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OPTIME helping prevent 360 hours of downtime

Producing several million sustainable beverage cans per hour across its European plants, a can manufacturer needed to avoid unplanned machine downtime; the company was looking for a condition monitoring solution that was easy to operate and provided a simple way for the maintenance team to keep a close eye on all the machines.

Schaeffler’s certified service partner Faber Industrietechnik recommended their OPTIME Condition Monitoring (CM) solution. More than 5,000 sensors now monitor process-critical machines in all the customer’s European plants. In approximately two years, OPTIME CM has detected more than 500 critical faults and has provided numerous early warnings. In this time, a total of 180 unplanned downtimes (360 hours) have been avoided.

Challenge

The customer produces several million beverage cans a day at one of its plants in Germany. Depending on requirements, up to 20 process steps may be required to manufacture the beverage cans from aluminium coils. Process-critical machines such as the deep-drawing (cupping) machine, body maker, printing machine and auxiliary units such as motors, fans and pumps are heavily stressed in the process. The machines operate in shifts around the clock seven days a week.

It is not possible for impending damage on machines to be “heard” because it is a “loud” process. In addition, the machines are sometimes difficult to reach. For safety reasons, some machines are protected behind a protective guard or grid. Keeping an eye on numerous drives also poses new challenges every day for the maintenance team.

In order not to jeopardise the operational processes and to avoid unplanned downtime, the company relied on regular manual measurements, which were performed by Faber Industrietechnik until 2020. If a machine fails unexpectedly, part of the production facility has to be stopped. This incurs extremely high costs in terms of personnel, material and scrap. Manual measurements are no longer sufficient for reliable planning. The customer needed a European-based solution that could be expanded to all world-wide locations for can and lid manufacturing.

Solution

What started as 50 OPTIME CM sensors installed in the first plant has turned into more than 5,000 sensors installed across several European plants by September 2023. Initially, only a few machines were monitored using OPTIME CM. After the initial successes, the solution was expanded to other European plants. In addition, lubrication monitoring using the Schaeffler OPTIME C1 is also used in some of the customer’s plants. 

Case 1 – Plant in southern Germany: 24 hours of unplanned downtime avoided

In a plant in Germany, auxiliary units such as main drives, pumps, gearboxes and fans on critical machines have been monitored with OPTIME CM since May 2021. Around six months after installation, several faults were displayed on the dashboard. Among these were, for example, bearing damage on the main drive motor of the exhaust air treatment unit, pump defects in the wet system, and various faults on other machines. 

Damage detected on an exhaust air motor

Shortly after the OPTIME sensors were installed, motor damage was detected. The maintenance team confirmed this. When the motor was inspected during a planned replacement, the bearing was found to be damaged due to passage of electrical current. Without OPTIME CM, the defect would not have been detected until much later. High consequential costs were therefore avoided.

Case 2 – Plant in eastern Germany: 31 hours of unplanned downtime avoided

In another plant in Germany, critical auxiliary units such as motors, gearboxes, fans, pumps and drives, as well as air extraction, air supply and air recirculation fans on all machines (i.e. the pin oven, decorator, body maker, and more) have been monitored with OPTIME CM since February 2022. From February 2023, the OPTIME C1 lubricator has been used primarily to supply pin ovens and exhaust fans with the necessary amount of grease.

Numerous faults have been detected at an early stage and several cases of unplanned downtime have been avoided. Here is an example:

Alarm on decorator 2

Two weeks before the main alarm limit was exceeded in April 2023, a slight rise in the ISO value on the guide roller on the decorator was seen on the dashboard display. The maintenance team confirmed that a defective bearing was the cause of this. The bearing was replaced as planned. This saved 7 hours and cost savings were in the 5-digit range. After the bearing was replaced, the machine ran as normal without further problems.


Successful project

Thanks to the close cooperation between Faber and Schaeffler, the can manufacturer was completely satisfied with the CM solution. Through Faber, OPTIME CM was made available to all countries and provided installation support in Germany, with Schaeffler supporting across Europe with the installation. Plans to extend the monitoring solution are underway.

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The customer produces several million beverage cans per hour across its European plants.

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Sensors monitor the main drive motor of the exhaust air treatment unit.

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Sensors monitor the decorator.

www.schaeffler.com

 

Spotless Performance From Dirty Water Pump

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In Northern Lincolnshire, a Chopper Pump made by Landia has completed five years of continuous service at the main, 2MW biogas plant run by Singleton Birch, who for over two hundred years, have produced high quality lime products.

Working underground as part of an automated system for dirty run-off water, the Landia pump chops up maize and other particles that end up in the drainage; sending the recirculated liquid to the site’s lagoon, or back to the digesters as and when required.

“The Landia Chopper Pump does an excellent job,” said Danny Mason, Renewable Energy Supervisor at Singleton Birch, where the AD plant’s three 2800m3 digesters use a feedstock of maize, chicken litter and sugar beet.

He added: “The pump is very easy to maintain and has really helped us out with drainage on site, chopping up solids that would block up lesser quality pumps. Landia take care of the full servicing, and always ensure that there isn’t any downtime.”

Invented by Landia in 1950, the Chopper Pump is designed with an external knife system that continuously reduces solids.

In addition to this Landia unit at Singleton Birch, Landia has numerous Chopper Pumps installed at biogas plants as part of its digester mixing system. These include Scottish Water, Eco Verde Energy, and Republic Services in California.

www.landiaworld.com

What is Envelope Demodulation and how does it detect bearing faults?

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If we look at the vibration time waveform from a damaged bearing, as detected by a vibration sensor (accelerometer) for instance, it will typically look like that shown below.

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The numerous high amplitude “spikes” are caused by the damaged bearing parts knocking against each other. Because the bearing noise spikes are of very short time duration, they produce high frequency components in the resulting vibration frequency spectrum. Consequently, examining the high frequency content of a vibration waveform is a very good indication of bearing wear. This is precisely what is done when the bearing noise is calculated in Bearing Damage Units (BDU). The waveform is firstly high pass filtered to remove any low frequency run-speed vibration signals and then the magnitude of the resulting signal is calculated to determine the bearing wear.

A reading of 100 BDU corresponds to 1g RMS (average) high frequency vibration and is pretty much indicative of a worn or damaged bearing. In other words, it may be helpful to think of the BDU figure as being very roughly equivalent to “percentage” bearing wear.

However, an even better measure of bearing wear can be achieved by looking at the Envelope Demodulated vibration waveform (DeMod). Although complex to explain mathematically, DeMod is relatively easy to implement on a high-end vibration analyser.

Such devices used to be prohibitively expensive, but not anymore. For example, the Test Products International TPI 9043/Ultra III costing from £5,000, combines a high resolution (24-bit ADC) three channel data capture unit (TPI 9043) with easy-to-use display software (Ultra III) that runs on any Android device (tablet or smartphone). With its 51,200 lines of resolution, the TPI 9043/Ultra III combo can produce DeMod frequency spectrum resolution of better than 0.1Hz, more than sufficient to enable clear identification of bearing fault frequencies.

The DeMod technique works on the principle that the component parts of worn bearing strike against each other as they spin and cause localised “ringing” in the bearing. This is exactly like striking a bell, where the harder the bell is struck, the louder it rings. By demodulating the vibration waveform, it is possible to determine how hard the bearing parts are being struck and therefore how badly the bearing is damaged.

By examining the DeMod frequency spectrum it is also possible to determine the frequency at which the bearing components are being struck and therefore identify the likely cause of the fault. For example, a peak at the bearing’s ball pass outer frequency (BPFO) would indicate a fault on the outer race of the bearing.

The DeMod spectrum for our damaged bearing clearly shows a series of peaks at harmonics of 152Hz, which corresponds to the BPFO for this particular type of bearing running at 50Hz. As you might have guessed, this bearing had a damaged outer race!

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Another major advantage of the DeMod technique is that it tends to localise the bearing noise and make it easier to pinpoint the source. The localisation is due to the “disco effect” where, just like the music at a discotheque, the higher frequencies do not travel as far as the lower frequencies. This is why you only hear the low frequency sounds outside a disco. In the same way, the “ringing” noise due to bearing wear detected by the Demod method, does not travel as far as the other lower frequency bearing noises detected by the BDU reading.  This additionally makes DeMod a very useful tool for localising bearing faults on rotating machinery.

Many modern vibration monitoring software packages, such as TPI’s C-Trend II, can automatically overlay the bearing fault frequencies on the DeMod plots by looking them up in a bearing database. This makes bearing fault identification even easier, but that’s going to have to be the subject of a future article…

For more information please contact TPI Europe’s head office on +44 1293 530196 or take a look on the website at www.tpieurope.com or email This email address is being protected from spambots. You need JavaScript enabled to view it.

Why effective parts management is critical to your maintenance success

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Picture this: A critical piece of equipment suddenly breaks down. You need a specific part to get it running again - but nobody knows where it is, or if it's even available. Downtime costs pile up, production grinds to a halt and stress levels rise. Sound familiar?

The challenge of spare parts management

This scenario is all too familiar to maintenance professionals. Managing spare parts is a challenging task - the balance between overstocking and running out is delicate. Effective spares management is key to minimising downtime, controlling costs and keeping production running smoothly. But traditional methods often fail to give you real-time information, visibility and control. That's where maintenance software like MaintMaster comes in.

How MaintMaster can transform spare parts management

Dedicated maintenance management software, such as MaintMaster, transforms the way you manage spare parts. With everything in one system, your team always knows where the parts are, how many are available and when they need to be reordered. No more manual tracking or sifting through paperwork. MaintMaster's powerful search functionality makes it easy to find parts, and its integration with procurement ensures that the parts you need are always available when you need them.

What sets MaintMaster apart is its ability to integrate and its flexibility to adapt to different processes. It connects seamlessly with other business systems, ensuring that all information - from suppliers to finance - flows smoothly. Need to track parts across multiple warehouses or sites? MaintMaster has you covered. Want to automate re-ordering to avoid stock-outs? It's all possible, tailored to your unique maintenance workflow.

MaintMaster also provides detailed analytics to help you understand usage patterns, optimise inventory levels and make data-driven decisions. With better visibility of your spares, you can reduce excess inventory, save costs and ensure the right parts are available when needed. This level of control helps to extend equipment life and improve overall operational efficiency.

MaintMaster's flexibility means it can adapt to the specific needs of different industries, from manufacturing to facilities management. It's designed to support the way your team works, with custom fields, workflows and reports that can be tailored to your exact requirements. This means you don't just get a software solution - you get a system that grows and evolves with your business.

Take the first step to smarter spare parts management

Improving your spare parts management doesn't have to be overwhelming. By implementing a system like MaintMaster, you can gain better visibility, reduce downtime and make your maintenance processes more efficient. Take the first step towards smarter spare parts management - start by assessing your current processes and exploring how a tool like MaintMaster can help address your challenges.

Contact:

MaintMaster Systems Ltd

Plexal, 14 East Bay Lane

Here East, Queen Elizabeth Olympic Park,

E15 2GW London, United Kingdom

Phone: +44 749 332 8466   E-Mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

Reduced energy consumption thanks to regular filter changes

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A brand-new filter has a pressure loss of approx.10 mbar. The degree of contamination increases continuously as a result of operating the plant – and with it the pressure loss. A clogged or partially clogged air filter causes increased energy consumption and leads to a significant reduction in energy and cost efficiency. The increased electricity consumption quickly adds up to £10,000 per year. These costs can be avoided with a regular filter change.

Filter solutions for every application

AERZEN offers filters in a series of options tailored to a wide range of machine technologies, such as positive displacement, screw and turbo blowers as well as screw compressors and room air conditions. For example, the F7 filter solution for demanding applications. The filter cartridge is identical in design to the standard filters. It can therefore also be easily replaced in existing Generation 5 machines. To operate blower and compressor packages safely in potentially explosive areas, AERZEN has designed suitable zone separation filters for the various ATEX requirements and zones. The change interval for the air filter depends on the degree of contamination of the sucked-in medium and can be determined precisely using the maintenance indicator.

Let’s Talk - email us at This email address is being protected from spambots. You need JavaScript enabled to view it. for more information.

Fluke delivers unmatched Safety to Solar professionals with tools specifically designed for high-voltage solar environments

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The new Fluke 283 FC True-RMS CAT III 1500 V Digital Multimeter and a283 FC Wireless Current Clamp provide the safety and accuracy to work in high-voltage solar environments with capabilities that streamline technician workflows  

Fluke, a global technology leader in the manufacture of compact, professional electronic test and measurement tools and software, announces the introduction of the  Fluke 283 FC Solar Digital Multimeter and the Fluke a283 FC True-RMS Wireless Clamp  which enable Solar professionals to work more confidently, without compromising safety in high voltage environments such as a testing individual panels, strings or invertors in a utility-scale solar photovoltaic (PV) array.

The new 283 FC Digital Multimeter from Fluke is designed to enhance safety and increase productivity, while also providing technicians with accurate, reliable, and repeatable results.

The Fluke 823 FC/PV Solar Kit includes CAT III 1500 V DC safety rated accessories that enable technicians to work confidently in high-voltage environments.  With Staubli MC4 test leads, professionals can quickly make reliable, secure connections to modules or strings to test DC voltage up to 1500 V DC, well suited to utility operations.

The TL175-HV CAT III 1500 V / CAT IV 1000 V rated silicone test leads offer flexibility for testing voltage, millivoltage, resistance, continuity, and capacitance on inverters, combiner boxes, PV arrays, and individual PV modules.

"Our digital multimeters are renowned for their exceptional accuracy, durability, and safety features making them the preferred choice of professionals across various industries for reliable and precise measurement,” said Jason Waxman, President of Fluke Corporation. “The Fluke 283 FC is uniquely positioned to cater to this market with both CAT III 1500 and CAT IV 1000 ratings prioritizing features that increase efficiency safety and reliability. It’s a powerful all-in-one tool for solar professionals."

Fluke 283 FC/PV Key Features and Benefits:

  • Highly Accurate Measurements: Provides precise voltage measurements for accurate frontline troubleshooting.
  • 60 A AC/DC Current Measurements: Safely troubleshoot individual strings of modules with the a283 FC wireless current clamp.
  • Visual and Audio Polarity Indicators: Help prevent accidental module wiring issues.
  • User-Defined Limit Gauge: Quickly make go/no-go troubleshooting decisions.
  • Unique Multimeter Readiness Self-Check: Ensures your meter is ready to test, providing confidence.
  • Large bright backlit display and illuminated keypad: ideal for working in dark environments.

The a283 FC True-RMS wireless current clamp simplifies the troubleshooting process without compromising safety and reliability. It measures both AC and DC current up to 60 A, ensuring precise readings for solar installations, electrical systems, and industrial equipment. Its thin jaw is designed specifically for cramped spaces like combiner boxes or inverters. Prioritizing safety at every step, the non-contact design allows for safe connections without touching live wires, plus wireless connectivity eliminates the hassle of tangled wires, allowing for measurements from a safe distance.

With the Fluke 283 FC digital multimeter and a283 FC wireless current clamp, technicians can measure voltage and current simultaneously and automatically calculate VA power. This feature eliminates the need to change the measurement setup, providing seamless and efficient data collection in the field.

Utilizing Fluke Connect with the Fluke Cloud Storage capability provides 283 FC users with an enhanced troubleshooting experience by allowing the 283 FC to transmit measurements to a smartphone or tablet for detailed analysis that is uploaded to the cloud.

For more information on the Fluke 283 FC True-RMS Solar Digital Multimeter and a283 FC Wireless Current Clamp, please visit Fluke 283 FC.

Revolutionizing oil analysis: Traditional vs Cutting edge technology

By Sanya Mathura (Strategic Reliability Solutions Ltd) & Neil Conway (Spectrolytic)

In our last article we focused on the question of whether oil analysis was still relevant today? While this is an age-old process, the benefits of oil analysis still continue to live on today although the methods involved have significantly evolved since its inception. In this article, we will do a deeper dive into the traditional methods of oil analysis versus some of the new cutting-edge technologies which exist today and whether we may see a replacement of one method over the other or a union moving forward.

If you’ve ever performed an oil analysis you know that this process follows certain standards which are listed in the report.  These standards govern the world of oil analysis and form the basis of how these tests are executed. There are committees dedicated to revising these standards to ensure that they are still relevant to the applications of today, one such committee falls under the ASTM body (American Society for testing and Materials).

Equipment has changed over time where oil sumps have become smaller but now produce more power. Oils are under more stress as they are expected to perform at higher temperatures under elevated environmental conditions and still protect the equipment. Global oil manufacturers work together with OEMs (Original Equipment Manufacturers) to ensure that the oils developed can work with their components in these increasingly harsher conditions. But what constitutes an oil “working properly”?

This is where oil analysis / sample testing plays a crucial role. Oil analysis tests have been standardized through authorized committees to ensure that the same test can be performed in different parts of the globe using the same procedures. This ensures that there can be a fair comparison of the results of these tests across the globe. These tests should also be repeatable (or get the same results every time they are performed). 

Typically, these tests are usually carried out in a laboratory environment, using state of the art equipment to achieve / maintain the required standards. However, sample taking, sample shipping and other human factors often result in misleading and / or extremely delayed reporting of the results. This is where emergent technology can alleviate some of these challenges.

Emerging technology – FluidInspectIR®

Spectrolytic’s FluidInspectIR-Inline is a comprehensive fluid monitoring system that uses an array of sensors (MIR, OPC, wear, viscometer, conductivity) to provide real time data on oil and fluid degradation parameters. At the heart of the system is a novel mid-infrared (MIR) sensor that measures the chemical composition of the fluid with parameters such as; TAN, TBN, ipH, oxidation, sulphation, nitration, water, glycol, soot, fuel dilution and additives. These can be measured, as a first in the field, with the same accuracy and in the same units as conventional labs.

There are a couple of areas where the FluidInspectIR can offer advantages as compared to traditional oil analysis. Here are a few of them:

Real Time Monitoring and Faster Results – with these online monitoring devices, users can readily get data throughout the day without waiting for the sample to be taken, shipped to a laboratory and then tested there. This significantly reduces the time between making decisions which could negatively impact the equipment’s performance. Within our industry, this time is absolutely critical as the cost of unplanned downtime for the affected assets can be millions of dollars.

Cost-Effectiveness – every time a sample is taken, there is a cost involved. The sample taking process is usually quite lengthy as often permissions have to be obtained since more organisations are trying to reduce potential health & safety risks by minimizing human-machine interactions.
Once a sample has been obtained it needs to be shipped to a laboratory. This not only has costs attached to it, but many couriers are now making it very difficult to ship oil samples. In addition, each shipment of a sample carries also an implied CO2 footprint.

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Figure 1: Comparison of different routes of oil sampling

As shown in figure 1 the resulting cost savings from utilizing real time inline sensors compared to other methods can be summarized as follows:

  • Human assets can be utilized more effectively without allocating time for them to take oil samples
  • Trend analysis based on real time; laboratory equivalent data allows the end customer to move from a time-based maintenance process to a data driven maintenance process
  • Early failures can be spotted very easily and unplanned down time, the nightmare of every asset manager, can be minimized
  • Oil drain intervals can be extended in a safe and controlled manner which can result in significant operational efficiency gains and reduced CO2 footprint

Accuracy and Reliability – getting an accurate representative sample using conventional oil sampling methods can be challenging at times. If the sample is taken at the wrong point (right after the filter or at a dead leg), it might not be representative of what is happening on the inside of the equipment. As such, it can completely derail the trend being established for that component and allow the users to believe that something is terribly wrong with that component.

With the FluidinspectIR online monitoring system, the sample delivery to the sensor is automated and standardized ensuring that the sample is delivered to the sensor in the correct way every time. Therefore, the users can rest assured of getting the sample taken at the right location (ensuring a proper representation of the system), at the same location (ensuring an accurate trend of the data) and with the same technique (which completely avoids any variation from human operators).

 As the FluidInspectIR uses mid-infrared spectroscopy which is identical to the technique used by laboratories (FTIR), the data provided by the FluidInspectIR system has, at least, the same accuracy as those produced by a laboratory as shown in figure 2 below.

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Figure 2: Comparison of the FluidInspectIR technology to periodic oil checks using a laboratory (red circles)

Actionable data and improved maintenance – with real time data, failures can be prevented and major unplanned downtime eliminated. With the online monitoring system, it is easier to trend an increase in wear metals, change in viscosity, water ingress or any other parameter changes which would warrant some form of maintenance intervention. This provides users with the information they need at the right time without any further delays due to shipping of samples or an inaccurate sample being sent off as shown in the case study in figure 3 where a diesel engine on a dredging vessel saw spiked concentrations of water that coincided with the vessel being moored in harbour. With the quick action of the inline sensors, they were able to save £115k over 9 months.

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Figure 3: Case Study for Diesel engine customer  

Data Integration and Remote Monitoring – traditionally, oil analysis results lived in databases which could be accessed electronically, or they were emailed and stored in a filing system. But these results are only available after a sample has been taken and sent off to the lab. This is how FluidInspectIR takes it a step further where assets can also be monitored remotely, in real time.

Imagine being able to monitor the conditions of a particular component while being offsite or multiple components for various sites. This can be particularly useful when trying to troubleshoot an issue related to a system process, especially across sites. This is one area that traditional oil analysis would not be able to mimic as the sample may not be taken at the exact same time as the ongoing system process therefore not allowing a correlation. 

Of particular importance is the ability to trend data across multiple assets. This can be critical if there is a significant environmental factor influencing the condition of the oil which may affect many of the components in the fleet. Being able to easily and quickly detect this can be the difference between a productive day and one that has gone into unplanned downtime.

The above offers some advantages of using these inline sensors but what really sets the FluidInspectIR apart?

Historical inline sensors have employed dielectric or impedance-based sensing. Impedance based sensing is slightly more advanced than dielectric sensing but still only measures a few electrical parameters such as oil resistance, capacitance and inductance which assist in detecting the polar molecules in the oil.

However, complex algorithms are usually used to convert the electrical data into a meaningful value such as TBN or develop a trend based on a dimensionless value. Laboratories use MIR Spectroscopy which is the same technology utilized by FluidInspectIR. As such, the data / results are given in the same units and accuracy as labs.  

The FluidInspectIR technology analyses the spectra in the wavelength ranges which have a chemical meaning for the application in which the sensor is being used, such as turbine oils, EALs, gear oils, engine oils etc. This specificity in the MIR spectrum, coupled with several mechanical and electrical design features allow lab accuracy in the field.

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Figure 4: Market validation and asset examples

The Hybrid approach

While the FluidInspectIR Inline sensors can provide actionable data required for preventive maintenance strategies, there are some parameters where a lab analysis would certainly be advisable. These are more specialized tests such as Air separation / Demulsibility or FZG loading tests which require some fairly complexed processes in which the oil has to stand for some time during the procedure or different loads have to be added until a particular characteristic is met.

With that being said, inline OCM technology has made significant advancements and the FluidInspectIR is currently considered state of the art providing lab equivalent data in real time. In addition, it is also capable of measuring nonstandard properties, such as oxidation by-products which can relate to varnish by-products or the potential to form varnish as well as monitor the quantity of antioxidants. The monitoring of these parameters could not have been done a decade ago as the technology simply wasn’t available.

The future of oil analysis will certainly be a hybrid approach where inline sensors continuously monitor the fundamental parameters and when limits are reached (either below or above), or the trending analysis shows a peculiar behavior, then specialized additional testing can be pursued using the lab infrastructure and expertise.

In this way, resources are conserved when the oil appears to be within its limits and functioning as it should. However, when these limits are reached and the component could be in danger, specialized resources will be deployed to ensure that the component does not suffer a fatality. The way forward for oil analysis is definitely a hybrid approach mixing the traditional with some of the cutting-edge technologies.

Bio:

Neil Conway – Applications Manager, Spectrolytic

Neil is the Applications manager for Spectrolytic where he develops and manages new and current measurement applications for all the product lines. Neil is also extensively involved in sensor characterisation, product development, customer training, and technical marketing.

Previously Neil has held Process Engineering positions in semiconductors with Motorola and Atmel and operated as Wafer Fabrication Manager with IR Sensor company Pyreos where he developed and commercialised the first thin film PZT IR sensor manufacturing line. 

Neil is a chartered Engineer (CEng) and Scientist (CSci) and corporate member of the Institution of Chemical Engineers (MIChemE) and holds a BEng (Hons) in Chemical & Process Engineering from Strathclyde University.

Bio:

Sanya Mathura, REng, MLE

Founder, Strategic Reliability Solutions Ltd

Sanya Mathura is a highly accomplished professional in the field of engineering and reliability, with a proven track record of success in providing solutions to complex problems in various industries. She is currently the Managing Director of Strategic Reliability Solutions Ltd, a leading consulting firm that specializes in helping clients improve their asset reliability and maintenance practices.

Sanya holds a Bachelor's degree in Electrical & Computer Engineering as well as a Masters in Engineering Asset Management from The University of the West Indies and has over 15 years of experience in the industry. She has worked with several well-known companies and has been recognized for her exceptional work in the field of reliability and lubrication engineering. Her expertise in developing and implementing asset management strategies, risk assessments, and root cause analysis has earned her a reputation as a subject matter expert.

As the head of Strategic Reliability Solutions Ltd, Sanya leads a team of highly skilled professionals who provide a wide range of services to clients across various industries, including oil and gas, manufacturing, and transportation. Under her leadership, the company has expanded its services and is now recognized as a leading provider of reliability engineering services in the industry across the globe.

In addition to her work at Strategic Reliability Solutions Ltd, Sanya is an active member of several professional organizations, including the International Council for Machinery Lubrication and writes technical papers for several organizations. She is also a sought-after speaker and has presented at various conferences and seminars on the topics of reliability engineering and lubrication. She is also an avid advocate for women in STEM.

MILWAUKEE® Introduces the Future of Precision Fastening for the Solar Industry

Developed and tested for the solar industry, M18 FUEL* ONE-KEYTORQUE-SENSE ½” Controlled Mid-Torque Impact Wrench with Friction Ring and M18 FUEL ONE-KEY TORQUE-SENSE ½” Controlled Compact Impact Wrench with Friction Ring are the industry’s most repeatable impact wrenches.

TORQUE-SENSE™ torque control overcomes common variances seen on the job site, maintaining target torque better than competitive products that use blow counting algorithms. This performance is enabled by new to world sensors designed in house by MILWAUKEE®, that feed sophisticated machine learning algorithms. Every trigger pull is recorded, and data can be downloaded via the ONE-KEY** application for customisable reporting to ensure confident installation. This product is ideal for utility-scale solar projects were eliminating the 2-step method on the jobsite can deliver up to 3X faster installation speed. MILWAUKEE® offers best-in-class performance and application speed with M18 FUEL technology, enabled by POWERSTATE brushless motors, REDLINK PLUS tool intelligence, and REDLITHIUM battery technology. Operating torque range for the Compact version is 68 – 203 Nm and 68 – 338 Nm for the Mid-Torque option.

Served by large construction companies that purchase large quantities of tools and support equipment, this segment’s growth requires complementary expansion in EPC (Engineering, Procurement and Construction) capacity. For industries serving these EPCs, important opportunities are consequently created, requiring significant growth in solar farm construction to meet this growing demand and innovative equipment to support this acceleration.

MILWAUKEE® is committed to improving productivity by providing performance-driven and trade-focused solutions so users can perform an entire day's work on one battery system. The M18 FUEL* ONE-KEY TORQUE-SENSE ½” Controlled Mid-Torque Impact Wrench with Friction Ring and M18 FUEL ONE-KEY TORQUE-SENSE ½” Controlled Compact Impact Wrench with Friction Ring are fully compatible with the entire M18 line, now offering more than 290 solutions.

*M18 FUEL is engineered for the most demanding tradespeople in the world. Delivering unrivalled performance, all M18 FUEL products feature three MILWAUKEE®-exclusive innovations—The POWERSTATE Brushless Motor, REDLITHIUM Battery Pack and REDLINK PLUS Intelligence Hardware and Software—that deliver unmatched power, run-time, and durability on the jobsite. Simply put, M18 FUEL tools are the most powerful 18V cordless tools in their class.

 **ONE-KEY is the first digital platform for tools and equipment. By integrating industry-leading tool electronics with a custom-built cloud-based program, ONE-KEYprovides a new level of control and access to information that revolutionises the way work gets done. The ability to customise, track and manage through ONE-KEY fundamentally changes the way users interact with their tools.

Specifications

M18 FUELONE-KEY TORQUE-SENSE ½” Controlled Mid-Torque Impact Wrench with Friction Ring

M18 ONEFMTIW2FC12-0X

  • Battery Type: Lithium-ion
  • Battery System: M18 FUEL
  • Impact Rate: 0 – 1800 / 0 – 2300 / 0 – 2800 / 0 – 3400 ipm
  • Max Bolt Diameter: M22
  • Max Torque: 338 Nm
  • No Load Speed: 0 – 1250 / 0 – 1725 / 0 – 2000 / 0 – 2400 rpm
  • Nut Busting Torque: 746 Nm
  • Tool Reception: ½” Square
  • Weight with Battery Pack (EPTA): 2.5 kg (M18 B5)

Kit Includes: (1) M18 FUELONE-KEY TORQUE-SENSE ½” Controlled Compact Impact Wrench with Friction Ring

 M18 FUELONE-KEY TORQUE-SENSE ½” Controlled Compact Impact Wrench with Friction Ring

M18 ONEFIW2FC12-0X

  • Battery Type: Lithium-ion
  • Battery System: MX FUEL
  • Impact Rate: 0 – 1650 / 0 – 2475 / 0 – 3000 / 0 – 3500 ipm
  • Max Bolt Diameter: M22
  • Max Torque: 203 Nm
  • No Load Speed: 0 – 1125 / 0 – 1525 / 0 – 1850 / 0 – 2325 rpm
  • Nut Busting Torque: 298 Nm
  • Tool Reception: ½” Square
  • Weight with Battery Pack (EPTA): 2.0 kg (M18 B5)

Kit Includes: (1) M18 FUELONE-KEYTORQUE-SENSE ½” Controlled Mid-Torque Impact Wrench with Friction Ring

Perfect Match

M18 ONEFMTIW2FC12 & M18 ONEFIW2FC12

SHOCKWAVE™ IMPACT DUTY impact sockets – ½” PACKOUT Impact socket set - 16 pc (4932480943)

To find out more about M18 FUELONE-KEYTORQUE-SENSE ½” Controlled Mid-Torque Impact Wrench with Friction Ring and M18 FUELONE-KEY TORQUE-SENSE ½” Controlled Compact Impact Wrench with Friction Ring, see video footage of it in action or find your nearest store, please visit https://uk.milwaukeetool.eu/.

Visit Milwaukee Tool UK's Instagram and LinkedIn for further information.

 

Restoring Efficiency in Petrochemical Heaters through Robotic Cleaning

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A leading Saudi petrochemical producer in Jubail, renowned for its commitment to innovation and sustainability, faced a challenge with three of its platforming charge heaters in the Oleflex (polypropylene) unit. An evaluation revealed that the primary issue was convection section fouling caused by the accumulation of refractory fibers and other debris.

Recognizing the need for a reliable and efficient solution, the company sought an approach that would not only address the immediate problem but also contribute to the overall reliability and optimization of its operations while aligning with its focus on innovation and sustainability.

The Solution: IGS Robotic Convection Section Cleaning

The petrochemical company partnered with IGS Tube Tech, a specialized robotic and field-applied industrial solutions provider. Tube Tech proposed deploying its robotic convection section cleaning ROV (remotely operated vehicle) to remove the accumulated fouling and restore the heaters' efficiency.

The robotic cleaning solution offered several key advantages:

  1. Effective Fouling Removal

The ROV, equipped with a high-powered cleaning lance and advanced maneuverability, could effectively dislodge and remove the refractory fibers and debris from the convection sections.

  1. Improved Safety

By utilizing a remotely operated robotic system, the cleaning process eliminated the need for personnel to enter the potentially hazardous heater convection sections, enhancing overall safety.

  1. Sustainable Approach

Aligning with the company's sustainability commitment, the robotic cleaning process generated minimal waste; the flow rate of the jetting arm is only 24-l/ min, and the flush bar is 67-l/min.

Implementation and Results

The IGS Tube Tech team carefully deployed the robotic convection section cleaning ROV, navigating through the three affected heaters. The robotic system effectively dislodged and removed the accumulated fouling, restoring the heaters' convection sections to their design specifications.

The targeted and thorough cleaning process effectively removed 90-95% of the accumulated deposits, restoring the heaters to their design parameters, and improving overall plant performance and productivity. Furthermore, the sustainable and safe nature of the robotic cleaning solution aligned with the company's commitment to innovation and environmental responsibility.

Conclusion

The successful implementation of the IGS robotic convection section cleaning solution at the petrochemical company's facility demonstrated the power of innovative and sustainable approaches to addressing complex industrial challenges. By leveraging advanced robotic technology, the company efficiently restored the efficiency of its platforming charge heaters while aligning with its strategic objectives of continuous improvement and environmental stewardship.

In October 2024 Integrated Global Services (IGS) was announced as a winner in the 2024 Gulf Energy Information Excellence Awards in the Best Controls, Instrumentation, Automation Technology – Downstream category for its patented Convection Section Cleaning Rover.

Integrated Global Services, IGS - Your Efficiency & Reliability Partner

Revolting for A Reason

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Andrew Jones, the Technical Director at Axair Fans explains the deeper why behind their latest innovative and disruptive campaign – We’re Revolting.

 You’ve hopefully seen our revolting advertising out in the wild – and if not, or simply as a reminder, it features a few candid shots of me and our team in compromising situations; picking noses, ears, smelling armpits, or showing their lunch still in-between their teeth. Revolting!

The visual is eye catching yes, but the messaging is powerful when you really get to grips with what we’re saying. If you’ve read my previous contributions on complacency in the fan industry, the importance of adding value to customer interactions, or the way we’re helping to bridge the skills gap in the industry, then you’ll understand that we’re leading a dramatic change from the front. A revolution if you will, and to lead a successful revolution, you need an initial revolt.

A revolution implies a successful revolt occurred which resulted in that major change, something we’re doing by making waves in changing the behavioural norms, advocating for a change in the way customer response times are reduced, how feedback on technical support is given within a set time, communication is paramount, and the same pre-sales support is delivered regardless of the value of the potential opportunity. Quite simply we’re waving the flag for what the customer deserves. We’re revolting!

We’ve not anchored our revolt on assumptions either, we’ve delivered and shared meaningful actions taken from research feedback, including customers not getting attention from the industry giants unless they’re a 6-figure customer, the average wait time on technical responses being 6 weeks or beyond, and the sheer amount of product fails with no final diagnosis or resolution. We realised that what we offer is unique, we’re focused on customer outcome. It deserves to be shouted about, because it’s the basics of what the customer experience should be about but quite simply isn’t in the industry. Complacency and fear are leading the way right now.

So, the next time you see a post with one of our team’s uncomfortable poses disrupting your social feeds, landing in your inbox or printed in an industry publication, give a thought to your current situation. Are you an advocate for change and how are you going about this? The way customers go about sharing their advocated behaviours is now more important than ever, word of mouth for example in the digital intense era we’re in, spreads incrementally through online channels, very different to 20 years ago. Increasingly people make their decisions based on the influence of peers and people like them, to decide who to put their trust into. LinkedIn is a prime channel with clear examples of grouped consensus, support and hyping each other up in this industry, specifically within the commercial kitchen sector. If you’re an advocate for changing fan supplier behaviour, then I encourage you to give yourself a nudge and examine the behaviours within your business. Maybe it’s reviewing your supplier list to see if they truly add value, looking at product variations outside of your comfort zone, or demanding greater collaborative efforts from your component suppliers.  As always, we’re here to support our customers outcomes and goals, that revolutionary change is right here in this text, as they say in Stoke, Viva la Revolution.

www.axair-fans.co.uk

Integrated Global Services Wins at Gulf Energy Information Excellence Awards 2024 at Houston Gala

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Integrated Global Services (IGS) has been announced as a winner in the 2024 Gulf Energy Information Excellence Awards, held on Wednesday evening at the Post Oak Hotel in Houston, Texas (U.S.). IGS was announced as the winner in the Best Controls, Instrumentation, Automation Technology – Downstream category for its patented Convection Section Cleaning Rover.

The black-tie gala recognized the energy industry’s leading innovations and thought leaders. “We received nearly 500 nominations this year, from which more than 180 finalists emerged. This is a record year for nominations, and a testament to the evolution in the technologies shaping the global oil and gas industry,” said John Royall, Chief Executive Officer, Gulf Energy Information. Honorees received awards in 29 categories, encompassing the full breadth of the oil, gas and energy industries. Today’s innovations are enabling operators to find, produce, transport and process hydrocarbons more safely, economically, efficiently and sustainably.

Commenting on the accolade, Jason Lynn, Senior Director ‑ Oil & Gas Sales, said:

"This award is a testament to IGS's commitment to innovation in the energy sector. Our Convection Section Cleaning Rover represents a significant leap forward in downstream automation technology, enhancing efficiency and safety in critical processes. We're honored to be recognized by Gulf Energy Information and proud to contribute to the industry's ongoing evolution towards safer, more economical, and sustainable operations."

A complete list of the categories and winners is as follows:

  • Best Advancement in Maintenance Technology – Midstream: GoVAC® MAX Pipeline Evacuation System – Onboard Dynamics
  • Best Catalyst Technology: FT CANS for Sustainable Aviation Fuel – Johnson Matthey
  • Best Completions Technology: 9645 MST System – Superior Completion Services, a Superior Energy Services Company
  • CCS/CCUS/Carbon Removal Project of the Year: STRATOS – 1PointFive
  • Best Coating/Corrosion Advancement Technology: AnX Coiled Rod – ChampionX Artificial Lift
  • Best Controls, Instrumentation, Automation Technology – Upstream: Autonomous Well Intervention – Aker BP and SLB
  • Best Controls, Instrumentation, Automation Technology – Downstream: Convection Section Cleaning Rover – Integrated Global Services
  • Best Deepwater Technology: TRU-ARMS™ – Baker Hughes
  • Best Drilling Technology: Predictive Drilling – Nabors Industries and Corva
  • DE&I in Energy: Growing Responsibilities and Opportunities for Women (GROW) – Sempra Infrastructure
  • Best Digital Transformation – Upstream: EWM™: The Extreme Weather Monitoring and Simulation Platform – FENNEX and Noble Corporation
  • Best Digital Transformation – Midstream: Reinforcement Learning Autonomous Optimizer – Saudi Aramco
  • Best Digital Transformation – Downstream: Honeywell Forge Performance + Production Intelligence – Honeywell
  • Energy Legal Services Provider of the Year: White & Case
  • Best EOR Technology: EquiFlow® Density Autonomous Inflow Control Device – Halliburton and Saudi Aramco
  • Best Exploration Technology: SFD® - Stress Field Detection – NXT Energy Solutions Inc.
  • Best Outreach Program: Securing Our Energy Future Project – Consumer Energy Education Foundation (CEEF)
  • Best Health, Safety or Environmental Contribution – Upstream: Manifa Producing Department (MPD) – Saudi Aramco
  • Best Health, Safety or Environmental Contribution – Midstream: Smart Helmet Solution – ADNOC Offshore
  • Best Health, Safety or Environmental Contribution – Downstream: Pioneering AI-driven Plant Video Surveillance Project with Jio Platforms – Reliance Industries Ltd.
  • Innovation in Pipeline Engineering: Green Hydrogen & Heat Production Through Pressure Reduction Stations in Gas Pipelines – METRON SA
  • Technology Licensor of the Year: Lummus Technology
  • Best Modeling Technology: Unified Ensemble Modeling – Halliburton Landmark
  • Best Oilfield Fluids and Chemicals: InvictaSet™ Self-Regenerating Cement System – Baker Hughes
  • Best Petrochemical Technology: Thermal Crude-to-Chemicals (TC2C™) – Lummus Technology
  • Best Pipeline Integrity Technology: From the Subsurface to Outer Space—Low-Earth Orbit IIoT for Sustainability – Saudi Aramco & Aramco Americas
  • Best Production Technology: Multicycle System for Actuated Response (MSAR) – Saudi Aramco and SLB
  • Best Refining Technology: FT Unicracking™ – Honeywell UOP
  • Energy Project of the Year – Upstream: Cat® Hybrid Energy Storage Solution – Caterpillar Oil & Gas
  • Energy Project of the Year – Midstream: Cedar LNG – Pembina Pipeline Corporation
  • Energy Project of the Year – Downstream: Balikpapan Oil & Gas Infrastructure Project – PT Pertamina
  • Hydrogen Project of the Year: MH500, An Innovative Methane Pyrolysis Unit – Modern Hydrogen
  • Most Promising Engineer – Upstream: Stacey Althaus – Aramco Americas
  • Most Promising Engineer – Midstream: Imran Ulhaq – Saudi Aramco
  • Most Promising Engineer – Downstream: Anderson Castillo Ramirez – Ecopetrol
  • Lifetime Achievement – Upstream: Angus Jamieson – Helmerich & Payne
  • Lifetime Achievement – Midstream: Douglas C. Osburn III – AUTOSOL
  • Lifetime Achievement – Downstream: Robert Haugen – Element Fuels
  • Energy Leader of the Year: Justin Bird – Sempra Infrastructure
  • Operators of the Year – Upstream: Woodside Energy
  • Operator of the Year – Midstream: Williams Companies
  • Operator of the Year: Neste

Additional information on the Gulf Energy Information Excellence Awards program can be found at www.e2awards.com.

For more information about IGS and its technologies, visit www.integratedglobal.com

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