Editorial

It is reported that when Sir John Barbirolli was once conducting the world-famous Halle orchestra in Manchester during a rehearsal, he shouted at the top of his voice…” where’s the piccolo?”.

A tiny instrument that the player obviously thought would go unnoticed amongst the ensemble of large, loud instruments. A salutary lesson on how a single seemingly insignificant element can affect the entire performance.

Stories like this resonate in industry too. Major manufacturing complexes often contain thousands of industrial components such as hydraulic pumps and industrial gearboxes. Some of these may seem like unimportant ancillary pieces of equipment but they are often vital to production and can bring the whole complex to a grinding halt when they fail.

A good example of this is a quarry where the mined aggregate is conveyed to a ship or loading point through a series of conveyor belts. The belts themselves are driven by electric motors utilizing gearboxes with each conveyor containing a multitude of roller bearings that support the belt itself as the aggregate is transported to its destination.

These conveyers can sometimes cover huge distances. Take the conveyer belt system between the Mount Saddleback mine and Worsley refinery near Collie, Western Australia, the 31 kilometre flight of the main conveyor is the longest single conveyor belt in the world. The total distance of the complete conveyor system is an incredible 51 kilometres (31.6 miles). It is used to transport 2,700 metric tonnes of bauxite ore per year, from which aluminium is produced. The roller bearings supporting the long belts may seem insignificant elements when compared to huge crushers, graders, screens and major parts of the overall process, and yet if a number of these bearings seize or fail, then the entire production can come to a halt.

Potential failures of these bearings can be identified utilizing thermal imaging cameras, a technique that has been successfully used for many years, saving millions in terms of lost production and catastrophic failure. However, a more recent approach is to utilize acoustic imaging cameras which can provide a much earlier warning signal when it comes to bearing failure.

The latest FLIR Si2 LD acoustic imaging camera has different operation modes, firstly the leak detection mode (LD) that is used for detecting minute gas and air leaks in pneumatic, vacuum or speciality gas systems. Secondly, Mech Mode which can detect mechanical problems with bearings and gears way before they fail. This early warning tool is easy and quick to use meaning that even long conveyor belts with hundreds of support bearings can be analysed very quickly on a regular basis providing an in-depth health check and an early warning system, hence potentially avoiding expensive downtime.

The FLIR Si2-Pro acoustic imaging camera comes loaded with a multitude of additional features. The improved performance means the new camera is capable of detecting problems at much greater distances. It shows a 70% improvement in acoustic performance compared to previous Si124 models. The camera is therefore more adapt at detecting multiple mechanical sources thanks to the improved multisource mode. The camera features a 2x and 8x digital zoom which provides images to the 5 inch colour touch screen which boasts a resolution of 1280 x 720 for both video and images with GPS, image tags and comments potentially added to images for further analysis to be conducted. Still images can be produced with both .nlz and .jpg format whilst videos can be formatted in .nlz. Data transfer can be conducted via Wi-Fi or USB with automatic over the air wireless updates ensure the camera is always up to date. Measurement data can be stored on the internal SD card up to 128GB with unlimited cloud storage available with FLIR Cloud. Weather detecting developing faults in high-voltage applications, leaks from pneumatic equipment or speciality gas installations; or mechanical issues such as bearings in conveyors, the FLIR Si2-series of cameras can provide the insights needed to maintain uptime and reduce operational expenditure. For more information on the Si2-Pro and other acoustic imaging cameras in the FLIR range, please contact your local Teledyne FLIR representative or your local FLIR distributor.

www.flir.com

Fay Hutchinson has joined the British Compressed Air Society (BCAS) in the newly created role of Learning Support Officer.

Working alongside Terry Collier, BCAS’s Learning and Development Officer, the new role will see BCAS further enhance the breadth and range of compressed air and vacuum training courses and approved accreditations available, with particular focus on increasing participation in its compressed air and vacuum technician (CAVT) apprenticeship.

Fay has a wealth of training experience, gained in roles both within engineering and the higher education sector. Starting her career in the stainless steel and aluminium sector, Fay holds a first-class honours degree in business management and a master of business administration (MBA) and has recently completed a level 6 diploma in career guidance and development.

Of particular benefit to BCAS and its members is Fay’s experience gained during her work with higher education institutes.  She has held several employer relationship roles, most recently at the University of Greenwich, where she has secured successful industrial work placements for students during their university studies.  She has also been actively involved in encouraging businesses to offer degree apprenticeships, using their apprenticeship levy where appropriate to either bring new talent into the business or to upskill existing members of staff.

Commenting on the appointment, Ashley Quarterman, BCAS Executive Director said:

“The industry is only too aware that recruiting and retaining skilled staff into the compressed air and wider engineering sector is challenging.  Offering high-quality training, whether through our apprenticeship scheme or one of our many CPD-approved courses, can help to deliver the next generation of engineers that our sector needs.

Continues…

“It is great to welcome Fay to the team and to be able to draw on all her experience in both the industrial and education sectors.  She understands how effective learning environments can be created, alongside the pressures faced by employers to continually train their teams and this will be of genuine benefit to our members.”

Fay added:

“I am really looking forward to using my skills to help further enhance the training support available to our members.  I am already speaking to members about our CAVT apprenticeship and some of the ways we can refine it further through progression routes, as well as being able to advise on the range of bursaries and levy funding that could be available.”

For further information about the British Compressed Air Society please visit https://www.bcas.org.uk

Plant setups need well-maintained pumps and valves. They need to handle fluids, pressure, and flow control smoothly for the sake of a productive operation.

The only way plant engineers can ensure that the pumps and valves operate in tip-top condition is through stringent monitoring. However, the job won't be as easy without PCB-based data loggers.

PCB (printed circuit board) data loggers are small but powerful tools that keep track of pump and valve health. The best ones provide insights that will reduce everyone's headaches, particularly when dealing with maintenance.

PCB-Based Data Loggers

Designed to monitor equipment performance, PCB-based data loggers are composed of printed circuit boards and sensors. The use of multi-layer PCB allows a compact build while serving as the core of the system.

These devices process data from sensors in real time. They keep track of the pressure, temperature, vibration, and flow rate. It's the ultimate machine that helps plant managers keep an eye on how their pumps and valves are holding up.

PCB-based loggers are also precise and versatile. They collect data continuously, which means they monitor the performance and raise alarms early before they cause real problems. This level of insight is critical for preventing loss.

What Data Do PCB-Based Loggers Capture?

PCB-based data loggers track key performance metrics, which are as follows:

• Pressure and Flow Rates: Fluctuations in pressure or inconsistent flow indicate blockages or leaks.
• Temperature: PCB-based loggers also check rising temperatures that indicate friction, poor lubrication, and other mechanical issues.
• Vibration Levels: High or unusual vibrations are often the first sign of misalignment or imbalance.
• Operating Cycles: Tracking how often pumps and valves cycle on and off helps gauge overall efficiency.
•  

PCB-based data loggers monitor these factors, ultimately giving plant engineers a clearer picture of equipment performance and whether it needs attention.

Why Use Data Loggers for Monitoring?

Manually checking pumps and valves isn't cost-efficient. Plant managers use data loggers to make monitoring seamless and accurate. Here's why they're worth it:

1. Continuous Monitoring: Loggers work 24/7. This ensures you never miss a potential issue.
2. Early Problem Detection: Catching anomalies early prevents costly breakdowns.
3. Data-Driven Maintenance: Real-time data lets you schedule maintenance when it's actually needed. There is no need to guess when to call the crew.
4. Improved Efficiency: With actionable insights, you can optimize operations and reduce energy use.

Integrating PCB-Based Data Loggers

Surprisingly, installing loggers to plant systems is incredibly easy. Most of the units are designed to attach directly to pumps or valves.

Once connected, the sensors feed data to the PCB. From hereon, data collection begins. Some loggers even sync with your plant's monitoring systems, letting you access data through dashboards or alerts.

When setting them up, plant engineers must configure the logger correctly. Make sure you're tracking the right metrics and setting thresholds for alerts. This way, you'll know when something is off without constantly checking the system.

PCB-based data loggers save plant engineers from a lot of guesswork. This technology provides a reliable way to track performance and spot issues before they blow up. It's all about working smarter, not harder, and these tools are a step in the right direction.

Europe's leading manufacturer of sweet biscuits implements preventive maintenance with Ultimo / Cross-site introduction planned

More than 100,000 tons of sweet biscuits per year, delivered to over 80 countries worldwide: Bahlsen is the leading biscuit manufacturer in Germany and one of the leading suppliers in Europe. The company uses IFS Ultimo for Enterprise Asset Management (EAM) to optimize maintenance management for its systems, achieve maximum uptime with preventive maintenance and standardize processes in four plants. 

In February 2023, Bahlsen introduced the cloud-based software solution at its production site in Berlin. A blueprint for desired maintenance processes was developed and tested here. Initially, 24 users used the Standard Asset Management. An important part of this is the integration of production, whose employees can report failures directly in the system or resolve reported failures straight away. The aim of the pilot project was to define the requirements for the system solution and establish common KPIs, which are then measured at group level. Ultimo was then transferred to the company's other plants using the experience gained in Berlin. Ultimo is also to be implemented at the logistics site. As a result, Ultimo is used to implement, centrally monitor and optimize standardized maintenance processes across the company. 

"Bahlsen produces bakery products in a total of five plants. With IFS Ultimo, we achieve the greatest possible transparency across all sites regarding the condition of our equipment and improved reporting and monitoring of maintenance activities. This data enables us to move from reactive to preventive maintenance and thus reduce downtimes due to unplanned maintenance to a minimum", says project manager Aimal Khan, Digital Manager at Bahlsen regarding the introduction of Ultimo.

Necessary downtimes can be efficiently planned and managed with Ultimo. Operators, maintenance staff and management access the same centrally managed data. In the long run, Bahlsen also intends to use the integrated Long Term Asset Planning module (LTAP). This enables maintenance staff to draw up long-term budget plans for their equipment based on the condition of the assets and the costs of maintenance, renovation and replacement. 

This allows informed decisions on maintenance measures and the implementation of preventive maintenance with maximum cost efficiency.

Heike Roth, Team Lead Inside Sales, IFS Ultimo, adds: "With IFS Ultimo’s cloud-based EAM software, Bahlsen benefits from shared maintenance KPIs that are defined, measured and monitored at group level. Together with the wide range of asset management functions, this maximizes productivity and efficiency. This strategic approach underlines the company's high standards of quality and innovative strength."

In addition to the flexible and powerful modules for planning, optimizing, executing and monitoring maintenance activities, the integration of Ultimo into intelligent Asset Performance Management (APM) platforms was also a reason for the decision to use IFS Ultimo for Enterprise Asset Management. The two companies work closely together in a strategic partnership to enable customers to make fast, accurate and data-driven decisions and to help the industry improve its operational performance and sustainability.

Ultimo is a cloud-based Enterprise Asset Management software with numerous modules for managing assets, work orders, projects, maintenance, and health, safety and environmental (HSE) issues. It helps to map and manage processes transparently and to simplify their execution. All data is centrally available to users in Ultimo and can also be used on the move thanks to the cloud-based solution - whether on a PC or laptop or the operator's or maintenance manager's mobile device directly at the equipment. For this purpose, dedicated Android and iOS apps are available.

www.ultimo.com

• Enterprise asset management (EAM) system manages and maintains manufacturing assets
• Improved operational efficiency with mobile-enabled engineers, better resource allocation, and predictive maintenance
• Powering ACC to increase production volume and support the automotive sector’s energy transition

Vehicle battery manufacturer, Automotive Cells Company (ACC), has implemented enterprise asset management (EAM) software from IFS Ultimo to drive the development and industrialization of the first French battery for the automotive industry. By managing and maintaining more than 20,000 manufacturing assets with the EAM system, the Mercedes and Stellantis-owned company has improved operational efficiency and enabled both corrective and preventative maintenance.

Powering the energy transition through sustainable, affordable, high-capacity, and longer-life batteries for electric vehicles (EVs), ACC expects to manufacture batteries for 150,000 Stellantis vehicles by the end of 2025, with the first block currently in ramp-up. With its machines running for longer periods, the software-as-a-service (SaaS) EAM system allows ACC to repair assets quickly, saving time and money, and ultimately increasing production volumes.

François Carrot, Information System Director at ACC, explains, “Price competition is the first challenge for ACC. To win this battle and become a key player in the European energy transition, ACC focuses on scrap reduction and increasing overall equipment effectiveness. Our team understands the importance of adopting a modern and efficient EAM to manage and maintain the industrial assets that are critical to our strategic ambition. Better resource allocation and responsiveness underscore the operational efficiency at ACC, which is pivotal to the commercial performance of manufacturing businesses.”

Delivered by integrator Inoteam, the system setup includes plans and photographs for each ACC machine. Using mobile applications on tablets, engineers simply scan a QR code to access documentation associated with each of the 20,000+ assets. This includes information on periodical maintenance, the history of all operations performed, along with comments from the people who have worked on it. Being mobile-enabled allows ACC engineers to conduct maintenance rounds and record various values ‘on-the-go’. The centralized EAM also manages stock to ensure the availability of parts during repairs.

Johan Made, CEO at IFS Ultimo adds, “It is our mission to be easy to do business with. That requires us to deliver solutions that are easy to use and fast to deploy. With ACC, we saw a young company poised for growth that needed to catalogue all the machines in its facilities, including tracking all corrective and preventative maintenance to avoid breakdowns. They needed an EAM to provide a reference system. And they needed it fast. Rolled out to users in just six months, the engineers find it intuitive and rich in data.”

ACC’s digital transformation journey with IFS Ultimo will progressively continue, with the addition of functionality for purchasing, as well as health, safety, and environment (HSE) with permits.

About ACC

Automotive Cells Company (ACC) is poised to become the European leader in automotive batteries. Backed by TotalEnergies-Saft, Stellantis, and Mercedes AG, with robust support from European authorities, particularly in France, Germany, and Italy, we are committed to developing and industrializing the next generation of cleaner energy sources for transport through sustainable, affordable, high-capacity, and longer-life batteries.

As a competitive high-tech company, we are investing billions in the early stages of our development. Our R&D Excellence Center is operational in Bruges (Bordeaux, Nouvelle-Aquitaine), alongside our state-of-the-art pilot plant in Nersac, France (Angoulème, Nouvelle-Aquitaine). Our first gigafactory in Billy-Berclau Douvrin, Hauts-de-France, the first of its kind in France, was inaugurated in May 2023 and is ramping up large-scale production. Over the next few years, we will further enhance our innovation and production capacities with a second block starting in 2026 in Billy-Berclau Douvrin. We have already established a global network of R&D associates, industrial partners, and suppliers.

About IFS Ultimo

IFS Ultimo, an IFS company, energizes the financial resilience, regulatory compliance and operational excellence for healthcare, manufacturing, and logistics businesses through its innovative software-as-a-service (SaaS) enterprise asset management (EAM) solutions. Focused on maintenance, uptime, safety, cost control, and efficiency, the Company is known for rapid deployment, ease of use and an unparalleled time to value. Ultimo supports over 100,000 technicians who manage more than 15 million assets for 2400+ customers worldwide. For further information see ultimo.com.

AI boosted Enterprise Asset Management software will significantly improve employee productivity and maximize asset performance

Enterprise Asset Management (EAM) software provider IFS Ultimo has integrated AI functionality into its next-generation EAM platform to enhance troubleshooting, and enable organizations to reduce the mean time to repair (MTTR) of their assets. By leveraging AI, EAM toolsets will be more intuitive, accessible and predictive, therefore driving unprecedented efficiency and effectiveness in asset management practices. The new AI features will be unveiled on Wednesday, October 16, 2024, at IFS Unleashed, Orlando, Florida, USA.

“AI will take EAM to the next level. Our vision for AI is to focus on real world use cases. When considering what AI to integrate into our platform, we are only embedding features which will add significant value for our customers and improve their user experience”, says Chris van den Belt, Head of Product Management, IFS Ultimo. “Infusing our EAM platform with AI functionalities will radically improve employee productivity and maximize asset availability.”

Many AI technologies are geared towards predicting and preventing failures and incidents. However, for the majority of organizations, these technologies are more of a long-term goal than a short-term reality. Reactive maintenance will continue to feature prominently in most organization's maintenance strategies. With this in mind, IFS Ultimo has made the conscious decision to harness the powers of AI to significantly reduce time spent on reactive maintenance. Realizing these short-term benefits starting today puts long-term objectives within arm's reach.

Use of AI minimizes downtime and boosts productivity 

It is estimated that 80 percent of time in MTTR is spent on diagnosing a problem. The biggest chunk of time wasted is due to a lack of communication and detail in failure reports. With Ultimo's built-in AI capabilities, organizations can realize tremendous value with each percentage point reduction in MTTR. This is not chump change: the average cost of downtime in manufacturing often exceeds $100K per hour. Beyond the clear financial stakes, the productivity impact is also profound, especially in an industry where skilled labor is already hard to come by. Furthermore, the immense increase in overall data quality unlocks a wide array of new and exciting possibilities for achieving operational excellence.

The newly integrated AI functionality provides better quality of failure reporting. Having to spend less time on diagnosing a problem means skilled employees will benefit from increased wrench time, increased asset availability, reduced admin time, improved collaboration and improved employee satisfaction.

More accurate failure reports accelerate troubleshooting

Front line workers spend the majority of their working day close to the assets they know so well. Any changes to the way these assets look, sound, smell or feel will not pass them by. Using a large language model (LLM), Ultimo detects the asset in question and provides a series of tailored suggestions that the reporter can easily add to the failure report without having to type. In doing so, all of the sensory observations are captured on the report accurately, providing maintenance teams with complete and accurate information to quickly solve the issue and increase asset availability and reliability.

This same approach will be used elsewhere in Ultimo to empower the faster resolution of diagnosed issues and enhance the accuracy of completed work activities registered in the system. The overall benefits include a substantial reduction of time spent on administration, severe improvements to data quality and a boost to employee satisfaction. Furthermore, Ultimo is working on integrated AI features that will greatly improve user experience, such as photo-based meter readings, auto-generated image and document captions and auto-translated multi-lingual data.

Chris concludes: “We are dedicated to developing our products to help users do their jobs more easily with our best-of-breed EAM software. AI has the capability to enhance EAM in future-ready and efficient ways - empowering employees, improving asset performance, and reducing costs. We are very excited to bring these new AI functionalities to our customers while making sure all relevant data protection is in place.”

For more information visit www.ultimo.com/ai.

1. IFS Ultimo earns coveted “LEADER” recognition for second consecutive Verdantix Green Quadrant®: EAM Software report
2. Industrial software company is acknowledged for strong capabilities in business intelligence, robust integrations, flexible pricing and slick user interface
3. Achieves top position for both market momentum and product capabilities

Today, IFS Ultimo announced it has been recognized as “a Leader” in the 2024 Verdantix Green Quadrant®: Enterprise Asset Management (EAM) Software report.

In the report, IFS Ultimo is acknowledged for strong capabilities in business intelligence, robust integrations, its slick user interface and flexible pricing. This marks the second consecutive report where Ultimo has achieved Leader status; a consistent standing since 2022.

This Verdantix Green Quadrant® analysis benchmarks the most prominent EAM software vendors in the market and surveys decision makers on operational excellence initiatives. The report indicates several trends influencing growth in the EAM space, including mobile functionality, rapid implementations and analytics for predictive maintenance strategies.

Based on the Green Quadrant analysis, Ultimo earned a top position for both market momentum and product capabilities in the Leaders’ Quadrant.

This leader standing is a testament to the investments Ultimo is making in its growth. In the last year, the company has increased investment in research and development, expanded marketing to drive awareness, and has grown its network of certified partners by almost 50 percent - all while maintaining its outstanding 98 percent customer retention rate.

In addition, Ultimo is committed to equipping customers with functionality that can play an important role in the execution of their environmental, social and governance (ESG) initiatives. These capabilities aid customers in maintaining compliant work environments, support reliability and reproducibility of information, map energy consumption and more.

Johan Made, CEO, IFS Ultimo, said, "Receiving recognition from a highly respected research firm like Verdantix underscores the strong momentum behind our growth and success. Since joining IFS Ultimo in January 2024, I’ve been continually impressed by the excellence of our product and the unwavering dedication of our team. Together, we consistently deliver measurable business value to our customers, ensuring their success, as well as offering capabilities that support them on their sustainable asset management journey.”

“IFS Ultimo offers standardized integrations with Microsoft Dynamics 365 and SAP, as well as custom integrations with Oracle and Infor,” explains Hugo Fuller, Senior Analyst, Verdantix. “The firm also has several integrations with connected worker solutions, including those offered by XMReality, Microsoft HoloLens, and POKA, which was also acquired by IFS, in 2023. IFS Ultimo has also built an extensive partnership network with implementation and technology partners. Partners include APM solution provider AVEVA, GIS technology provider Esri, and SAP.”

To learn more about the 2024 Verdantix Green Quadrant®: EAM Software report, visit www.verdantix.com, or www.ultimo.com/verdantix.

Independent research firm, recognizes eMaint as a leader in the market citing strengths in inventory management, inspections, work order management, and analytic capabilities.

Fluke Reliability, a wholly owned subsidiary of Fortive Corporation [NYSE: FTV], which empowers reliability and maintenance teams with the hardware, software, and services they need to optimize asset performance, today announced that its EAM solution, has been positioned as a Leader in the 2024 Green Quadrant EAM (Enterprise Asset Management) Verdantix report.

The Verdantix Green Quadrant for EAM, positions eMaint as a Leader in the Enterprise Asset Management Category, recognizing its market-leading inventory management capabilities, strong inspections, and work order management capabilities.

Ranked highly for inventory management capabilities, eMaint’s Parts and Materials Management module was called out as key contributor for both the analysts and customers interviewed. The module includes a full suite of requisitioning, purchasing, and receiving capabilities with robust stock management, transaction records, and reporting functionality.

Recognising the functionality Fluke Reliability has added through acquisitions and strategic partnerships this year, the report highlighted how the acquisition of Azima DLI added predictive maintenance capabilities and how partnerships with Verusen and Augmentir added AI-based spare parts optimization and connected worker functionality for broader personas respectively.

Verdantix also highlights eMaint’s inspection capabilities and work order management as core strengths, offering manufacturers powerful configuration options that can be customized to suit the plant and workers within. Coupled with eMaint’s flexible scheduling and out-of-the-box low-code and customizable templates, the software demonstrates its ability to meet diverse operational needs.

Another key differentiator is eMaint’s open, REST-based API architecture, which enables seamless integration with a wide range of enterprise systems and IoT platforms, including ERPs (enterprise resource platforms) and Fluke Reliability’s Azima DLI Watchman 360 vibration analytics platform. This integration enhances customers' ability to monitor and analyse asset health with greater precision and efficiency.

"In recent years, the Enterprise Asset Management market has experienced significant transformation driven by the challenges faced by organizations as they adjust to evolving market demands,” commented Hugo Fuller, Senior Analyst, Verdantix. “Within this landscape, the Verdantix research finds that eMaint possesses strengths to address the needs of manufacturers seeking Enterprise Asset Management solutions.”

Jason Waxman, President of Fluke Corporation and Fluke Reliability, said, “After focusing on building the most industry-centric and configurable EAM solution on the market, it feels great to be recognized as a Leader in Enterprise Asset Management by Verdantix. This acknowledgment underscores our commitment to delivering innovative solutions that strengthen our customer's operational resilience as they embark on their journey to connected reliability.”

Commenting on the recognition, Aaron Merkin, Chief Technology Officer of Fluke Reliability, said, “There is a heightened demand for advanced predictive maintenance technologies, and mobile-first intelligent asset management software that empowers businesses to anticipate issues, optimise performance, and extend asset lifecycles. eMaint's position as a leader in enterprise asset management attests to its capacity to deliver value and ensure return on investment for our customers in a volatile landscape.”

To read the full Verdantix report, visit https://www.verdantix.com/research-portal.

Integrated Global Services (IGS), a leader in industrial surface protection solutions, has been announced as a finalist for the prestigious Gulf Energy Excellence Awards 2024 in the Best Controls, Instrumentation, Automation Technology category. The company's recently launched Tube Tech Convection Section Cleaning Rover has earned recognition for its innovative approach to enhancing efficiency and sustainability in the energy sector.

The Gulf Energy Excellence Awards, celebrating the most innovative and impactful technologies in the energy industry, will take place on October 9, 2024, at The Post Oak Hotel in Houston, Texas. IGS's selection as a finalist alongside other industry leaders underscores the company's commitment to driving technological advancements in the downstream sector.

IGS's Convection Section Cleaning Rover represents a significant leap forward in fired heater maintenance. The system can remove 90-95% of fouling deposits from convection sections, dramatically improving heat transfer efficiency and reducing fuel consumption. This technology not only enhances operational efficiency but also contributes to substantial reductions in CO₂ and NO_x emissions, aligning with the industry's emissions targets.

Al Geraskin, Head of Product Management and Innovation at IGS, commented on this achievement:

"Being recognized as a finalist for the Gulf Energy Excellence Awards is a testament to our team's dedication to innovation and our commitment to solving critical industry challenges. Our Convection Section Cleaning Rover is not just a cleaning tool; it's a comprehensive solution that enhances safety, improves efficiency, and contributes to our clients' environmental goals. This nomination validates our approach to developing technologies that deliver tangible value to the energy sector."

The technology stands out for its ability to access 90-95% of the surface area in complex convection sections, a significant improvement over traditional cleaning methods. Its automated operation enhances safety by reducing the need for manual entry into confined spaces, while its high-definition camera provides valuable data for asset monitoring and maintenance planning.

https://integratedglobal.com

• OPTIME wireless condition monitoring and lubrication sensors are installed at WEIG Group’s carton production plant in Mayen, Germany, to continuously monitor a critical centrifugal pump and motor.
• A total of 4 OPTIME sensors monitor the pump and motor, including sensors that monitor motor lubrication.
• The OPTIME solution provides early warning of any potential issues, allowing maintenance to make repairs in a structured, planned way before the equipment breaks down.

Birmingham, UK | September 3rd, 2024| Schaeffler’s OPTIME wireless condition monitoring and automatic lubrication solution is helping prevent unplanned downtime of a critical centrifugal pump and motor at the WEIG Group’s cardboard production plant in Mayen, Germany. The site benefits from the early detection of failures, as the OPTIME app keeps the maintenance team informed on the condition of the pump at all times, as well as monitoring the lubrication of the motor.

WEIG, an accredited, owner-operated group of companies in the international paper and cardboard industry, employs 1,800 people at locations in Europe and South America. With a turnover of one billion euros, its portfolio comprises a closed value-added cycle, from wastepaper recycling to the production and marketing of paper as well as cardboard and cardboard products such as folding boxes and plasterboard. Its business model is based on an efficient recirculation system and a clear commitment to sustainability and resource conservation.

The challenge

The WEIG Group were looking for a predictive condition monitoring solution for the maintenance of a centrifugal pump at its cardboard plant in Mayen. An unplanned shutdown of this pump would bring the entire production line to a standstill. To prevent this, WEIG chose the OPTIME CM predictive condition monitoring solution from Schaeffler’s OPTIME Ecosystem.

OPTIME CM is a wireless condition monitoring solution that gives the maintenance team greater transparency due to the digital service provided by the OPTIME app. The OPTIME C1 lubricator from the Ecosystem was also used. After a few months in use, the solution prevented an unplanned shutdown of the centrifugal pump.

The machines in WEIG‘s cardboard division operate around the clock, seven days a week. Gypsum plasterboard and folding boxboard are produced mainly from waste paper. The machines in the line are exposed to high speeds, extreme humidity and high operating temperatures, including the centrifugal pump. In continuous operation, this pump mixes pulp with water to form a paper fibre pulp which it then conveys onwards. The pump rotates continuously so that a certain quantity can be constantly supplied. If it fails, the entire production process is stopped. 

Oliver Schmitt, maintenance expert at WEIG explains why the maintenance team were looking for a predictive monitoring solution: “The pump is often at risk from cavitation. Due to the high flow velocity in the suction line, the pressure can fall below the vapour pressure and vapour bubbles form. When the liquid flow reaches the impeller of the pump, the negative pressure changes to positive pressure. In the worst case, the vapour bubbles can implode.”

As this streaming pump had not yet been monitored, the maintenance department was looking for a predictive condition monitoring solution.

Solution for pump and motor

Schaeffler’s OPTIME Ecosystem is a single solution that combines its OPTIME CMS (with the sensor variants OPTIME 3, OPTIME 5, and OPTIME 5 Ex) for wireless condition monitoring, and its intelligent, interconnected lubricator OPTIME C1 for automatic lubrication. This creates a cost-effective predictive maintenance solution, which effectively and sustainably minimises downtime and high maintenance costs.

With OPTIME C1, all users need to do to get the latest status of their lubrication points is to check the app from wherever they are located. The app tells them which lubrication points are insufficiently supplied with grease and which cartridges need to be refilled or replaced.

What did the installation show?

After around three months of using the OPTIME sensors, the maintenance team received warning messages. An increased level of background noise was recorded on the motor, bearing damage and cavitation was detected on the pump. The maintenance team confirmed the unusual behaviour of both units.

Insufficient lubrication turned out to be the cause of the motor noise. After installing an OPTIME C1 lubricator, the controlled lubrication significantly reduced the characteristic values of the motor bearing to normal values.

The increased characteristic values on the pump indicated bearing damage. An analysis of the measurement data showed damage to the inner ring of the A-side bearing. This damage could be confirmed on the dismantled bearing.

Since these corrective maintenance measures were performed, there have been no further rolling bearing defect frequencies and the characteristic values have remained below the alarm thresholds.

Cost of unplanned downtime of the centrifugal pump

If the centrifugal pump fails unexpectedly, the entire production process comes to a standstill for six to eight hours. Production workers are then unable to carry out their work. Assuming that production stands still for six hours and the damage is serious, high costs can be incurred.

Savings in the five-digit range possible

Oliver Schmitt, Master Professional, Vibration Analyst, WEIG Karton states: “Within a very short period of time, OPTIME CM has become a reliable partner of our maintenance department. One look at the OPTIME app is enough to know how our machines are doing. I am delighted with the simple installation, easy handling and all-round service from Schaeffler. Our future plans: to install more sensors and lubrication systems from the OPTIME Ecosystem.”

How the OPTIME Ecosystem works

The OPTIME Ecosystem consists of many elements that work together to reduce downtime. It starts with the OPTIME user interface, which provides a complete overview of all machines and lubrication points. With the intuitive mobile app, the dashboard and the export viewer, access to the right information is easy, independent of location and always possible at the right time.

This is made possible by the OPTIME Cloud & Analytics. With unlimited processing power and capacity, huge amounts of data can be processed that are easy to understand and edit. This data comes from the OPTIME vibration sensors and intelligent lubricators via the OPTIME gateway: a standalone device that makes secure cloud connectivity and IT integration easy.

The automatic and self-healing OPTIME mesh network connects all OPTIME devices with each other. The easy-to-set-up mesh network requires little energy and enables large-scale installations. This means that machines can be monitored from any location with OPTIME CM Condition Monitoring and machine lubrication can be simplified with OPTIME C1.

The OPTIME Ecosystem also includes the OPTIME connector service and the OPTIME REST API. The OPTIME connector service makes it quick and easy to connect even more devices to the OPTIME Ecosystem. The OPTIME REST API makes it easy to connect the OPTIME Ecosystem with other existing systems.

OPTIME is part of the Schaeffler Lifetime Solutions portfolio, which offers a comprehensive range of products, services and solutions for industrial maintenance. It is designed to support maintenance engineers over the entire lifetime of a machine.

https://medias.schaeffler.co.uk/en/monitor/optime-ecosystem

OPTIME wireless condition monitoring and lubrication sensors are installed at WEIG’s carton production plant in Meyen to monitor a critical centrifugal pump and motor.

Condition monitoring and lubrication combined: the centrifugal pump and motor are monitored by four OPTIME sensors and 2 OPTIME C1’s.

www.schaeffer.com