Read it now: Brief Survey of Centrifugal Pump Best Practices
Authorhouse Publishing has published a new book written by Robert X. Perez on how to determine the right pump by considering the overall cost of ownership
Authorhouse Publishing has published a new book written by Robert X. Perez titled How to Select the Right Centrifugal Pump—A Brief Survey of Centrifugal Pump Best Practices.
Choosing a centrifugal pump from the countless options available can be daunting. Many factors such as the required flow, differential pressure, and suction conditions must be weighed against the capital costs and cost of energy for the pumps considered.
Robert X. Perez outlines the case on how to determine the right pump by considering the overall cost of ownership, which includes capital cost, operating costs, and maintenance cost. His selection methodology focuses mainly on hydraulic design considerations, but it also touches on mechanical design details. A…
The age of $40 oil may be here to stay
The ongoing journey toward lubrication perfection
In pursuit of lubrication perfection
Lubrication plays a major role in Turkey’s energy production
GE plans app store for gears of industry
Company expects its future profits to increasingly lie in aftermarket asset performance and maintenance services
General Electric has seen the future of manufacturing. It involves competing with some very big technology companies.
GE recently announced a push into computer-based services, connecting sensors that are on machines to distant computing centers where data will be scanned for insights around things like performance, maintenance and supplies. The company plans to spend about $500 million annually building the business, according to the executive in charge.
“We think it will change the industrial world,” said William Ruh, the head of GE’s software business. “We’re talking about where an industrial company goes to get its applications.”
While some of GE’s software revenue comes from moving existing practices into a new category,…
Can current network bandwidth supply meet IoT, machine-to-machine communication demands?
Choose the right tool for vibration analysis
Combine vibration monitoring and ultrasound for more cost-effective predictive maintenance
Use vibration monitoring to improve PdM and prevent failures before they occur
Simple steps to accurate alignment
How vibration analysis can detect alignment problems
Thermal growth and alignment
How to use ultrasound to improve lubrication practices
How ultrasound technicians are improving reliability at your plant
Thermography heats up
Use thermography to diagnose electrical problems
IR technology offers a tool with multiple applications
Taking condition monitoring and predictive maintenance to the cloud
IBM and National Instruments create testbed for the IoT.
A new collaboration between IBM and National Instruments (NI) has yielded the industry’s first condition monitoring and predictive maintenance testbed for the Internet of Things (loT).
The IBM cloud-based environment combines National Instruments' monitoring and data acquisition capabilities with IBM’s analytics tools to help organizations across industries better monitor complex automation devices, predict failures and help reduce maintenance costs.
To learn more about IoT, read “IBM, NI create condition monitoring and predictive maintenance testbed for the loT” from Control Design.
Your machines are talking to you. Do you always understand what they are saying?
A tale of 2 industrial plants
Regulate water temperature
Welding QC simple with real-time temperature readings
Fight rust to keep your plant running efficiently
Reduce corrosion costs
Combat corrosive conditions with prevention and early detection
Perform system maintenance to slow degradation of rotating equipment
Survey: Nearly all factory operations will be online by 2020
40% of respondents believe that now is the right time to invest in smart manufacturing, Internet of Things
Smart manufacturing is about creating an environment where all available information—from within the plant floor and from along the supply chain—is captured in real-time, made visible and turned into actionable insights.
Smart manufacturing comprises all aspects of business, blurring the boundaries among plant operations, supply chain, product design and demand management. Enabling virtual tracking of capital assets, processes, resources and products, smart manufacturing gives enterprises full visibility which in turn supports streamlining business processes and optimizing supply and demand.
SCM World’s recent field survey on smart manufacturing and the Internet of Things finds that while one in five today admit their factory…
More companies using big data to manage workers, optimize productivity
OSIsoft-SAP partnership deepens predictive analytics on the plant floor
New technologies help avoid machine faults
Ten things you need to know about cloud security
Is the cloud safe enough for your machine data? Here's what you need to know
It seems that every time the cloud is brought up, the conversation to follow is focused on how secure, or not secure, it really is. Here are 10 things you need to know about cloud security.
1. The cloud security market is growing, up to $9 billion by 2019.
2. 43% of companies experienced a data breach last year, up 10% from the year before.
3. A private cloud strategy may initially offer more control over your data and easier compliance to HIPAA standards and PCI, but it is not inherently more or less secure.
4. Cloud and security top IT initiatives in 2015, according to the 2015 Network World State of the Network report.
5. Storage is perceived as the riskiest cloud app.
6. Your employees are your biggest threat: employees caused almost…
How to plan for manufacturing success (hint: hire gamers)
Remote monitoring through turbine retrofit
Work with IT to foster remote monitoring
Ten things you need to know about cloud computing
Improving performance and uptime of heavy rotating equipment
Fluid handling tools you can use
Handle fluid with care
Pumps in peril?
Omnify Software announces strategic partnership with Octopart
Integration helps engineers save time during design
Omnify Software, a provider of web-based Product Lifecycle Management (PLM) software for discrete manufacturers, today announces a strategic partnership with Octopart, the electronic parts search engine, in order to give Omnify Empower users direct access to component information in Octopart without leaving their Omnify Empower environment.
The Octopart Search integration is an add-on module to the Empower PLM system. With this module, Empower users can search the Octopart database of a growing list of more than 30 million parts across thousands of suppliers. Users can check and create vendors, vendor parts, and associated items through a formal Part Request in Omnify Empower, while populating attributes/parameters, datasheets, and…
Small firms breathe easier as Minnesota capital-equipment sales tax rebate program ends
Material handling meets energy efficiency
Big data in the material handling industry: From supply chain to fulfillment
Boost motor efficiency for a better payoff
Common sense management of EISA motor changes
What is your compressed air survey ROI?
Compressed air system solutions for deep surface mining
Back to basics: Getting to the bottom of leaks in your compressed air system
How to optimize robots' energy use? Slow 'em down
Consistent speed of movement can cut industrial robots' energy use by 40 percent
By minimizing the acceleration of industrial robots, energy consumption can be reduced by up to 40 percent – while retaining the given production time. This is the result of a new optimization algorithm that was developed by researchers at Chalmers University of Technology.
"We simply let the robot move slower instead of waiting for other robots and machines to catch up before carrying out the next sequence," a Chalmers professor who initiated the research says.
Read the full story on Phys.org.
Seven ways 3D printing is disrupting global manufacturing
Motoman Robotics teams with community college for workforce development
When robots eliminate jobs, will humans will find better things to do?
Chinese factory replaces 90% of human workers with robots, production soars
MakerBot Thingiverse announces winners of summer STEAM student challenges
Winning designs help teachers integrate 3D printing in the classroom
MakerBot Thingiverse, the world’s largest 3D printing design community, is pleased to announce the winners of the education-focused Thingiversity Summer STEAM Challenges.
Over the course of two months, nearly 900 members of the Thingiverse community submitted designs across the five challenge categories of Science, Technology, Engineering, Art, and Math (STEAM). After much deliberation, the first-place winners in each category were each awarded a MakerBot Replicator Desktop 3D Printer. All of the winning designs are available free on Thingiverse.
“We are blown away by the creative designs the Thingiverse community submitted for the Thingiversity Summer STEAM Challenges, ranging from solar-powered LED lamps to a gravity battery to a 3D…
U.K. navy test-launches 3D printed drone from warship
Is manufacturing really new?
Real optimization in a virtual factory
Practical considerations for modern BFW pumps
Mechanical or electrical trip system testing?
How a 49-year-old food processor beefed up its data tech
In this case history, a food plant uses IIoT to improve data gathering and analysis.
SugarCreek is a 49-year-old processor of bacon, meatballs, sausage patties and chicken for both foodservice and retail. It's just finishing up a gut-rehab of a brownfield plant, a 70,000-sq.-ft. facility acquired from a bankrupt food processor in Cambridge City, Ind., which has been expanded to 418,000 sq. ft. While the new equipment, floors and walls are apparent, less obvious is the considerable investment in technology.
As a result, one of the key architects is SugarCreek's chief information officer. Ed Rodden quickly points out he has spent as much time on the business side as on IT, and that he's no "IT guy."
He does, however, see the huge potential of data gathering and analysis at many more points than are taken advantage of by most…
Plant Services CMMS/EAM Software Review
Read David Berger's column, Asset Manager
Subscribe to the Asset Management E-News
Sign up for the 2015 asset managment webcast
Big data in the material handling industry: The NIST project
Improve plant productivity with communication, data gathering, and analysis
How the Internet of Things might change your plant
6 mistakes to avoid with EAM software
Bring-your-own-device policies put plant data in the palm of your hand
Chicago is training electricians in smart grid renewable energy applications
Chicago is now home to the Renewable Energy Training Field, a facility to train electricians and support electrical contractors in smart grid renewable energy applications.
Chicago is now home to the Renewable Energy Training Field, a facility to train electricians and support electrical contractors in smart grid renewable energy applications. The Renewable Energy Training Field, solely funded and created by the National Electrical Contractors Association (NECA) of Chicago and the International Brotherhood of Electrical Workers (IBEW) Local 134, will prepare electricians across the Chicago metropolitan area to meet the fast-growing demand for commercial, industrial, municipal and residential applications of solar and wind.
NECA Chicago and IBEW Local #134 came together to build this facility on the grounds of the IBEW/NECA Technical Institute (IN-TECH), in Alsip, IL a southwestern Chicago suburb. The…
How to determine the best electrical safety practices for your plant
Do capacitor systems really save energy?
Electrical safety experts answer your questions
Get real about your energy goals
Establish energy benchmarks and be realistic about resources needed to meet them, columnist Peter Garforth says.
Senior managers increasingly are realizing the wide range of risks and opportunities related to their companies’ energy use. As a result, managers who in the past would have had minimal interest in energy-efficiency programs are becoming more…
Energy management motivation: Fighting mixed signals, misaligned goals and unpredictable resources
Track energy costs like you would operating costs
Establishing an energy management dashboard the right way
Proposed facility smart grid standard open for public review
ASHRAE, NEMA collaborate on proposed standard for consumers to describe, manage and communicate about electrical energy consumption
A proposed standard from ASHRAE and the National Electrical Manufacturers Association (NEMA) to create smart facilities supporting smart grids is part of an international effort. The proposed standard is open for public review from Aug. 7 until Oct. 6, 2015.
To read the draft standard or to submit comments, visit www.ashrae.org/publicreviews.
ASHRAE/NEMA Standard 201P, Facility Smart Grid Information Model, would provide a common basis for electrical energy consumers to describe, manage and communicate about electrical energy consumptions and forecasts.
Committee chair Steve Bushby said 201P also is being considered for adoption as an international standard through the International Organization for Standardization. In addition, the…
Your guide to better power quality
Mersen acquires ASP, a Chinese leader in overvoltage protection
Overcome potential problems with power quality
Reduced HVAC energy waste
Survey reveals the protection measures being used to lift machine availability to new heights.
ARC Advisory Group and Plant Services recently conducted a survey targeting manufacturing operations that rely on heavy rotating machinery in a power capacity range of 200 HP to 30,000 HP. This includes heavy-duty pumps, turbomachinery, centrifugal…
GE and Cascade apply new technologies, super-computer capabilities to improve gas turbine combustion
New twists in turbines: How recent developments are delivering business benefits
Improved heat exchanger technology
5 factors driving technological advancements.
Heat exchanger efficiency is crucial. Fortunately, the chemical industry is benefiting from improvements as equipment makers such as Alfa Laval, Klaren International and Heatric leverage the latest materials and technologies to boost performance.
Five main factors — energy efficiency, capacity, emissions, water use and uptime — drive the chemical industry’s demand for improved heat exchanger technology today, says Gert Ternström, market development manager, petrochemical industry, Alfa Laval, Lund, Sweden.
“The overall focus is very much on process optimization and here compact heat exchangers offer great benefits,” he stresses.
To learn more about heat exchangers, read “Exchanger Technology Heats Up” from Chemical…
Reaping the energy benefits of cogeneration
Drive down your energy costs with heat of compression recovery
Compressed air systems' waste heat improves plant economics
Heat recovery — Great in theory, tough in practice
Context-aware technologies: The next frontier in mobile asset management
How to achieve better HVAC and dust collection
Heat recovery and energy efficiency go hand in hand
Loose nut costs U.S. Air Force $62.4 million in accident
Additionally, 27 airmen were put at risk, investigators find
A U.S. Air Force reconnaissance airplane caught fire in April, endangering the lives of 27 airmen aboard the plane - all because a retaining nut connecting oxygen tubing was not tightened properly, accident investigators have determined. The report blamed a private defense contracting company for the accident.
"Failure by L-3 Communications depot maintenance personnel to tighten a retaining nut connecting a metal oxygen tube to a junction fitting above the galley properly caused an oxygen leak. This leak created a highly flammable oxygen-rich environment that ignited," U.S. Air Force investigators wrote in report published August 3.
Investigators determined the ensuing fire caused $62.4 millon in damage to the RC-135V, which electronically…
How to take your plant one step closer to lean
Implementing lean operating systems
Lean manufacturing leads to production gains
Nike supplier to open first U.S. factory in Cincinnati
Legend Sportswear to get 45 percent, five-year job creation tax credit
A fast-growing specialty textile company based in China plans to open its first U.S. manufacturing operation in the Cincinnati region, thanks in part to a tax incentive from the Ohio Tax Credit Authority.
Legend Athletic Wear is the North American subsidiary of Legend Sportswear Pty Ltd., an Australian specialty textile company based out of Shanghai, China. On Monday, the tax credit authority approved Legend Athletic Wear for a 45 percent, five-year job creation tax credit. Legend’s clients include a who’s who of sports apparel companies, including Nike, Adidas and others.
Read the full story on bizjournals.com.
Industrial production rises but manufacturing flat
6 tips for fixing your kitting process
Perspective: It's time for manufacturers to start taking responsibility for suppliers
'The economy will always destroy jobs': Our future in an IT-driven world
Automation will continue to "vaporize" certain jobs, but there may be no need to panic.
“Today, we can say there are two kinds of companies: production companies that make, manufacture, distribute, and retail things, and information companies where most of the work happens in software and on computers,” says business futurist and author Robert Tercek. “We trend to treat those IT companies separately — but those IT companies are beginning to pervade many other industries.”
Read the full blog post on Recruiter.com.
Midwest manufacturing activity slides in August
Management of change
What you need to know before implementing change management
Eight common misperceptions of management of change
Kentucky manufacturers work to expand apprenticeship-style education
More than 70 regional manufacturing companies taking part in education initiative
If you want something built to suit your needs, sometimes it’s best to jump in and build it yourself.
That’s why manufacturing companies across the state are rolling up their sleeves to take part in a rapidly expanding educational partnership that’s been gaining attention in Kentucky and across the country. The program, based on a model launched in 2010 by Toyota Motor Manufacturing Kentucky in partnership with Bluegrass Community and Technical College (BCTC), combines apprentice-style work experience with classroom training to create job-ready workers for Kentucky’s advanced manufacturing industry.
Read the full story at bizlex.com.
Ten companies approved as SMRP Education Providers for reliability and physical asset management
Bumble Bee forced to pay $6M for maintenance worker cooked alive
Don't let plant knowledge leave with your retirees
The costs of additive manufacturing continue to drop, and quality is rising
For the last decade, 3D printing has been the playground of the maker community, while commercial applications have been limited to prototyping. But now, industrial 3D printing has reached its tipping point, and is about to go mainstream in a way that will revolutionize the economy. As costs continue to drop and quality rises, it will be impossible to put this genie back in the bottle.
Here are seven ways that 3D printing production is already in use today and disrupting business as we know it:
1. True rapid prototyping. Recent breakthroughs in automation coupled with the entry of global distribution companies like UPS have changed everything, in some cases leading to same-day production and shipping, and these changes are dramatically…
Fuel sealing systems testing
Seven tips for picking an outside contractor
Offshoring and outsourcing
The benefits of maintenance outsourcing
3 principles to reduce cyber risks to your control systems
Department of Homeland Security offers valuable resources to combat cybersecurity incidents.
While the world is becoming more and more interconnected and “connecting machines to IT systems provides a number of benefits,” such connectivity, if not installed properly, can introduce many security challenges. These inter-connections can enable security vulnerabilities and potential pathways for compromise of the control environment by malicious threat actors.
The mission of the Department of Homeland Security’s (DHS’s) National Cybersecurity and Communications Integration Center (NCCIC), and specifically the Industrial Control Systems Cyber Emergency Response Team (ICS-CERT) is to assist critical infrastructure asset owners to reduce cyber risks to control systems and processes that operate the nation’s critical…
Require safety compliance in your supply chain
How to measure the safety of your plant
Safety is everyone's job
Toyota workers injured, lines shut after Tianjin explosion
Are new OSHA rules on electrical safety regular or supersize?
The history of electrical safety
OSHA issues proposed rule to clarify employer record-keeping
Proposal clarifies ongoing obligation to make and maintain accurate records of work-related injuries and illnesses
The Occupational Safety and Health Administration (www.osha.gov) recently issued a Notice of Proposed Rulemaking that clarifies an employer’s continuing obligation to make and maintain an accurate record of each recordable injury and illness throughout the five-year period during which the employer is required to keep the records.
“Accurate records are not simply paperwork, but have an important, in fact life-saving purpose,” said Assistant Secretary of Labor for Occupational Safety and Health Dr. David Michaels. “They will enable employers, employees, researchers and the government to identify and eliminate the most serious workplace hazards: ones that have already caused injuries and illnesses to occur.”
OSHA is issuing this…
Small labels, big safety message
Got questions about arc flash? We've got answers.
Arc flash hazard experts answer your questions
Mitigate arc-flash risk
Arc flash: Trained but not applied
Best practices for conducting an arc flash risk assessment
NFPA 70E 2015: What's changed and what you need to know
The effect of growth on electrical equipment reliability and safety
How will IIoT affect the future of manufacturing?
NIWeek speakers explore the future of big analog data and the Industrial Internet of Things.
Each August, engineers and designers gather in the Live Music Capital of the World and enthusiastically bear the triple-digit heat to drink from the cool, refreshing hose of industrial innovation and listen to presentations of the newest applications of National Instruments’ technology. This year, NIWeek in Austin, Texas, focused on the latest developments surrounding the Industrial Internet of Things (IIoT) and big analog data (BAD).
“We’re in the early stages of the Internet of Things,” said Jeff Kodosky, one of the co-founders of NI and the “father” of its LabView platform. “The IIoT is about connecting machines and systems to improve reliability, productivity and safety. Sensors and devices will create huge amounts of…
Get practical advice on how to make the IIoT work for you at Smart Industry
Six tips for remote HMI/SCADA users to protect plant operations, drive cost savings
Ensure that your critical ICS data is protected
Smart manufacturing: A path to profitable growth
Automation supplier revenues continue slide in Q2 2015
Wireless technology gets extreme: Overcoming harsh environments
Wireless leak detection offers continuous monitoring and significant savings
ABB acquires full ownership of CGM
Manufacturer group takes action on recent FCC ruling
Drop in oil prices, strong dollar had significant impact on growth
Automation suppliers saw their revenues drop by over 3 percent during the second quarter of 2015. The precipitous drop in oil prices and the strong dollar had a significant impact on growth for many process industry suppliers. Based on the corresponding drop in order activity, many suppliers have trimmed their expectations for business in the quarters ahead.
Discrete automation suppliers continued to benefit from stronger investment activity in the electronics and automotive industries in Asia and North America, and Japanese suppliers continued to gain disproportionate benefit from a weaker yen.Compared to the second quarter of 2014, the total combined revenues of automation suppliers to both the process and discrete manufacturing…
Maintenance Close-Up: Tool box, electrical enclosure or filter housing
Maintenance Close-Up: Thermometer, enclosure heater or temperature transmitter
Maintenance Close-Up: Enclosure, switch or lift truck
Will you be working for a robot in the future?
How much do you know about robots?
Running robots mean flowing profits
Direct-drive technology outperforms traditional motion control systems
New report challenges government findings, claims U.S. manufacturing still hurting
Dow plummets 1,000 points at open as global selloff deepens
ABB Foundation grants $20,000 to Columbus inner-city school
Franklinton Preparatory Academy provides adaptive learning to at-risk youth
ABB (www.abb.com) has awarded a grant of $20,000 through its ABB Foundation to the Franklinton Preparatory Academy (FPA), a public vocational charter school in Columbus, Ohio.
FPA’s mission is to provide an adaptive learning environment to at-risk youth to ensure that they receive the education they need for a successful life path, whether in the workplace, at college, the military or elsewhere. The school is located in the Franklinton area of Columbus, one of the most economically challenged areas of the state where school dropout rates are high.The ABB Foundation grant money was invested to purchase Google Chromebook tablet computers for an Extended Learning Laboratory that is key to the school’s adaptive learning approach.Dan…
4 ways to conquer critical moments
Mayor: Small-business growth, advanced manufacturing helping to power New Orleans' comeback
Study: Work to reinvent post-Katrina New Orleans remains unfinished
Training operators and maintenance staff with 3D visualization
Three things you can do to (re-) engage an apathetic workforce
What are the core actions to take in order to reignite your team's competitive fire?
The shortage of skilled workers is already surfacing as a constraint to manufacturing companies for engineers, scientists, skilled trades, electronic techs, certain machine operators with special skills and so on. In contrast, those performing manual labor and running outdated, legacy equipment are finding themselves disadvantaged.
There may be many underlying issues at play, but these three actions can help leadership get beyond worker frustration and disegagement, and reignite your team's competitive fire. (Hint: communicate clearly and consistently, and make sure your actions match your words.)
Read the full article here.
Why a domestic manufacturing renaissance won't be easy to pull off
Do you know what young engineers are looking for?
Is your plant suffering from poor engineering quality? You're not alone.
Are internships the key to closing the skills gap?
Arne Duncan: Inspire and prepare more students to excel in STEM fields
IL community college, state university push to boost local engineering workforce
Training and Career Center
Tom Moriarty says be more productive and satisfied by taking responsibility for your circumstances.
Have you ever been bummed out because you were in a hurry to get somewhere and you got stuck at a traffic light because the car ahead of yours just got through the intersection after driving the past 3 miles under the speed limit? Did you get mad…
Mitch Landrieu cites Goldman Sachs' 10,000 Small Businesses initiative as turbocharging post-Katrina focus
Nearly 10 years ago, Hurricane Katrina shone a spotlight on the major challenges the greater New Orleans region had been facing for decades: high poverty, structural unemployment, major population declines, a non-diversified economy and migrating businesses. All this meant that in the 40 years preceding, the area had underperformed the national average in job creation by more than 40 percent.
Today, with our partners at GNO, Inc. and the NOLA Business Alliance, New Orleans is diversifying its economy, creating jobs in digital media and bioscience, and fostering an emerging environmental industry focused on coastal restoration and sustainability, all while sustaining foundational industries like energy, international trade, advanced…
U.S. futures signal big rebound on Wall Street
Check out WATCHMAN Reliability Services
The new TRIO 8-Series and 10-Series Vibration Data Collectors and Analyzers feature a lightweight portable design to meet the demands of the field while delivering data at improved safety and efficiency levels. TRIO Data Collectors are WATCHMAN Portal-Enabled allowing complete visibility into your facility's PdM program with real-time results and business level metrics.
Azima DLI provides predictive maintenance services and products to industry. Often providers of troubleshooting instruments confuse the industrial market as to the differences between their capabilities and true condition monitoring.
Learn how RaaS, or Reliability as a Service, can benefit your new or existing condition based monitoring program. RaaS offers a complete solution that gives you access to the latest data collection technologies, expert advice and visibility across departments while increasing the sustainability of your program.
Azima DLI CEO Burt Hurlock explains how machine health monitoring has evolved and what that means to large-scale enterprises.
In modern business environments, collaborative work models provide better ROI and accountability. Strategic partnerships have become a must, not a luxury. Recognizing the benefits and intelligently selecting and leveraging a PdM service partner allows the plant to keep control of its assets while optimizing productivity and cost effectiveness. This special report investigates how to determine which tasks can be outsourced, what the impact is on uptime and professional growth, and which KPIs can help to measure your success.
Return on investment (ROI) is a divisive issue among maintenance professionals. In a recent joint survey by Plant Services and Azima DLI, more than half of respondents indicated they didn't measure their return on predictive maintenance and condition monitoring investments. The ability to quantifiably measure the effectiveness of a department's execution and output could serve as the difference between increasing the annual budget and receiving further cuts. This special report helps to explain the benefits of tracking and reporting ROI.
How many companies want to buy more maintenance? None, obviously. Management wants to invest in predictability, cost-effectiveness and on-time delivery. Yet most plants still operate in run-to-fail mode and spend too much on repairs. Learn how to make the move to a successful PdM program and find out the six ways you can switch from run-to-fail to run-to-profit.
Engineers see the value of predictive maintenance (PdM), but unfortunately there's no line on the spreadsheet for it. The difficulty of demonstrating return on investment (ROI) is one of the top barriers to success identified by plant engineers and middle management. Read this Special Report and learn how to prove the cost-effectiveness of your PdM program.
The current crop of predictive maintenance (PdM) management software now delivers instantaneous decision-making power for those engineers and plant managers charged with wringing the maximum utility from their facilities while conserving maintenance costs. Capable of instantly analyzing and interpreting vibration data – along with ferrography, used-lubricant analysis and visual inspections – today's PdM software not only delivers integrated and prioritized information to plant managers in their offices, but throughout the entire organization via enterprise-wide "electronic in-trays," text messages, pager alerts and even HTML pages accessible via a common Web browser.
The Conoco Phillips Ferndale Washington Refinery was constructed in 1954. Ferndale is an integrated single train fuels refinery with the following operating units: FCC, HF Alkylation, Reformer and the typical array of supporting units. The refinery's capacity is 110,000 Bbl's per day and it has about 1,000 pieces of equipment. The rotating equipment group has full responsibility for the condition, effectiveness and mechanical integrity of the machinery. The staff consists of three rotating equipment reliability engineers, one part time vibration monitoring technician and a maintenance superintendent.
This paper presents a comparison of machinery condition monitoring results obtained through the use of troubleshooting tools and traditional predictive maintenance instruments and software.
Mill technicians at Orchids Paper suspected that two roll bearings were deteriorating on their most critical paper machine. Relying on Azima DLI's WATCHMAN Insight program to provide early warnings on impending machine faults, the Mill technicians collected vibration data from the suction pressure roll and top press roll bearings. The data was then posted to Azima DLI's Reliability Portal for an analyst to review.
A potentially catastrophic electrical fault was discovered at Total Petrochemicals during a routine annual infrared thermography survey performed by Azima DLI. The reactor appeared to be operating normally but the infrared inspection revealed a faulty wire connection and critical heat damage to the aluminum bus bar that would otherwise have gone undetected until failure.
When one of its two Through Air Fans developed a large crack in a blade, Kimberly Clark’s Owensboro, Kentucky paper mill was six weeks away from its scheduled outage. Taking the damaged fan down early would cripple mill production by 50% for weeks, but trying to run the fan until the shutdown could result in catastrophic consequential damage if it failed. Azima DLI was hired to take frequent vibration readings and determine whether the fan could stay in operation until the outage. If the fan had to be taken out of service, the mill faced nearly $5 million in production losses.
Cloud Computing is opening up many possibilities in the world of Predictive Maintenance (PdM). The benefits are quickly realized by companies who choose to leverage this technology.
You must have a lean and reliable operation in order to maximize profits. Knowledgeable decisions become essential to preventing costly mistakes. Any industrial plant depending on mechanical production assets needs to ensure maximum performance and reliability. Failure to do so, can lead to unexpected downtime that can reduce or completely interrupt plant production and profit generation.
Leading companies do not compromise their machine condition monitoring programs and jeopardize their profits. A proper asset reliability program is critical to your machinery health and should be performed by the industry's leading experts. WATCHMAN Reliability Services by Azima DLI puts the industry's leading experts on your team, offering you the greatest defense against unplanned and costly downtime.
WATCHMAN Professional is a premium machine condition monitoring service program that provides predictive monitoring for plants or enterprises with 250 or more machine assets where unplanned outages cannot be tolerated.
WATCHMAN Insight is a comprehensive machine condition monitoring service program that provides predictive monitoring for moderate sized plants or enterprises with 75 to 250 machine assets where unplanned outages are disruptive and costly.
WATCHMAN Select is a machine condition monitoring service program that provides predictive monitoring coverage for smaller plants or enterprises with 15-150 machine assets.
Engine and compressor analysis is used to diagnose the presence of mechanical problems to avoid catastrophic failure and allow repairs to be effected on a scheduled basis. Additionally, fuel savings achieved by properly balancing engines and by replacing leaking compressor valves routinely saves enough in fuel and electricity costs to pay for a subscription-based analysis program.
Azima DLI provides a full range of condition monitoring services, including infrared testing, an inspection process using infrared cameras as a means to “see” and “measure” thermal energy emitted from equipment at your plant. In other words, it allows us to see what the human eye cannot.
Among its condition monitoring services, Azima DLI provides a highly reputable oil analysis program. Oil analysis is part of the tribology field, which is the science and technology of interacting surfaces in relative motion.
Durable, powerful, and lightweight, the new TRIO 8-Series vibration data collectors feature a thin 10” tablet controller giving users more visible area while in the field. The CX8 and CA8 series of vibration data collectors and diagnostic instruments are durable with an IP-52 environmental rating. These controllers offer tremendous portability while still maintaining a durable standard expected in today’s industrial environments.
TRIO CX10 and CA10 provide a rugged 10” tablet that is up to the demands of harsh industrial environments. The TRIO CX10 and CA10 vibration data collectors and diagnostic instruments are lightweight at just 2.9 pounds and just 1.2 inches thick but are rugged enough for your IP-65 rated environments and have stringent MIL-STD-810G standards for protection against dust, water, vibration, drops, extreme temperatures and varying altitudes.
Azima DLI's training courses are designed to provide you with the knowledge and tools you need to meet all of your condition monitoring program goals. Our flexible course offerings range from onsite training at your facility to web-based classes that allow you to work at your own pace. You will always be getting the highest quality of training from our expert staff of condition monitoring professionals.
Azima DLI is the leader and premier provider of predictive maintenance analytical services and products that align with customers' high standards for reliability, availability and uptime. We deliver machine health reliability solutions with global reach that reduce risk, improve safety, increase production and optimize efficiency.
Azima DLI's subscription based programs are delivered through a suite of predictive maintenance best practices, best technology and best customer solutions at the plant and enterprise level. Our WATCHMAN Reliability Services utilize flexible deployment models, proven diagnostic software and unmatched analytical expertise to deliver sustainable, scalable and cost-effective condition-based maintenance programs. The company's offerings enable customers to implement comprehensive, predictive maintenance programs that ensure asset availability and maximize productivity. Azima DLI is headquartered in Woburn, Massachusetts with offices across the U.S. with international representation in Asia-Pacific, Central America, Middle East, Europe and South America. To learn more please visit us at www.AzimaDLI.com
To learn more about how WATCHMAN Reliability Services can deliver outstanding value to your company, contact us at toll free U.S. at 800-482-2290, international at (+1)781-938-0707, or visit us online at www.AzimaDLI.com.
Azima DLI World Headquarters
300 TradeCenter, Suite 4610
Woburn, MA 01801 USA
toll free 800-482-2290
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Azima DLI Government Services
1050 NE Hostmark Street, Suite 101
Poulsbo, WA 98370 USA