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Five steps to zero downtime: Downtime is money

Lee Sullivan, regional manager for industrial automation software company, COPA-DATA UK, explains his five steps towards zero downtime.

Digitalisation — not just for big business

When mobile phones were first released in the mid-1980s, a handset would set you back £3000 ($4000) — the equivalent of almost £7500 ($10,000) today. PWE looks at how smaller food manufacturers can take advantage of low-cost digital technology.

The answer to this month’s trouble shooter is provided by Henkel. Q: What are the options for stopping bearing spinout?

A: By the nature of what they do, bearings are prone to spinning within their housings. This action inevitably causes damage, regardless of the type of fit employed. Where, for example, a bearing is secured by a press fit, the actual metal-to-metal contact accounts for as little as 30% of the total surface of the joint. Small micro-movements at the joint interface can then produce particles which abrade and reduce the contact surface even more.

Cost-effective machine safety solutions

Machine safety is the responsibility of all machine designers, manufacturers and end-users from both a legal and moral standpoint. In the past the desire to offer the very best protection has sometimes been tempered with the need to keep costs down, prompting the question – ‘What price safety?’

The cost of leaking

Peter Crossen, VP of NCH Europe, looks at the cost of a leaking pipe.

Q. How can I quickly and effectively monitor vibration on rotating equipment?

The answer to this month’s trouble shooter is provided by Sam Thiara, Emerson Automation Solutions.

Short term monitoring solution helps mill prolong operating life

By implementing a temporary monitoring solution for assessing the condition of the trunnion drive end bearing on a cement tube mill, Schaeffler has helped Sunstate Cement prolong the operating life of its mill, thus avoiding the significant cost of replacing the bearing and the associated downtime. PWE reports.

Smart sensing transformation

PWE looks at how the arrival of smart sensing technology is set to transform the maintenance of low voltage (LV) motors.

Vital electrical equipment gets a new lease of life

When the Mucomir Hydro-power station in Scotland identified the urgent need for a new Brushless AC Exciter it turned to Quartzelec, the independent engineering service provider who is recognised as an expert in rotating electrical machines, to develop, implement and commission the retrofit solution.

The importance of fluid analysis

It is critical that machinery and equipment in the manufacturing industry operates at optimal efficiency at all times. By taking a closer look at fluid analysis, the industry could save money and improve reliability. Steve Haughton, technical manager at Finning UK & Ireland (Finning), discusses the advantages of a condition-based approach, outlining how fluid analysis can provide visibility of equipment performance and health.

The answer to this month’s trouble shooter is provided by MISTRAS Group Limited.

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The answer to this month’s trouble shooter is provided by MISTRAS Group Limited.

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Vision of the future

There is no shortage of vision systems that can offer complex inspection capabilities at incredible speed but their performance often falls short in harsher industrial environments.

The future of maintenance engineering

Jonathan Wilkins, marketing director at obsolete equipment supplier EU Automation, discusses how Industry 4.0 is changing the way businesses approach maintenance, and what is the role of the maintenance engineer in the factory of the future?

The answer to this month’s trouble shooter is provided by John Saysell, head of business development & training, MCP Consulting Group Ltd. Q Should I be more aware of Safe Isolation Procedures?

A

Quicker troubleshooting

Smart devices have created connections across industrial operations with the potential to empower plant or distributed workers. For many producers going through a digital transformation, these modern tools can take too long to deploy, with too much investment required to decipher and deliver relevant data to the right employees.

The answer to this month’s trouble shooter is provided by Sam Thiara, Emerson Automation Solutions. Q. How do I prevent safety valves from sticking and creating an explosion risk?

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Preventing stray current build-up in electric motors

When a motor is in use it is possible for the shaft to become electrically charged, which can be dangerous and also cause internal damage to the motor. Many solutions to this are expensive and also add significantly to the total lifetime running costs of the motor.

Predicting the future of maintenance

Gernut van Laak, group automation solutions leader of ABB's Food and Beverage Programme, explains how plant managers can budget for maintenance and ensure optimum efficiency for all processes.

The answer to this month’s trouble shooter is provided by Sam Thiara, Emerson Automation Solutions. Q. How can I quickly and effectively monitor vibration on rotating equipment?

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A successful blend of tradition and technology

PWE takes a look at how a CMMS solution is helping increase production efficiency at Simpson’s Malt.

Lubrication systems simplified

A new addition to SKF’s range of lubrication products, the LMC 301 is a programmable controller for applications where sophisticated control of lubricant delivery is required. Designed for use with pumps that have no built-in controller, the LMC 301 combines all critical lubrication system management functions in a single package, simplifying system setup, operation, monitoring and maintenance.

Condition monitoring for high availability demands

SPM Instrument has added to its Intellinova range with the Intellinova Parallel EN. It is particularly well suited for applications where a critical success factor is the capacity to complete the required measurement within a very limited timeframe, e.g. due to short process cycles.

The answer to this month’s trouble shooter is provided by Phil Nicholas, business development manager – Linear and Actuation Technology at SKF.

What should I look for when choosing between a ball screw and a roller screw?

How do I identify and prevent bearing fatigue?

The answer to this month’s trouble shooter is provided by Phil Burge, country communications manager at SKF.

Localised decision making for industrial automation

The phrase ‘localised decision making’ immediately conjures up images of council meetings where a group of people make decisions that will affect those in the immediate vicinity.

Predictive maintenance turns from an art to a science

It’s a challenging problem to accurately predict reliability with limited data. That’s why over the years igus has built up a large database of life calculations and other engineering information about the performance of its bearings, cables and energy chains in various applications.

Condition monitoring services extended

Precision bearing manufacturer Schaeffler UK has extended its range of condition monitoring (CM) services for the UK market. The company says that with its combination of knowledge in bearing failure analysis, vibration monitoring, fitting and maintenance of bearings, and its own portfolio of condition monitoring equipment, it is positioned to offer CM services to a wide range of industry sectors, including rail, wind energy, paper, steel, food, mining and quarrying and pharmaceuticals.

Diagnostics service drives down stress levels

Drive lifetime is prolonged with a new service from ABB, which analyses existing conditions to predict future maintenance needs and optimise operation. ABB-certified engineers analyse the performance and condition of the drive on-site, and use their expertise to provide detailed diagnostics and maintenance recommendations for the end user.

What are the correct procedures for aligning belts?

The answer to this month’s trouble shooter is provided by Phil Burge, country communications manager at SKF

Smart condition monitoring

Predictive maintenance is the best answer to minimising the risks of equipment failure, however, monitoring practices in the past have been expensive, problematic and at worst, unreliable. The solution is to switch to what Mitsubishi Electric refers to as ‘Smart Condition Monitoring’, a system which can connect to rotating equipment and provide plant-wide 24-7 monitoring. PWE reports.

Manual tube bender and spring back

This article is based on guidance provided in the British Fluid Power Association’s training course titled ‘Small Bore Tubing Integrity Course – using twin ferrule compression fittings’. Following on from our look at tube preparation in our November edition, this month, we look at tube bending principles.

How do I prevent safety valves from sticking and creating an explosion risk?

The answer to this month’s trouble shooter is provided by Sam Thiara, Emerson Automation Solutions.

Refinery uses new IIoT technologies to improve performance

Delek Refining, Inc. will use a new Industrial Internet of Things (IIoT)-based Connected Performance Services (CPS) offering to improve the performance of its refinery in Tyler, Texas, it was announced by Honeywell recently.

Online condition monitoring solution

Norwegian biorefinery Borregaard has chosen SPM Instrument to supply online condition monitoring equipment for its production-critical chemical washers in the fibre line.

Tube end requirements – correct cleaning

This article is based on guidance provided in the British Fluid Power Association’s training course titled ‘Small Bore Tubing Integrity Course – using twin ferrule compression fittings’. Following on from our look at tube preparation in our October edition, this month, we look at tube end requirements.

New retrofit safety valve solution

Industries with highly automated processes, such as food & beverage and pharmaceuticals face many challenges, especially in terms of maintaining a safe environment. As increased legislation continues to require higher standards, Bürkert Fluid Control Systems has developed a series of safety valve solutions that can be retro-fitted to existing control systems or incorporated into new designs.

Intelligent condition monitoring

A condition monitoring system installed on a paper coating machine has enabled the Mitsubishi HiTec Paper Europe plant in Bielefeld, Germany to switch from time-based to condition-based monitoring, helping to avoid unnecessary machine shutdowns. Enabling the new system is a Mitsubishi Electric L-series PLC that operates as a bidirectional gateway between the controller and sensors. PWE reports.

Tube preparation

This article is based on guidance provided in the British Fluid Power Association’s training course titled ‘Small Bore Tubing Integrity Course – using twin ferrule compression fittings’. This month, we look at tube preparation.

The answer to this month’s trouble shooter is provided by Andy Jones, MD at Mattei Compressors Ltd.

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Model Predictive Torque Control protects against gas supply interruptions - Application story

ABB’s Model Predictive Torque Control* (MPTC) software protects compressor operation during power supply disruptions, saving time and money. PWE reports.

Adjustable (positional) connectors

This article is based on guidance provided in the British Fluid Power Association’s training course titled ‘Small Bore Tubing Integrity Course – using twin ferrule compression fittings’. This month, we continue our look at associated threads, focusing on adjustable (positional) connectors BS EN ISO 6149, ISO-1179 and ISO-11926/SAE J1926.

The answer to this month’s trouble shooter is provide by SKF. Q: Why would I need a magnetic bearing?

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Manufacturer secures annual energy saving following compressed air upgrade

Annual energy savings of at least £10,000 and increased productivity have been realised by Heritage Trade Frames, a fabricator of domestic and commercial windows, doors and conservatories in the North West of England, after opting for a compressed air systems upgrade from Atlas Copco.

Avoiding complacency!

Howie Emerson, implementation consultant, Bentley Systems, looks at safety and asset health monitoring in the power industry and how to avoid complacency and encourage strong responses to weak signals.

Avoiding complacency!

Howie Emerson, implementation consultant, Bentley Systems, looks at safety and asset health monitoring in the power industry and how to avoid complacency and encourage strong responses to weak signals.

End terminations identification – part 3

NPT SAE J514/SAE J516

Prioritise your storage tank maintenance

Risk-based inspection systems and advanced non-destructive testing methods are helping storage tank owners comply with ever-increasing stringent regulations, as well as reducing maintenance costs, says Tim Bradshaw, general manager, MISTRAS Goup, UK operations.

End terminations identification – part 2

This is part of a series of articles based on guidance provided in the British Fluid Power Association’s newly introduced training course titled ‘Small Bore Tubing Integrity Course – using twin ferrule compression fittings’. This month, we present part 2 of guidance regarding end termination identification.

Question: How can I assess the structural integrity of process storage tanks without busting the maintenance budget or causing costly plant downtime?

The answer to this month’s trouble shooter is provided by MISTRAS Group Ltd.