS OF USING<br />
PREVENTATIVE MAINTENANCE<br />
IN CONSTRUCTION<br />
1<br />
Significant Cost Savings<br />
in Many Areas of The<br />
Business<br />
In the intricate world of construction,<br />
where financial margins are<br />
often razor-thin, the role of preventative<br />
maintenance stands out as a beacon of<br />
fiscal responsibility. At first glance, the<br />
outlay for regular equipment upkeep<br />
might appear as an added expenditure.<br />
However, delving<br />
deeper into the<br />
financial matrix<br />
reveals a different<br />
narrative.<br />
Unplanned<br />
equipment breakdowns,<br />
often<br />
resulting from<br />
neglect, can lead to<br />
exorbitant repair<br />
costs. According<br />
to the National<br />
Research Council, the financial implications<br />
of such reactive maintenance<br />
can be up to nine times more than a<br />
well-planned preventative approach.<br />
Beyond the direct repair expenses, the<br />
ripple effects of these breakdowns, such<br />
as project delays and potential contractual<br />
penalties, further strain project<br />
budgets.<br />
Moreover, the longevity of machinery<br />
is intrinsically tied to its maintenance<br />
regimen. By investing in preventative<br />
care, construction firms can<br />
significantly defer the hefty capital out-<br />
Preventative<br />
maintenance stands out<br />
as a pivotal practice,<br />
underpinning the<br />
operational longevity<br />
and efficiency of critical<br />
machinery.<br />
2<br />
The Role of Preventative<br />
Maintenance in Ensuring<br />
Equipment Longevity<br />
in Construction<br />
In the construction realm, equipment<br />
longevity is not just a financial asset<br />
but a cornerstone for seamless operations<br />
and sustained business growth.<br />
At the heart of this longevity lies preventative<br />
maintenance—a proactive<br />
approach that ensures machinery not<br />
only endures but operates at its zenith,<br />
bringing manifold strategic benefits to<br />
construction entities.<br />
Central to<br />
4/<strong>2023</strong> maintworld 27
CONSTRUCTION INDUSTRY<br />
formance and minimizing errors—a<br />
crucial edge in an industry where precision<br />
is non-negotiable.<br />
Lastly, preventative maintenance<br />
not only ensures the equipment's operational<br />
longevity but also preserves<br />
its intrinsic value. When the juncture<br />
arises to upgrade or divest, equipment<br />
that has been consistently maintained<br />
through preventative measures commands<br />
a premium in the secondary<br />
market, testifying to the enduring<br />
value of preventative care in the construction<br />
sector.<br />
3<br />
Enhanced Safety as<br />
a Result of Well-Maintained<br />
Assets<br />
In the construction sector, where the<br />
interplay of machinery and manpower<br />
is constant, safety remains paramount.<br />
Preventative maintenance emerges as a<br />
critical strategy to address the inherent<br />
Equipment<br />
longevity is not just<br />
a financial asset but<br />
a cornerstone for<br />
seamless operations<br />
and sustained<br />
business growth.<br />
risks, ensuring that equipment functions<br />
optimally and safely, thereby safeguarding<br />
the workforce.<br />
The Occupational Safety and Health<br />
Administration (OSHA) has highlighted<br />
equipment-related incidents as a significant<br />
contributor to on-site injuries.<br />
However, the proactive approach of<br />
preventative maintenance can mitigate<br />
these risks. A study by the National<br />
Safety Council underscores this, revealing<br />
that up to 70% of machinery-related<br />
accidents could be averted through<br />
timely inspections and consistent<br />
maintenance. This proactive approach<br />
ensures that potential equipment malfunctions<br />
are identified and rectified<br />
before they escalate into safety hazards.<br />
Moreover, the Bureau of Labour<br />
Statistics notes that the construction<br />
domain experiences a higher rate of<br />
fatal work injuries than many other sectors.<br />
Equipment malfunctions, unfortunately,<br />
play a pivotal role in these<br />
statistics. By integrating preventative<br />
maintenance into their operational<br />
protocols, construction firms can substantially<br />
diminish these incidents. This<br />
not only protects the workforce but also<br />
reinforces the company's commitment<br />
to safety.<br />
By proactively ensuring the health<br />
and efficiency of equipment, construction<br />
companies can create a safer envi-<br />
28 maintworld 4/<strong>2023</strong>
CONSTRUCTION INDUSTRY<br />
ronment for their employees, reduce<br />
potential liabilities, and deliver projects<br />
that stand as testaments to both quality<br />
and safety.<br />
4<br />
Environmental Benefits<br />
The construction industry,<br />
with its heavy reliance on<br />
machinery and equipment,<br />
has a significant environmental footprint.<br />
However, preventative maintenance<br />
emerges as a potent tool in mitigating<br />
these environmental impacts,<br />
offering benefits that extend beyond<br />
mere operational efficiency.<br />
• Reduced Fuel Consumption:<br />
Machinery that undergoes regular<br />
preventative maintenance operates<br />
at its peak efficiency. According to<br />
the U.S. Department of Energy, wellmaintained<br />
equipment can reduce<br />
fuel consumption by up to 10-15%.<br />
This not only translates to cost savings<br />
but also means fewer fossil fuels<br />
are burned, leading to a reduction in<br />
greenhouse gas emissions.<br />
• Decreased Emissions: Emissions<br />
from construction equipment,<br />
particularly older models, can be<br />
a significant source of air pollution.<br />
The Environmental Protection<br />
Agency (EPA) notes that preventative<br />
maintenance, including timely<br />
oil changes, filter replacements, and<br />
engine tune-ups, can reduce emissions<br />
by up to 40%. This plays a<br />
crucial role in improving air quality,<br />
especially in urban areas where construction<br />
activities are frequent.<br />
• Waste Reduction: Preventative<br />
maintenance also means fewer parts<br />
replacements and less waste. A<br />
study by the Construction Industry<br />
Research Board found that regular<br />
equipment checks can reduce waste<br />
from worn-out parts by up to 50%.<br />
This not only conserves resources<br />
but also reduces the burden on landfills.<br />
• Resource Conservation: Efficient<br />
machinery requires fewer resources,<br />
from lubricants to replacement<br />
parts. The International Journal of<br />
Construction Management highlights<br />
that preventative maintenance<br />
can lead to a 20% reduction in the<br />
use of ancillary materials, further<br />
diminishing the industry's environmental<br />
impact.<br />
• Noise Pollution: Well-maintained<br />
equipment tends to operate more<br />
quietly, reducing noise pollution—a<br />
significant concern in urban construction<br />
sites. The World Health<br />
Organization has identified noise<br />
pollution as a major environmental<br />
health risk, and by ensuring equipment<br />
operates smoothly through<br />
preventative maintenance, construction<br />
companies can contribute to<br />
quieter, more liveable urban environments.<br />
PREVENTATIVE MAINTENANCE<br />
AS PART OF A COMPREHENSIVE<br />
MAINTENANCE STRATEGY<br />
While preventative maintenance offers<br />
numerous benefits, it should not be<br />
viewed in isolation. Instead, it should<br />
be a part of a comprehensive maintenance<br />
strategy that also includes<br />
corrective maintenance (fixing things<br />
when they break down) and predictive<br />
maintenance (using data analytics to<br />
predict when a machine might break<br />
down). By integrating preventative<br />
maintenance into a broader strategy,<br />
construction companies can ensure that<br />
their equipment is always in the best<br />
possible condition, leading to efficient<br />
operations and successful project completions.<br />
IN CONCLUSION<br />
The integration of preventative maintenance<br />
into a holistic maintenance strategy,<br />
encompassing both corrective and<br />
predictive maintenance, is emblematic<br />
of a forward-thinking, responsible, and<br />
sustainable approach to construction.<br />
Such a comprehensive strategy not only<br />
ensures the optimal performance of<br />
equipment but also safeguards the wellbeing<br />
of workers, the environment, and<br />
the broader community.<br />
In the ever evolving and competitive<br />
arena of construction, companies that<br />
prioritize and invest in preventative<br />
maintenance position themselves at the<br />
forefront, setting industry standards<br />
and paving the way for a safer, more<br />
efficient, and environmentally conscious<br />
future. In essence, preventative maintenance<br />
is not merely an operational<br />
choice but a defining pillar for construction<br />
entities aspiring for excellence, sustainability,<br />
and enduring success.<br />
4/<strong>2023</strong> maintworld 29
EQUIPMENT MAINTENANCE<br />
Text: ALGHAITHAN, ABDULLAH K, Saudi Aramco Mobility and Logistics Services Department<br />
Images: SAUDI ARAMCO MOBILITY AND LOGISTICS SERVICES DEPARTMENT<br />
The Impact of Corrosion<br />
on Heavy Equipment<br />
It is self-evident that cranes<br />
and heavy equipment<br />
are indispensable in<br />
various industries such<br />
as construction, mining,<br />
rigging, and notably in<br />
hydrocarbon sectors.<br />
Consequently, property<br />
owners and contractors are<br />
required to adhere to high<br />
standards of maintenance,<br />
in accordance with OSHA<br />
guidelines, to ensure a safe<br />
working environment for all<br />
employees.<br />
Leading maintenance operations<br />
on a financial scale<br />
poses a potential challenge for<br />
any maintenance organization<br />
managing their assets,<br />
which could be valued at millions, if not<br />
billions, of dollars. Corrosion, defined<br />
as the gradual deterioration of metal<br />
components due to environmental factors<br />
like high temperature, humidity,<br />
and chemical exposure, presents a significant<br />
challenge to cranes and heavy<br />
industrial equipment. This corrosion<br />
severely compromises the functionality<br />
of cranes and heavy industrial equipment,<br />
resulting in substantial economic<br />
losses, environmental pollution, and<br />
Data preprocessing<br />
Failure<br />
Prediction<br />
Industrial<br />
Sensors<br />
Data<br />
De-noising<br />
Training<br />
Anomaly<br />
Detection<br />
Acquisition<br />
Examples of Economic Loss by Corrosion.<br />
Dimensionality<br />
Reduction<br />
(optional)<br />
Remaining<br />
Useful Life<br />
30 maintworld 4/<strong>2023</strong>
EQUIPMENT MAINTENANCE<br />
Corrosion control aims<br />
at ensuring the efficient<br />
operation and upkeep of<br />
physical assets.<br />
even loss of life. A comprehensive corrosion<br />
control policy is crucial to attain<br />
and sustain the requisite levels of quality,<br />
safety, and reliability within the<br />
maintenance organization.<br />
Effects of corrosion on Cranes<br />
and Heavy Equipment:<br />
The neglect of corrosion control measures<br />
in industrial settings has led to tragic<br />
outcomes, including loss of life, injuries,<br />
significant economic losses, and severe<br />
environmental damage. Corrosion has<br />
been linked to numerous injuries and fatalities.<br />
For instance, on March 15, 2009, a<br />
50-ton hydraulic crane accident at a construction<br />
site in New York City resulted<br />
in the death of seven individuals. The hydraulic<br />
crane, while hoisting a heavy load,<br />
suddenly collapsed.<br />
Investigations revealed that the<br />
crane's right lifting cylinder had been<br />
inadequately maintained, and corrosion<br />
had weakened the lifting cylinders. Various<br />
national studies conducted in several<br />
countries over the past fifty years<br />
have consistently estimated the costs<br />
of corrosion to be around 3% to 4% of<br />
each nation's Gross Domestic Product<br />
(GDP). Considering a global GDP figure<br />
of 3.4% (as of 2013), the estimated<br />
worldwide cost of corrosion is a staggering<br />
US$2.5 trillion. Another study, conducted<br />
from 1949 to 1994, summarized<br />
the economic losses resulting from corrosion<br />
in the subsequent table.<br />
Maintenance Solutions for<br />
Corrosion Control:<br />
Maintenance solutions aimed at controlling<br />
corrosion are a crucial aspect of<br />
industrial operations, ensuring the longevity,<br />
safety, reliability, and efficiency<br />
of heavy equipment and infrastructure.<br />
By adopting effective corrosion<br />
control practices, it is estimated that<br />
significant savings, ranging from 15%<br />
to 35% of corrosion-related expenses,<br />
could be realized. This translates to<br />
annual global savings of approximately<br />
US$375 to $875 billion. These solutions<br />
encompass a variety of strategies, from<br />
protective coatings to predictive maintenance,<br />
all aimed at mitigating the<br />
destructive effects of corrosion. Implementing<br />
effective maintenance solutions<br />
not only protects valuable assets<br />
but also minimizes economic losses,<br />
environmental impacts, and potential<br />
safety hazards. Below are the best industry<br />
practices for maintenance solutions<br />
against corrosion.<br />
INTERNATIONAL STANDARDS<br />
International standards are instrumental<br />
in guiding corrosion control<br />
and maintenance solutions for heavy<br />
industrial equipment, providing a<br />
universally recognized framework<br />
that emphasizes consistency, quality,<br />
and safety in practice. Below are<br />
4/<strong>2023</strong> maintworld 31
EQUIPMENT MAINTENANCE<br />
Corrosion specific Management system elements<br />
Policy<br />
Strategy<br />
Objectives<br />
Enablers, controls<br />
and measures<br />
Plans<br />
Procedures and working practices<br />
• Organizations<br />
• Contractors<br />
• Resources<br />
• Communications<br />
• Risk management<br />
• Management of change<br />
Corrosion Management System Pyramid.<br />
• Training & competency<br />
• Incident investigation<br />
• Documentation<br />
• Assurance<br />
• Management review<br />
• Continuous improvement<br />
• Based on corrosion type, life cyde, return<br />
on investment (ROI), asset criticality,<br />
regulations, and mitigation options<br />
• Implementation approach<br />
• Verification / inspection<br />
• Mitigation procedures<br />
some of the standards pertinent to<br />
corrosion control for cranes and industrial<br />
equipment:<br />
1. **ISO 12944**: This standard<br />
outlines guidelines for protective<br />
coatings, covering aspects such as<br />
types of coatings, application methodologies,<br />
and inspection criteria.<br />
By adhering to these standards, a<br />
standardized approach to combating<br />
corrosion across various industrial<br />
settings, including those involving<br />
cranes and industrial equipment, is<br />
ensured.<br />
2. **ISO 8502**: This standard<br />
addresses the preparation of steel<br />
substrates before the application<br />
of paints and related products. It<br />
includes tests for assessing surface<br />
cleanliness and evaluating dust on<br />
steel surfaces prepared for painting.<br />
This standard is applicable to cranes<br />
and heavy equipment constructed<br />
with steel structures.<br />
Advanced Maintenance<br />
Methods and Technologies<br />
Beyond adherence to international<br />
standards, numerous advanced methods<br />
and innovative approaches exist<br />
for maintenance solutions in corrosion<br />
control. When integrated into<br />
corrosion control practices, these<br />
advanced methods and technologies<br />
enhance corrosion mitigation.<br />
Predictive maintenance, facilitated<br />
by condition-based monitoring,<br />
32 maintworld 4/<strong>2023</strong>
EQUIPMENT MAINTENANCE<br />
leverages the power of artificial intelligence<br />
(AI) and predictive analytics<br />
to forecast corrosion rates and refine<br />
maintenance schedules. Through the<br />
seamless integration of a multitude<br />
of sensors and cutting-edge technologies,<br />
condition-based monitoring<br />
programs continuously assess the<br />
health of equipment, collect and process<br />
data, and accurately detect any<br />
anomalies. Advanced cathodic protection<br />
systems, such as Impressed<br />
Current Cathodic Protection (ICCP),<br />
offer more precise control over corrosion<br />
inhibition. This proactive<br />
strategy not only minimizes downtime<br />
but also optimizes maintenance<br />
efforts, ensuring that resources are<br />
deployed precisely when needed to<br />
combat corrosion effectively.<br />
Furthermore, a Corrosion Management<br />
System (CMS) should be<br />
incorporated into the corporate management<br />
system. Effective integra-<br />
tion of corrosion management within<br />
an organization entails more than<br />
just technology; it necessitates the<br />
incorporation of corrosion decisions<br />
and practices within the organization’s<br />
management system. This<br />
integration extends from specific<br />
corrosion procedures to overarching<br />
organizational policies and strategies,<br />
encompassing all levels of the<br />
management system.<br />
To maximize the benefits of corrosion<br />
management, it's crucial to articulate<br />
traditional corrosion practices<br />
within the language and context of<br />
organizational policies, ensuring commitment<br />
to the corrosion management<br />
system across all organizational levels.<br />
This approach aids in managing corrosion<br />
processes throughout all stages<br />
of asset integrity management, as depicted<br />
in the subsequent figure.<br />
Providing methods and solutions<br />
on how to measure and improve the<br />
quality of maintenance is a key consideration<br />
for any maintenance organization.<br />
While corrosion control presents<br />
significant challenges and risks, proper<br />
maintenance processes and procedures<br />
can mitigate the detrimental effects.<br />
Corrosion control aims at ensuring<br />
the efficient operation and upkeep<br />
of physical assets, be it a maintenance<br />
facility, a commercial building, or a<br />
fleet of vehicles. By adhering to maintenance<br />
guidelines and referencing<br />
international standards, any maintenance<br />
organization can enhance the<br />
safety, reliability, and longevity of their<br />
cranes and heavy equipment.<br />
4/<strong>2023</strong> maintworld 33
BIOCATALYSIS<br />
Fig 1. Our modern life is increasingly characterized by a more or<br />
less organised effort of human societies to achieve balance with the<br />
global ecosystem and provide reasonable living standards for all.<br />
With the means and tools of biocatalysis, these goals are achievable<br />
without a zero-sum game.<br />
34 maintworld 4/<strong>2023</strong>
BIOCATALYSIS<br />
What biocatalysis<br />
has to offer for<br />
green industries<br />
and city planning?<br />
In our world, anything nearly perfect tends to be stamped as fantasy.<br />
Does this kind of statement imply the character of human endeavour,<br />
its very essence? On the contrary, nature represents purity and clarity.<br />
Text and images: ELIAS HAKALEHTO AND TARMO HUMPPI<br />
ABOUT THE AUTHORS:<br />
• Elias Hakalehto, PhD, Adjunct<br />
Professor in the Universities of<br />
Helsinki and Eastern Finland,<br />
Microbiologist and Biotechnologist,<br />
CEO of Finnoflag Oy, Vice President<br />
of the International Society of<br />
Environmental Indicators.<br />
• Tarmo Humppi, PhD, Principal<br />
Scientist, Chemist, Retired from the<br />
Finnish Defence Research Agency.<br />
All of us have been staring at<br />
the starry night. The organisation<br />
of the macrocosm can<br />
equally well be seen in the<br />
microscopic world. There,<br />
the microorganisms make the wheels of<br />
the microcosmic universe turn around.<br />
Together with plants and animals, they<br />
comprise the constituents of the biosphere.<br />
Why, then, do human industries get contented<br />
with anything less? Microbes and<br />
their enzymes could make the wheels turn<br />
around in future industries.<br />
Recently, it has become increasingly<br />
evident that heavy and fast industrialization<br />
not only elevated our standard of living but<br />
has also led us to the brink of abysmal ecocatastrophes.<br />
Fortunately, we have the vast<br />
resources of molecular universes in our use<br />
to avoid their aftermath or repair the damages.<br />
Sadly, we have wasted those resources<br />
for a long time.<br />
"There is plenty of room at the bottom".<br />
The saying of physicist Richard<br />
Feynman in 1959 gives us many leads.<br />
It has actualized in the IT revolution of<br />
our times. This has enabled giant steps<br />
in industrial control and maintenance<br />
of machinery, steering and adjustments<br />
of processes, flow of information, and,<br />
last but not least, ecological efficiency.<br />
We have eventually come closer to<br />
the ways of functioning of biological<br />
entities, ecosystems, and the cells and<br />
Fig 2. Food production around and in the cities can happen in a cleaned-up environment of biocatalytically furnished soil, water and air.<br />
Bioprocesses are developed for the removal of recalcitrant substances, pollutants and eutrophication. The past burdens can be converted<br />
into novel products by biocatalysis.<br />
4/<strong>2023</strong> maintworld 35
BIOCATALYSIS<br />
Fig 3. Biohydrogen is an example of the immense metabolic capabilities of micro-organisms, which could be utilized, besides energy<br />
production, for the future traffic solutions, as well as for the manufacturing of complementary bulk or commodity chemicals for the<br />
petrochemical and other industries as well as for precious specialty chemicals, not forgetting the organic fertilizers. The latter are<br />
increasingly available and effective facilitators of food and feed production, horticulture, hydroponics and forestry.<br />
microbes in particular. The miniaturisation<br />
of technical solutions has brought<br />
us nearer the scale of microbes, molecules,<br />
atoms and their structures, which,<br />
indeed, have a lot of space for variation<br />
and production.<br />
POWER OF BIOCATALYSIS<br />
Biocatalysis in Nature could be described<br />
as allowing low reaction energies<br />
in the microscale. This is the secret<br />
of all the incredible effectiveness of<br />
organismal life around us. This built-in<br />
energy network of living cells and their<br />
enzymes facilitates our lives and that<br />
of plants, animals and microorganisms.<br />
Why could we not exploit it in our industries<br />
more intensively than so far?<br />
The low-energy route could decisively<br />
help us avoid the often predicted loss<br />
of natural resources. It could also lower<br />
the emissions of manufacturing, agriculture,<br />
energy production and all sectors<br />
of our economy (Fig. 1).<br />
Moreover, as integrated with human<br />
or AI intelligence, this nature-born enormous<br />
efficiency could ultimately boost<br />
future endeavours for investigating, innovating<br />
and developing novel disruptive<br />
technologies for our use. This technology<br />
platform is by far more sustainable than<br />
any other imaginable solution. Using<br />
it effectively, we could also harness the<br />
biological multitudes and reactions for<br />
cleaning up our polluted and intoxicated<br />
planet Earth.<br />
DREAMS AND REALITY<br />
OF THE FUTURE INDUSTRIAL<br />
BIO-REVOLUTION<br />
In natural ecosystems, energy flows, and<br />
materials circulate. This could also be<br />
achievable in the industrial ecosystems. Ten<br />
years ago, we, Member of the Swedish Royal<br />
Academy of Engineering and Chairman of<br />
the Scandinavian Simulation and Modelling<br />
Society, Professor Erik Dahlquist,<br />
and Professor Semida Silveira, the current<br />
Professor in Practise in the Systems<br />
Engineering Program at Cornell University,<br />
Ithaca, New York, and one of the authors of<br />
this article, microbiologist Elias Hakalehto,<br />
published a calculation that the annual<br />
biomass increase could provide twice the<br />
energies needed globally. Also, the various<br />
petrochemical goods could be produced in<br />
complementary biorefineries based on organic<br />
sources. A citation of our chapter<br />
"Concluding remarks and perspectives on<br />
the future of energy systems using biomass"<br />
in the book edited by E. Dahlquist, "Biomass<br />
as Energy Source. Resources, Systems and<br />
Applications", published in 2013 by CRC<br />
Press, Taylor & Francis Group, Boca Raton:<br />
"In the chapter on global biomass resources,<br />
we have seen that biomass can<br />
fulfil most of the energy resources as well<br />
as for replacement of fossil fuels for the<br />
production of plastics and similar. What<br />
we still have to do is to use all materials<br />
and resources in an efficient system, where<br />
the same fibres, for instance, are used<br />
many times for different purposes before<br />
they eventually are combusted, instead of<br />
combusting stem wood directly. What is<br />
considered waste should instead be seen as<br />
a valuable resource."<br />
This valuable principle and method for<br />
global survival have been applied in practical<br />
experiments of the ABOWE European<br />
Union Baltic Sea Region biorefinery project,<br />
ending in 2014. In the "Zero Waste from Zero<br />
Fiber '' project in Tampere, funded by the<br />
Finnish Government in 2018-19, the ecosystem<br />
engineering of massive past industrial<br />
lake bottom sediments into valuable chemicals,<br />
energy gases and organic fertilisers was<br />
accomplished in an economically feasible<br />
way. These projects are referred to in the<br />
<strong>Maintworld</strong> magazine 3/<strong>2023</strong> and before, as<br />
well as in the recent lectures at the European<br />
Geosciences Union (EGU) general assembly<br />
in 2022 and <strong>2023</strong>. Indeed, we could see the<br />
shoots of true ecodevelopment emerging and<br />
potentially growing into "sheaves in the field<br />
of progress", as the statement made a century<br />
ago by the first Finnish president,<br />
K.J. Ståhlberg, could be modified.<br />
We need today the political will as it was<br />
summed up in our 2013 book chapter (see<br />
above): "Only facts are not enough. Good examples<br />
are also significant, and these have<br />
to be presented in a convincing way. Then<br />
both regulatory frameworks and interest<br />
from investors could be achieved. Thereby<br />
system development can take place." - Furthermore,<br />
a citation from the same source:<br />
"In fact, it could be much better to treat<br />
and recycle the wastes in a sustainable way<br />
36 maintworld 4/<strong>2023</strong>
BIOCATALYSIS<br />
including the microbiological and biotechnological<br />
solutions, than by just discharging<br />
the organic loads into the water and maritime<br />
ecosystems, or to the atmosphere."<br />
This principle could be equally applicable<br />
in the "cradle of Finnish industries" in Tampere,<br />
as well as globally in any place where<br />
forest or other biomass industries will be<br />
developed into true circulation economics<br />
(see above).<br />
BIOHYDROGEN SOURCE<br />
In 1874, French writer Jules Verne predicted<br />
in his book "Mysterious Island" the<br />
future we aim for and head toward. This<br />
old reasoning and imagination of one of the<br />
most eminent early science fiction authors<br />
illustrates the roots of an essential and potential<br />
avenue for future development: biohydrogen.<br />
Its implementation could now<br />
lead to sustainable planning of cities, their<br />
food production and traffic, and societies in<br />
general too. See Fig. 2.<br />
Quotations of the "Mysterious Island"<br />
(1874) by Jules Verne:<br />
• "...I believe that water will one day be<br />
employed as fuel, that hydrogen and<br />
oxygen which constitute it, used singly<br />
or together, will furnish an inexhaustible<br />
source of heat and light of an<br />
intensity of which coal is not capable."<br />
• "Some day the coalrooms of steamers<br />
and the tenders of locomotives will,<br />
instead of coal, be stored with these<br />
condensed gases, which will burn in<br />
the furnaces with enormous calorific<br />
power..."<br />
• "...there will be no want of either light<br />
or heat as long as the productions of<br />
the vegetable, mineral or animal kingdoms<br />
do not fail us. I believe, then,<br />
that when the deposits of coal are<br />
exhausted, we shall heat and warm<br />
ourselves with water. Water will be<br />
the coal of the future."<br />
In the previous <strong>Maintworld</strong> article (in volume<br />
3/<strong>2023</strong>), Elias Hakalehto took up the<br />
potential of biologically produced hydrogen,<br />
or biohydrogen, in solving global and local<br />
energy needs. It could be made using anaerobic<br />
bacteria or other microbes to split the<br />
water in renewable energy sources into Hydrogen<br />
and Oxygen (Fig. 3). These microbes<br />
could be photosynthetic ones, such as algae<br />
or cyanobacteria, or the fermentative anaerobic<br />
bacteria using their enzymes to split<br />
the water molecule. Then, the various steps<br />
for utilising the bio-catalytically liberated<br />
energies could also include their capture,<br />
purification, storage and use in the fuel cells<br />
or elsewhere. Such motors could power future<br />
flying vehicles, for instance.<br />
Biohydrogen could be converted and<br />
reacted into other gaseous fuels, such as<br />
methanol or ammonia. Besides in the aviation<br />
industries, they could be applied for<br />
maritime, industrial fuels, etc. Hydrogen<br />
gas can be coupled with biogas methane,<br />
thus forming hythane. If Carbon dioxide is<br />
simultaneously emitted in this reaction, it<br />
could be separated from biohydrogen and<br />
used for greenhouses, where it is a precious<br />
raw material for plant growth.<br />
RETURN TO THE ROOTS OF<br />
INDUSTRIAL BIOTECHNOLOGY<br />
In 1904, one of the founders of the industrial<br />
fermentation, Chaim Weizmann,<br />
became a lecturer at the University of<br />
Manchester. His method for the microbiological<br />
production of acetone was piloted<br />
in London in 1915. He used Clostridium<br />
acetobutylicum (the Weizmann organism)<br />
to produce acetone, butanol, ethanol<br />
and hydrogen gas (Fig. 4). Later on, in<br />
1939, in Helsinki, a Dutch microbiologist,<br />
A.J. Kluyver took for the first time up the<br />
potential of microorganisms to assimilate<br />
Carbon dioxide. - What an opportunity<br />
for climate-friendly bio-based production<br />
and sequestration of carbon-containing<br />
molecules, substances, polymers, etc.! -<br />
We have also proven that the generation<br />
of Carbon dioxide significantly boosts the<br />
onset of microbiological or bioprocess<br />
reactions (Hakalehto and Hänninen 2012,<br />
Gaseous CO2 signal initiate growth of<br />
butyric acid producing Clostridium butyricum<br />
both in pure culture and in mixed<br />
cultures with Lactobacillus brevis, in the<br />
Canadian Journal of Microbiology). The<br />
same phenomenon was also documented<br />
for the Weizmann bacterium (Hakalehto<br />
2015, Enhanced microbial process in the<br />
sustainable fuel production. In: Jinyue,<br />
Y (ed.), Handbook of clean energy systems,<br />
by JR Wiley & Sons).<br />
Fig 4. A simplified scheme of the central metabolism of Clostridium acetobutylicum<br />
bacterium. Acetone, butanol and ethanol are the liquid end-products of the solvetogenic<br />
reactions. Hydrogen gas is generated as a function of ferredoxin enzymes. The starting<br />
molecule of the cascade is glucose, which usually results from the hydrolysis of organic,<br />
plant-derived macromolecules such as cellulose or starch. The by-product Carbon dioxide<br />
is readily usable in greenhouses or algal ponds.<br />
UPSTREAM AND DOWNSTREAM<br />
IN BIOTECHNOLOGY<br />
The former term designates in microbial<br />
biotechnology the production of valuable<br />
chemicals or gases by biological organisms,<br />
whereas downstreaming means the collection,<br />
purification and concentration of<br />
these biorefinery products into applicable<br />
forms. This is a well-studied field nowadays,<br />
but more research and development is always<br />
needed to boost the applications. And,<br />
as Professor Malcolm D. Lilly often stated<br />
during his most excellent bioengineering<br />
lectures in 1984-5 at the University College<br />
London: "Downstream processing is a losing<br />
game", meaning that it is impossible to<br />
reach perfection or complete recovery of<br />
the produced bio-based (or other) products<br />
in the industries. On the contrary, there are<br />
some losses at every step of that effort. But<br />
as developers, both scientific and societal,<br />
we should ensure that we could end up as<br />
victorious as possible.<br />
4/<strong>2023</strong> maintworld 37
AUTOMATION AND ROBOTICS<br />
Text and images: MOBILE INDUSTRIAL ROBOTS<br />
Simplifying the transition to a<br />
robot-assisted work environment<br />
The rapid advance of automation and robotics means that some work tasks can now be done by<br />
machines and robots – from production to material handling processes. Even though automation<br />
is often necessary for enterprises to increase productivity and keep costs down, these advances<br />
are not always welcome by employees.<br />
38 maintworld 4/<strong>2023</strong>
AUTOMATION AND ROBOTICS<br />
There is no denying that<br />
the word automation can<br />
evoke images of robots<br />
taking over jobs, and breed<br />
apprehension in employees.<br />
But automation can be a great<br />
tool for businesses, freeing employees<br />
from dirty, dull and dangerous<br />
tasks while boosting team effectiveness<br />
and creativity. The challenge for<br />
employers is often to communicate<br />
the benefits of automation and show<br />
people how it can change the future<br />
of work for the better.<br />
Here we share some ideas on how<br />
to introduce new technology with<br />
positive impact on your workforce.<br />
1<br />
Communicate your<br />
automation plans in<br />
good time.<br />
It is very important that you communicate<br />
what is going to happen to your employees.<br />
If you do not explain the process,<br />
this can create feelings of uncertainty<br />
amongst staff members. If you describe<br />
the process and leave room for questions,<br />
employees are less likely to feel threatened<br />
or fearful about the change but<br />
instead engaged and interested<br />
2<br />
Involve your employees<br />
in the process.<br />
Making your employees<br />
part of the process is the best way to<br />
smoothening your upcoming path to<br />
automation. It is important that you<br />
listen to the workforce’s concerns and<br />
reluctance, so you can explain and<br />
correct misguided information. It is<br />
also crucial that you give them space<br />
to give ideas and make proposals. They<br />
are the people working daily with<br />
both current and future systems at<br />
the facility and therefore, they are the<br />
ones who can best identify points of<br />
interest within the space which could<br />
benefit from additional help and relief<br />
through automation. Information<br />
gathered from employees is an excellent<br />
resource for deploying the robots<br />
most effectively.<br />
3<br />
Make the process enjoyable<br />
for your employees.<br />
MiR AMRs take the most<br />
repetitive and heavy tasks, allowing<br />
your employees to focus on high-value<br />
activities. Help them to see that the<br />
robots are a tool for them to perform<br />
even better in their jobs. Rather than<br />
thinking that robots are being installed<br />
to take over their jobs, employees<br />
can see automation processes as<br />
something to work alongside.<br />
Let your employees know that the future<br />
of work is not robots that are here<br />
to replace them, but rather that they<br />
will help and work alongside people, increasing<br />
efficiency but also safety. E.g.,<br />
MiR AMRs take over manual tasks that<br />
are usually met with high absences due<br />
to work injuries. Show your employees<br />
that the robots will help them have better<br />
health and better job results.<br />
DENSO, a leading mobility supplier,<br />
deployed six MiR250 robots in its<br />
800,000-square foot powertrain component<br />
production facility in Athens,<br />
Tennessee. A pilot program between<br />
its warehouse and production areas<br />
delivered results within six months,<br />
freeing six workers from pushing carts<br />
and allowing them to move to valueadded<br />
roles.<br />
After installing six MiR 250 robots,<br />
Travis Olinger, logistics and automation<br />
engineer in DENSO’s Total<br />
Industrial Engineering (TIE) group,<br />
explains: “Overall employee morale has<br />
improved, with employees recognizing<br />
DENSO as an innovative company that<br />
wants to make employees’ jobs easier<br />
and that the company cares about the<br />
ergonomic aspect of the job.”<br />
4<br />
Train your employees to<br />
work with the robot.<br />
Nobody likes something<br />
they do not understand, and automation<br />
does not work on its own. Training<br />
your employees with the robot<br />
will help them to understand the<br />
robots and processes better. It will<br />
also give them new and valuable skills<br />
in their career. MiR AMRs are easy to<br />
program and learn, and we also offer<br />
our free online learning platform MiR<br />
Academy, which can help your staff<br />
ease into working with robots and the<br />
new workflows surrounding them.<br />
MiR Academy has learning programs<br />
for all levels.<br />
“The MiR interface is really user<br />
friendly, the way of building mission is<br />
very easy made through building blocks<br />
instead of code lines. Thus, it is understandable<br />
enough even for people without<br />
previous programming experience,”<br />
Benjamin Paillusson, PC&L Improvement<br />
Leader in Faurecia Clean Mobility<br />
Písek, Forvia.<br />
5<br />
Make your employees familiar<br />
with the robot.<br />
There are different ways<br />
of making your employees perceive<br />
robots as part of the staff instead of a<br />
threat. Autonomous mobile robots are<br />
collaborative and therefore it is easy<br />
to “personalize” the robots for higher<br />
engagement of the employees. For example,<br />
asking your employees to name<br />
the robots is an excellent way to add<br />
fun and familiarity into the upcoming<br />
changes. Creating events around the<br />
robot, where the employees feel part of<br />
the integration process, can help them<br />
feel part of the change and be more proactive<br />
towards automation.<br />
4/<strong>2023</strong> maintworld 39
CIRCULAR ECONOMY<br />
MAINTENANCE –<br />
a crucial factor<br />
for achieving circularity<br />
40 maintworld 4/<strong>2023</strong>
CIRCULAR ECONOMY<br />
Let us start with defining circular economy,<br />
or circularity as it is also commonly<br />
referred as. Circular economy is<br />
all about reducing waste and prolonging<br />
the lifespan of products, components,<br />
and materials. It is contrasted to the linear<br />
economy where raw materials are processed into<br />
products that are consumed and then disposed.<br />
Instead of a linear lifecycle, the products, components,<br />
and materials are given one or more<br />
life cycles when they reach the end of life. The<br />
ecosystem perspective is prominent; circular<br />
economy is not achieved by a single company – it<br />
is a joint effort seen in the entire value chain and<br />
on societal level. Moreover, circular economy is<br />
a way to achieve sustainable development, i.e.,<br />
a development that meets the needs of today<br />
without compromising the possibility to meet<br />
the needs of future generations. Therefore, we<br />
must apply a now-centred perspective as well<br />
as a future-centred perspective on circularity.<br />
All these perspectives are distinguishable in the<br />
definition of circular economy given by Krichherr<br />
et al. (2017, p. 229) 1 :<br />
Maintenance plays<br />
a huge role in achieving high<br />
level of circularity.<br />
Circular economy is a buzz word today, but what does<br />
circular economy mean and how is the term connected<br />
with maintenance? In the following, we will try to shed<br />
some light on the concept and explain how maintenance<br />
acts as a facilitator for achieving circular strategies.<br />
Text: MIRKA KANS, Associate professor (docent), Chalmers University of Technology<br />
Images: STOCKPHOTO<br />
“…an economic system that replaces the ‘end-oflife’<br />
concept with reducing, alternatively reusing,<br />
recycling and recovering materials in production/distribution<br />
and consumption processes. It<br />
operates at the micro level (products, companies,<br />
consumers), meso level (eco-industrial parks) and<br />
macro level (city, region, nation and beyond), with<br />
the aim to accomplish sustainable development,<br />
thus simultaneously creating environmental quality,<br />
economic prosperity and social equity, to the<br />
benefit of current and future generations”.<br />
How to assess the “circularity” of e.g., a company<br />
or a nation? For businesses, the Science<br />
Based Target Initiative (SBTi) allows for formulating<br />
environmental targets that comply with<br />
the Paris agreement of not exceeding a global<br />
warming of 1.5°C. Thousands of businesses have<br />
started using science-based targets aiming at<br />
net zero emissions by 2050. SBTi reports that<br />
the global emissions increased by over 3% from<br />
energy and industry between 2015 and 2019, but<br />
also that the emissions in the SBTi companies<br />
decreased by 25% in the same period. Circularity<br />
is an important aspect for achieving the sustainability<br />
development goals, or Agenda 2030,<br />
agreed upon by the United Nations in 2015 2 . The<br />
level of goal fulfilment spans from 39% to 87%,<br />
with Finland, Sweden, and Denmark being<br />
the top three countries 3 . If we measure global<br />
4/<strong>2023</strong> maintworld 41
CIRCULAR ECONOMY<br />
circularity in terms of virgin material<br />
use, the trend is rather discouraging.<br />
According to the recently<br />
launched Circularity Gap Report 4<br />
the world is 7.5% circular, which<br />
could be compared with 9.1% in 2018<br />
and 8.6% in 2020.<br />
Very disappointing reading, you<br />
may think. On the upside, there is<br />
an immense potential in applying<br />
circularity on all levels to reach the<br />
set targets. Several circular strategies<br />
exist that could be applied to reduce<br />
virgin material use and prolong the<br />
lifespan of products, components,<br />
and materials. The 10R model 5 is<br />
commonly used to describe circular<br />
strategies from less circular to highly<br />
circular (see Figure 1). On the bottom<br />
(R9 and R8), we find strategies to recover<br />
some value from material, such<br />
as using biomaterial waste as fuel in<br />
heating plants or making toilet paper<br />
out of scrapped books. The next five<br />
strategies (R7-R3) aim to prolong the<br />
lifespan of a product. Repurposing and<br />
remanufacturing are strategies for<br />
giving the product or its components<br />
a new life cycle either by restoring<br />
or altering the functionality while<br />
refurbish, repair, and reuse are strategies<br />
aiming at prolonging the existent<br />
life cycle and functionality of the<br />
product. An old school bus could for<br />
instance be sold on the second-hand<br />
market, undergo maintenance, or be<br />
repurposed as a mobile home. The<br />
final three strategies (R2-R0) aim to<br />
reduce the resources in production<br />
and consumption. Reduced resources<br />
in the production may address energy<br />
consumption or material by increasing<br />
the availability and quality rate or<br />
reducing performance losses. Reducing<br />
resources in consumption may<br />
be achieved by offering a product as a<br />
service or by offering performance instead<br />
of a product. The latter could for<br />
instance be in form of renting or leasing<br />
a car instead of buying and owning<br />
one as a consumer, or by arranging<br />
the transportation need in other ways<br />
such as train or bus services.<br />
Maintenance plays a huge role in<br />
achieving high level of circularity.<br />
Let us start by looking at the rethink<br />
and reduce strategies. Rethinking<br />
strategies rely on companies acting<br />
as service providers rather than<br />
producers and sellers of products.<br />
The ownership of the product that<br />
creates the customer value is kept<br />
by the provider, who benefits in an<br />
asset management strategy for these<br />
Figure 1. Circular strategies and the role of maintenance as a facilitator<br />
42 maintworld 4/<strong>2023</strong>
CIRCULAR ECONOMY<br />
products. The longer the lifespan of<br />
the asset providing value, the higher<br />
life cycle profit might be achieved.<br />
From a production perspective, it is<br />
well known that efficient asset management<br />
in the form of preventive<br />
maintenance strategies has significant<br />
impact on the production processes<br />
in terms of higher availability,<br />
dependability, and quality output.<br />
For the strategy reuse, maintenance<br />
plays an indirect role. The<br />
main idea is to resell the product<br />
on the second-hand market. For<br />
products in bad shape, maintenance<br />
in the form of cleaning, repair, or<br />
The longer the<br />
lifespan of the asset<br />
providing value, the<br />
higherlife cycle profit<br />
might be achieved.<br />
the similar is necessary. This could<br />
be conducted by the second-hand<br />
dealer or by a specialised contractor<br />
offering maintenance services. If<br />
maintenance is not done before the<br />
sales, the new owner might need to<br />
buy maintenance services instead.<br />
Maintenance is a direct activity<br />
in repair and refurbish. For fulfilling<br />
these circular strategies, maintenance<br />
services are offered to the<br />
owner of the product. Maintenance<br />
is, from this perspective, a business<br />
model rather than an operations<br />
strategy. In this context, refurbishing<br />
is the same thing as doing<br />
maintenance in the end-of-life of<br />
the product. We can assume that the<br />
product has a partial or complete<br />
functional failure, and that corrective<br />
and preventive maintenance is<br />
needed. The maintenance need is,<br />
thus, higher for this product than for<br />
a product in need of repair.<br />
Lastly, we have the remanufacturing<br />
and repurposing strategies.<br />
Cleaning and repair, i.e., common<br />
maintenance activities, are necessary<br />
sub-activities in the remanufacturing<br />
or repurposing process. Remanufacturing<br />
is defined as ”returning<br />
a used product to at least its original<br />
performance with a warranty<br />
that is equivalent or better than that<br />
of the newly manufactured product”<br />
6 . If we scrutinize the definition<br />
of remanufacturing, it is obvious<br />
that maintenance plays a larger role,<br />
as remanufacturing aims at regaining<br />
the function of a product to at<br />
least its original performance. Based<br />
on this reasoning, remanufacturing<br />
could be viewed as a maintenance<br />
activity on the industrial scale.<br />
In conclusion, we see that maintenance<br />
is a crucial factor for achieving<br />
circular strategies both within the<br />
company and throughout the full life<br />
span of the product. Maintenance<br />
allows for reduction of virgin raw<br />
material by making the products and<br />
production more efficient. It prolongs<br />
the lifespan of products and<br />
components by appropriate services<br />
for individual users and businesses,<br />
and by centralized and industrialized<br />
maintenance of products at the<br />
end-of-life.<br />
REFERENCES<br />
[1] Kirchherr, J., Reike, D., & Hekkert, M. (2017). Conceptualizing the circular economy: An analysis of 114 definitions. Resources, conservation and<br />
recycling, 127, 221-232.<br />
[2] https://unstats.un.org/sdgs/report/<strong>2023</strong>/<br />
[3] https://dashboards.sdgindex.org/rankings<br />
[4] https://www.circularity-gap.world/<br />
[5] http://www.pbl.nl/sites/default/files/cms/publicaties/pbl-2016-circular-economy-measuring-innovation-in-product-chains-2544.pdf<br />
[6] British Standard Institute, 2009. BS 8887-2:2009 Design for manufacture, assembly, disassembly, and end-of-life processing (MADE) Terms and definitions.<br />
4/<strong>2023</strong> maintworld 43
ELECTRIC MOTOR STORAGE<br />
Best practices for storing<br />
ELECTRIC MOTORS<br />
Storing an electric motor for more than a few weeks involves several steps to ensure it will<br />
operate properly when needed. For practical reasons, these are governed by the motor’s size and<br />
how long it will be out of service. Factors like the temperature, humidity and ambient vibration in<br />
the storage area also influence the choice of storage methods–some of which may be impractical<br />
for smaller machines or need to be reversed before the motor goes into service. With these things<br />
in mind, here are some common recommendations for storing motors.<br />
Text: CHUCK YUNG, senior technical support specialist at EASA, Inc., St. Louis, MO USA<br />
Images: EASA, STOCKPHOTO<br />
Good, readily available<br />
records are essential for<br />
any motor storage program.<br />
One method is to<br />
attach a form like that in<br />
Figure 1 to each motor to document the<br />
storage dates, maintenance procedures<br />
completed, and the results of all tests<br />
performed during the storage period.<br />
For motors in long-term storage, a good<br />
practice is to replace the form annually<br />
(or at other designated intervals). Store<br />
electronic copies of the previous forms for<br />
future reference, or simply keep them in<br />
an envelope attached to the motor.<br />
Figure 1: Motor storage tag.<br />
STORAGE CONDITIONS<br />
Short-term storage. Motors that<br />
will be in storage for just a few weeks<br />
primarily require protection from the<br />
weather (see “Indoor storage” and<br />
“Outdoor storage” below) and ambient<br />
vibration (more on this later).<br />
Long-term storage. Motors slated<br />
for several weeks to several years<br />
in storage and all above-NEMA size<br />
machines require additional preparations<br />
to protect their machined surfaces,<br />
bearings and windings.<br />
Indoor storage. If possible, store<br />
motors indoors in a clean, dry area.<br />
Place horizontal machines in a horizontal<br />
position and vertical motors in<br />
a stable vertical position.<br />
Unless the storage area is climate<br />
controlled, prevent condensation<br />
from forming inside the motor by<br />
energizing the space heaters (if supplied)<br />
to keep the windings 5-10°C
ELECTRIC MOTOR STORAGE<br />
(10-20°F) above the ambient temperature.<br />
(For other ways to prevent condensation,<br />
see “Special care for windings”<br />
below.)<br />
Outdoor storage. Don’t! Seriously,<br />
if a motor is too large to store indoors, it<br />
is likely to be a very expensive machine.<br />
It’s worth the cost to construct an enclosed<br />
storage facility. When outdoor<br />
storage is absolutely necessary, protect<br />
the motor with a waterproof cover (e.g.,<br />
a tarp), allowing a breathing space at<br />
the bottom. Wrapping it tightly in plastic<br />
and placing it outdoors will cause<br />
condensation to form inside the motor<br />
due to the temperature extremes and<br />
humidity.<br />
Outdoor storage also requires preventive<br />
measures to keep out rodents,<br />
snakes, birds or other small animals<br />
that can damage the winding insulation.<br />
If insects are prevalent, keep them from<br />
blocking ventilation and drain openings<br />
by loosely wrapping the motor and covering<br />
all openings.<br />
Shafts and machined surfaces<br />
Apply a viscous rust/corrosion inhibitor<br />
(e.g., LPS2, Techtyl 502C or RustVeto)<br />
to exposed machined surfaces and<br />
sleeve bearings, allowing it to remain<br />
intact throughout the storage period. In<br />
humid and rainy/snowy environments,<br />
have the service center paint as much of<br />
the motor’s interior surface as practical,<br />
and coat the windings with a topical<br />
fungicide in tropical environments.<br />
(Note: Disassemble the machine and inspect<br />
the sleeve bearings before placing<br />
it into service.)<br />
BEARING PROTECTION<br />
Grease-lubricated motors. For longterm<br />
storage, completely fill the bearing<br />
cavities with compatible grease to prevent<br />
rust and corrosion staining that<br />
can occur if moisture collects between<br />
the balls and races.<br />
Oil-lubricated motors. Do not ship<br />
or move these motors with oil in the<br />
reservoir. After placing the motor in<br />
storage, fill the reservoir with enough<br />
oil to cover the bearings but without<br />
overflowing the stand tube or labyrinth<br />
seal. Fill sleeve bearing machines to just<br />
below the labyrinth seal and vertical<br />
motors to the “max fill” line.<br />
The oil should contain a rust and corrosion<br />
inhibitor and be moisture free.<br />
Check it every three months by drawing<br />
a sample from the drain. Since water<br />
Figure 2: False brinelling.<br />
weighs more than oil, any moisture will<br />
be evident.<br />
Ambient vibration. This can damage<br />
motors, even when they are not<br />
rotating. Proximity to rail lines, busy<br />
roads, and/or production floors can all<br />
contribute to the ambient vibration.<br />
Even low-magnitude vibration, over<br />
time, can damage bearings while they<br />
are stationary–e.g., false brinelling (see<br />
Figure 2). Solutions vary. For example,<br />
one mill that had ambient vibration<br />
from nearby machinery stored its motors<br />
on scrapped conveyor belting.<br />
False brinelling damages the bearing<br />
race at uniform intervals matching the<br />
spacing of the rolling elements. Although<br />
the damage initially may appear<br />
slight or even invisible to the naked eye,<br />
it often progresses rapidly once the motor<br />
is in service.<br />
Shaft rotation. Turning the motor’s<br />
shaft at least monthly during long-term<br />
storage redistributes lubricant on machined<br />
surfaces to inhibit corrosion.<br />
Motors with ball or roller bearings also<br />
benefit from monthly rotation, since<br />
the rolling elements stop in different<br />
positions each time. Larger, 2-pole machines<br />
require more frequent attention<br />
than smaller (NEMA-frame) machines.<br />
Motors with spring-loaded spherical<br />
bearings are more difficult to turn, but<br />
they still require manual rotation to<br />
coat the bearings with oil. With sliding<br />
plate (i.e., Kingsbury) bearings, lift the<br />
shaft before rotating it–from below<br />
with a short jack and a bearing ball<br />
centered on the shaft, or from above<br />
with an overhead crane and eyebolts. To<br />
avoid bearing damage, be careful not to<br />
lift the shaft more than a few mils.<br />
Machines with heavy rotors and<br />
long frames in ratings of about 2000<br />
hp (1500 kW) and larger sometimes<br />
require more frequent (weekly) rotation<br />
to prevent shaft bowing caused<br />
by the weight of the rotor. As an extreme<br />
example, power plants often<br />
keep large turbine generators rotating<br />
slowly all the time to prevent sag.<br />
While it is uncommon, removing and<br />
vertically suspending the rotors of<br />
very large critical machines also can<br />
prevent sagging.<br />
SPECIAL CARE FOR MOTOR<br />
WINDINGS<br />
Methods for preventing condensation.<br />
Motor windings must stay clean<br />
and dry to keep the insulation from<br />
degrading. Unless the storage area is<br />
climate controlled, condensation can<br />
form in the motor if the temperature of<br />
the winding dips below the dew point.<br />
As mentioned earlier, the usual way<br />
of avoiding this is to keep the winding<br />
5-10°C (10-20°F) above ambient temperature.<br />
If the motor has space heaters,<br />
energize them while it is in storage; if<br />
not, add them. Another option is to use<br />
the windings as a resistance heater by<br />
supplying low-voltage DC current (approximately<br />
8-12% of rated amperage).<br />
An energy-saving alternative is to lower<br />
the dewpoint of the storage room with a<br />
dehumidifier.<br />
4/<strong>2023</strong> maintworld 45
ELECTRIC MOTOR STORAGE<br />
Figure 3: Insulation<br />
resistance (IR) tests<br />
can be performed with<br />
a megohmmeter or<br />
motor analyzer.<br />
Insulation resistance (IR) tests. Measure and<br />
record the IR of the winding(s) before storing a motor<br />
even a few weeks, and again just before putting it<br />
in service (see Figure 3). Correct all IR readings to a<br />
standard temperature and address any decrease in IR<br />
before installing the motor. If a motor will be in storage<br />
for a long time, take IR readings annually.<br />
Polarization index (PI) and dielectric absorption<br />
ratio (DAR) tests. For form coil windings,<br />
conduct a PI test in addition to the IR test. The PI<br />
test variables skew results for windings with lots of<br />
exposed conductor surface area, so use the DA ratio<br />
test for random windings and DC armatures (see<br />
Tables 1 and 2).<br />
Table 1: Dielectric absorption ratio recommendation<br />
Table 2: Dielectric absorption ratio (DAR) assessment<br />
Type of winding<br />
Minimum insulation resistance<br />
60:30 seconds Condition<br />
Form-wound coils (PI)<br />
P1=<br />
10-minute IR (to ground)<br />
1-minute IR<br />
≥ 2.0<br />
< 1.1 Poor<br />
1.1 to 1.24 Questionable<br />
1.25 to 1.3 Fair<br />
Random-wound coils (DA)<br />
DA=<br />
1-minute IR<br />
30-seconds IR<br />
> 1.25<br />
1.4 to 1.6 Good<br />
> 1.6 Excellent<br />
46 maintworld 4/<strong>2023</strong>
ELECTRIC MOTOR STORAGE<br />
If the windings need to be cleaned and dried, measure the<br />
IR again. If it is greater than 5000 megohms, disregard the PI<br />
(see IEEE 43); otherwise, recalculate the PI.<br />
CARBON BRUSHES<br />
DC machines, wound-rotor motors and some synchronous<br />
machines have carbon brushes. For long-term storage, lift the<br />
brushes away from the commutator/slip rings to prevent a<br />
chemical reaction (sometimes called “photographing”) that<br />
can discolor the underlying commutator or slip ring. When<br />
practical, store the springs in the relaxed state to prevent a<br />
gradual loss of spring pressure.<br />
Putting the motor into service<br />
To ensure proper operation when removing a motor from<br />
storage and putting it into service, perform the following:<br />
• Use compressed air to clean the outside of the motor, and<br />
visually inspect it.<br />
• Assess the condition of the insulation system by measuring<br />
the IR with a megohmmeter.<br />
• Oil-lubricated motors:<br />
• Drain the oil before moving the motor to the<br />
installation site.<br />
• If there is water in the oil, check for and replace any<br />
rusty bearings.<br />
• If sleeve bearings received a protective coating,<br />
disassemble the machine and clean the bearings with<br />
an appropriate solvent before putting the motor into<br />
service.<br />
• Fill the oil reservoir to the correct running level after<br />
installing the motor.<br />
• Grease-lubricated motors:<br />
• Moisture in the grease usually indicates rust-damaged<br />
bearings that need replacement.<br />
• After several years in storage, the grease probably will<br />
be hard and the drainpipe will be plugged; usually it is<br />
best to disassemble the motor, remove the old grease<br />
and repack with fresh, compatible lubricant.<br />
• Run the motor 10-20 minutes without the drain plug to<br />
purge excess grease.<br />
• Vibration and alignment:<br />
• If the storage area has ambient vibration, inspect and<br />
replace damaged bearings before installing the motor.<br />
• After installing and aligning the motor, document the<br />
uncoupled baseline vibration levels; check the levels<br />
again after a week or two of service.<br />
• For motors with rolling element bearings, check for<br />
bearing fault frequencies in the vibration spectra.<br />
• On large machines that are susceptible to shaft sag,<br />
monitor the vibration levels during startup to avoid<br />
catastrophic damage.<br />
High-cost machines obviously justify more precautions than<br />
inexpensive, readily available motors. What is not always apparent<br />
is that some “smaller” motors are equally important to<br />
production and can have enormous consequences if they fail.<br />
TIPS FOR TRACKING IR TEST RESULTS<br />
Attach a card to each motor and record the IR,<br />
temperature and date of each test.<br />
TIPS FOR ROTATING THE SHAFT<br />
Rotating the shaft keyway position in 150-degree<br />
increments every month makes it easy to spot a<br />
neglected motor. If you visualize a clock face, each<br />
increment represents 5 hours: For example, if the<br />
keyway position for September is 12:00, October<br />
will be 5:00, November will be 10:00, and so on.<br />
This puts the rolling elements in a different position<br />
each time and avoids rocking the rotor back and<br />
forth between just two positions (see Figure 1).<br />
TIPS FOR OIL-LUBRICATED MOTORS<br />
Never move a motor with oil in the reservoir. If oil<br />
sloshes over the stand tube, it could contaminate<br />
the windings or even initiate capillary action that<br />
can siphon oil from the chamber. Before putting<br />
the motor into service, always drain the oil and<br />
replace it with compatible lubricant. (Drain it. Move<br />
it. Refill it.)<br />
REFERENCES<br />
IEEE Std. 43-2013: Recommended Practice for Testing Insulation Resistance of Electric Machinery. Institute of Electrical and Electronics Engineers, Inc.<br />
New York, NY, 2013.<br />
4/<strong>2023</strong> maintworld 47
PHOTOVOLTAIC ENERGY<br />
Photovoltaic systems<br />
in the limelight<br />
Germany has around 2.6 million photovoltaic (PV) systems producing solar power on rooftops<br />
and sites. Demand for qualified installation companies in the country is high, resulting in<br />
time pressure during PV system installation. When it comes to ensuring the long-term safety<br />
and efficiency of PV systems, due diligence is a top priority. This applies in particular to<br />
commissioning of new PV systems and performance of modernisation measures.<br />
Text: MBA, B. ENG. STEFAN VEIT, Head of Product and Quality Management Electrical Engineering, Team Lead Electrical/<br />
Building Technology, TÜV SÜD Industrie Service GmbH<br />
Images: TÜV SÜD<br />
Owning a PV system is<br />
becoming increasingly<br />
popular, with benefits<br />
including greater independence<br />
from the<br />
energy market, energy savings and climate<br />
protection. Large-scale producers,<br />
such as businesses, trades, and agricultural<br />
enterprises with a power output<br />
of 30 kWp or more, benefit particularly<br />
from good returns that make up for the<br />
high costs of installation.<br />
The German government is seeking<br />
to significantly speed up the expansion<br />
of solar power. Its PV Strategy aims at<br />
raising the proportion of PV in Germany’s<br />
power mix to over 30 per cent<br />
by 2035. 1 To reach this goal, PV systems<br />
must make full use of their maximum<br />
efficiency. However, this is not always<br />
the case at present. According to estimates<br />
by the German Insurance Association<br />
(GDV), around 400,000 of the 2<br />
million PV systems in Germany in 2020<br />
had been installed incorrectly, revealing<br />
not only technical defects, but also economic<br />
deficits.<br />
48 maintworld 4/<strong>2023</strong>
PHOTOVOLTAIC ENERGY<br />
Possible causes alongside production<br />
faults or damage in transit also include<br />
errors in installation and planning. In<br />
addition, age-related wear, accumulation<br />
of dirt on the panels or weatherrelated<br />
damage can also result in<br />
impaired efficiency. When PV modules<br />
are connected in a string, one defective<br />
cell is all it takes to cause a significant<br />
reduction in output.<br />
Faults may reduce the system’s<br />
efficiency, the service life and, in a<br />
worst-case scenario, even cause a fire.<br />
Many of these defects can be easily<br />
remedied by, say, replacing defective<br />
modules or cleaning panel surfaces.<br />
Steps to prevent shading of the solar<br />
modules by roof structures should<br />
already be taken in the planning<br />
stage. During PV system operation,<br />
vegetation may have to be cut back<br />
regularly.<br />
TESTING AND INSPECTION –<br />
BEFORE DAMAGE OCCURS<br />
Early identification of deficiencies may<br />
eliminate high secondary costs, and<br />
even generate additional yield. Along<br />
with economic advantages, testing<br />
and inspection also serve to identify<br />
safety-relevant defects. For this reason,<br />
law and technical standards require<br />
periodic electrical safety tests of PV<br />
systems to be performed. In particular,<br />
the accident prevention regulation<br />
DGUV V3 and the standards EN 62446<br />
(VDE 0126-23), IEC 62548 and DIN<br />
VDE 0105-100/A1 do apply in Germany.<br />
Depending on the age of the system and<br />
other operating conditions, PV systems<br />
TÜV SÜD<br />
TÜV SÜD is a German certification<br />
and inspection organization.<br />
TÜV SÜD provides a wide range of<br />
testing, inspection, certification,<br />
and consulting services in various<br />
sectors, including automotive,<br />
industrial, energy, healthcare,<br />
and more. Their primary focus is<br />
on ensuring the safety, quality,<br />
and sustainability of products,<br />
processes, and systems.<br />
may have to be tested and inspected<br />
every one to four years.<br />
Experts frequently identify simple<br />
defects by means of visual testing performed<br />
to evaluate a system’s actual<br />
state of repair. Target-performance<br />
comparison can be carried out with the<br />
help of simulation software; it offers<br />
indications of defects that may also impact<br />
on the output of the PV systems.<br />
By applying the voltage-current<br />
characteristic, the software measures<br />
the actual performance of the system<br />
and compares it to the manufacturer’s<br />
specifications. In case of deviations,<br />
imaging processes are introduced to<br />
provide more detailed information.<br />
Defects increase electrical resistance,<br />
and thus build up more heat.<br />
The resulting hotspots are captured<br />
by thermal imaging cameras. Inactive<br />
modules, disconnected substrings and<br />
performance degradation caused by<br />
ageing, i. e. potential-induced degradation<br />
(PID), are further anomalies that<br />
can be identified using this method,<br />
provided an adequate level of current<br />
is produced by solar radiation.<br />
HIGHEST PRECISION<br />
ELIMINATES LOOPHOLES<br />
By contrast, inverse thermography, also<br />
known as reverse-current thermography,<br />
is weather- independent. It detects even<br />
the smallest defects at an early stage. In<br />
this “reversed” method, current is fed<br />
into the PV systems and the difference in<br />
temperature is measured when current<br />
4/<strong>2023</strong> maintworld 49
PHOTOVOLTAIC ENERGY<br />
flows through the cells. Drones can also<br />
be used to capture images. The only other<br />
method offering even greater detail is<br />
electroluminescence measurement (EL<br />
measurement). This method likewise<br />
involves feeding external current into the<br />
modules. Using special cameras at night,<br />
the experts then record the electromagnetic<br />
radiation at wavelengths of approximately<br />
1,150 nm. EL measurement<br />
thus enables the experts to look inside a<br />
solar cell and identify defective bypass<br />
diodes, failed cells, micro-cracks and<br />
even performance degradation caused by<br />
light and elevated temperature induced<br />
degradation (LETID).<br />
PHOTOVOLTAIC ENERGY<br />
Photovoltaic energy, commonly known as solar energy, is a renewable and<br />
sustainable source of electricity generated by converting sunlight into<br />
electrical power using photovoltaic cells (solar panels). These cells contain<br />
semiconductor materials that absorb photons from the sun and release<br />
electrons, creating a flow of electricity. Solar energy is clean, environmentally<br />
friendly, and increasingly used to power homes, businesses, and more.<br />
It helps reduce greenhouse gas emissions and dependence on fossil fuels.<br />
Owning a PV system<br />
is becoming increasingly<br />
popular, with benefits<br />
including greater<br />
independence from the<br />
energy market, energy<br />
savings and climate<br />
protection.<br />
CONCLUSION<br />
Modern test methods such as thermography<br />
enable testing and inspection to be<br />
performed during operation or outside<br />
the system’s regular service hours. EL<br />
measurement, for example, is performed<br />
at night. In addition, modern test methods<br />
do not require modules to be dismantled.<br />
The use of drones reduces the need<br />
to set up cranes or lifting platforms.<br />
The longer a defect goes undetected,<br />
the higher the secondary costs it causes.<br />
In this case, planners and installation<br />
and maintenance companies benefit<br />
from the support provided by recognised<br />
testing, inspection, and certification<br />
(TIC) companies like TÜV SÜD.<br />
Drawing on their technical expertise<br />
and using ultramodern technical<br />
equipment, they track down safety- and<br />
efficiency-relevant defects and identify<br />
opportunities for improvement.<br />
Combining safety inspections with efficiency<br />
checks also pays off for smaller<br />
systems, particularly when they are still<br />
within the manufacturer’s or installation<br />
company’s warranty period.<br />
REFERENCES<br />
[1] PV Strategy, Federal Ministry for Economic Affairs and Climate Action: https://www.bmwk.de/Redaktion/DE/Publikationen/Energie/photovoltaik-stategie-<br />
<strong>2023</strong>.pdf?__blob=publicationFile&v=4<br />
50 maintworld 4/<strong>2023</strong>
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