Your Guide to

ISO 55000 Certification

AMMJ
Asset Management And Maintenance Journal
May 2014 Issue

This is a “Complimentary” AMMJ

It is for personal use only and is not for use in a company
or government departments and it cannot be printed.
Go to page 60 to see the benefits of being a full
paying subscriber to the AMMJ.

Go To Contents Page
AMMJ May 2014 Go To Contents Page Go To Last Page
 AMMJ
Click On The Page Number/Title To Go To That Page

PLANT ENGINEERING
AND SERVICES

Contents 44 Early Equipment Management -

delivering capital projects faster,
May 2014 cheaper and better
47 Wearable automated safety suit
50 Equipment, services & people NEWS
MAINTENANCE AND
RELIABILITY

3 Your guide to ISO 55000 STORES, PURCHASING,

certification
9 The leverage of work order
planning
11 Measuring the success of your
root cause analysis program
13 Wireless vibration monitoring
improves reliability at Barking
power station
16 It’s time to get serious about
machine inspections
20 Optimize applications of gear units
23 Monitoring and alarming wear
metals
25 The Doc Palmer maintenance
planning workshops
26 Shock pulse and vibration
monitoring optimize hoist reliability
28 2014 Inspection and Condition
Monitoring Listing
37 Maintenance & reliability NEWS
PARTS AND MATERIALS
55 Spare parts management stages
of excellence
56 Do process improvements threaten
your spare parts management
57 The sky’s the limit for MRO spares
59 TECHNICAL REPORTS AND
RESEARCH PAPERS
- Thermal Imaging Monitors Condition
And Performance Of Cement Kilns
- Convergence of Information and
Operation Technologies to Build a
Successful Smart Grid
- Infrastructure Imperatives -
Smart Infrastructure Facility
60 AMMJ Subscription Page
61 AMMJ Information Page

AMMJ May 2014 Go To First Article Go To Contents Page Go To Last Page

 ide t o
Yo u r G u
5 0 0 0
5
S O
I rtificat n
i o
Ce
This article discusses the process for certification
of Asset Management systems against the ISO
55000 suite of standards. It contains information
that will be useful for individuals wishing to become
ISO 55000 auditors, organisations wishing to
become Conformity Assessment Bodies (CABs),
as well as for organisations wishing to have their
Asset Management systems assessed against the
requirements of ISO 55001.
Background
On January 10 2014, the International Organisation for
Standardisation (ISO) published the ISO5500X suite of
standards for Asset Management. This suite consists of
three separate documents:
• ISO 55000:2014 - Asset management -
Overview, principles and terminology
• ISO 55001:2014 - Asset management -
Management systems - Requirements
• ISO 55002:2014 - Asset management -
Management systems - Guidelines for the
application of ISO 55001
As the titles suggest, ISO 55000 contains definitions of
key terms, as well as describing the principles which
underpin the other two documents. ISO 55001 contains
the specification of the requirements which an Asset
Management system must meet in order to be certified
compliant.
3
AMMJ May 2014 Go To Next Article
Sandy Dunn. Assetivity Australia
ISO 55002 is a guidance document, intended to shed light
on how ISO 55001 should be interpreted.
The key point here is that certification will take place against
the requirements of ISO 55001 – not ISO 55000. However
in order to interpret the (fairly broad) compliance statements
contained within ISO 55001, it will be essential for auditors
and those being audited to also understand the contents of
ISO 55000, and, to a lesser extent, ISO 55002.
So how does this certification process work? Who can
offer certification services? And what skills do certifying
auditors have to have? To answer these questions, we
need to understand the framework that is applied by ISO
for certification against all of its management systems
standards (for example ISO 9001 – Quality Management
Systems, ISO 14001 – Environmental Management
systems, etc.).
The ISO Framework for Certifying
Management Systems
In ISO-speak, Conformity Assessment is the process used
to show that a product, service or system meets specified
requirements (see http://www.iso.org/iso/home/about/
conformity-assessment.htm). Conformity Assessment is the
process that an organisation must go through in order to for
their management systems to be certified as complying with
the requirements of any of the ISO Management standards
(including ISO 55001 - Asset Management).
ISO itself doesn’t provide certification or conformity
assessment – this service is provided by so-called
“Conformity Assessment Bodies” or CABs. However
ISO has produced standards to help make conformity
Go To Contents Page
assessment as consistent as possible amongst these
CABs. These standards specify what a CAB needs
to do to be seen as capable of performing conformity
assessments such as management system certification.
ISO has also assisted with the establishment of
Mutual Recognition Arrangements (MRAs), whereby
certification obtained in one country is recognised as
being acceptable in other countries.
The ISO committee that performs these activities related
to conformity assessment is called the Committee on
Conformity Assessment (CASCO) . Amongst its other
activities, CASCO has established liaisons with many
international organisations involved in conformity
assessment and certification in order to ensure the
consistent application of assessment standards
throughout the world. Amongst these is the International
Accreditation Forum (IAF).
The IAF is the world association of Conformity
Assessment Accreditation Bodies (CAABs). Its primary
function is to develop a single worldwide program of
conformity assessment. Once again, the IAF does not
directly provided certification or conformity assessment.
Instead, its membership is open to (mostly National)
bodies that conduct and administer programmes
by which they in turn accredit CABs. IAF members
are required to join the IAF Multilateral Recognition
Agreement (MLA) recognising the equivalence of other
members’ accreditations to their own. Members of the
IAF include organisations such as:
• The Joint Accreditation System of Australia and New
Zealand (JAS-ANZ), in Australia and New Zealand
• The United Kingdom Accreditation Service
(UKAS), in the United Kingdom
• The American National Standards Institute - American
Society for Quality National Accreditation Board LLC
(ANAB), covering Management Systems
accreditation in the USA
• The National Accreditation Board for
Certification Bodies (NABCB), in India
• and many others
Go To Last Page
 e t o
0 0
uid 0 n
G 55ficatio
S O rti
I Ce
To see a complete list of IAF
members, visit http://www.iaf.nu/
articles/IAF_Members_&_Signatories/4
These National CAABs in turn certify
CABs as being competent to perform
assessments and issue certificates of
conformance against specific standards.
They also ensure that CABs are not
subject to conflicts of interest. CAABs
provide ongoing authoritative oversight
of CABs in order to ensure that
standards are being applied consistently
and to an appropriate level of quality.
One of the items to note, with regard
to being independent of conflicts of
interest, is that CABs are not permitted
to both certify compliance with standards
and also provide consultancy services
to assist organisations to achieve
compliance – not even if the certification
is provided to an organisation for which
no consultancy services were provided.
This is considerably more stringent
than the requirements for the Institute
of Asset Management (IAM) Endorsed
Assessors Scheme, used for assessing
compliance with PAS 55, and many
existing IAM Endorsed Assessors may
have difficulty (or may choose not to)
become CABs due to this requirement.
• Conformity Assessment Bodies are not
required to be able to certify
organisations against all the ISO
Management Standards – they may
elect to certify organisations against
a subset of these standards. So, for
example, some CABs may elect solely
4
AMMJ May 2014
to assess compliance with ISO 9001,
and their CAAB would only authorise
them to certify against this standard.
For a list of CABs in your country, and
the standards that they are authorised
to assess against, contact the relevant
CAAB in your country
(see http://www.iaf.nu/articles/IAF_
Members_&_Signatories/4).
These will often be listed on a page on the
relevant website.
As an example, JAS-ANZ (the CAAB
for Australia and New Zealand) has the
following information on its website:
• A list of authorised CABs (http://www.jas-
anz.org/index.php?option=com_content&
task=blogcategory&id=44&Itemid=1)
• A list of Management Systems JAS-ANZ
authorises CABs against (http://www.jas-
anz.org/index.php?option=com_content&t
ask=blogcategory&id=23&Itemid=1 )
As at 26 January 2013, the Asset
Management Systems scheme is not
yet listed, so there are currently no
CAB’s authorised by JAS-ANZ to certify
compliance with this scheme. This is
hardly surprising, given the recency of
issue of ISO 55000/1/2.
Similar lists exist for other countries.
For example,
• UKAS (the UK CAAB) provides a list
of CABs at http://www.ukas.com/about-
accreditation/accredited-bodies/
• ANAB (the USA CAAB) provides a list of
CABs at http://anabdirectory.remoteauditor.com/
• NABCB (the India CAAB) provides a list
of CABs at http://www.qcin.org/nabcb/pop/
rbodies.php
LogbooksOnline
Get a grip on your
production performance
with the LogbooksOnline
web based solution...
For more LogbooksOnline information visit:
www.omcsinternational.com/downloads/
Production Log DemoV3_r1.pdf
information@omcsinternational.com
www.ReliabilityAssurance.com
Telephone: +61 3 9315 0330
Facsimile: +61 3 9315 0332
Go To Contents Page
Web-based logbooks are the way of the future
and OMCS International is leading the way,
offering users a configurable system which can
be used for any form of operation – power, water,
pipelines, transport, oil and gas, mining etc...
Imagine the capability to design
your own logbooks... for every
part of your business... without the
costly overhead of professional
developers to keep it up to date as
your requirements change!
Using LogbooksOnline
is like using a whiteboard.
Users can create their
own fields, data types,
calculations, trigger points
and trigger functions!
LogbooksOnline is a result of over a decade of research across all industry
types. It is a simple and effective tool for improving methods of data collection
and loss reconciliation and is designed to sustain any reliability initiative.
LogbooksOnline lets you produce production run reports with spectacular
graphs which can be printed, e-mailed or embedded into reports.
LogbooksOnline is a module of one of the best reliability assurance software
available, PMO2000®.
Production Run
Log Record
Log Book Plant Downtime Supervisor
Entries Readings Input Records Instructions
Go To Last Page
 e t o
0 0
uid 0 n
G 55 atio consistency and impartiality of the process and reporting audit results in a that they may need to demonstrate this

O
S rt i f ic So the structure for certification
audit and certification of management consistent manner. experience within their client’s industry, or

I Ce
authorities looks something like
what is shown in Figure 1.
Ensuring the Competence of Assessors
One of the standards that has been
established by ISO which applies to Conformity
Assessment is ISO/IEC 17021:2011 -
Conformity assessment - Requirements for
Bodies Providing Audit and Certification of
Management Systems. This contains principles
and requirements for the competence,
5
systems of all types, including
Asset Management Systems. It is
a requirements standard intended
for use by CAABs (e.g. JAS-ANZ
or UKAS), when assessing and
accrediting Conformity Assessment
Bodies (CABs).
The expectation is that CABs that use
ISO 17021:2011 will be able to ensure
competent audit teams, with adequate
resources, following a consistent
Figure 1
All CABs were given 2 years from
the publication of ISO 17021:2011
on 1 February 2011 to demonstrate
conformance with that standard, and so
now, in early 2014, all CABs should be
compliant (see http://www.iso.org/iso/
iaf-iso-communique_iso17021-2011-
transition-rev2rf.pdf for more details).
Amongst other things, this requires
them to demonstrate that they have
established competence criteria for and
performed evaluation of their auditors.
ISO 17021:2011 defines competence as
“the ability to apply knowledge and skills
to achieve intended results”.
Of particular relevance to the
assessment of Asset Management
systems is the section of ISO/
IEC 17021:2011 that relates to the
competence of auditors assessing Asset
Management systems. This is contained
in Part 5 of ISO 17021:2011 (ISO 17021-
5). As of February 3, 2014, this update
to ISO 17021:2011 has not yet been
published, but if it falls in line with the
competency requirements contained in
other parts of ISO 17021:2011 for other
management systems, it is likely that
auditors will need to demonstrate that not
only do they have the requisite auditing
skills and knowledge of ISO 55000, but
also that they have sufficient experience
in applying asset management principles
and techniques in order to allow the
organisations that they are auditing to be
able to “achieve intended results”. This
is likely to mean that auditors will need
to demonstrate practical experience in
applying Asset Management principles
and techniques, and may also mean
a closely related one.
However, on January 29, 2014, the
Institute of Asset Management (IAM)
advised all of its current PAS55 Endorsed
Assessors that, although ISO17021-5 has
been approved, they do not anticipate
that any country will launch Accreditation
of Assessor Bodies in less than two
years. For that reason, they propose to
continue the existing Endorsed Assessor
appointments. The IAM’s Assessment
tool has been updated to allow its use for
assessing conformance with either PAS55
or ISO55001 (at the time of writing, this
last functionality is in final testing).
An IAM Endorsed Assessor cannot,
unless it is a CAB, issue a Certificate of
Conformance against ISO 55001 that will
be globally recognised. However asset-
owning organisations can have confidence
that IAM Endorsed
Assessors have been formally deemed to
have the competencies and experience
required by the IAM, and that they are
equipped with the skills and tools to be
able to accurately and efficiently identify
any gaps that may prevent an organisation
from achieving formal ISO 55001
certification. Assetivity is an IAM Endorsed
Assessor.
So what does this all mean in a practical
sense?
If Your Organisation Wishes to be
Certified against ISO 55001
There are a few things that you will need
to consider if you wish to your Asset
Management systems to be certified as
compliant with the requirements of ISO
55001.

AMMJ May 2014 Go To Contents Page Go To Last Page

 e t o
0 0
uid 0 n Formal
G 55 at i o certificates of
S O t i f i c compliance can only
be issued by a certified
I r
Ce (CAB). Conformity Assessment Body
If you require a formal
certificate of compliance, ensure
that you select a CAB that is properly
authorised by its CAAB to deliver a
compliance assessment against the
requirements of ISO 55001. At time of
writing (February 3, 2014), there are no
CABs that have been certified by their
CAAB to deliver this service. To find an
appropriate CAB, first go to the list of
CAABs on the IAF website (at http://
www.iaf.nu/articles/IAF_Members_&_
Signatories/4), select your country, and
then click on the link through to the
CAAB that is relevant for your country.
Then navigate your country’s CAAB
website (or otherwise contact them) to
find a CAB (or CABs) that has been
authorised by them to deliver compliance
assessments for the Asset Management
systems scheme (ISO 5500X). Note that
all CABs are required to comply with the
requirements of ISO/IEC 17021:2011,
and (once it has been released), the
requirements of ISO 17021-5. These
specify the competency requirements
for auditors, and more specifically, the
competency requirements for Asset
Management systems scheme auditors.
Also, bear in mind that even though
all authorised CABs will have met the
minimum requirements to become
ISO 5500X certification bodies, there
are likely to be significant differences
between them – particularly in terms of
their experience within your industry,
and their knowledge of the specific
requirements and practices that exist
6
AMMJ May 2014
within your industry. So it may be worth New Training Course - Introduction to ISO 55000
shopping around to make sure that you
get the best value assessment for your
$ - and this may not necessarily be the
cheapest.
Learn
Learnabout
aboutISO
ISO 55000
55000 -- the
thenew
newinternational
internationalstandard
standardfor
for Asset
Asset
Finally, if your organisation is already
certified against other Management Management andthe
Management and thebenefits
benefitsititcan
canbring
bringtoto your
your oganisation
organisation
Systems schemes (Quality
Management, Safety Management,
Environmental Management etc), you
Assetivity offers this training course as a detailed work through of the main compo-
may wish to consider whether there nents of ISO 55001 for people who are leading development, implementation or
are synergies in having all of these maintenance of an organisation’s asset management system.
assessments done at the same time,
by the same CAB – or whether there
is value in engaging specialist CABs Participants will gain a detailed insight into:
with the necessary experience to
º The structure and intent of the ISO 55000 series of standards
assess some, or all, of these systems º The four fundamentals underpinning asset management
separately. º The key elements and recommended structure for an asset management
system
If Your Organisation is Seeking
º How to use the standards effectively
a “Gap Assessment” Against the º Additional tools and techniques to support the standards
Requirements of ISO 55001
If you do not require a formal certificate
of compliance, but are only seeking to
assess the extent of any gaps between
your current Asset Management Introduction to ISO 55000 1 Day Perth - 20 May 2014, 1 July 2014, 11 November 2014
Brisbane - 19 August 2014, 7 October 2014
system and the requirements of
ISO 55001 (for example, as part of
a pre-certification audit, or in order
to establish an Asset Management
For more information, further Assetivity courses, dates and to enrol visit,
improvement program), then you have www.assetivity.com.au/training
more options open to you. While formal
certificates of compliance can only
be issued by a certified Conformity
Assessment Body (CAB), there are no
restrictions on the organisations that
can provide gap assessments and/
or consultancy to assist with bridging
those gaps. If all that you are seeking
is a gap assessment (and potentially Phone 1300 ASSETI (1300 277 384)
some assistance with bridging that
gap), then you may be better served Perth | Brisbane
by approaching one of the many www.assetivity.com.au
Follow us on:
Go To Contents Page Go To Last Page
 e t o
0 0
uid 0 n
G 55ficatioAsset Management consultancies
S O rti (such as Assetivity) who can provide
I Ce this assistance, rather than a CAB. This is
particularly the case during the early stages of
adoption of ISO 55000, as at the time of writing this
article there are currently no recognised specialist
Asset Management consultancies that are CABs,
and the restrictions on becoming a CAB will
essentially mean that few, if any, of the stronger
consultancies will apply to become a CAB. Equally,
the existing CABs will be unlikely, in the early days,
to have auditors who will have the requisite skills
in Asset Management to provide a meaningful gap
assessment. While this will undoubtedly change
over time, auditor competence is likely to be a
significant issue and barrier to effective compliance
assessments, at least in the short term.
Organisations that are not CAB’s, but which
provide “gap assessments”, such as consulting
organisations, are not required to comply with the
requirements of ISO/IEC 17021-5. Indeed they
cannot receive certification against ISO 17021:2011,
as this is only available to CABs. Most of the
reputable consulting firms will have adequately
skilled and experienced personnel who meet those
requirements and are therefore capable of providing
high quality advice, but caveat emptor. If you are
procuring Asset Management consulting services it
will be essential to check out the credentials of both
the organisation you are hiring, and the staff that
they are putting forward to assist you.
One way of identifying organisations that have
demonstrated competence in assessing Asset
Management System gaps is by referring to the
Institute of Asset Management’s (IAMs) list of
Endorsed Assessors at http://bit.ly/MfdgyE. At the
time of writing this article, 39 organisations have
been endorsed by the IAM as being competent to
assess against the requirements of PAS 55, the
precursor to ISO 55000.
7
AMMJ May 2014
If Your Organisation Wishes to
become a CAB for ISO 55001
The situation here is different depending on whether
your organisation is already a certified Conformity
Assessment Body (CAB) or not.
If your organisation is already a CAB, then you will
first need to ensure that your audit team holds the
competencies outlined in ISO 17021-5, when it is
issued. This will, more than likely, involve recruiting or
otherwise engaging additional personnel with those
competencies. In addition, you will need to ensure that
your organisation meets any additional requirements
placed on it by your CAAB that are necessary to
become accredited by your CAAB to certify against
the requirements of the Asset Management Scheme
and ISO 55001. It is likely that CAABs will not certify
CABs as Asset Management System accreditors
until such time as ISO 17021-5 is released and CABs
can demonstrate that they meet the requirements
contained within that standard. Even then, CAABs
may place additional requirements on CABs before
certifying them as Asset Management System
assessing organisations. If you are a CAB, then I
suggest checking with your CAAB regarding their
specific requirements before going too far in promoting
your capabilities in this area. While it should be
expected that the requirements will be largely identical
from country to country, some National CAABs
may have slightly different ways of assessing those
requirements.
On the other hand, if your organisation is not yet a
CAB, then it will first be required to become one. This
is not a simple exercise, and may take many months.
As an example, the process for Australian or New
Zealand organisations to become accredited by JAS-
ANZ to become accredited as an ISO 9001 Quality
Management System CAB involves five steps:
• Application - applying involves
• Meeting the accreditation criteria contained in nine
separate documents – including ISO/IEC 17021:201
Go To Contents Page
• Reviewing and ensuring that your organisation
complies with eight separate policy documents
• Completing up to 4 separate application documents
• Desktop assessment of your organisation’s
documented systems by JAS-ANZ
• On-site assessment of your organisation’s
documented systems and competence by JAS-ANZ
– including witnessing your organisation performing a
Quality Management Systems assessment
• Review of JAS-ANZ’s report on your documented
systems by JAS-ANZ’s Accreditation Review Panel (ARP)
• Final Decision regarding your organisation’s
application
(See http://www.jas-anz.org/index.php?option=com_content
&task=blogcategory&id=21&Itemid=1 and
http://www.jas-anz.org/index.php?option=com_content&tas
k=view&id=46&Itemid=1)
The criteria and processes in other countries are likely to be
different, but no less rigorous. Check with the CAAB in your
country for the exact process that applies.
The first hurdle to be overcome in order to become a
CAB (for most organisations with an interest in, and
competencies in, Asset Management) is to demonstrate
independence and a lack of conflict of interest. This
generally will not only mean that your organisation (as
a CAB) must not provide consultancy services in Asset
Management (although the provision of training is generally
considered acceptable), but that your organisation must not
be organisationally related to another organisation which
provides consultancy services in Asset Management (such
as may exist, for example, if a subsidiary organisation,
parent organisation, or organisation sharing a same parent
organisation as yours provides consultancy services).
This fairly strict restriction is clearly intended to avoid
the situation where the application of creative corporate
ownership structures is used to give the appearance of
independence, when, in fact, organisational independence
and freedom from conflicts of interest are compromised.
Go To Last Page
 e t o
0 0
uid 0 n
G 55ficatio
S O rti
I Ce If a CAB engages an Asset Management
consultant, under contract, in order to
provide the necessary competent personnel
required to conduct an assessment, this may also
breach the requirements relating to independence
and conflict of interest. The specific requirements
may vary from country to country, but as an example,
in Australia, JAS-ANZ states that individual assessors
(including contract assessors) would have a conflict
of interest if any of the following conditions apply
either to them personally, or to the organisation that
they work for:
• having worked with, or consulted to the organisation
(being assessed) in the past two years; or having
reasonable future prospect of such work;
• having any immediate family member working with
or consulting to the organisation (being assessed) in
the past two years; or having reasonable future
prospect of such work;
• owning shares or any immediate family member
owning shares in the organisation (being assessed)
or its parent organisation;
• having, or immediate family member having any
other commercial or voluntary arrangement or
directorship with the organisation (being assessed);
• having a relationship with either an applicant or an
accredited CAB; or
• is in direct competition with an applicant or
accredited CAB.
(See http://www.jas-anz.org/images/stories/
Documents/Procedures/procedure07.pdf).
What this all means is that, essentially, organisations
will need to decide whether they wish to be a CAB
or a consulting organisation in the field of Asset
Management. Unlike the situation that exists at
the moment for IAM Endorsed Assessors, one
organisation cannot be both a consultant and official
certifier. It should be emphasised, however, that
AMMJ May 2014
there is nothing to stop consultancies from providing “gap
assessments” against ISO 55001 or providing other ISO
55001 assessment services.
They cannot, however, issue certificates of compliance that
will be formally recognised by CAABs and the international
community. The rigour associated with becoming a CAB
also means that it is highly unlikely that sole traders will
invest time in becoming a CAB.
Given all of this, the most likely outcome is that existing
CABs will extend their current service offerings to embrace
certification against ISO 55001. They will clearly need to
engage competent Asset Management professionals in
order to do so.
If You Wish to Become an ISO 55000 Assessor/Auditor
Once again, you have a choice to make. As an individual,
if you wish to become an “official” ISO 55000 Assessor/
Auditor – one who is part of a team that can officially
accredit organisations as being compliant with the
requirements of ISO 55001 – then you will need to either
be employed by, or contract your services to, a Conformity
Assessment Body (CAB) which is, in turn, accredited by a
CAAB to provide Asset Management System certification. It
is possible that you could form an organisation specifically
to provide ISO 55001 accreditation services – but your
organisation would need to follow the process outlined in
the previous section in order to become a CAB.
You will also need to ensure that you meet the competency
requirements outlined in ISO/IEC 17021:2011, and in
particular those contained in
ISO 17021-5, when it is issued. In general terms, it is
expected that these competencies would include:
• Understanding of, and demonstrated competence in,
auditing in general
• Detailed knowledge and understanding of ISO 55000,
ISO 55001 and ISO 55002
• Understanding of, and demonstrated ability to practically
apply the key Asset Management processes & tools being
assessed (such as Risk Management, Life Cycle Cost
Analysis, Asset Management Strategy development etc)
Go To Contents Page
• Understanding of, and demonstrated ability to
understand and apply any industry-specific Asset
Management requirements or tools relevant to the
organisation being assessed
While some of these competencies can be acquired
through training and study (for example, in order to
obtain the detailed understanding of the ISO 5500X suite
of standards), much of this competence can only be
acquired through practical experience in actually “doing”
Asset Management. As such, those that are already
experienced in Asset Management will have a head start
on those that do not, in terms of meeting the Auditor
competency requirements.
If you do not wish to become an “official” ISO 55000
Assessor/Auditor – or if you simply wish to build your
knowledge and skills prior to becoming an official
Assessor/Auditor, then you may wish to consider working
for a consultancy that assists organisations to become
compliant with ISO 55000. This will give you exposure
to the performance of ISO 55000 gap assessments and
will also provide you with a more detailed knowledge and
understanding of ISO 55000, 55001 and 55002 and how
to apply these standards in practice.
In either case, I believe that it is likely that there will be
increasing demand for experienced Asset Management
consultants and assessors over the next few years as
ISO 55000 gains currency and traction.
Conclusion
In summary, we are heading into exciting times regarding
Asset Management – times that are full of both promise
and, for many, the unknown. I hope that you have found
this article useful in providing some clarity around the
ISO 55000 certification process. Should you wish to
discuss this article further, please feel free to contact me.
Alexander (Sandy) Dunn
www.assetivity.com.au
Go To Last Page

The Leverage
of Work Order
Planning
Richard (Doc) Palmer
Richard Palmer and Associates USA
Let us presume you have superb communication
and teamwork. You have good storerooms and
ready spares. Technicians have first class hand
tools and a tool room plus equipped shops in which
to work. Training is conducted at all levels and
many improvements are made to work processes.
There is also a CMMS with an equipment database.
Management is supporting PM, PdM, and project
work. Work order planning (including scheduling)
is supposed to bring it all together. But how do you
measure the leverage of work order planning? How
much does it help?
Planning helps both the quality and productivity of
maintenance. Quality is directly affected by having
the workscope, instructions, parts, tools, and crafts
all correctly identified and ready before the job
starts. Quality is indirectly affected by the boost
in productivity because the freed up workforce
allows more time to be spent on difficult jobs and
proactive work. Proactive work includes root cause
9
AMMJ May 2014 Go To Next Article
This Is the 6th In A Series of Articles From Doc Palmer
analyses on repair jobs and corrective maintenance
to fix small problems before they get out of hand.
Proactive work also includes project work to improve
less reliable equipment, and attention to preventive
maintenance and predictive maintenance.
The reduction of delays is where planning impacts
productivity. 25% to 35% productivity is typical of
traditional-type maintenance organizations using
“wrench time” as a measure. Consider the case of
35% productivity of available maintenance persons:
that is, on the average, a typical person on a 10
hour shift is only making productive job progress
for 3 1/2 hours. The other 6 1/2 hours are spent
on “non-productive” activities such as necessary
break time or undesirable job delays such as getting
parts, instructions, or tools. Simply implementing a
fundamental planning and scheduling system should
help improve productivity to about 45%. Then as
files become developed to allow avoiding problems
of past jobs, productivity should increase to 50%.
Finally, a good CMMS should boost productivity to
over 55%.
Go To Contents Page
Paradigm shift: now you may be thinking that “there
is no way our wrench time is below 80% in the first
place because we are always busy. We are working
as hard as we can. Sure, there are some delays,
but they are unavoidable.” Unfortunately, a minute
here and a minute there getting tools, traveling, and
the like add up to significant delays. Yes, you can be
busy, but if you are getting a part instead of working
on the job site, you are in a delay situation that
might have been avoided. Wrench time is properly
measured with a statistical work sampling study.
Separate studies done over time indicate if planning
is getting better or worse. At issue is not so much
the time the technicians spend doing productive
work. What is truly important is the analysis of the
non-productive time. For example, how much time is
spent waiting for parts?
How many planners? It is intuitive if a planner could
help multiply the productivity of a single craft person
by a factor of 1.57 (55%/35%), that a breakeven point
would be to take one of every three craft persons and
convert them to planners:
Without Planner:
3 persons at 35% each = 3 X 35%
= 105% total productivity.
With Planner:
2 persons at 55% and 1 planner at 0%
= (2 X 55%) + (1 X 0%) = 110% total productivity.
But experience has shown that a single planner can
plan for twenty to thirty persons, so there is never
any question that a person cannot be taken out of the
workforce to become a planner.
A 30 person maintenance force is leveraged as
30 persons X 1.57 to yield a 47 person effective
workforce.
This means that you are getting the effect of having
17 extra persons on your team without having to hire
anyone new; 17 persons for the cost of one planner.
Seventeen persons at $25/hr (including benefits) for a
year are worth $884,000.
Go To Last Page
 Consider a 90 person workforce,
leveraging to get a 1.57 improvement
yields a 141 person workforce; 51 extra
persons. This is worth $2,652,000 for a
year.
And remember, the above cases are
conservative in considering a boost from
35% wrench time to 55%. Finally, the
practices should help leverage other
tools such as a good CMMS to boost
productivity to as much as 55%.
The above cases are dramatically
improved if you are starting at 25%
wrench time and move to 55%, which is
a 55/25 = 2.2 factor improvement. The
30 person workforce is increased to
66 persons in effect and the 90 person
workforce is increased to 198. What an
improvement to the maintenance force!
And what do you do with all these “extra”
persons? In the company with much
reactive work, you leverage or use them
to put out all the fires. In the company
with reactive work under control that is
focusing on planned work, you leverage
them to do more proactive maintenance
work dealing efficiently with situations and
avoiding fires. And in those world class
companies with preventive maintenance
well in hand, you leverage them to invest
in training to further increase labor skills
and in projects to improve equipment or
other work processes.
In each of these companies you also
have the capacity to grow or allow natural
attrition without hiring. You certainly do
not lay them off and blow apart Deming
principle #12 “Joy in work.”
While the measure and value of the
“extra” productivity can be calculated
rather easily in terms of workforce, how
you use this extra labor is what matters.
10
AMMJ May 2014
Getting more work done and done right The Institute of
Asset Management
leads to other significant savings that
are as easy to calculate, but are more
difficult to attribute. Remember planning
does not work in a vacuum, but brings the
other aspects of maintenance together.
Nevertheless, these are important CALL FOR PAPERS CONFERENCE
considerations.
27 - 28 November 2014 | Millennium Gloucester Hotel, London, UK
Beyond just getting enough maintenance
work completed to keep the plant on
Abstract submission deadline: Friday 25 July 2014
line and stay in business, there are
considerations of increased availability The annual Asset Management Conference was attended last year by over 300 asset management professionals
of existing capacity, improved efficiency, from around the world representing a wide range of asset intensive industry, public and academic sectors.
and deferred capital investment for more
Submit your paper and showcase your work!
capacity.
For an electric utility with a 1000
megawatt steam system, each 1%
availability improvement might be worth
over $300,000/year in power transaction A SYSTEMATIC APPROACH FOR REALISING THE VALUE OF YOUR ASSETS
capability. Each 100 Btu/KWH
improvement in efficiency might be worth 11 June 2014 | Hilton, Rotterdam, The Netherlands
over $400,000/year. And a single 1% This Congress will bring together high level asset owners, service providers and contributors to ISO 55000 who
sustainable, improvement in availability will share their experiences of deriving benefits from working with a structured system of asset management.
for a 1000 Mw system means 10 Mw of
Register your place today!
future power plant that does not have to
be built. At $1200/kW construction prices,
that is $12 million.
The leverage of work order planning on
maintenance can be measured to see
that it is definitely a good investment.
Doc Palmer, PE, MBA, CMRP is the
author of McGraw-Hill’s Maintenance
Planning and Scheduling Handbook and
as managing partner of Richard Palmer
and Associates, he helps companies
worldwide with planning and scheduling
success.
For more information visit Find out more at www.theiet.org/asset #IETasset
www.palmerplanning.com or email Doc
at docpalmer@palmerplanning.com Media partners
The Institution of Engineering and Technology is registered as a Charity in England and Wales (No. 211014) and Scotland (No. SCO38698).
Go To Contents Page Go To Last Page

Measuring the
success of your
RCA program
Jack Jager Principal Apollo RCA Trainer and Facilitator
ARMS Reliability www.apollorootcause.com
The ability to demonstrate the
success or failure of Root Cause
Analysis (RCA) is a crucial stage of
incident investigation that is often
missed. After all, if you don’t measure,
how do you (and others) know if your
program is working and whether it’s
worth the effort?
Measuring the success of an RCA
program is important both for the short-
term and the long-term. In the short
term, you need to know if the changes
implemented as a result of the RCA
findings are effective. Longer term, you
need the proof that your RCA program
works – so that you gain ongoing support
from management for this important tool.
Yet some companies fail to measure the
success of their RCA programs. Here,
we look at what’s stopping them, and
how to overcome it.
First, why is measurement so important?
The goal of RCA is to improve processes
or reduce the severity or impact of
incidences. In RCA, you typically
generate a raft of possible solutions and
only implement some of them.
11
AMMJ May 2014
RELIAbILITy
IS NOT A
LUxURy
Implementing RCA solutions without
measuring their effectiveness is akin to
trial and error.
Measuring the changes caused by RCA
MANAGING A PLANT IS FULL OF RISKS
solutions – good and bad – is critical Asset Reliability doesn’t have to be one of them
to knowing whether your RCA efforts
were successful. You need to know the
“before” and “after” states of whatever
• Maintenance Optimisation • Fault Tree Analysis DOWNLOAD
FREE TRIAL SOFTWARE
the RCA is trying to improve, and • Availability Modeling • Hazop
assess how effective the solution is.
Measurement is probably more • Reliability Prediction • Life Cycle Costing
important for the “bad” results. You SPEAK TO OUR
need to know if a solution isn’t working. www.armsreliabilitysoftware.com SOLUTIONS TEAM
A negative result will show you that
the problem was not understood well Availability Workbench, Reliability Workbench, FaultTree+, Hazop+ and NAP are registered trademarks of Isograph Software. ARMS Reliability are authorised distributors, trainers and implementers
enough (in which case you can go back
to your cause and effect chart) or that
FREE eBook
poor choices were made in terms of
which solutions to implement.
In this way, a “bad” measure still DOWNLOAD
leads to a positive outcome. It allows
positive decisions to be made to revisit PART 4
the issue. After all, if the problem PART 4: THE FINAL 26 TIPS TIPS 76 - 101
was significant enough to warrant an
investigation in the first place, you need 101 TIPS & TRICKS TO IMPROVE
to know whether to revisit it or not. YOUR ROOT CAUSE ANALYSIS
Go To Next Article Go To Contents Page Go To Last Page

What’s stopping you from
measuring RCA success?
In some cases, the lack of measurement
boils down to the fact that the RCA
process is still relatively immature, and
has not yet evolved into a complete
process. In these instances, you need to
deepen your commitment to grow your
RCA program so that it captures this
crucial step.
In other cases, unfortunately,
measurement is simply shelved in the
“too hard” basket.
Yet it doesn’t have to be hard. To
measure the success of RCA, you simply
need to set some parameters or criteria.
Identify what you are trying to achieve
– both the “big picture” goals and those
relating to the RCA program itself.
What measures would indicate
success of your RCA process?
The big picture will show:
• Improved availability of plant (less
downtime) – either mobile plant or fixed
plant (production infrastructure)
• Improved production data – weekly,
monthly, per quarter, biannual and
annual
• Less downtime when things go wrong
• Lower frequency of problem
occurrence or similar types of problems
• Less impact of problems – problems
are less severe or the ramification of
these problems are less severe
• Less time spent reacting to problems
and more time available for planning
and making improvements
12
AMMJ May 2014
Get practical and
results-focused strategies
for turnaround excellence
At a more local level, RCA program
measures will show things like:
• Ratio of total number of incidents
which should trigger an RCA against
how many RCAs were performed
• Percentage of solutions generated
Shutdowns Turnarounds
against how many were implemented
• Percentage of people who have been
trained in the process against those
Superconference
who have actually conducted RCAs or
are using the process informally
• Indication of the timeframe needed to
begin investigations (shorter is better)
• Indication of the timeframe required to
implement solutions
June 18 – 19, 2014 | Houston, Texas
By collecting information of this nature,
you will be able to demonstrate how This is your best opportunity to meet and engage with others in the turnaround community
successful the RCA program is. In and learn how to overcome your turnaround challenges to achieve exceptional results.
doing so, you will gain valuable support
from management and co-workers. Hear from Chevron Phillips, Jacobs, Ascend Performance Materials, LyondellBasell,
Shell Chemicals, Lanxess, Allied Reliability, Suncor Energy USA and many
Remember, you can easily tell
someone a story of how good the others who will provide you with practical techniques for project success.
RCA process is – but if you can’t show
them the actual benefits in terms of RegisTeR Now — and take advantage of our special team rates!
production, availability or dollars, then 1-877-927-7936 | www.ShutdownsHouston.com
the story counts for nothing. You have
no evidence to prove it. Quote priority service code 908AX02
Instead, let the data from your
measurement tell its own story.
SponSorS
ARMS Reliability are the global
partners and providers of the Apollo
prESEnTEd by
Root Cause Analysis™ methodology.
To view our worldwide training pArTnErS
schedule or to book a course, visit
www.apollorootcause.com
Go To Contents Page Go To Last Page
 Wireless
Vibration
Monitoring
Improves Reliability and Enhances Safety
at Barking Power Station, UK
Taking advantage of the ease in
which new measurement devices
can be introduced to an existing
Smart Wireless network, our Barking
Power Station is using a wireless
vibration transmitter to monitor rotating
equipment remotely and in real
time. The introduction of this device
is helping to improve maintenance
schedules and prevent unexpected
downtime says Travis Culham,
rotating machinery engineer.
Rotating machinery will eventually wear
and require maintenance to prevent
failure, but understanding when to
schedule maintenance becomes all
the more important when a machine is
critical to operations or has a record of
catastrophic failure.
Monitoring techniques for rotating
machinery have improved greatly in
recent years, with advanced vibration
monitoring and analysis tools now able
13
AMMJ May 2014
One piece of equipment can
bring my entire operation down.
I need to predict and diagnose my
to identify even the slightest changes most complex machinery issues.
YOU CAN DO THAT
in the condition of an asset - as they
are taking place. Online vibration
monitoring can help to predict when a
failure will occur and alert maintenance
as to the health status of the
equipment. Early warning of impending
failures can prevent process shutdowns
that lead to lost production.
Continuous monitoring is making
an important contribution to these
improvements. At Barking Power many Easily predict and solve machinery problems. The CSI 2140 can be used
of the largest and most critical pieces to monitor a broad range of machinery – from variable speed equipment, complex gearboxes,
of rotating equipment have vibration high-speed compressors, and sleeve bearing turbo machinery. With four-channel monitoring
and pre-configured Analysis Experts, you can easily test and diagnose your toughest equipment
monitoring permanently installed: issues. Scan the code below or visit www.EmersonProcess.com/Reliability1 to learn more.
ideally, all rotating equipment should
be monitored, but the cost of doing so
would be prohibitive.
For smaller, lower cost and less critical
assets, we perform manual monitoring
to try and detect potential problems
before they develop into more serious The Emerson logo is a trademark and service mark of Emerson Electric Co. © 2013 Emerson Electric Co.
incidents that can cause unscheduled
outages. Where possible, handheld
Go To Next Article Go To Contents Page Go To Last Page
 monitors are used to take readings during the crucial plant start-up and shutdown
phases. This can work reasonably well, especially if performed regularly and the data
is carefully analysed, but sometimes it is simply not possible to perform all the manual
measurements we would like.
MAINTAINING STARTING MOTOR AVAILABILITY
One of our starting motors, housed in a gas turbine auxiliary compartment, illustrates
the challenge. With no available cable infrastructure in place, it was not possible to cost-
effectively add continuous vibration monitoring. Instead, manual readings were taken
using a handheld collector and then downloaded for analysis.
When a potential problem was identified through excessive vibration, we needed
to monitor the motor more frequently whilst waiting for the next scheduled period of
downtime. This was important as these motors have a history of problems that can lead
to total failure requiring replacement of the entire motor. Despite the potential problem,
we wanted to continue to run the motor; otherwise this affected our ability to run the
related turbine, reducing our maximum output capacity by 200MW.
A wireless vibration transmitter mounted outside the turbine enclosure
14
AMMJ May 2014
Shutting the motor down immediately and completing a total overhaul would
make the turbine unavailable for approximately 36 hours. Potentially this could
cost our company as much as £50,000 in lost revenue, depending on the price
and demand for power on that day.
The problem we faced was that it was essential to know if the motor was about
to fail so we could take it offline before serious damage resulted. But because
the vibration indicated a possible impending failure it was agreed that we would
not expose any of our staff to this potential situation. Safety is our number one
priority so we cannot allow personnel to enter areas like this where a potential
safety situation may arise. The question therefore was how could we monitor this
motor and assets like it in critical situations? An alternative solution was required
- we needed to install a vibration monitoring capability on a temporary basis,
quickly and cost-effectively.
Vibration sensors attached to a steam turbine barring gear box
Go To Contents Page Go To Last Page
 IMPROVING RELIABILITY AND SAFETY
The ideal solution to our problem was provided by an
Emerson’s CSI 9420 wireless vibration transmitter. A
smart wireless network had already been installed at
the plant to collect stranded control valve diagnostic
data. One of the key advantages of this type of
wireless technology is the ease with which new
devices can be added to the network - you simply
install a new device and it automatically connects
to the wireless network and starts transmitting data
immediately. This could provide a very quick, easy and
cost-effective solution, with the added advantage that
you can position devices where and when you need
them most.
We installed the transmitter on the starter motor that
is located within a gas turbine auxiliary compartment,
which effectively acts like a faraday cage. The
placement presents a tough environment for wireless
and it was thought that a repeater transmitter
would be needed to bridge back to the network.
However, having installed the device during a period
of downtime, it instantly joined the network and
transmitted data without any problems.
The smart wireless network is extremely robust and
the performance in this application exceeded our
expectations. This success gave us great confidence
- if smart wireless technology could be applied
here, then it could be applied pretty much anywhere
throughout the plant.
Vibration data was transmitted from the motor, via a
wireless gateway, directly into our existing Ovation™
expert distributed control system data historian. This
enabled us to monitor vibration during operation, and
by trending the data we were able to determine when
the motor was going to fail.
The wireless transmitter provided continuous visibility
to the health of the motor enabling it to be run with
15
AMMJ May 2014
confidence. Fortunately, there was no failure whilst the
plant remained online and the motor was fixed when
market conditions allowed a period of downtime for
maintenance, minimising the financial impact of the
outage.
This experience confirmed that the performance of
the wireless vibration transmitter was as good as
a portable vibration measurement device, but with
additional advantages. For example, there was no
need to physically obtain the readings, which was
paramount for this application. Vibration monitoring
of the starter motor using a handheld collector was
simply not an option. Without the wireless vibration
transmitter, we would have been unable to monitor
the starter motor safely and would have had to take it
out of service – with all the negative production impact
that would have entailed. Additionally, removing the
need for maintenance personnel to visit the plant floor
reduced risk.
Another advantage is that the data is continuous and
always available. When we used a handheld collector
the data would usually be collected one day and then
analysed the next. The data is now easily trended
in the Ovation historian providing alerts to potential
problems. This frees up maintenance resources to do
other jobs.
MOBILE MONITORING
The success of this initial application encouraged
us to use the wireless vibration transmitter as a
mobile device to monitor various types of rotating
equipment, where and when it is required. Generally
the equipment we are monitoring with the wireless
transmitter is deemed less critical to the process. The
assets can often be found in hard to reach locations
and do not currently have permanent health monitoring
in place, but the transmitter provides us with the
opportunity to perform very accurate continuous
Go To Contents Page
monitoring of such assets. It can be configured
for a variety of low power accelerometer sensor
input options including one accelerometer, one
accelerometer with embedded temperature, or two
accelerometers. This provides great flexibility.
We can now apply the vibration monitoring to
problematic machinery for a period of time and
trend the results, which alerts us as to when the
asset is likely to fail and allows us to improve our
maintenance scheduling. As another example of
this, when we were concerned about the condition
of one of our turbine barring motors, we decided to
install the wireless transmitter to keep an eye on it.
Without this capability we would have had to take it
offline immediately, even if failure was not imminent.
By gaining visibility as to the actual health of the
motor we were able to run it for an additional three
months. This extra time enabled us to tackle more
pressing tasks, and optimally schedule the motor
maintenance.
CONCLUSION
At Barking Power we want to continue to use
technology to avoid forced outages by gaining a
greater understanding of the health of our machinery.
The advantages are clear. We no longer need to
have plant personnel make as many trips to the fi
eld, so safety improves. We receive vibration data
transmitted from the motor, via a wireless gateway,
directly into the existing Ovation™ expert distributed
control system’s data historian. This enables us to
estimate when a motor is going to fail. The real-time
information from the wireless vibration transmitter
provides valuable insight that can prevent unplanned
shutdowns and improve maintenance scheduling and
reliability.
www.emersonprocess.com
Go To Last Page
 It’s Time to Get Serious About
Machine
Inspections
Drew D. Troyer
While the exact numbers vary from
industry to industry and plant to plant,
the typical industrial plant allocates
about 40% of its labor performing
basic care preventive maintenance
tasks, which includes lubrication,
cleaning, inspections, etc.
Typically, about 70% of that labor is
allocated to inspections that are carried
out by maintenance technicians and
operators. Inspections represent a
sizable investment of the scarce labor
available to plants. Regrettably, for most
organizations, the ambiguity of technician
and operator inspection rounds
compromises effectiveness.
In this article, we’ll discuss the critical role
inspections play in asset management
and common problems that plague the
inspection process, and we’ll discuss a
game plan for putting our inspections
process on the right track to success.
16
AMMJ May 2014
Mainstream ™
The asset management conference for companies
that care about leadership, people and culture
Sigma-Reliability.com USA
The Inspect-to-Work Process
In years past, maintenance was easy.
We fixed broken equipment and every
few years we would schedule to rebuild
equipment with the intention of improving
reliability. Unfortunately, the process of
disassembling then rebuilding perfectly
operating equipment introduced failure
modes that created failure.
In other words, our preventive Perth, WA (AUS) Brisbane, QLD (AUS) Austin, TX (USA)
maintenance tasks, which were 12 - 14 May 2014 18 - 20 May 2014 16 - 19 June 2014
intended to improve reliability, actually
compromised it. Starting in the 1990s, we
started transitioning to condition-based
maintenance strategies – we only fixed
equipment that was known to be broken
based in inspections and monitoring.
When it comes to Reliability and Maintenance conferences,
While it varies from industry-to-industry
and plant-to-plant, in round numbers, Mainstream’s focus on people and leadership is unique.
planned maintenance accounts for 80% of
all the work done in a plan. Of that, about
Please visit www.mainstreamconference.com to find out why.
50% is basic care (lubrication, cleaning,
inspections, etc.) and 50% is condition-
directed corrective work.
Go To Next Article Go To Contents Page Go To Last Page

Of the condition-directed corrective work, about 70%
should be driven by routine rounds and sensory
inspections and about 30% by more sophisticated
condition monitoring techniques such as vibration
analysis, lubricant analysis, thermography etc. So,
not only are we investing a heavy component of our
plant labor to carry out inspections, we’re depending
heavily on the effectiveness of those inspections to
catch problems early and deal with them effectively.
If the inspection process doesn’t work, our ability
to leverage the power of planning, scheduling
and work management practices is severely
compromised. Achieving world-class equipment
asset reliability management is extremely dependent
upon the effectiveness of our inspections and work
identification processes.
Figure 1 What goes wrong in the plant - lack of or ineffective
procedures is the leading cause of failure in industrial plants.
17
AMMJ May 2014
Where Are We Going Wrong?
A few years ago, I conducted a survey of plant
maintenance & reliability professionals. I asked a
simple question: “what goes wrong in the plant?”
I utilized the failure cause dimensional categories
specified in the DOE NE 1004 standard – the
standard for conducting root cause analysis (RCA)
in as nuclear power plant.
Drumroll…and the winner is : –
Lack Of Or Ineffective Proceedures (figure1).
Candidly, this was not a surprise to me. Having
reviewed and critiqued literally thousands of
preventive and corrective maintenance plans
over the years, I’ve observed the same problems
over and over. Most notably, these procedures
are ambiguous. They lack the fit, tolerance,
Go To Contents Page
quality and quantity details required to carry out precision and
proactive equipment care. We send operators and technicians
to the machine with instructions to “check pressure,” “check
temperature,” “inspect belts,” “grease bearings,” etc. – you get
the picture.
These work assignments require the operator or technician
who is carrying out the tasks to “just know” the right pressure,
temperature, etc. The human factors of failure (people making
mistakes) account for about 80% of all failures in the plant. By
sending our people out in the plant with ambiguous instructions,
we’re setting them up for failure. We need to take a hard look
at our inspections and our other PMs & redefine them to set our
people, and our plants, up for success (see figure 2).
Figure 2 - Examples of the “rights” and “wrongs” of
inspections and other PM tasks.
Go To Last Page
 Get the Right Asset Management
Setting the Ship Right – A How to Guide
CMMS/EAM hierarchy. Moreover, CMMS/EAM
3 Procedure Creation Tool –
In creating your game plan for inspections excellence, systems aren’t equipped to handle the detail of As figure 2 suggests, a work instruction has
here are some tips that are based upon my many years inspections and other PM work. Think about fixed and variable elements. The instruction
of experience. it – if you have 1000 assets with an average of for carrying out an inspection, lubricating a
four components each, and each component bearing, tensioning a belt, etc. may always
1 Accept the Reality and Commit has 10 associated inspections or other PM be the same, but the fit, tolerance, quality
You’re first step is to accept the fact that your tasks that require clarity and bespoke definition, and quality details will vary for each piece of
inspections are setting your people up for failure. you’re talking about 40,000 tasks in total. It’s equipment. Your procedure management tool
Review your PMs and candidly ask yourself the a big job and you’ll want to equip yourself with should enable you to achieve the following:
question “have we provided the important information tools to make short work of it and to set yourself a) Build down from the CMMS/EAM
required for success?” Then, estimate how much labor up to manage change. hierarchy while retaining its integrity (fig 3).
you’re dedicating to the inspection process, as well as
other PMs. In most plants, 20-30% of maintenance Figure 3 Example of procedure management software that allows one to build down
labor plus a bunch of operator labor is dedicated to from the CMMS/EAM hierarchy to the point at which work is performed.
performing routine PM inspection rounds.
Do you really want to continue to invest so heavily in a
process that’s inherently flawed and set up for failure?
Moreover, estimate the extent to which ambiguity in
your inspection rounds is compromising the crucial
inspect-to-work process, which causes you to miss
opportunities to cheaply make minor adjustments
and repairs before they become big and expensive
problems. You’ll need to estimate the financial benefits
associated with correcting your inspection and other
PM processes, because it’s a big job.
Don’t Expect Too Much From
2 Your CMMS/EAM System
Make no mistake - Computerized Maintenance
Management Systems (CMMS) - or Equipment Asset
Management (EAM) systems – are maintenance
accounting systems. They were designed primarily
by accountants and for accountants who want to
track how much we’re spending on an asset. That’s
important information, but no more so than managing
the reliability of your equipment assets. Most CMMS/
EAM system hierarchies are set up at the asset level
(e.g. a pump includes the pump, coupling, motor, MCC,
foundation, etc.). Most maintenance work is performed
at the component/subcomponent/part/point level – as
many as five or six levels down from the asset in the
18

AMMJ May 2014 Go To Contents Page Go To Last Page

 b) Create standard work plan templates, but inserting variables h) Easily transfer data to the CMMS/EAM or other PM 3 for the price of 2
for the fit, tolerance, quantity and quality details required for
precision in carrying out the inspection or PM work item. For
execution software tools.
i) Locally and globally manage change to reflect changes in
SPECIAL OFFER!!
complex work, I suggest complying with DOE STD 1029 -
Maintenance
operating context and or parameters – this is critical to
Writers Guide for Technical Procedures. continuous improvement.
c) Attach templates to the appropriate level in the hierarchy
(e.g. asset, component, subcomponent, part, point, etc.) to 4 Get to Work!
Planning &
define the scope of required work for the machine. I’m convinced that most of our inspection task lists and
d) Summarize a list of variables that must be defined for each
asset (e.g. the measurement location, the measurement
other PMs are vague because it’s really hard work to do the
calculations and collect the empirical data required to define Scheduling
Workshop
value defining what’s OK & what’s not OK, etc.). all those fit, tolerance, quality and quantity details. If you need
e) Attach pictures and drawing illustrating where work should help to do it – get it. Don’t use a trial and error approach.
be performed and, in some cases, defining acceptable and Creating vague instructions is easy.
unacceptable conditions where numbers don’t work (figure 4). However, allocating such a large percentage of our labor to an
f) Merge templates, defined variables, pictures, etc. to create ineffective process is – well – stupid. And it’s a pity, especially
Presented By
customized inspection work plans for each machine, which
provide all the relevant information the maintenance
since doing inspections correctly can drive so much value for
reliability and in the all-important inspect-to-work process – so
Doc Palmer
technician or operator needs to be effective. be smart and make the process effective. He is widely recognised as one of
g) Copy and paste of maintenance plans for identical assets the best in the World in providing
Look at Mobile
– a real time saver. 5 Computing Solutions.
training and consulting in the
area of Maintenance Planning
Figure 4 - Visual plant elements like this can help a Mobile computing provides “knowledge logistics” – getting and Scheduling.
lot for inspections that aren’t inherently quantitative. the right information to the right person at the right time. It
also streamlines the data collection process, eliminating the For every 2 delegates you
need for data input from clipboard sheets – a process that’s pay to attend you can send a
inherently fraught with errors and omissions. Also, in most third delegate for FREE
cases, an unacceptable condition revealed by an inspection
typically only has one or two choices for corrective measures.
You can set these systems up to prompt a “fix as found” order Venues
and record of work done, or to automate the work request Sydney 15-16 May 2014
form a few choices. Standardized work requests lead to
standardized work plans, leveraging the repeatable nature of Melbourne 19-20 May 2014
maintenance work. Brisbane 22-23 May 2014

Conclusions Download Workshop

Done correctly, inspections will play a large role to launch
Brochure From:
you into the upper quartile of equipment asset managers. www.theammj.com/
Ambiguous work instructions render the inspection process DocPalmer.pdf
ineffective and a significant waste of company resources. It’s
time for you to get serious about inspections.
19

AMMJ May 2014 Go To Contents Page Go To Last Page

 Optimize Applications
of Gear Units
Amin Almasi Rotating Equipment Consultant
Abstract
Gear units can be eliminated in many machinery
trains in industrial plants and should usually
be avoided. Gear units should only be used in
special machinery trains that other direct drive
solutions cannot be employed.
Introduction
For nearly all machinery applications, operators
preferred to utilize direct-driven rotating
machines and avoid gear units. Clearly, there
is a preference in industry for using direct drive
rotating machine trains. In other words, there is
a bias against using a gear unit in any rotating
machine applications. This article explains
scientific reasons and operational knowledge
and experience for this preference (or bias) and
also explains the risks and issues with a gear
unit. In addition, special cases where gear units
should be used are briefly discussed.
The usual story is a vendor (or a consultant),
after some initial evaluations particularly a
driver speed match analysis, informs operator
(or purchaser) that there cannot be an obvious
machinery train solution that could avoid the use
of a gear unit. This is a common story of many
machinery trains which have used gear units.
20
AMMJ May 2014 Go To Next Article
Figure 1 An example of a direct driven train
Australia amin.almasi@ymail.com
For a high-speed application, many vendors (or
consultants) still offer a conventional electric motor
with a gear unit (particularly for a high-speed
compressor train such as a high-speed centrifugal
compressor). In other words, there is an unjustified
bias against high-speed, direct-drive electric motors.
The use of high-speed, direct-drive electric motors
should more positively be evaluated. The risk and
the possible operational issues of modern high- Figure 2 An example of a machinery train with a gear unit
speed, direct-drive electric motors are usually less
than the problems and issues associated with gear
units.
For low-speed machinery trains, the gear unit
application can be easily avoided. Proper driver
types could be selected for machinery options
to avoid high-speed drivers for low-speed driven
machines. Steam turbine drivers should usually be
limited to direct drive applications. For example, a
high-speed steam turbine driver for a reciprocating
compressor or a screw compressor using a gear
unit for speed-match is usually a poor decision
which could most often be avoided. Using a gear
unit with a gear ratio of “15” to “25” could sometimes
be offered by some consultants to match the speed
of a high-speed steam turbine driver to a low speed
reciprocating compressor. This is a complicated
arrangement which has caused many torsional,
dynamic and operational issues.
Go To Contents Page Go To Last Page

Gas turbine models should properly be selected to
facilitate the direct drive machinery arrangement.
Usually proper models of aero-derivative gas
turbines can offer direct-drive trains compared to
old-fashioned frame-type gas turbines which are
used only in very limited speed ranges.
Gear Unit in a Machinery Train
Gear units have been around for many years and
there are tens of thousands of gear units that have
been operated over long periods of time in a wide
range of sizes and power-ratings. There are also
many gear units for high-gear ratios (say above
“10”), and high-speed applications (high-speed
drivers). It is estimated more than 10,000 gear units
are in operation for medium/large size machineries
worldwide. Risks, operational issues and high
capital and operational costs associated with gear
units have been accepted as a fact in many plants.
Many operators know there are operational issues,
painful installation/commissioning procedures,
delays in commission/start-up, numerous
unscheduled shutdowns, huge costs and many risks
associated with gear units. Because of all these
issues and risks there is a feeling or a preference/
bias in operation teams worldwide to avoid the use
of gear units. However, there is a perception that
there is no other solution among many engineering
and operation teams. On the other hand, vendors
and consultants who select machine arrangements
and offer gear units as a good solution will not live
with their decisions and will not face with issues and
problems of gear units. Operators will face all these
issues and problems.
An optimum design should always minimize the
number of rotating machinery pieces mounted in
a machinery train of a plant, avoiding gear units.
This optimum solution could reduce significantly
the capital cost, the operational cost and the
maintenance cost.
21
AMMJ May 2014
Many gear-unit manufacturers and gear-unit
supporters (engineers or advisors that support gear
units) have accepted issues and failures associated
with gear units. However, they generally try to
show these problems as normal phenomena or
blame other reasons. It is usually claimed that the
underlying cause for most of gear driven machinery
train failures (and issues) is not the gear unit, but
poor “application engineering” or “inadequate
maintenance” of gear units. In other words, gear-
unit vendors (or consultants) who support gear unit
applications nearly always confirm a relatively high
failure rates, maintenance costs and issues with
gear units, but try to relate them to the inappropriate
“application engineering” or “inadequate
maintenance”. Short discussions in these two fields
soon reveal that:
• A gear unit is a complex piece of equipment
that needs a very careful application. Any small
mismatch or carelessness could lead to an issue.
Obviously there are many risks.
• A gear unit is a sensitive item which requires
special commissioning procedures and intensive
(and costly) maintenances.
Gear unit power losses should also be respected.
The reality is gear unit power losses are not so
high that can discourage gear unit applications.
These losses may not be significant in a way to
cause a drastic change in simple commercial
evaluations usually used in industry. However, the
main problem is operational issues, difficulties in
commissioning/operation, delays (and unscheduled
shutdowns) and generally risks associated with
gear units cannot be properly incorporated in those
commercial evaluations and studies.
Go To Contents Page
The operation of gear units, even the normal
operation, is always associated with wear because the
gears are sliding/rubbing most of the time. The low life
and high wear rates of gear units should also be noted
(for most of gear units). The followings damaging
modes need to be considered:
• Gear or tooth low/high cycle fatigue because of
torsional vibration, misalignment or overload
(due to excessive power/load).
• High wear rates caused by rubbing and excessive
deformations.
• Overheating issue, typically because of inadequate
lubrication, have caused many problems in
gear units.
• The complex lubrication oil issues (and problems)
of gear units.
Gear unit driven machinery trains are usually
subjected to complex torsional issues. Most gear unit
operational problems occur during the start-up of
a new installation and are often related to torsional
vibration issues. When designing and applying a gear
unit for a particular rotating machine, the most critical
engineering step is to perform a proper torsional
analysis.
The biggest challenge with a torsional analysis is that
some of input parameters to perform the analysis,
such as operating range, coupling stiffness (and
damping), shaft geometries, and rotating inertias,
may not always be available or sub-suppliers may
not be willing to share them. Inaccurate data have
caused unsuitable torsional studies and consequently
have resulted in many operational issues or gear unit
failures.
A resonance for a torsional critical speed (particularly
the first torsional critical speed) may result in a
high vibration. This high vibration may cause a high
vibration trip and if the trip level is increased to let the
machine operates, the vibration mechanical fatigue or
the premature failure can be occurred.
Go To Last Page
 Another issue that usually leads to failures in gear
units is inadequate or improper lubrication. Improper
lubrication can be related to the oil flow-rate (high or
low rates), an incorrect type of lubrication oil, or the
lubrication oil degradation. It is critical to use correct
oil type, proper oil flow-rate and suitable oil quality
for any gear unit. A gear unit operation depends
strongly on the lubrication oil. The lubrication oil of
all machines in a gear unit driven train is usually
supplied by a common lubrication oil system. A
major issue is that a compromised oil type or a
compromised oil skid design could be selected to
serve all equipment in a machinery train which may
be severely impact the gear unit reliability.
There are other root-causes for gear unit failures. The
gear unit sizing can be a major issue. Undersized
gear units have cause many operational problems.
These are also many installation and commissioning
problems. Commissioning issues are known for
nearly all types of machinery trains, but installation/
commissioning problems for gear units are more
complex, widespread and difficult to solve.
There are many gear units which have been
integrated in large machinery trains and currently
in operation. What are not usually mentioned are
efforts, lengthy delays and high costs associated with
these gear unit driven applications. The painful and
lengthy commissioning, operation or maintenance
activities for gear units have been usually forgotten.
The high vibration, high noise and significant
dynamic forces for nearly all gear units should also
be highlighted. Sometimes, the vibration at no-load
or part-load could be more than the vibration at the
full-load. This may seem a bit strange, but this is the
case for some gear unit driven machines.
Gear units can be eliminated in many machinery
trains and should usually be avoided. Gear units
should only be used in special machinery trains that
other direct drive solutions cannot be employed.
22
AMMJ May 2014
Case Study
This case study is about serious
commissioning problems and lengthy start-
up delays associated with a steam turbine
driven reciprocating compressor train in a
plant. The reciprocating compressor is a four-
cylinder four-crank high-pressure compressor
with a speed around 300 rpm. The train
power is around 4.2 MW, which is a large
machine for a critical and high risk service
that increases the process gas pressure from
around 8 Barg1 to above 130 Barg in four
stages (four cylinders). The steam turbine
was designed to operate at around 5300 rpm
and a complex gear unit was employed to
match the steam turbine speed (around 5300
rpm) to the reciprocating compressor speed
(approximately 300 rpm). The gear unit is a
complicated one with a gear ratio around “17”.
The issue reported here for this compressor
train is a common problem which has been
widely identified in different plants for steam
turbine driven reciprocating compressors.
This issue could be strange to some
operators because many electric-motor
driven reciprocating compressors (direct-
drive trains) have been employed in different
plants worldwide without this kind of issue.
During the no-load test, the compressor train
was tripped because of high vibration. The
alignment, the leveling and the gear mesh
patterns have been checked and everything
was in order. The vibration was gradually
increased when the machine started. The
measured vibration was around 68 micron
at around 2500 rpm. At around 4100 rpm,
the vibration of 173 micron was exceeded
trip level (around 2.5-times the vibration of
Go To Contents Page
68 micron at 2500 rpm) and the compressor
was shut-down by the automatic control
system. In other words, from around 2500
rpm to approximately 4100 rpm, the vibration
increased (quasi-linearly) from 68 micron to
173 micron which caused the compressor
train trip.
The vibration measurement was recorded.
By analyzing the recorded vibration the root-
cause of high vibration was found. The study
was shown that the high vibration (and trip)
was because of a torsional problem (the
resonance with first torsional critical speed)
due to inaccurate coupling data. The solution
was a correct torsional study and another
coupling set to solve the torsional resonance.
The Author
Amin Almasi is a rotating equipment
consultant in Australia. He is chartered
professional engineer of Engineers Australia
(MIEAust CPEng – Mechanical) and IMechE
(CEng MIMechE) in addition to a M.Sc.
and B.Sc. in mechanical engineering and
RPEQ (Registered Professional Engineer
in Queensland). He specializes in rotating
machines including centrifugal, screw and
reciprocating compressors, gas turbines,
steam turbines, engines, pumps, subsea,
offshore rotating machines, LNG units,
condition monitoring and reliability. Almasi
is an active member of Engineers Australia,
IMechE, ASME, and SPE. He has authored
more than 100 papers and articles dealing
with rotating equipment, condition monitoring,
offshore, subsea and reliability.
1) Barg - pressure in bars above ambient pressure
or atmospheric pressure.
Go To Last Page
 Monitoring and
Alarming Wear Metals
What Alarm Levels Mean for Machine Wear
While it is certainly true that maintaining a healthy, clean
lubricant will minimize machine wear, there are still many wear
modes that can arise in spite of these efforts - misalignment,
imbalance, overloading, improper installation, fatigue, and the
list goes on. Abnormal wear, for whatever reason, happens
more often than we like to think about. Therefore, it is essential
to have a strategy in place to monitor machine wear.
Oil analysis remains the best tool for early detection of wear
problems. Wear metal levels detected using spectroscopy will
begin to rise well before the machine exhibits symptoms in the
form of vibration, temperature, or noise. As we see increasing
levels we need to determine an appropriate alarm level to
alert us of a potential problem. However, it is very difficult to
determine what alarms to set for wear metal levels particularly
in industrial applications where equipment categories, such as
gearboxes, are so general.
Do you know how much iron is too much in a gearbox?
Consider how many different sizes, types, loads, environments,
and applications could be included in that question. Now add
the many lubrication systems and lubricant types that are in
use. This simple question becomes much more complicated.
Does it seem realistic
that there could be a good answer to such a question?
Probably not. Yet in most cases, this is exactly the type of
question that we are asking each time we take an oil sample.
If we expect our oil analysis programs to detect machine wear
problems effectively, we need to ask better questions.
23
AMMJ May 2014 Go To Next Article
In oil analysis well placed alarms and limits are like trip wires
alerting operators and technicians to a threatening condition.
Testoil www.testoil.com
What we really want to know is what is normal. But first we
need to define “normal”. According to Webster’s Dictionary,
normal is “conforming to a usual or typical pattern”. Now we
are getting somewhere.
Now how can we identify a pattern in a broad category such
as gearbox? The answer is really fairly simple - by evaluating
as much data as we possibly can. However, before we
get too far into this, let’s look at how wear metals have
traditionally been evaluated in the past.
This situation would reveal a steady increase in wear metal
Understanding Alarm Levels Fixed Limits levels and cause a false positive reading when the level
broaches the fixed alarm. Other gearboxes might be lubricated
Many programs have used fixed limits, which gives a simple by a filtered circulating system, where wear particles are
pass or fail criteria for each wear metal. Figure 1 is an removed by filtration as rapidly as they are generated. In this
example of what fixed alarms might look like. case, the wear metal trend would be flat, and a significant
The drawback to this type of alarming technique is that it change could occur without surpassing the fixed alarm. Such an
does not account for different contributing factors. Looking exception would likely be missed by a fixed limit system.
back at our example of gearboxes, there are many sizes and Figure 1 An example of fixed alarms
shapes of gearboxes. Some gearboxes are lightly
loaded and have a constant speed, which would
lend itself to a low wear rate.
Such a gearbox might be in serious trouble if the
iron level were to reach 200 ppm. On the other
side of the spectrum, you may have a low speed,
reversing, heavily loaded gearbox that has never
had less than 500 ppm of iron in its oil.
The lubrication method can have a large impact
on wear metal levels as well. Many gearboxes are
splash lubricated with small oil level systems.
Go To Contents Page Go To Last Page
 Figure 2 An example of fixed alarms.
This graph represents the amount of iron in a given sample.
The yellow line is the marginal, the red is the critical and the
blue shows the rising level of iron over a period of time.
Understanding Alarm Levels
“Trend Analysis”
Trend analysis allows the development of a pattern of behavior
for a particular unit. If the sampling technique and intervals
are consistent, regular monitoring of the wear metal levels
will also highlight the changes in the wear rate. This helps to
account for many of the variables within the equipment group.
An uncharacteristic increase in iron, as seen in Figure 2, would
indicate a change in the wear rate.
Many techniques can be applied to evaluating trend data, such
as averages, standard deviations, and linear regression. All are
intended to identify a condition that is not normal in relation to
the machine’s past behavior. What is missing here is identifying
what is normal for that machine type. Is it normal for a gearbox to
generate this level of iron?
Understanding Alarm Levels
“Family Analysis”
Family analysis is a technique that compares the wear metal
levels of groups of similar or identical equipment to identify what
is a “usual or typical pattern”.
Equipment is grouped together by family. A family may consist of
identical equipment located in many plants, such as GE Frame
7 turbines in many power plants across the country. You might
also group equipment together based on load, size, lubrication
type, and operating parameters, such as a group of agitators at a
chemical plant.
The wear metal data is then evaluated as a whole. The data for
each machine is then compared to the family to evaluate its wear
rate. As an example, let’s say that we have a family of 50 motor
24
AMMJ May 2014
bearings at a steel mill. The average tin reading is 7 ppm
with 90% of the bearings reading less than 10 ppm. It would
then be safe to assume that it is “normal” for these bearings
to have less than 10 ppm tin in their oil. If one of the bearings
were found to have 35 ppm of tin, it would be safe to say that
its wear rate is “abnormal”. An effort could then be initiated to
determine the cause of the higher wear rate and correct the
problem.
The problem could be detected, identified, and resolved Figure 3 Alarming selection decision tree
before any damage occurs. Ultimately, this effort helped to
avoid premature failure and any cost that might have been
incurred if the bearing had to be replaced.
Family analysis techniques can have a significant impact on
both large and small programs. A large company could use
such a program to monitor large fleets of similar equipment
among their plants, as well as to benchmark performance
of individual plants. Companies with less equipment can
compare their wear rates to equipment in many other plants
and take advantage of the lab’s vast database of equipment
data.
Blending The Techniques
Realistically, the ideal analysis program blends the three
alarming techniques that we have discussed. However, you
can see how cumbersome applying the data evaluation
process to every wear metal for every machine tested in a
program could be. With computers, you can automate this
process so that each parameter is evaluated using numerous
techniques and the best possible analysis is obtained.
Computers are now capable of using statistical calculations,
database mining, and a rule - based knowledge hierarchy
to compare the test data to fixed limits, trend analysis, and
family analysis to select the most appropriate evaluation for
each application. It is possible that for one specific sample,
the limit schemes can vary depending on information About TESTOIL
available, as diagramed in the decision tree in Figure 3.
For example, there may be a customer limit on water TESTOIL is a full - service oil testing laboratory owned by
content, family limit (machine) for iron, family limit (fluid) Insight Services. The firm’s comprehensive range of oil analysis
for IR oxidation, individual machine limit for copper, and services assists reliability engineers with condition monitoring
empirical limit on particle counts. In other words, different and identification of machine wear.
parameters may be alarmed with different techniques. Email: info@testoil.com Web site: www.testoil.com
Go To Contents Page Go To Last Page
 o f 2 Doc Palmer will be
p r ER!! ice in Australia to Present:
e
r th OFF d you
f o L tten
3 PECI A o a

The Maintenance
p ay t R EE
S t
o u
es y gate fo r F
g a
2 d ele d d ele

Planning & Scheduling

ev ery d a thir
For n s en
ca

The Workshops are presented

by Richard (Doc) Palmer
Workshop (2 Days)
Doc Palmer has over three decades of industrial Maintenance planning and scheduling should dramatically improve the
experience as a practitioner within the maintenance productivity of maintenance. For example, a group of 30 maintenance technicians
department of the Jacksonville Electric Authority, a should be performing the work of 47 persons when aided by a single planner. Yet
major United States electric utility. From 1990 through
1994, Palmer was responsible for overhauling the
most maintenance organizations do not have a planning function and most that
existing maintenance planning organization. The do are frustrated.
resulting success played a role in expanding planning Created by the author of McGraw-Hill’s Maintenance Planning and Scheduling
to all crafts and stations owned and operated by the Handbook, Doc Palmer, this Workshop reviews the fundamentals and then
utility. provides class exercises to illustrate the principles and
Publisher McGraw-Hill subsequently sought out techniques to achieve success.
Palmer to author the Maintenance Planning and Who Should Attend:
Scheduling Handbook published in 1999 and now This Planner/Scheduler workshop not only covers the
theory and vision, but the nuts and bolts of how planning Maintenance Planners and
in its third edition (2013). Palmer also directed the
purchase and implementation of a CMMS and and scheduling work. Schedulers, Maintenance
administered the preventive Supervisors, Trades,
The second part to establishing the planning function Technicians. Maintenance
maintenance program.
involves the practical application of these skills in each Engineers & Managers.
Currently Palmer provides
organization. Throughout the event, the workshop
guidance, mentoring, and
training for companies encourages the thoughtful development of planning and
internationally for maintenance scheduling activities within your own facility by your team.
planning success. This course allows class participants to take specific Venues
He is recognised as one of the practices home to their own organizations to implement Sydney 15-16 May 2014
best in the World in providing a new planning organization or dramatically improve an
training and consulting in the existing one. Melbourne 19-20 May 2014
area of Maintenance Planning Brisbane 22-23 May 2014
and Scheduling. Download Workshop Brochure From:
www.theammj.com/DocPalmer.pdf
25

AMMJ May 2014 Go To Next Article Go To Contents Page Go To Last Page

 Shock Pulse and
Vibration Monitoring
Optimize Hoist Shock pulse measurement and vibration
analysis are both widely used for monitoring
the condition of industrial equipment. The two
Reliability at Boliden
complement each other perfectly, providing an
ideal reliability solution for mining applications.
At Swedish mining company Boliden, the
integration of a recently developed shock pulse
Tim Sundström Renstrom Mine Sweden technology with vibration analysis brings peace
of mind to maintenance engineers.
Mine operators are increasingly recognizing the
benefits of investing time and effort in predictive
maintenance strategies. In this capital-
intensive industry, equipment uptime is the key
to profitability. The higher the complexity of
equipment, the greater the risk of breakdowns
and costly downtime. Maximum productivity at
minimum cost is a prime objective.
At the Renström mine in northern Sweden,
Boliden successfully monitors the mechanical
condition of the multi-rope friction hoist using
a combination of vibration and high definition
shock pulse measurement. First installed in
1953 in a tower mounted setup, the Renström
mine hoist had its second revamp in 2013,
converting it to a ground mounted hoist system.
The Renström mine hoist case
The hoist is a critical application and its
performance vital to mine operations. Tough
operating conditions and high availability
requirements makes it imperative to know the
mechanical condition of the hoist at all times.
To ensure peak performance and maximum
equipment life, an online condition monitoring
system now monitors the new hoist at
Figure 1 The multi-rope friction hoist at the Renström mine Renström, providing real-time, condition based
information on the status of critical components.
26
AMMJ May 2014 Go To Next Article Go To Contents Page
Mats Johansson, Maintenance Manager at
Renström stated that:
‘The mine hoist is critical equipment (Arated)
for us and the heart of our business. If the hoist
malfunctions, production more or less comes
to a halt. On this type of equipment, we need
good control and that makes online monitoring
necessary.’
The hoist basically is made up of a frequency
controlled motor, a two-stage gearbox, a drum,
the wires and two skips. The skips are mounted
at the tail end of the wires with a lifting capacity
of approximately 5 tons each. Delivered by
ABB, the 400 kW motor and gearbox has a
total ratio of 13.609:1. Upon installation of the
new hoist at Renström in July, 2013, the online
system Intellinova Compact with the SPM HD
shock pulse measurement technology was also
installed and commissioned, providing very good
baseline measurements from the brand new
hoist.
The combination of vibration and shock pulse
measurement is ideal for monitoring mine hoist
performance. The shock pulse technology is
very suitable for detection of bearing damages
in typical industrial environments, while vibration
technology is optimal for low frequency-related
fault conditions like unbalance, loose gears and
misalignment.
The technical solution
Fifteen transducers are used to cover the motor,
gearbox and drum; ten shock pulse transducers
to monitor bearing condition, and four vibration
transducers to detect low frequency vibrations
like gear mesh frequencies in the gearbox or
unbalance in the drum. In addition, RPM is
measured on the motor drive shaft, one pulse
per revolution.
Go To Last Page

Figure 2 Overview of the
Renström mine hoist
Using shock pulse transducers with the SPM
HD technology renders superior capability to
detect bearing condition. The multiple gear-mesh
frequencies in a gearbox significantly affect normal
vibration transducers, making the spectrum and
overall values very hard to interpret. The shock
pulse transducer however is not affected by normal
mesh frequencies - as long as the gear teeth are in
good condition and no impacts are emitted - but the
slightest irregularity in the contact surfaces between
the gearbox teeth will trigger an immediate response
with precise and easily interpreted readings. The
shock pulse and vibration combination hence covers
this application very efficiently.
Measurement setup
A common working principle for all hoist types is
the cycle time; a hoist is in operation for a limited
time, followed by a stop time for loading and
unloading. From a condition monitoring viewpoint, the
measurement ‘window’ is limited by this cycle time. In
shallow mines, short cycle times may be a challenge
in terms of very limited measuring times. For the hoist
at the Renström mine however, this is not a problem.
The hoist completes one cycle – lifting one skip from
900 meters up to ground level - in 120 seconds.
It accelerates fast and the drum quickly reaches
a stable 51.3 RPM. Based on the 120 second
cycle time at 51 RPM, one hoist cycle equals 102
revolutions of the drum. Selecting a measuring
27
AMMJ May 2014
Figure 3 An SPM HD spectrum perfectly matching
outer race defect frequencies. The levels are very
low with an HDm value of 10 dB.
time of 20 revolutions for all measuring points
on the slowest shaft ensures enough readings
without using triggered measurements. All other
shafts will make more revolutions so for them, the
measuring time is less critical. Even though some
measurements may be lost if the measurement
window happens to hit a rapidly changing RPM due
There are also signs of outer race damage on the
to acceleration or retardation, most of the readings
drive side bearing of the drum (see Figure 3); although
will be taken during stable RPM conditions.
still very small, it can be clearly seen in the readings.
The parameters measured and trended are HDm for Measurements also occasionally show relatively
all shock pulse measurements (a moving average high random impacts close to the coupling between
filter with ten readings has turned out to be useful gearbox and drum.
to avoid false alarms caused by single impacts) and
With the exception of these deviations, the hoist is
vibration velocity RMS (here too a moving average
running very smoothly with low and stable readings in
of ten values is used). Due to the relatively high 1
general. The suspected unbalance and small bearing
X readings on the drum, a trend showing the 1 X
defect are closely monitored through continuous
symptom trend was added.
measurement and trending.
The measurement interval is set to thirty minutes for
Taken together, the monitoring results and system
each measuring point. The long cycle time of 120
performance thus far have provided full control of this
seconds gives plenty of time to measure, resulting in
mission critical application. Shock pulse monitoring
many readings per day on all measuring points. The
integrates perfectly with vibration analysis, providing
number of readings per day is fifteen, on average.
an ideal reliability solution for all types of hoist systems
This is more than enough, so fewer readings per
as well as other critical mining equipment. Boliden
day might be considered to avoid a rapidly growing
implements the same condition monitoring solution on
database - two readings a day for example might
an Autogenous Mill at the Garpenberg mine in central
suffice.
Sweden with very good results.
Reliable results and optimal control
During the first six months of measurements - Boliden Renström
from July, 2013 to January, 2014 – a number of The Renström mine is currently Sweden’s deepest
interesting observations were made. Early on, mine at 1340 m. The ore is polymetallic and contains
very good quality readings revealed that gearbox zinc, copper, lead, gold and silver, which is extracted
data provided by the supplier were incorrect, since using the cut-and fill method.
the readings did not match the expected results www.boliden.com/Operations/Mines/Boliden-Area/Mills
according to gearbox specifications.
Furthermore, an exact 1 X vibration peak on the
Article by Tim Sundström ©SPM Instrument AB 2014
drum is higher than expected for this 50 RPM
application. Slightly higher than 2 mm/s, this may For further information, please contact apt Technology
be caused by wire oscillation but more likely by Pty Ltd (part of the apt Group).
unbalance. info@aptgroup.com.au • www.aptgroup.com.au
Go To Contents Page Go To Last Page
 2014 Listing of Inspection
2014 Inspection & Condition Monitoring Listing
& Condition Monitoring
Equipment & Services
Alstom MSc
sales.msc@alstom.com
www.alstommsc.com.au
Condition Monitoring Products
• Do you need a condition monitoring (CM)
provider who actually uses, understands
and supports the products they sell?
• Do you need a CM provider who can
provide technical support in Australia, with
a 25 year track record of customer
service?
• Do you need a CM solution, not just
products or services?
If so, then read on.
Alstom MSc is a premium provider of
condition monitoring solutions to industry.
The unique benefit that we offer is an
integrated package of leading technologies,
expert consultancy skills, training &
customer support.
In dealing with Alstom MSc, you can
be assured we have the product range,
technical know-how and resources to deliver
& support a condition monitoring package
that works for you.
Our range of condition monitoring products
includes:
28
AMMJ May 2014
• PORTABLE VIBRATION MONITORING
We offer the world renowned range of
Emerson CSI Machinery Health Analysers
with AMS Machinery Manager software.
• ONLINE VIBRATION MONITORING
Give your machines the best possible
protection from failure with smart wireless
monitoring systems, online systems & full
turbine supervisory protection from
Emerson.
• VIBRATION SENSORS
We provide the extensive range of CTC
sensors, cables & mounting hardware for
monitoring online or inaccessible
machines.
• OIL QUALITY SENSORS
The powerful and easy to use Tan Delta Oil
Quality Sensor allows online monitoring of
oil condition for fixed and mobile plant.
• IR THERMOGRAPHY
We represent FLIR, the world leader in
thermography with a wide range of
cameras.
• ULTRASONICS
Top quality, easy to use German made
Sonotec ultrasonic detectors.
• MEASUREMENT AND TEST PRODUCTS
We stock a wide range of machinery
measurement and test products.
Condition Monitoring Services
Alstom MSc has a 20 strong technical team,
with experienced condition monitoring
Go To Next Article
technicians and engineers in every mainland
Australian state providing a variety of
technical services.
• TRAINING:
We partner with the globally recognized
Vibration Institute to offer their certification
program, as well as a range of courses on
CM other technologies.
• CUSTOMER SUPPORT:
Our entire range of products is backed up
by our dedicated direct support team.
• ROTOR DYNAMICS:
Multichannel monitoring, troubleshooting
and balancing on gas, steam, hydro and
wind turbines.
• VIBRATION MONITORING:
Routine vibration surveys, advanced
troubleshooting and diagnostics.
• ALIGNMENT AND BALANCING:
In-situ balancing, shaft alignment and
pulley alignment.
• IR THERMOGRAPHY:
Electrical, refractory and mechanical
routine scanning and investigations.
• OIL ANALYSIS:
Full range of laboratory tests for
contamination detection, wear analysis
and lubricant condition.
• CM PROGRAM ASSISTANCE:
Database tailoring, mentoring, auditing.
• SYSTEM DESIGN COMMMISIONING:
Online system commissioning, DCS
integration, instrumentation testing.
Go To Contents Page
apt Group
(of Companies)
info@aptgroup.com.au
www.aptgroup.com.au
Condition Monitoring Products
The apt Group (of Companies) holds
Distribution rights for a number of well
respected Condition Monitoring Solutions,
for assessing Mechanical & Electrical plant.
The range is suitable for both large and
small industrial facilities, production critical
and balance of plant machines.
• SPM Instrument
– Condition Monitoring Solutions
A wide product portfolio is available, from
high-tech portable instruments to online
systems &
comprehensive, advanced software.
SPM (Shock Pulse Method) is a patented
technique for using signals from rotating
rolling bearings as the basis for efficient
condition monitoring of machines.
From the innovation of the method in 1969
it has now been further developed and
broadened and is now a worldwide accepted
philosophy for condition monitoring of rolling
bearings and machine maintenance.
SPM®HD is a refined version of the
classical True SPM®-method, using digital
signal processing and advanced algorithms,
to ensure the highest possible quality of
measurement results, even on low speed
machines – down to 1 RPM.
Go To Last Page
2014 Inspection & Condition Monitoring Listing

Mechanical Discipline Support Services

These intelligent solutions from SPM
Instrument, are cost-effective, constructive
and complete. They make an excellent
foundation for a proactive approach to
maintenance and to integrate into normal
maintenance activities, providing an overall
picture.
Immediate and evaluated condition
information is presented as green – yellow
– red condition codes, for instant and easy
recognition of trouble spots. This greatly
improves the effectiveness of available
resources.
The range includes:
Portable Instruments –
The BearingChecker is a lightweight
• ALL-TEST ProTM
– Electric Motor Diagnostics
A comprehensive range of hand held
instruments covering off-line and on-line testing
of motors, generators and transformers.
To detect & measure the severity of AC motor
stator and rotor problems, DC motor field
winding problems, power problems and cable
issues.
Motor Circuit Analysis (MCA) - portable
off-line static impedance based testing
instruments, assess the condition of AC/DC
motors, providing in-depth analysis of the motor
circuits - turn-to-turn shorts, open turns/coils,
reversed coils, coil-to-coil shorts, connection
defects, air gap defects, rotor defects - broken
bars, eccentricity and casting voids.
Machinery Diagnostics; Vibration Analysis;
Modeling; Alignment; Balancing; NDT; Oil
Analysis; Reliability Analysis.
Electrical Discipline (LV & HV)
Motor Circuit Analysis; Electrical Signature
Analysis; Thermal Imaging; Switchboard
Inspections; Power Factor Correction/
Condition Analysis; Insulation Resistance;
Sweep Frequency Response Analysis; Tan
Delta; Excitation Current; Partial Discharge
Etc.
For Substations, Circuit Breakers, Busbars,
Motors, Transformers, DC Systems and
Power Cables.
Plant Surveys; Installation & Commissioning;
Database Establishment/Management;
Data Analysis; Training/Seminar Programs;
Technical Support; Repair & Calibration.
On-site and remote data analysis/
management services are available “around
the clock”.
The apt Group (of Companies), promote
Precision Engineering / Maintenance
practices. Both in-house personnel and
world-renowned advisors are available
to undertake site audits, review in-house
processes and assist with change as
needed.

Condition Monitoring
The
and pocket sized instrument for
Electrical Signature Analysis (ESA) -
measurement and evaluation of bearing
instrumentation for complete on-line dynamic
condition. The VibChecker provides
Motor/Power Diagnostics.

Solutions
fast and cost effective on-site vibration Group
measurements and assessment, whereas • Guide Infrared Cameras of Companies

the Leonova™ Diamond & Emerald are
New multifunction handheld data loggers /
analysers.
Continuous Monitoring –
The MG-4 is a standalone continuous
monitoring unit, the CMM is of modular
configuration, whereas the Intellinova® is
a high performance online system; all use
well-proven measurement methods and
modern technology.
Shaft Alignment & Balancing -
Is an optional Leonova™ Diamond
function. When applied, component
wear will be reduced, downtime will be
minimised and energy consumption
lowered.
A wide range of SPM Shim kits, balance
weights, sensors & accessories are also
available.
For Predictive Maintenance; Research
Development; Machine Vision and Surveillance. The apt Group provide a
• APIPro – Asset Management Software & comprehensive range of portable
APT – Asset Performance Tools & on-line instruments, along Vibration & patented Shock Pulse Instruments to measure the severity
with software, for predictive
For managing resources; scheduling activities; technology for machine & bearing of AC motor stator & rotor problems,
& preventive maintenance on
tracking performance; calculating and monitoring (down to sub-1 RPM). DC motor field winding problem,
optimizing asset performance. industrial equipment. Laser alignment & dynamic balancing. power problems & cable issues.
Condition Monitoring Services
For a total Condition Monitoring Package, contact us today
The apt Group (of Companies) is an
Independent Engineering Consultancy – aptgroup.com.au | info@aptgroup.com.au | 1300 700 002
for Condition Monitoring & Plant Reliability
Solutions.
Contractual / one-off plant surveys, project
engineering and advise in system/component
selection/implementation is available. Highly
qualified personnel apply best practices,
international standards and corrective
recommendations in the following disciplines:

29

AMMJ May 2014 Go To Contents Page Go To Last Page

2014 Inspection & Condition Monitoring Listing
Aquip
Systems Pty Ltd
sales@aquip.com.au Key features:
www.aquip.com.au • Customized inspection workflows
Inspection and CM Products
PRÜFTECHNIK’s Condition Monitoring
products include both online and offline
formats. The OMNITREND PC platform
is common to all systems, allowing you
to create comprehensive databases and
archives along with flexibility and reliability.
Off-Line Systems:
VIBXPERT II:
A high performance, fully featured 1 or
2 channel FFT data collector and signal
analyzer for the monitoring & diagnosis
of machine condition. Now available with
multiplexing options allowing collection of up
to 54 channels with the press of one button.
Full VGA colour screen for immediate
analysis. Optional features include
Balancing and Orbits.
VIBSCANNER:
Expandable mid-range data collector for
vibration data, temperature, speed and
process parameters. Add-on modules
available for Full Spectrum, Time Waveform,
Balancing & Laser Alignment.
VIBCODE:
The breakthrough vibration transducer with
automatic measurement point identification
for all systems, guaranteeing accuracy,
repeatability and measurement integrity.
30
AMMJ May 2014
ON-LINE: Machine protection and
Vibration Analysis
VIBNODE, VIBROWEB XP, VIBROWEB,
VIBRONET SIGNALMASTER:
Intelligent machine monitoring systems
that can perform measurements,
evaluation, archiving & alarm warning.
Very-fast multiplexer systems are
available with up to 120 measurement
channels. The internal web server & email
server within these systems provides
convenient remote access from any PC.
VIBGUARD
NEW 20 channel synchronous on line
system. Never miss a second of data. This
system uses the new Vibguard Viewer
software and is perfect for monitoring
of complex machines. It is constantly
collecting data on up to 20 channels.
NOW available in a PORTABLE version
for troubleshooting.
Prüftechnik Laser Alignment: 25 years
of excellence from the Inventors and
Market Leaders!
Rotalign Ultra iS:
The tool of choice for Service providers
and OEMs
Rotalign Ultra iS laser and Sensors have
been redesigned and now offer a laser
that is 10 times brighter, detectors that
are 100% bigger than before and 10
times more resistant to ambient light. The
sensors also have built in accelerometers
and inclinometers that are accurate to
0.1 degrees. Many new features are now
available including flatness, positional
displacement measurement, parallelism,
The 2014 Listing of Condition Monitoring (CM) Products and
Services was compiled by Len Bradshaw (May 2014).
The data given is as received from the respondents.
multi-coupling and bore alignment.
NEW Capabilities include cardan shaft
alignment without removal of the shaft.
Intermediate and entry level - because
one size does not fit all!
OPTALIGNsmart RS and SHAFTALIGN
incorporate a range of Prüftechnik’s
patented features as standard, along
with the latest technology in graphics and
human interface. Systems are tailored
to suit your needs by selecting only the
features you require. If your needs change
in the future and you wish to add-on,
additional features are simply unlocked with
a password – no time off-site!
Asset Inspekt Pty Ltd
riaan@assetinspekt.com
www.assetinspekt.com
Inspection and CM Products
SOLUTION: INSPECTION
TOOLBOX (iTB)
Asset Inspekt’s services are fully supported
by the Inspection Toolbox software solution.
It allows us to provide Enterprise Inspection
Management and Asset Condition
Information Management.
Inspection Toolbox allows customized
authoring of workflows, planning and
scheduling of inspections, electronic
Go To Contents Page
capturing of inspection data and automatic
report/data management.
• Automatic triggers for adverse responses
• Video, Audio, Photo and PDF resources for
inspectors
• Web based reporting
• Planning and scheduling function
• Full inspection lifecycle control
Benefits:
• Reduced inspection life cycles
• Historic data for informed management
decisions
• No more paper
• Reduced reworks and mistakes
Inspection and CM Services
1. INSPECTION MANAGEMENT
Asset Inspekt provides an integrated
Enterprise Inspection Management (EIM)
service. It is the effective and efficient visual
inspection of any asset type across multiple
asset domains, the coordination of the
inspections and coordination of the outcomes
to achieve the client’s desired goals and
objectives. This includes the understanding
of our client’s needs, scoping of the
inspection criteria, designing the inspection
methodology and managing the logistics
through to data capturing and reporting. We
assist our clients in setting up their inspection
KPI’s, monitoring the KPI’s and delivering
their inspection outcome expectations.
Go To Last Page
2014 Inspection & Condition Monitoring Listing

2. INSPECTION PLANNING
We are fully equipped to understand the
inspection planning process to develop
intelligent work flows for inspections. As
part of the planning we will consult with
the client to understand the outcomes
required for inspections. We will review
the existing inspection strategies and
compile an updated strategy to deliver
expected inspection outcomes. Part of
inspection planning includes budgeting of
inspections, inspection history reviews,
resource allocation, resource utilisation
and determining tracking tags for future
trending reports.
3. WORKFLOW AUTHORING
The authoring process changes the
outcome expectations into an easy to
follow work flow diagram that enables
the inspector to capture the required
data effective, accurate and consistent.
Resources are used to guide the inspector
through a complex workflow diagram.
This reduces mistakes and reworks on
inspections and in effect reduces the
client’s inspection logistic costs.
4. INSPECTION LOGISTICS
Asset Inspekt utilises Project Management
FLIR Systems
Australia
info@flir.com.au
www.flir.com.au/ammj-cm
Inspection and Condition
Monitoring Products
FLIR Systems is the world leader in infrared
cameras, having the widest range and offering
the highest standard of any supplier for
predictive and preventative maintenance.
The FLIR range
Now all the thermal imagers in the Ex,
Exx and T-Series ranges come standard
with FLIR’s patented MSX® technology for
extremely sharp, detail-rich imaging.
Across the entire FLIR range, innovative
features are standard including built-in visual
camera, Wi-Fi and Bluetooth . Connect to
smart phone or tablet via Wi-Fi for processing
and sharing results as well as for remote
control.
FLIR’s Ex-Series range sets a new benchmark
in feature-packed thermal imaging technology
at very affordable prices. And now FLIR’s Exx-
Series offers even more with the addition of
FLIR’s GF-Series optical gas detection
cameras letting you find hydrocarbon, natural
gas, carbon monoxide, refrigerant gases
and SF6 leaks quickly, accurately and safely
without shutting systems down for inspection.
A variety of software packages turning tools
into solutions. All users of FLIR’s thermal
imaging camera systems can work more
efficiently and productively by utilizing
the most professional camera-software
combinations.
FLIR’s T-Series Thermal Imaging
Cameras Now Have More Built-in
Features for Even Greater Efficiency
If you want powerful communication and onboard
infrared camera tools, superior thermal imaging, and
the most ergonomic way to get more IR surveys done,
FLIR T-series is as good as it gets.
Leveraging FLIR’s 50-year history as the
world’s largest supplier of thermal imaging
technology to military, government, and
commercial customers, FLIR introduces
a new line of test & measurement
products built upon FLIR’s commitment
to innovation, quality, and reliability. FLIR
Test & Measurement includes True RMS
digital multimeter, two power clamp meters,
NCV detector/light, moisture meter and
videoscope.

principles to schedule, plan and control
inspections. We provide a Responsibility
Assignment Matrix for the complete life
cycle of inspections to make sure all
stakeholders are aware of their roles and
responsibilities. A communications plan
is generated to determine responses to
specific adverse inspection findings to
reduce risks associated with the assets
inspected. Schedules are created to utilise
the full potential of resources on multi-
domain inspections.
MSX® and auto orientation.
Designed for entry-level users who want to get
the most out of their thermal imaging camera,
the FLIR Ex and Exx ranges are perfect for
electrical and mechanical inspections, HVAC,
plumbing and building diagnostics.
The T-Series remains FLIR’s most flexible
and professional grade handheld thermal
camera in the range and leads the field in
image quality, ergonomics and user-friendly
features like image sketch directly onto LCD
touchscreen, voice annotation, tilt-lens and
• Touchscreen & Simple Buttons – As intuitive
as a smartphone’s
• GPS & Compass – Automatically embeds
pointing direction and geo-location
• Annotation – Add voice or text comments to images
or use the touchscreen to sketch
• Illumination – LED lights up dark areas and laser
pointer adds markers for visible images
Find out more at www.flir.com.au/ammj
1300 729 987 NZ: 0800 785 492 info@flir.com.au The images displayed may not be representative of the actual resolution of the camera shown.

auto-orientation.
31

AMMJ May 2014 Go To Contents Page Go To Last Page

2014 Inspection & Condition Monitoring Listing
2014 Listing of Inspection & Condition
Monitoring Equipment and Services
Opening of live components is
dangerous work. FLIR IR Windows
eliminate the need for opening electrical
cabinets to perform inspections, and
to the risk of a hazardous arc flash
incident.
Inspection and Condition
Monitoring Services
FLIR offers unsurpassed support in
before and after sales service. This
includes demonstrations and advice
on the right camera for the application,
training options, as well as rental
systems and a dedicated service
department.
When you buy an infrared camera from
FLIR, it comes fully guaranteed, with
many FLIR cameras eligible for FLIR’s
industry-leading 2-year product and 10-
year detector warranties*.
At FLIR we understand that turnaround
times are critical, so we have an in-
house, dedicated service department
offering full service, repairs and re-
calibration. FLIR Systems’ certified
service centre is headed by its factory
trained and experienced service
manager.
FLIR also provides various levels
of infrared training, from half day
introduction courses, onsite training
through to FLIR’s ITC course. The
Infrared Training Center (ITC) offers
the world’s leading infrared training and
thermographer certification programs.
(*Terms and conditions apply)
32
AMMJ May 2014
FLUKE
Australia
auinfo@fluke.com
www.fluke.com.au
Inspection and Condition
Monitoring Products
Fluke strives to create infrared cameras that
are intuitive and easy to use with advanced
focusing features that integrate the accuracy
of distance laser technology and auto focus –
so you get in-focus images every, single, time
with LaserSharp® Auto Focus.
Blend digital and infrared images into one
clear image with Fluke patented IR-Fusion®.
The Fluke lines of infrared cameras are not
just about accuracy, they are about reliability,
durability, image quality and performance.
With Fluke Infrared Cameras:
• Capture up to five additional measurements
with Fluke’s CNX™ Wireless System for
more complete analysis and reporting
(Capable with most of Fluke Infrared
Cameras)
• Detect and communicate issues faster with
patented Fluke IR-Fusion® technology with
AutoBlend™ mode
• Faster communication with wireless image
transfer directly to your PC, Apple® iPhone®
or iPad®
• One-handed, easy-to-use user interface
• Ruggedised high resolution 640x480
capacitive touch screen for quick menu
navigation
loose, misaligned, or unbalanced parts,
• Capture additional digital images to show
machines have a tale to tell. Now you can
location or additional site details with
get fast, accurate and actionable answers
IR-PhotoNotes™ Annotation System
with revolutionary vibration testers from
• Stream videos (USB and HDMI) Fluke.
• Text and voice recording and annotation get These tools redefine vibration testing for
additional details saved with the image file mechanical troubleshooting and predictive
• Included SmartView® and SmartView maintenance, and help you:
Mobile App Analysis and Reporting • Quickly and reliably understand
Software machinery health and condition severity
Take a vibration expert along.
• Increase efficiency by working against
In the world of mechanical maintenance,
a prioritised list of problems
vibration remains one of the earliest • Take control of downtime costs by
indicators of a machine’s health. anticipating problems earlier and
Whether it’s the rumble of worn bearings identifying root causes
or the shaking, shimmying, or thumping of of recurring failures
Fluke.
Specialising in
Condition
Monitoring Tools.
Fluke Infrared Cameras and Vibration Testing
Equipment designed specifically for professionals
who need to quickly understand the root cause
of equipment conditions.
www.fluke.com.au +61 2 8850 3333  auinfo@fluke.com
Go To Contents Page Go To Last Page
 Fluke redefines mechanical
2014 Inspection & Condition Monitoring Listing
troubleshooting with it revolutionary
vibration products:
The Fluke 810 Vibration Tester, the
most advanced troubleshooting tool for
mechanical maintenance teams who
need an answer NOW!
Control unplanned downtime, prevent
recurring problems, set repair priorities
and manage your resources with an
entirely new approach to vibration
testing. The 810 offers a simple step-by-
step process that reports on machine
faults the first time measurements are
taken, without prior measurement history.
Not to mention the Fluke 805 Vibration
Meter - where vibration pens have tried,
the Fluke 805 Vibration Meter succeeds.
• FOOLPROOF
Testing instead of false alarms.
• REPEATABLE Results you can trust
instead of random readings.
• EASY TO USE
Instead of confusing indicators and
menus.
Inspection and CM Services
(Fluke utilises an extensive network of
industry experts to deliver a full portfolio
of training solutions through:
• Free online webinars
• Hands-on Thermal Imaging &
Troubleshooting Motors and Drives
workshops run throughout the year
• Advanced training
In addition; Newcastle Innovation, the
commercial arm of the University of
Newcastle together with Fluke Australia
offer a Level 1 Infrared Thermography
course comprising of 40 hours of
instruction in the theory, technology and
application of thermography.
For more information on the services
Fluke Australia has to offer, go to
www.fluke.com/au/trainingcentre
33
AMMJ May 2014
Mobius Institute
learn@mobiusinstitute.com
www.mobiusinstitute.com
Inspection and CM Products
RELIABILITY IMPROVEMENT TRAINING
(VIA E-LEARNING)
Improving reliability can be the difference
between profit and loss. iLearnReliability
will teach everyone what they need to know
so that reliability is improved – forever.
iLearnReliability provides the strategy and
the training to follow the strategy along with
the individual skills and motivation so that the
strategy will be successful.
VIBRATION ANALYSIS, ALIGNMENT AND
BALANCING E-LEARNING
iLearnVibration, iLearnAlignment and
iLearnBalancing are innovative e-learning
products that are excellent training tools and
important resources. Fully narrated with lots
of animations, anyone can learn with these
products. And if you forget, just go through
the material again! Thousands of people
worldwide can’t be wrong!
Inspection and CM Services
VIBRATION ANALYSIS TRAINING AND
CERTIFICATION
The Mobius Institute training material is
recognized as the best in the world. And
Clyde Volpe of Vibration Institute of Australia
(VIA) must be one of the best instructors
in the world. To achieve certification and
to become a better analyst, attend the VIA
live course or the Mobius Institute distance
learning course. The certification is ISO/
IEC 17024 accredited – there is no higher
standard. Developed in Australia, over 13,000
people have been trained in 130 countries!
SKF Australia
R.S.Senthil.Vel@skf.com
www.skfcm.com/reliability
Condition Monitoring Products
SKF is the leading supplier of condition
monitoring and maintenance diagnostic
systems, hardware and software that
enables us to monitor operations and
identify problems both mechanical and
electrical faults.
1. Basic Condition Monitoring
SKF Basic condition monitoring kits
combine instruments to enable a “multi-
parameter” approach to monitoring
that includes vibration, oil condition,
temperature, speed, and more to
help ensure the accurate and reliable
assessment of machine condition.
2. Portable data-collectors/Analyzers
for Condition Monitoring
SKF offers a wide variety of portable
data collectors/analyzers including data
collection, machinery vibration analysis
and monitoring, early detection of bearing
defects or gear tooth wear, electric motor
monitoring and field machinery balancing.
Easy menu selection and control enable
the user to quickly and efficiently perform
a wide variety of operations.
3. Online Surveillance condition
monitoring systems
SKF’s On-line surveillance systems
complement the use of periodic data
collection instruments, facilitating a round-
the-clock monitoring of machinery that
collects data 24 hours per day, 7 days per
week from permanently installed sensors.
Go To Contents Page
4. On-Line Machinery Protection Systems
SKF Condition Monitoring offers a spectrum
of machinery protection and monitoring
solutions backed by decades of experience
and global support that includes monitoring,
protection, analysis and diagnosis of critical
machinery.
5. SKF Wireless Solutions
SKF Wireless sensors / systems offers
a simple, reliable and secure means of
expanding condition based maintenance into
plant areas where the cost to install a wired
system is prohibitive, making data available
to existing process control and information
systems.The low deployment costs makes
this wireless solution ideal for expanding walk
-around routes, troubleshooting and difficult
to reach areas.
6. SKF Remote Monitoring Services:
SKF remote monitoring services makes
it possible for any company with Internet
access to implement a world-class predictive
maintenance (PdM) program for periodic or
continuous monitoring of critical machinery.
This service is ideal for plants with limited
staff trained in predictive maintenance
techniques; operations with sites located
remotely from a central facility; and original
equipment manufacturers that desire to
provide a value added service to their
customers. With the Remote Monitoring
Service, SKF will supply the expertise,
Condition monitoring tools and training
necessary to set up a complete condition
monitoring program anywhere in the country/
world.
Go To Last Page

2014 Inspection & Condition Monitoring Listing
7. Baker Motor Testing and Diagnostic
Systems:
SKF acquired Baker Instruments in June
2007. Baker Instruments Company is
dedicated in developing and manufacturing
motor reliability tools that offer a broad
spectrum of capabilities.
Dynamic (on-line) monitoring combined
with comprehensive static testing (offline),
enhances motor condition awareness
including efficiency and performance
information.
8. Measurement and Laser alignment
Systems:
SKF is an exclusive distributor for Easy-
Laser, precision laser alignment system for
industrial applications.
SKF also offers a suite of other
complimentary products such as Online
and Offline Thermography systems,
Ultrasonic Inspection kits, low cost vibration
sensors etc.
Condition Monitoring Services
SKF RELIABILITY SYSTEMS
SKF offers Asset Efficiency optimization
(AEO), a management process designed
to achieve maximum efficiency and
effectiveness from work management
activities focused on business goals,
increasing profitability
1. SKF Energy and Sustainability
Management (ESM)
This program provides benefits to a
customer by establishing an “opportunity
map” of potential savings and improved
practices, including potential areas for:
• Reducing energy consumption
• Improving poorly operating energy
intensive systems
34
AMMJ May 2014
• Improving facility economic performance
• Improving facility environmental
performance
2. Maintenance Strategy.
SKF can assist in developing and
implementing maintenance strategies using
the following commonly applied techniques:
• RCM: Reliability Centered Maintenance:
• SRCM®: Streamlined Reliability
Centered Maintenance:
• RBM: Risk Based Maintenance
3. Work identification.
For increasing plant reliability SKF
recommends following processes/programs
to identify appropriate maintenance tasks:
• Operator Driven Reliability (ODR):
• SKF Predictive maintenance (PdM)
• SKF Proactive Reliability Maintenance
(PRM)
• Motor testing and diagnostics service
4. Work Execution.
SKF can assist by providing project
management, supervision, and inspection,
mechanical installation skills where
customers do not have either the tools or
specialized knowledge in these tasks.
1. Application knowledge:
SKF has extensive application knowledge
through branch offices around Australia, as
well as the industrial specialists to draw on
to solve customer problems with regards to
rotating equipments.
2. Reliability Training:
SKF engineers are on hand to provide
specialist knowledge and training for our
customers. We have offices both globally
and locally, as one of largest global
suppliers of condition monitoring/ reliability
services.
Asset Management
Focusing on developing
maintenance strategies
and improving
performance
A new book edited by Dr Alan Wilson
Published by Conference Communication
This book describes relationships between physical
asset management & maintenance. It gives detail on
the roles and tasks of the maintenance function in
meeting the requirements for ISO 55000 with regard
to:
• Asset management policies and objectives
• The preparation of the strategic asset
management plan and ‘road map’
• The development of the asset strategies prepared
from the basis of risk, compliance, and experience
• The application of life cycle management and
examples of the involvement of the maintenance
function in early asset management, and
continuous improvement
Compiled by experienced maintenance managers, &
experts in the asset management and maintenance
field, with in-depth contributions from industry
professionals, consultants, university instructors,
and practitioners in specific asset management and
maintenance techniques, this edition contains a
wealth of information never before gathered together
in one package.
Structured in an approach recommended for
co-ordinating the asset management and
maintenance functions, and for developing the two
key strategies of asset maintenance strategies
and maintenance management strategies, this
comprehensive reference contains a wide scope of
experience and examples.
A template for development of the maintenance
strategies in relation to physical asset
management:
The book costs £77 including p&p in the UK; £85 to be sent to Europe; and £98 to all non-European
destinations. It can be ordered online at www.maintenanceonline.co.uk
Alternatively, telephone +44 (0)1252 783111 or email info@maintenanceonline.co.uk
Go To Contents Page
Asset
Management
focusing on developing maintenance
strategies and improving performance
Dr Alan Wilson
Published by
The chapters in the book are grouped under six
major policy sectors to provide a template to follow
for the implementation of a total maintenance
strategy required to support physical asset
management. These sectors are as follows:
• Asset management and maintenance,
• Policies, objectives and benchmarking,
• Asset performance, reliability & economic costs,
• Risks control, integrity & inspection management,
• Asset strategies,
• Management audit, strategy, standards & budgets.
The book provides options for how asset
maintenance managers can:
• Involve and gain the support of management
colleagues,
• Develop and implement new maintenance
strategies aimed at improvements in performance
and costs.
It is intended to be used by corporate directors,
asset and maintenance managers, and operations
managers or superintendents of any discipline
looking to develop their asset management
strategies; and by those looking to develop their
careers.
This new edition of the book has evolved both
from his own experience and that of his colleagues
throughout the world who have kindly promoted this
exchange of information for mutual benefit.
Go To Last Page
2014 Inspection & Condition Monitoring Listing
Tensor Systems
tensorsystems@bigpond.com
www.tensorsystems.com
Inspection and CM Products
Tensor Systems is a 37 year old business
which designs, manufactures, installs
and offers Total Customer Support for it’s
Online Permanent Monitoring Systems
incorporating Vibration, Electrical and Oil
analysis.
We have a great depth of knowledge
available to our clients as we started as
consultants and learned enough to develop
our own system in Australia with automated
analysis features others have not yet
thought of.
Our typical customer industries are Steel
making, mining, plastics, and remote
installations such as water distribution with a
target of wind power generation.
Our Online Machine Condition Monitoring
Systems using vibration, speed, load,
electrical & oil analysis costs as little as
$45 per sensor per month to our clients,
for a minimum of 3 years, and has a “once
only” installation, high quality data base
construction and commissioning cost.
Total Customer Support (TCM) assures
clients of timely analysis and trend
information in plane English, so they can
enjoy the benefits of Condition Monitoring
without having to become experts.
The systems sequentially measures each
sensor for 0-32KHz acceleration, then
demod accel & velocity to around 100 orders,
simultaneously with tacho and load sensors for
“exact state” trending.
Unattended, it measures, analyses and trends
24/7 year after year. Automated diagnostics
then separate and trend shaft, gear and bearing
35
AMMJ May 2014
faults groups accurately. Automated diagnostics
then accurately separate and trend shaft, gear
and bearing faults groups.
It is this automation that detects and trends
small bearing faults in the presence of much
higher, but normal gear vibrations.
This avoids huge amounts of analysis time.
Humans are not good at this endless very
detailed analysis, and quickly get bored and
miss things.
SMS messages are sent immediately to all
on the list when a significant trend alarm is
breached, so key personnel are aware of the
situation. Status emails are also sent to all on
the list each morning.
This is where the cost benefit appears,
compared to walk around systems which
require personnel to spend more time analysing
than measuring, and often provide only 1
measurement per month. Compare the cost /
benefit ratio of your existing system to this one
and prove it to yourself.
Inspection and CM Services
Condition monitoring via the internet and also
a monthly data collector service for less critical
machines.
We solve machinery problems, not just measure
vibration.
This requires an engineers understanding of the
dynamics presenting as vibration, plus years of
theoretical research and practical experience to
interpret it correctly.
Forces x Modal Parameters =
Vibration we measure.
The route cause is best understood by the
forces, which we have to work backwards from
vibration the understand and estimate.
On site dynamic balancing can be easy or
become very difficult, and recognizing why is the
key to success. We balance rigid and flexible
rotors, the latter being particularly challenging.
Vibration Institute
of Australia
clyde@viaustralia.com.au
www.viaustralia.com.au
Inspection and CM Services
The Vibration Institute of Australia (VIA)
is the leading Condition Monitoring and
Reliability training centre in in Australia and
also offers courses in over 20 countries
worldwide. These courses are run both public
and in-house which can be tailored to the
organisation’s requirements.
VIBRATION ANALYSIS
VIA is accredited by and utilises the
Mobius Institute training materials which
are internationally recognised in over
50 countries, using professional slides
and interactive simulators, with real case
histories. VIA provides vibration training and
certification exams in ISO Category I, II, III
and has launched the ISO Category IV in
2014. VIA is bringing out Bob Eisenmann
Sr, author of “Rotor Dynamics” as the key
presenter for the Category IV course as he
is recognised leader in his field and brings a
wealth of knowledge to Australia.
The unique benefit of attending a VIA course
is the highly motivated and inspirational
lecturer, Clyde Volpe, who has over 25 years’
experience in Vibration Analysis. He is able
to translate complex concepts into practical
applications that can be implemented in the
field.
SHAFT ALIGNMENT
VIA offers the Beginners to Advanced
Shaft Alignment Course presented by John
Piotrowski, author of the 800-page industry
reference book “Shaft Alignment Handbook”.
Back by popular demand for 2014, this
comprehensive course is recommended
for anyone who is responsible for the
installation, maintenance, and reliable
Go To Contents Page
operation of rotating machinery. The course
provides the knowledge to accurately align
any type of rotating machine in a variety of
different ways. No single alignment method
or system is promoted over another, instead
we provide you with the scope of what is
available to measure and align any simple
or complex drive system you may encounter.
This course is a lecture and lab workshop
using hands-on practical work with machinery
alignment demonstrators. It provides you with
the knowledge and confidence to help drive
your Reliability Improvement Program.
INTRODUCTION TO RELIABILITY
ENGINEERING
VIA is offering a new course as an
Introduction to Reliability, presented by
Daré Petreski, a Certified Maintenance &
Reliability Professional with over 25 years’
experience in multiple technique Condition
Monitoring, Maintenance, Reliability
and Asset Management, encompassing
Business Development, On-Site Application/
Implementation, Education, Training &
Development.
Daré has lead organisational initiatives in
the planning, designing, implementation
& expansion of predictive/condition based
maintenance & reliability programs by
correlating multiple predictive technologies/
techniques. He has facilitated Root Cause
Analysis (RCA) and Reliability training
across Australia, the Asia Pacific & Southern
Africa and has presented papers at multiple
Maintenance & Reliability conferences, both
in Australia and overseas.
Daré is an energetic and interactive
presenter who has the ability to explain
the field of Reliability Engineering through
powerful visuals that bring clarity to the
nearly incomprehensible.
Go To Last Page
2014 Inspection & Condition Monitoring Listing
Vitech
Reliability
sales@vitechreliability.com
www.vitechreliability.com
Vitech Reliability has been providing a
specialist approach to condition monitoring
and reliability based technologies in
Australia since 1994. We service Australia,
New Zealand and South East Asia with
offices in Perth, Melbourne and Brisbane.
Vitech Reliability provides accurate, durable
and cost effective solutions designed to
ensure customers improve overall reliability
and productivity.
Recognising the diversity of applications
and requirements within industry, Vitech
Reliability has four distinct product groups:
• Vitech Mechanical Reliability – Vibration
Monitoring, Machine Diagnostics and CM
Solutions for Rotating Plant.
• Vitech Electrical Reliability – Electric Motor
Analysis and Infrared Thermal Imaging.
• Vitech Machine Support – Machinery
Alignment and Corrective Technology
• Vitech Test and Measurement – NDT
Inspection Technologies and Dynamic
Measurement Solutions.
Inspection and CM Products
Fixturlaser
Leaders in laser shaft alignment and
specialist measurement solutions.
NXA Pro – Next generation digital laser
based shaft alignment tool
XA - Shaft alignment system
Go Pro
36
AMMJ May 2014
ONEPROD by ACOEM
Vitech Reliability are now partnered with
ACOEM’s Industrial Solutions division to
present their ONEPROD brand of Online
Industrial Monitoring products.
ONEPROD offers smart monitoring,
diagnosis and solutions, drawing upon its
unique expertise in the field of vibrations
and acoustics. With its 01dB, Metravib and
ONEPROD brands, ACOEM works with
decision-makers in industry, defence and the
environment throughout the world.
The Eagle and Falcon are the latest
innovations from Acoem’s ONEPROD brand.
Eagle is a self-powered wireless sensor
that does not require any cables. Ideal for
inaccessible machines, mobile machines,
and distant machines. This brilliant new
device offers a smart solution for the early
detection of machine faults through vibration
analysis. Falcon is a smart portable data
collector and analyser which will change the
way we do walk-around vibration monitoring.
SIUI
Vitech Reliability is now the national
distributor for SIUI Co Ltd. SIUI specialises
in the R & D, manufacture & distribution of
ultrasonic testing equipment, probes and
accessories. Vitech is now distributing SIUI’s
NDT products, including their CTS-4020E
Flaw Detector, SUPOR Phased Array Flaw
Detector, CTS-703 Portable TOFD Flaw
Detector, CTS-808 Multi-Channel Digital
Ultrasonic Flaw Detector, CTS-59 Thickness
Guage, and their vast array of Ultrasonic
Probes. All their products offer impressive
functionality and capability at a very
affordable cost.
Vibro-Meter CM Systems
Vibro-Meter provides advanced and highly
reliable sensing, protection and condition
monitoring systems for thousands of
high capital rotating machines worldwide.
Superior quality sensors for harsh
environments as well as high performance
condition monitoring systems and software.
Vibro-Meter’s VM600 platform integrates
all protection, condition and performance
monitoring functions in a single system.
Wilcoxon Research
For over 40-years manufacturers of
accelerometers, vibration sensors, and
accessories for industrial condition
based monitoring (CBM) applications.
• Industrial accelerometers, cables and
terminations solutions
• 4-20mA loop powered Transducers
• Signal Conditioners
• LifeTime Warranty available
SDT Ultrasound Systems
Portable ultrasound instruments designed for
predictive maintenance.
Mobius - iLearn Interactive
Innovative and interactive computer-based
vibration and shaft alignment training
products, vibration analysis tools and
vibration certification courses.
• iLearn Vibration • iLearn Alignment
• Distance Learning
FLIR Systems
The global leader in Infrared Cameras, offer
a wide range of low cost, innovative and high
end Infrared Cameras for Predictive and
Preventative Maintenance. These include:
• InfraCam and InfraCam SD – Low cost
portable infrared cameras
Beran Instruments
Manufacturers of online and portable turbine
diagnostic and monitoring solutions.
• 767 - 32-ch portable multi-channel
diagnostic and motoring system
• 766 - 32-ch on-line multi-channel
diagnostic and motoring system
Go To Contents Page
Endevco
World leaders in extreme vibration and
pressure sensing technologies.
• Extreme temperature industrial
accelerometers
• Precision pressure transducers
• Test & measurement accelerometers
PDMA
Electric motor and generator testing systems /
asset management.
• MCE – Offline motor testing
• Emax – Online motor testing
• MCEmax – Combined tester
SIUI
Vitech Reliability is now the national distributor
for SIUI Co Ltd. SIUI specialises in the R &
D, manufacture & distribution of ultrasonic
testing equipment, probes and accessories.
Vitech is now distributing SIUI’s NDT products,
including their CTS-4020E Flaw Detector,
SUPOR Phased Array Flaw Detector, CTS-
703 Portable TOFD Flaw Detector, CTS-808
Multi-Channel Digital Ultrasonic Flaw Detector,
CTS-59 Thickness Guage, and their vast array
of Ultrasonic Probes. All their products offer
impressive functionality and capability at a very
affordable cost.
Baseline Series
Vibration tools and termination products.
• BLS-UVLA vibration listening amplifier for
data collectors or stand alone
stethoscope use.
• BLS-TB series accelerometer termination
boxes
• Assorted accelerometer mounting
hardware.
Inspection and CM Services
Vitech Reliability also provides the following
services:
• Product, VA and Alignment Training
(class room & customised on site)
• Installation & Commissioning of systems
Go To Last Page
 Maintenance
News
& Reliability
Maintenance and Reliability
Spidler® - Revolutionising Mining Practices
According to good asset management practices,
approximately 10% of all conveyor idler rollers should be
replaced annually to manage the risk of physical failures.
In an average iron ore port operation, this figure means
that more than 10,000 idler rollers require replacement
each year.
Safety and uninterrupted production have always been
paramount for modern mining operations.Most mining
areas are subject to constant improvement and innovation
in order to better realise safety and production goals.
One such area is that of conveyor systems, which form
the backbone of bulk material handling in most mining
operations.
Due to the high equipment utilisation rates, this target is
rarely achieved, as, idler roller change-outs is a physical
and hazardous task. Coupled with the fact that a single
idler roller breakdown typically results in around 69
minutes of production downtime, this means that good
idler roller asset management can result in significant
safety and production benefits. Accordingly, an efficient
and safe way to change-out idler rollers without affecting
production has long been sought after by the
resources industry.
At an average iron ore port operation, a typical production
delay due to a single idler roller failure causes more than
$1 million of lost revenue per delay. Meaning that 20
failures per year could cost in excess of $20 million. By
using the Spidler® to replace faulty idler rollers means that
production can continue uninterrupted, which equates to a
significant value proposition. However, it is only half of the
estimated total value and cost savings the Spidler® can
deliver to a single conveyor through changing conveyor
operating and maintenance practices.
37
AMMJ May 2014 Go To Next Article
News
In response to the physical and financial risks involved
in manually changing conveyor idler rollers, Sandpit
Innovation and Lewis Australia have developed the
Spidler®, an advanced robotic machine designed to
replace carrier idler rollers while the conveyor continues to
operate.
“Considerable time and effort was spent in understanding
the current people and process elements used to manage
and replace conveyor idler rollers,” said Sarah Coleman,
Director of Sandpit Innovation.
Such inherent understanding of the people and process
elements has shown that the Spidler® has four main value
drivers that deliver substantial value and results:
• Overcoming health and safety risks - using robotics
and automation technology to eliminate human
safety concerns.
* Increase production - average unplanned idler roller
change out causes around 69 minutes of production
downtime.
• Extend roller life and reduce labour - idler rollers are
changed on condition and do not require manual
intervention.
• Reduce shutdown time - idler rollers can be changed at
any time and do not require large batch changeouts. The Spidler® enables work identification and the work
Running on light gauge rails mounted to the conveyor management process to be fully optimised and provides the
stringer frame, the Spidler® is not limited by surrounding following: The Spidler® can provide the means to detect
terrain, weather conditions or conveyor angle, which were rapid failures & random failures Since the machine is ‘on-
all highlighted as key limitations in potential designs. line’, it supports a reliability based change-out strategy The
“We analysed the potential operational value in changing Spidler® can support new operating philosophies which are
different aspects of the process and the commonalities currently not attainable
between designs, allowing us to design a machine For more information on the Spidler® and to see a virtual
that was truly fit-for-purpose and addressed the core tour, visit www.spidler.com.au
problems,” added Sarah Coleman.
Go To Contents Page Go To Last Page
 Maintenance & Reliability News
News

Multifunctional Clamp
Meter
Södra Cell Värö expands its online FLIR Unveils New Line Of Test And The new FLIR CM78 is a
condition monitoring to rotary lime kiln Measurement Tools 1000A clamp meter that
Maintenance and Reliability

combines a True RMS

A new facility for lime reburning with larger capacity
is now being built at the Södra Cell Värö pulp mill
in Sweden. The plant with a rotary lime kiln and
associated lime mud filter is a part of the pulp mill
chemical recovery process. In conjunction with the
construction of this facility, online condition monitoring
equipment will be installed during the first quarter of
2014. A total of thirty-eight shock pulse and vibration
transducers, vibration transmitters (4-20 mA) and
RPM transducers are installed on vacuum pump, lime
kiln drives, lime mud filter, hammer mill and fans etc in
order to detect deteriorating mechanical condition in
time for scheduled maintenance.
In the spring of 2013, the first Intellinova Compact
online system was installed at Södra Cell Värö. The
system uses the SPM HD measurement technique
and vibration analysis for condition monitoring of
three roller presses, used to wash and dewater the
pulp. This system is now expanded to include the lime
reburning process.
Preventive maintenance manager Stefan Glendell
comments on the plant’s further investment in online
condition monitoring: “At Södra Cell Värö, we are
convinced that online measurement is an important
tool for us in our quest to continuously improve the
availability of our process machines. SPM delivers
a technology that we believe in. This in combination
with good support functions and competitiveness led
us to choose SPM once again.”
Södra Cell Värö just north of Varberg on the Swedish
west coast is one of the world’s largest and most
modern pulp mills. Its annual production is 425.000
tonnes of pulp. The plant also produces green
electricity, district heating and biofuel in the form
of dried bark. Production takes place in a highly
automated work process, around the clock all year
round, except for planned maintenance shutdowns.
info@spminstrument.se
www.spminstrument.com www.aptgroup.com.au
New product lineup includes True RMS digital multimeter,
two power clamp meters, NCV detector/light, moisture
meter, and videoscope
Building upon its 50-year history as the world leader in
thermal imaging technology, FLIR Systems, announces the
launch of a new line of test and measurement equipment.
Exhibiting the same standard for quality, accuracy,
reliability, and durability that our customers have come to
expect from FLIR, these new T&M tools were engineered
from the ground up to include world-class capabilities –
advanced diagnostics, enhanced productivity, and increased
connectivity – that address our customers’ real-world needs.
Three New Electrical Meters
This brand new T&M product line includes three new
electrical meters – the FLIR DM93, FLIR CM83, and FLIR
CM78. All feature large/clear LCD displays, bright dual-
LED worklights to illuminate dimly lit work areas, Bluetooth
connectivity to Android™ and Apple® mobile devices
running the latest FLIR Tools Mobile app, and the ability to
connect with METERLiNK®-enabled FLIR thermal cameras
so that users can embed electrical readings into their
thermal images.
Streamline VFD Troubleshooting
The new FLIR DM93 is a rugged DMM designed with
advanced VFD filtering and shielding that help professional
users accurately analyze non-traditional sine waves and
noisy signals found in VFD-controlled equipment. Other
features include LoZ Mode to eliminate ghost readings in
long-run scenarios and Continuous Data Recording to detect
intermittent glitches.
Simplify Power and VFD Analysis
The new FLIR CM83 is an industrial power clamp meter with
power analysis and advanced VFD filtering for accurately
testing three-phase systems and VFD-controlled equipment.
Other features include Harmonics Mode to find noise from
different electrical draws, Phase Rotation to confirm power
is evenly balanced, and Inrush Current to detect start-up
related current spikes.
digital multimeter and non-
contact clamp meter along
with an IR thermometer
with laser spot and a Type
K thermocouple. Useful for
working on high-powered
equipment, this new clamp
meter enables users to
take accurate AC/DC
readings up to 1000A or
1000V safely and quickly.
NCV Detector Plus
Worklight
The FLIR VP50 is a
compact, CAT IV-rated NCV detector. The FLIR VP50 has a
powerful LED light for illuminating dimly lit areas, along with
a dual-LED convenience light at the probe tip. Other features
include vibration feedback and multi-colored LED alarms for
inspections in noisy areas, and high/low sensitivity works with
industrial equipment and low-voltage systems.
Versatile Moisture Meter
The new FLIR MR77 is a rugged moisture meter incorporating a
pinless sensor and a wired pin probe to capture moisture readings
up to 0.75” below the surface of various building materials, a spot
IR thermometer with laser pointer, field-replaceable temperature/
humidity sensor, Bluetooth connectivity to Android devices, and
compatibility to METERLiNK-enabled FLIR IR cameras.
New HD Videoscope
The FLIR VS70 is a rugged videoscope with intuitive handset
controls that let users maneuver the narrow camera probe into
tight areas to deliver clear video and images to a large 5.7” color
LCD display. The FLIR VS70 features wide-angle 180-degree
and standard 90-degree camera views, SD card storage of video,
image and audio files, a six-to-eight hour battery life, USB port
for convenient battery charging, and the headset allows for voice
annotations during inspections to clarify findings.
For more information about FLIR’s new line of T&M tools, please
visit www.flir.com.au/measurement

38

AMMJ May 2014 Go To Contents Page Go To Last Page

 Maintenance & Reliability News
News
Maintenance and Reliability
Want to know where your tools are? Ask your
toolbox. Snap-­on Industrial’s automated tool
control system works to help end FOD
Foreign Object Damage (FOD) is a well recognised
and serious threat in every manufacturing and repair
environment – from mining and aviation right across
to food production. FOD occurs when tools and repair
equipment are accidentally left within machinery, with
a high risk of causing harm. Snap-­on Industrial’s latest
product release, the Level 5™ Automated Tool Control
(ATC) System Toolbox combines networked tool storage
and inventory management software into a fully integrated
and automated system – and is helping to combat FOD on
the frontline.
This is a tool storage and control system used to
automatically track individual tools by user without bar
codes, scanners, RFIS tags or other add-­ons.
Level 5 ATC toolboxes start with keyless entry, where
each technician’s identification key card is uniquely coded,
enabling the system to record exactly who has entered
the specially designed cabinet to remove or return tools
and exactly when. The system automatically scans the
contents of each of the cabinet’s robust tool drawers,
using Snap-­on’s technology to detect which tools have
been issued or replaced, removing the requirement for
technicians to rely on memory, or manually account for
tools in and out of a storage system.
The boxes are network-­ready, either through Ethernet
or wireless connection. This means all activity within
the Level 5 ATC boxes can be reviewed centrally.
The powerful and easy-­to-­use software permits an
administrator to view the status of every box – including
the number of tools issues, the active users and all of the
history. System alerts – either through email or SMS – can
be customised for lost or broken tools, as well as tracking
calibration requirements.
“Snap-­on Tools Australia and New Zealand is pleased to
be launching the Level 5 ATC boxes into the market,
39
AMMJ May 2014
with several aviation companies already installing the
technology into their operations,” said Snap-­on Tools
Industrial Manager, Peter Marinovic, “We know from
experiences across our network that the correct use of
the Level 5 ATC constitutes best practice in countering
FOD in a wide variety of manufacturing and repair
environments.“ Snap-­on Industrial’s Level 5 ATC makes
workplaces safer and more productive,” he said.
Platforms
• 35” single bank roll cab, holding approx. 450 tools
• 54” single bank roll cab, holding approx. 750 tools
For further information contact:
www.snapontools.com.au
Go To Contents Page
A Fluke introduces new Portable
Appliance Testers that let users
complete more tests per day
Dedicated keys for one–touch testing, auto-test
capabilities and fast storage and transfer of test results
reduce total test time by nearly 50 per cent
Fluke Corporation introduces the Fluke 6200-2 and 6500-2
Portable Appliance Testers (PAT) with powerful auto-test
capabilities and simplified controls, including one-touch
test routines, that increase the number of tests users can
performed per day without compromising results.
The Fluke 6500-2 can reduce total test time by nearly 50
per cent through the use of professional mode, dedicated
keys for one–touch testing, auto-test capabilities and fast
storage and transfer of test results through the new USB
data ports.
The lightweight, rugged Fluke 6200-2 and 6500-2 perform
all the tests required for Class I and Class II appliances
and conform to the EN61010-1 safety standard. They
feature one-touch testing with dedicated keys for each
test and pre-set pass/fail levels to speed testing. The large
display makes it easy to view test results and a separate
IEC socket provides easy mains/extension lead testing.
Users can also store and reuse common test sequences
for consistent retesting of appliances.
The 6500-2 also features an integrated QWERTY
keyboard for rapid data entry, backlit display, memory
for backup storage and an additional USB port for data
transfers to PCs. It also offers new test capabilities
including:
* 250 V insulation
* RCD-protected appliances
* optional 110 V test functionality for verifying appliances
at building sites.
For more information on the Fluke 6200-2 and 6500-2
Portable Appliance Testers visit:
http://www.fluke.com/fluke/auen/products/Portable-Appliance-Testers.htm
Go To Last Page

News
Maintenance and Reliability
Fluke Earth Ground Testers speed verification
of reliable grounding of electrical equipment
New tools can save up to 50 % of set up and tear down
time while helping solve power quality problems
Fluke Corp. introduces the 1623-2 and 1625-2 Earth
Ground Testers with advanced features and accessories
that speed verification of a reliable connection to earth for
grounded electrical systems, helping solve power quality
problems and lowering the risk of shock to users.
New world-class accessory reels can save up to 50 per
cent of set up and tear down time compared to existing
wire reels.
Studies have shown that as much as 15 per cent of utility-
based power quality problems are related to poor earth
grounding. Fluke’s new Earth Ground Testers identify
poorly grounded systems, helping increase uptime.
The new Earth Ground Testers help engineers and
electricians meet electrical codes, engineering standards
and local regulations to ensure that in the event of a
40
AMMJ May 2014
Maintenance & Reliability News
lightning strike or utility overvoltage current will find a
safe path to earth. They perform all four types of earth
ground measurements:
* 3- and 4-pole fall-of-potential * 4-pole soil resistivity
* selective testing * stakeless testing.
The advanced testers feature USB connectivity for easy
storage of up to 1,500 records with time stamp and fast
downloading of measurements eliminating the need for
manual data transfer. Their large displays make it easy
to read measurements in any environment.
New accessories include heavy-duty stakes that can
be hammered into hard ground, colour-coded wires to
reduce errors and a professional, rugged carrying case
speed.
The 1625-2 model has advanced features including:
* automatic frequency control (AFC), which identifies
existing interference and chooses a measurement
frequency to provide more accurate values
* R* measurement, which calculates earth ground
impedance with 55 Hz to more accurately reflect the
resistance that a fault-to-earth ground would
experience
* adjustable limits for quicker testing
* battery level status on the display.
The 1623-2 and 1625-2 may be purchased as
standalone testers or in kits that include test leads,
clamps, batteries, EG stakes, cable reels and carrying
case. Optional accessories include a 320 mm (12.7
inch) split core transformer for performing selective
testing on individual tower legs.
For more information about the Fluke 1623-2 and 1625-
2 Earth Ground Testers, visit:
www.fluke.com/fluke/auen/products/categoryegt.htm
Go To Contents Page
Apptricity® Jetstream and Apptricity Smartfleet
Software Now on Microsoft Surface®
Leading enterprise mobile software provider Apptricity
extends its productivity apps to Microsoft Surface tablets.
Apptricity, a provider of the Jetstream suite of mobile supply
chain, e-procurement and financial productivity solutions,
has expanded the availability of Apptricity Jetstream
solutions and Smartfleet Field Services for fleet-based
inventory management to Microsoft Surface tablets.
The Smartfleet solution extends Jetstream’s enterprise
platform for work order, asset, inventory and warehouse
management to the vehicle in fleet-based businesses.
Accessible on virtually any mobile device – now including
Microsoft Surface – Smartfleet boosts efficiency,
productivity and responsiveness in field services.
“Smartfleet was made for a solution like the Microsoft
Surface, making the enterprise mobile,” said Tim Garcia,
Apptricity founder and CEO. “We are committed to Surface
and even gave our management Microsoft Surface tablets
as gifts during the holiday season. We’re proud to be a
Microsoft partner on a multitude of Apptricity solutions.”
The Apptricity Corporation, a Microsoft partner, extends the
Jetstream platform and Smartfleet solutions by emulating
the Surface user interface originally known as Metro.
The company also recently installed Microsoft Surface
into a major carrier pilot. Throughout organizations, from
dispatchers to field-service engineers to the C-suite,
Smartfleet empowers everyone with real-time visibility
into relevant data that helps them make smarter decisions
and better serve customers. Truck rolls are significantly
reduced, lost equipment is no longer an issue and
operations become measurably more effective and efficient.
Companies save money, time and effort immediately upon
execution.
To learn more about Apptricity Jetstream or the company’s
fleet management software, Smartfleet Field Services,
please contact an Apptricity representative at
214-596-0601 or visit http://www.apptricity.com
Go To Last Page

News
Inspectahire relies on the FLIR GF320
Optical Gas Imaging camera for maintenance
inspections and hydrocarbon leak detection
in the offshore oil and gas industry
Maintenance and Reliability
Inspectahire is a leading international supplier of specialist
remote visual inspection technology and solutions
to companies in many industries around the world.
Supported by the most advanced technologies around,
Inspectahire helps its customers manage their safety,
profitability and environmental impact of their assets.
When the company is tasked with the detection of fugitive
hydrocarbon emissions, FLIR’s GF320 Optical Gas
Imaging (OGI) camera is their preferred technology to use.
Inspectahire offers equipment rental, contracting and
project engineering services supported by a team of skilled
engineers who have a wealth of inspection knowledge
and experience. Their expertise extends to a wide range
of equipment and assets, both onshore and offshore, and
in all environments – including harsh and hazardous. All
Inspectahire’s advanced inspection solutions are carried
out in accordance with the requirements of ISO 9001 best
practice.
Oil & gas industry
Having worked for three decades in the Oil & Gas industry,
both in the North Sea and worldwide, Inspectahire has
built up a strong expertise in this sector. Safety and cost
are two of the biggest concerns in the offshore oil and gas
industry today. Inspectahire realizes this as no other and
Inspectahire has been using thermal imaging Thanks to thermal imaging cameras,
cameras for a long time to detect dangerous Inspectahire can easily detect gases in difficult
gas leaks. to reach or hazardous locations.
41
AMMJ May 2014
Maintenance & Reliability News
therefore aims to tackle those challenges by using the best
technologies available.
“The offshore oil and gas industry are proactive in their search
for the best technologies for detecting emissions that may
affect the safety, profitability and environmental impact of their
assets,” comments Cailean Forrester, Managing Director of
Inspectahire. “At Inspectahire we strive to identify and offer the
best available technological solutions for all remote inspection
scenarios.”
Safety & economy
Dangerous gas leaks are a concern to every oil and gas
production plant. Not only do some of the gases harm the
environment, but the leaks also cost companies substantial
amounts of money. “The company has been using thermal
imaging cameras for a very long time to detect dangerous gas
leaks,” comments Cailean Forrester “Thanks to thermal imaging
cameras, we can easily detect gases in difficult to reach or
hazardous locations. And we can help companies prevent
costly downtime of their production plant.”
Contact measurement technologies vs. thermal imaging
“We have been using certain contact measurement tools
like laser detectors or leaks sniffers,” says Cailean Forrester.
“But the problem is that you have to go right up to the object,
which is not always safe or even possible. In other words,
this approach is limited and not very precise. With a thermal
imaging camera like the GF320 however, you can keep a safe
distance and still detect gas leaks with great precision.”
With the GF320 camera, you can keep a safe
distance and still detect gas leaks with great
precision.
Go To Contents Page
Accurate and ergonomic
The Inspectahire team is using the GF320 optical gas
imaging camera for maintenance inspections and
for all its hydrocarbon detection jobs, in hydrocarbon
production plants or for the inspection of any material
that uses hydrocarbon as a fuel. The GF320 camera
offers a range of tangible benefits compared to
traditional hydrocarbon leak sniffers, because it
can scan a broader area much more rapidly and
monitor areas that are difficult to reach with contact
measurement tools. The portable camera also greatly
improves operator safety, by detecting emission at safe
distance.
“The camera is very ergonomic and very sensitive,”
comments Cailean Forrester. “If a hydrocarbon leak is
there, you will certainly see it with the GF320 camera,
even if it is a small one. Small leaks can become big
ones, that is why it is important to be able to detect
them in an early stage. With the GF320, we are sure of
an accurate and reliable detection.”
Disclaimer: The images displayed may not be representative of
the actual resolution of the camera shown. Images for illustrative
purposes only. Technical specifications subject to change without
notice.
www.flir.com info@flir.com.au
Small leaks can become big ones, that is why
it is important to be able to detect them in an
early stage
Go To Last Page

Maintenance & Reliability News
News
Maintenance and Reliability
Guidelines for Medium Voltage equipment
installed in harsh environments
Mines are often situated in rural locations where high
levels of humidity are prominent. Rural locations often
mean harsh environments, which unfortunately can also
lower the service life of electrical assets such as medium
voltage switchgear.
It is helpful therefore, to understand how severe
environment conditions can influence the integrity of a
switchboard and what steps can be taken to maximize
service life.
Firstly, it helps to understand what normal service
conditions are. These are defined in IEC 62271-1 High
Voltage Switchgear and control gear – part 1.
However perhaps the two key points to keep in mind are:
• The average value of the relative humidity, over a period
one month does not exceed 90 %;
• The average value of water vapour pressure, over a
period one month does not exceed 1.8 kPa;
Severe condition on the other hand, includes high levels of
humidity and pollution can cause rapid corrosion of metal
parts and surface degradation of insulating parts. Common
sources of humidity include; the atmosphere, water leaks
in the building or substation, water in cable trenches and
excessive plant growth around the substation. When air
becomes saturated with water vapour, condensation takes
place resulting in the formation of liquid water.
Two processes can lead to condensation:
• An increase in humidity
• A drop in temperature at constant humidity
When this occurs, along with dust and pollution, it
can cause rapid corrosion of metal parts and surface
degradation of insulating parts inside a switchgear.
Therefore, maintenance of switchgear becomes all the
more crucial.
If corrosion in the switchgear occurs, it can result in an
uncontrolled arc, and the resulting explosion will not only
cause failure in the equipment, but could also result in
injury to personal.
42
AMMJ May 2014
There are some guidelines that can be followed in order
to manage condensation problems. These can include:
Ventilation:
• Keep substation ventilation to the minimum level
required level
• Use natural ventilation
• If forced ventilation is required, run fans continuously
• Locate substation ventilation openings as far as
possible from the MV cubicle
Avoid temperature variation:
• Install anti-condensation heaters inside MV cubicles
and let them run continuously, i.e. without automatic or
manual control
• Improve the thermal insulation of the substation
• Avoid substation heating if possible
• If heating is required, make sure the temperature
regulation system avoids large temperature swings or
leave heating on continuously
• Eliminate cold air drafts from cable trenches, under
doors, etc Control humidity:
• Avoid excessive plant growth
• Repair any leaks in the substation roof
• Install an air condition system
Pollution:
Switchgear installed in industrial and urban regions are
prone to pollution. If no precautions are taken, pollution
will deposit on insulating components, leading to
degradation by corona and tracking.
Go To Contents Page
WANTED
Your maintenance & reliability News:
News items must be sent to the AMMJ at least 2
weeks before the publication date.
Submit News items as PDF’s or Word Docs.
editor@theammj.com
To manage pollution, the following guidelines can be taken:
• Regular cleaning to prevent degradation from
pollution. Manufacturer‘s outline cleaning procedures.
Typically a clean cloth and water is best (no alcohol or
solvent) however manufacture guidelines should be
followed
• Visual inspections at least once a year. Manufactures
outline ‘identifies’ or areas on the switchgear that are
prone to pollution and dust. Check for corrosion, visible
discharges around the cable terminations and chalking
(white tracks)
In conjunction with these precautions, Schneider Electric
can provide a tailored preventative maintenance program
to optimise the level of performance of MV installations. In
addition to minor preventative maintenance operations such
as visual inspections and cleaning, Schneider Electric can
replace components that have been assessed as having
minimal safety risks. This is done by state of the art software
which maps the link between the process and electrical
network.
For sites with critical infrastructure, Schneider Electric also
provides 24-7 support.
For more information on maintenance services, contact a
local Schneider Electric service representative, or
http://www.schneider-electric.com.au/sites/australia/en/products-
services/services/installed-base-services.page
Go To Last Page
 Maintenance & Reliability News
News
Leonova Phase II Upgrade
Maintenance and Reliability
The Leonova line of instruments offers patented, state-of-the-
art technologies to ensure the most efficient portable condition
monitoring available. These versatile and powerful instruments
have been designed to provide outstanding performance and
usability for all industrial environments, including extreme EX
zones.
The ’Phase II’ upgrade of Leonova Diamond and Leonova
Emerald offers a significant performance increase, a strong
set of vibration analysis functions and much more. Below is an
overview of the further developments included in ’Phase II’.
Parallel measurement execution for greater efficiency (DIA/EME)
Parallel execution of multiple measuring assignments enables
very rapid data acquisition and processing while maintaining
excellent measurement accuracy. Taking full advantage of the
parallel processing capability, the ’Phase II’ upgrade significantly
reduces measuring times, thus making large-scale measuring
routes more efficient.
High-level vibration analysis for gearboxes (DIA/EME)
The Leonova instruments now offer an advanced and powerful
combination of functions especially suited for gearbox analysis.
The new Pseudo Tach function in Condmaster Ruby 2014
replaces the need for a physical tachometer on the same shaft
as the monitored object. Pseudo Tach creates a synthetic
43
AMMJ May 2014
pulse train synchronous to a shaft that is inaccessible
for tachometer mounting. When combined with Time
Synchronous Averaging and HD Order Tracking, crisp
and clear measuring results enable vibration analysis of
the complete gearbox, including intermediate shafts.
User Defined Transducers (DIA/EME)
To measure process parameters such as pressure, flow
or current, user defined transducer types can now
be set up.
Faster computation of machine fault symptoms (DIA/EME)
Significantly faster computation of machine fault
symptoms enables much faster saving of measurement
data. The higher the spectrum resolution, the more
noticeable the improvement. With a 12800 spectrum
line resolution, symptom computation is about ten times
quicker. In addition, Phase II for Leonova Diamond also
comes with the following enhancements.
Shaft Centerline Plot (DIA)
Shaft Centerline Plot displays
changes in radial rotor
position over a range of speed
and is especially useful for
assessment of lubrication
during start-up of journal
bearing machines. The plot can be viewed and exported
from the Condmaster Ruby 2014 diagnostic software.
Frequency Response Function (DIA)
Frequency Response Function (FRF) is used to measure
the vibration response (natural frequencies) of a machine
structure. FRF measures a structure’s mechanical
response to a known applied input force by using for
example an impact hammer and a vibration transducer.
The FRF measuring assignment is set up in Leonova
Diamond and after the measuring round is uploaded,
the settings and measuring results can be viewed in
Condmaster Ruby 2014.
The spectrums and time signals can also be exported
from Condmaster as .txt or .uff files (UFF58) and
analyzed in other software.
Go To Contents Page
Cepstrum Analysis (DIA)
Cepstrum analysis is especially useful for detection and
analysis of vibrations and gear faults in gearboxes. Its
strength is finding periodic components and repeated
patterns in a time signal, which can be difficult to find in
other types of spectra. While a frequency spectrum or
FFT reveals the periodicity of a signal in the time domain,
the cepstrum reveals the periodicity of a spectrum. In the
cepstrum, overlapping sets of sidebands or harmonics
will be separated, much like the spectrum separates
repetitive time patterns in the waveform.
Time Signal Recording (DIA)
Parallel with RPM, recordings of shock pulse or vibration
time signals can be made for a user specified length
of time, triggered by rpm or manual on/off. This feature
enables simultaneous recording of individual time signals
from up to five different transducers. Via the Leonova
Service Program, the recorded time signals can be
exported in .uff format (UFF58) for further analysis in
external software, for instance ME’scope, MatLab or
LabVIEW.
Multiple two- and three channel measuring assignments
per measuring point (DIA)
In Condmaster Ruby 2014, several two or three-channel
vibration measuring assignments can now be set up per
measuring point, providing the possibility to use more
measuring techniques - in two or three directions or
positions.
Live Phase (DIA)
Live phase can be used on
problem machines to confirm
an unclear or suspected
source of vibration. Phase
is the position of a rotating
part at any instant, relative
to a fixed reference. The Live phase function shows the
vibration direction in degrees and the amplitude in real
time.
www.spminstrument.com www.aptgroup.com.au
Go To Last Page
 EEM Steps and Goals
Articles

Early Equipment Goals Define Design Refine Improve

Equipment, Services and People

2. High

Management
3. Detailed 4.Manu- 6. Comm-
Steps 1. Concept Level 5. Install Stabilise Optimise
Design facture Ission
Design

Demand Planning Inventory Building Renew Supply Chain

COMMERCIAL Ramp Up
Delivering Capital Projects Faster, Base Case LCC Model LCC Function Review LCC Operating Review

Cheaper, Better OPERATIONS

Operations Strategy
Develop Provisional
Best Practice
Refine Best
Practice/Train
Cross Shift
Learning
RESET
VISION
Refurbishment
Design/
Module Build Specialist
Dennis McCarthy DAK Consulting UK TECHNICAL Scope Modules Develop Knowledge
Training
Sign Off Base
www.dakconsulting.co.uk
• Lost opportunities to
Most managers and engineers have had firsthand challenge and
experience of capital projects that failed to live up to optimise design choices; Figure 1
expectation when introduced and needed significant • Critical decisions were delayed or not taken;
attention during routine operation. The excess capital
EEM Steps and Goals
• Communication between project stakeholders
costs of these troublesome assets can be huge. interrupted or lost. The EEM route map consists of 6 steps (see figure 1)
which systematically deliver Flawless Operation from day 1
Opportunity costs are high too. One organisation As can be seem from the above, the root causes of through the achievement 3 goals.
we supported estimated that improvements in capital problem projects are not generally technical issues but
project delivery was enough to recoup the original relate to people and how they work together. • Steps 1 and 2 contain activities to Define the correct
capital investment during the first year. scope of the project and involve the right expertise;
Early Equipment Management • During Steps 3 and 4 contain activities to tease out
What goes wrong? Early Equipment Management was developed to latent design weaknesses and enhance project value to
Research into the causes of projects failures indicate a support the collaboration of project stakeholders achieve a robust Design ;
number of common failings at the early projects steps across the end to end capital project process through: • During steps 5 and 6 contain activities to Refine the
including: • Cross functional Commercial, Operational and operational design and develop internal competence.
• Missing or badly design user specifications so that: Technical teams following a structured decision
- Project accountabilities and roles are ill defined; process for each EEM step. Avoiding Common Pitfalls
- Avoidable risks and preventable problems are not • The use of EEM design standards and checklists Below is an overview of common capital project pitfalls and
identified and dealt with until too late in the process. within each step to surface problems and enhance how EEM principles and techniques help to avoid them.
• Resources released late or not released. project value; Steps 1and 2 Goal: Define
• Insufficient training & support for project stakeholders. • Formal stage gate reviews at key decision The root causes of later problems can be due to
As a result problems occur at later steps including: milestones to avoid the transfer of problems weaknesses in the way investment priorities are set and
• Conflicting views of what is needed; to later steps; project scopes defined.
44

AMMJ May 2014 Go To Next Article Go To Contents Page Go To Last Page


Articles
For example a company at the start of its EEM
journey decided to invest in upgrading equipment to
bring in house a product which currently was packed
by an outside company. A cost hike from the outside
Equipment, Services and People
packer had recently focussed attention on the need
to curtail this increased cost.
As part of EEM Step1, the EEM team identified that
this was not the best use of the investment and that
if the funds allocated were spent elsewhere it would
produce greater benefits. Normally, the original
investment request would have been carried out
without question but following this review a much
larger project with a faster payback was identified.
Based on this experience, Investment projects briefs
were then set out in terms of the desired outcome
and prioritised targets.
The EEM team role was to:
- Translate targets into metrics;
- Define problems to overcome to deliver those
targets;
- Set out scenarios to consider;
- Evaluate those scenarios and develop a
preferred approach.
At this stage of a project there is often little
qualitative data to support the evaluation of
scenarios. There is a need to codify tacit knowledge
to make and objective choice between options.
EEM supports this by the use of 6 qualitative design
targets. Each of which has a significant impact on
life cycle costs but can be difficult to measure even
with hands on experience.
These 6 target areas are set out in the right hand
graphic. This also shows the 1 to 5 scale used
to calibrate assessments. (1 being low, 3 being
LCC Influence
acceptable and 5 being optimum).
Where necessary, following this qualitative
assessment, further analysis can be carried out to
confirm the evaluation basis, refine the preferred
concept and support the submission of the
application for capital project funding.
45
AMMJ May 2014
EEM Design Benchmarks
Figure 2 EEM Qualitative Design Targets
Definition
Safety and Function is intrinsically safe, low risk, fail
safe operation able to easily meet future
Environmental statutory and environmental limits
Function is immune to deterioration
Reliability requiring little no intervention to secure
consistent quality
Process is easy to start up, change over
and sustain “normal conditions”. Rapid
Operability close down, cleaning and routine asset
care task completion.
Deterioration is easily measured and
corrected, Routine maintenance tasks
Maintainability are easy to perform and carried out by
internal personnel.
Process is able to meet current and likely
future customer QCD features and
Customer Value demand variability. Provides a platform
for incremental product improvement
EEM Step
Process has clearly defined cost and
value drivers to support Life cycle cost
Life Cycle Cost reduction, enhance project value and
maximise return on capital invested
Go To Contents Page
3.Acceptable 5. Optimum
Little non standard work
Foolproof/failsafe operation
Moving parts guarded, few projections
High level of resource recycling
Meets SHE and fire regulations
Easy escape routes and good Uses sustainable resources
ergonomics
Low failure rate
High MTBI
Low idling and minor stops
Stable machine cycle time
Low quality defect rate
Easy to measure
Flexible to technology risks
Flexible to material variability
Good static and dynamic precision
Simple set up and adjustment
mechanisms One touch operation for height,
position, number colour etc
Quick replace tools
Flexible to volume risk
Simple process control
Flexible to labour skill levels
Auto load and feeder to fed processing
Easily overhauled
Easy failure/detection/repair
Self correcting/auto adjust
Off the shelf/common spares used
Long MTBF, Short MTTR
Inbuilt problem diagnostic
Easy to inspect and repair
Predictable component life
Fit and forget components
Easy order cycle completion Capacity for future demand
Maximum control of basic and Robust supply chain
performance product features Simple logistics//forecasting needs
Flexible to product range needs Flexible to potential market shifts
Clarity of current capital and High level of resource recycling
operational cost drivers and process Flexible to financial risks (e.g.
added value features vendor)
Potential for value engineering gain Easily scalable to 400% or to 25%
Resource economy Access to high added value markets
Go To Last Page
 Articles
EEM Steps 3 and 4 Goal: Design
Following funding approval of the preferred option
and selection of a vendor, the priorities for EEM
Equipment, Services and People
Steps 3 and 4 are to tease out latent design
weaknesses and enhance project value.
Common mistakes here are trying to pass off risk to
the vendor without a clear understanding of what the
risks are or whether the vendor is able to manage
them.
Experience shows that there is more to gain from
collaborating with vendors to develop better designs.
Even where the options to modify technical design
are limited, the understanding gained about changes
to operations, workflow and skills needed etc make
this an important activity on the road to flawless
operation.
Our analysis shows that the difference between an
“average” and “simplified” design can be worth a
30% reduction in capital costs. The same analysis
shows that “complex” designs can increase capital
costs by more than double when compared to the
“average” design. That alone is enough reason to
take care at the design review stage. However,
capital costs are normally a small % of the total life
cycle costs and achieving flawless operation from
day one can be worth as much again.
EEM design collaboration involves a 2 part review
process:
• Meeting 1 involves assessment of an outline
design against EEM standards to confirm
strengths and priorities. Use “Day in the Life Of”
approach and layouts to make clear operational
realities and outline ways of working;
• Meeting 2 involves the vendor explaining in
detail how the more detailed design meets those
standards.
That way the vendor can show that they really do
know what is needed to achieve Flawless Operation
from day 1.
46
AMMJ May 2014
EEM Steps 5 and 6 Goal: Refine
After completion of the detailed design process,
human error is the biggest risk to the capital project. As many capital projects originate due to the
A common mistake here is relying on vendor training introduction of new products or services, the biggest
alone to develop in house competence. gains from EEM are achieved when the principles are
Competence is achieved over time and needs applied at the product design stage. The approach is
reinforcement. In addition, when introducing then known as Early Management.
new equipment, this is the ideal time to engage EEM can also be applied to projects relating to
representatives across shifts to agree a common equipment optimisation, low cost automation or
approach. business systems implementation.
Within an EEM project, the evolution of ways
of working is managed as a core part of the
For help with your capital project delivery process
specification process at each step. That is the contact DAK Consulting info@dakconsulting.co.ok.
only way to be sure that MORSE principles
For more in depth training check out our EEM 3 day
(Maintainability, Operability, Reliability, Safety and training workshops at:
Environment) are hard wired into the design.
http://www.dakacademy.com/newsite/courses/dak-
To further refine ways of working problem prevention academy-courses/early-equipment-management.html
techniques are applied to provisional ways of
working so that they can be easy to do right, difficult
First published in the M&E Journal
to do wrong, simple to learn. This incorporates the
PDCA (Plan, Do, Check, Act) approach by testing
ways of working as part of the commissioning
process.
Early Equipment Management 3 Day Training
Implementing EEM Workshop
Like EEM itself, successful implementation
programmes adopt a stepwise approach:
15-17 July 2014, Cheshire
1. Define: Review current capital project processes A toolbox of best practices designed to deliver flawless
and identify strengths and priorities for action; operation from production day one for new or upgraded assets.
2. Design: Use a pilot project(s) to improve the
current processes, define EEM standards and Providing “hands on” syndicate sessions to help participants
deal with gaps in related business processes. apply
apply theory
theory into practice.
3. Refine: Train managers, design engineers project
managers and CI facilitators in lessons learned Call 01491 845504 or email for full workshop
from the pilot
brochure sue.catt@dakconsulting.co.uk
4. Improve: Capture lessons learned from each
project and use to update design standards. “Developing Improvement Leaders” www.dakacademy.com
Reinforce EEM policy by training of each new
project delivery teams including key stakeholders.
Go To Contents Page Go To Last Page

Wearable
Articles
Safety Suit
Equipment, Services and People
Markus Aleksy ABB Germany and
and Barry Kleine ABB New Zealand
Safety of personnel is a topic constantly on
our minds, and the increasing complexity of
our industrial plants makes it continuously
more difficult to monitor for safety issues and
respond to emergencies.
Whether it is service personnel performing
activities in rural areas away from frequently
used traffic routes, personnel working in
confined spaces, or simply people working
alone, the challenge is to promptly identify
and respond when that person is in trouble.
Issues such as remoteness and changes in
environmental conditions can make it difficult
for management to fully comply with all the
required Health and Safety legislation.
To overcome these concerns, ABB have
developed a wearable safety suit which
collects information related to environmental
conditions, such as gas levels and
temperature, as well as the health of the
wearer. This user customisable unit not
only alerts the wearer to a potential harmful
environment, but issues regarding the
health of the wearer or environmental risk
can be sent to a control centre without user
interaction. This second feature allows the
control centre to advise the user of issues they
47
AMMJ May 2014 Go To Next Article
see, or send assistance even when the user is not
able to call for help.
The wearable safety suit was designed alongside
service engineers and technicians to ensure it
addressed requirements while still being user
friendly. Alongside these personnel, 39 potential
uses for wearable computing were documented.
Existing equipment was identified and used as
the base of the design to address the high priority
opportunities. By incorporating sensors and
actuators into the high-visibility vest and operating
it via a mobile phone, the related overheads were
reduced significantly, as no additional tools were
needed.
System Overview
The wearable system consists of two major
components. The first is the automated safety
suit. It integrates several
sensors and actuators, such
as a body temperature sensor,
a carbon monoxide sensor, an
environmental temperature & Sensors BAN Actuators
humidity sensor and a heartbeat
sensor. All the components
are connected via a body area
network (BAN) to the central CPU
processing unit (CPU) by using
Safety Vest
conductive material.
Go To Contents Page
A Bluetooth module is then used for transmitting the
data to the second component - a mobile device. The
latter is used to organize the sensor data and take the
decision according to the user specifications. The mobile
application can be initially set up with predefined sensor
thresholds, emergency contact number, and e-mail
address of the supervisor. These parameters can be
adjusted by the user before going to execute the work on
the site.
The mobile device can automatically send messages with
GPS coordinates of the user location to a supervisor or/
and a control central whenever the dangerous sensor
levels are detected.
In addition to being a real time monitoring unit, the sensor
data can be stored in a local database. The retrieved
information can be used for further processing, such as
analysis of the working conditions, and hazard controls
can be updated as required.
Safety Suit
The automated safety suit contains different sensors
for monitoring user’s and environmental conditions.
Additionally, the suit is equipped with actuators, such as
a speaker and vibrator to provide the vital alerts when
undesirable or dangerous sensor thresholds are detected.
In this prototype, e-textile technology - an electronic
textile that has electronic components embedded within
the clothing - is used for integrating the sensor and
micro-controller inside the safety suit. Inside the suit, the
sensors and controller are connected using a silver plated
nylon thread. A Bluetooth device is used to transmit all
the sensor data from the suit to mobile phone.
Figure 1: Architecture of the wearable automated
safety suit monitoring system
GPS Control Center
Internet
Database
Bluetooth
Mobile Device Supervisor
Messages
Go To Last Page

Articles
Sensors
Sensors play a critical role in developing the
Equipment, Services and People
automated safety suit for monitoring the wearers’
health and environmental conditions. A range of
sensors can be installed such as:
1. Heartbeat sensor
The heartbeat sensor is used for monitoring the
heart rate of the user, as this is the largest factor in
the ability of the medical officials to see the signs of
distress. Low and high heart rates for a long period of
time causes cardiovascular problems. A pulse sensor
is used for calculating the heart rate, which is then
transmitted to the wearer’s mobile via serial interface.
2. Carbon monoxide
Carbon monoxide (CO) is one of the primary toxic
gases in industrial environments. CO is a colourless,
Figure 2: Safety suit
48
AMMJ May 2014
odourless and tasteless gas which is not significantly
detected by human senses. In some cases, people
are exposed to extreme risk when working in industrial
environments such as in confined spaces, mines,
and at high altitudes. It is extremely dangerous when
people don’t realize its existence and they may suffer
with dizziness and headache. The CO sensor installed
in the safety suit measures the gas levels in parts per
million (PPM) and transmits the data to the wearers
mobile phone using Bluetooth via the micro-controller.
The sensor is located on the suit near to the chest
location.
3. Body temperature
A sudden change in the body temperature can indicate
infection and stress, and exposure to temperatures
can result in exhaustion, weakness and fainting. The
body temperature can be measured using electrical
and optical devices which are located on the chest and
it is interfaced to the micro-controller.
4. Environment temperature and
humidity sensor
Temperature is one of the complex
issues in industrial working area as it
will create thermal discomfort to the
employee. A hot working environment
creates discomfort to the workers’
health, efficiency, and performance -
affecting the employees’ heart rate,
body temperature and sweat rate.
High humidity over a longer period
of time makes the problem worse
under these conditions. Therefore,
it is hard to perform work orders in
these harsh working environments. A
fully calibrated, high quality and high
accuracy sensor is integrated into the
workers safety suit and connected via
micro-controller by using conductive
thread.
Go To Contents Page
Feedback devices
Feedback devices are playing a major role in wearable
applications. They provide the physical alerts to the
field service engineer when abnormal conditions are
detected. The safety suit uses a speaker and vibrator
to give vital signals to the user. The speaker is located
on the chest and the vibrator is located on the hip.
Emergency panic button
The additional feature in the safety suit is an
emergency panic button located in right arm shoulder
position. The functionality of the emergency panic
button is to send an alert signal to the users’ mobile
phone by pressing the button when the user is in
danger situation or has any health problems. The
mobile application will make a phone call and / or send
an email or SMS to their supervisor. Moreover, the
mobile application is responsible for sending sensor
data and updating the control center.
Mobile application
The ABB Safety Suit can be integrated with many
portable devices already on the market. The purpose
of the mobile application is to collect sensor data,
display alerts and notifications on the device when
abnormal conditions are detected. It is based on the
Android operating system which is common to many
devices and is very easy to learn and use.
First of all, some user preferences have to be specified
beforehand to ensure that the wearable safety suit
will perform the right actions in case of abnormal
situations. The alert preferences include time-out
specification, alert actions, and information related to
contact data, such as e-mail address, phone number
etc. Additionally, thresholds for utilized sensors have to
be set up.
The main screen of the application presents real time
data transferred from the safety suit via Bluetooth.
It allows the user to monitor his/her vital signs and
sensor data in a number or graphical manner.
Additionally, the application allows the supervisor of
the work in the field, or the control center, to view the
vital signs of the employee engaged in action.
Go To Last Page
 This application will automatically send
SMS and/or e-mails to the supervisor
Articles
of the employee including information
of employee location and type of alert
being raised in that situation. When the
conditions are critical the application will
Equipment, Services and People
make a phone call to the supervisor so
that they could be alerted.
Conclusion
The increasing complexity in industrial
plants means remote, difficult and
sometimes solo work. The convergence
of wearable sensors, networking
and communication technologies,
and mobile devices simplifies the
development of wearable computing
applications from off-the-shelf
components, and makes it a lot easier
to monitor the safety of our personnel.
As sensor development continues, so
will the prospects of this safety suit.
Figure 3: Mobile application running on Android OS
49
AMMJ May 2014
Alongside the continual development of the
safety aspect, other opportunities will be
integrated with this suit to aid the wearer in
their job.
Using the available technologies, ABB has
chosen to take a lead in the monitoring
and support of the health and wellbeing
of their employees. From making it
easier to personnel to monitor their own
environment, to being able to automatically
Engineers Without Borders
send assistance even when the person
is physically unable to, ABB has taken a
step forward in protecting its most valuable
asset.
For ABB, this is just the start of creating new
and advanced wearable computing systems,
based on standardized components,
which improves the safety, ability and
effectiveness that we do business.
Contact: markus.aleksy@de.abb.com
Go To Contents Page Go To Last Page

Equipment,
News
Services & People
Equipment, Services and People
High precision geometric measurements with Fixturlaser
The Fixturlaser NXA Geometry
package includes software for standard
straightness, bore alignment, circular and
rectangular flatness. The measurement
and adjustment process is achieved
promptly and easily thanks to the unique
intuitive graphic user interface with live
values displayed in micron resolution.
The user friendly graphic interface is a
distinctive feature in all measurement &
alignment tools developed by Fixturlaser.
Rectangular Flatness
50
AMMJ May 2014
News
The new geometry package is no
exception from the rule; it has an intuitive
and 3D animated interface with icons and
color coded symbols that prompt the user
through the measurement and adjustment
process.
Other helpful features include live values
in micron resolution during measurement
and simultaneous live adjustment, in both
vertical and horizontal orientation (X and
Y values), during the adjustment process.
Bore Alignment
Go To Next Article
WANTED your news on plant engineering, assets,
plant equipment, tools, energy, HVAC, plant
services, bearings, compressed air systems,
lighting, people issues, training, environment, etc..
Send to: editor@theammj.com
Circular Flatness
Also, an additional sensor can be used as
a reference sensor, which you zero at the
start of the measurement process. You
are then able to control, at any time during
the measurement, that the transmitter
has not been moved during the actual
measurement, which would otherwise
cause incorrect measurement values.
Hans Svensson, CEO Elos Fixturlaser AB,
says: “We have developed a geometry
package that goes hand in hand with
our shaft alignment package. They
complement each other in order to achieve
optimal machine conditions which will
result in fewer unplanned stoppages,
component wear, and lower costs. Not Standard Straightness
to mention the green benefits that these
reductions entail!”
ELOS Fixturlaser is a global player and
a leader in developing innovative, user-
friendly equipment for shaft alignment.
By helping industry worldwide to become
perfectly aligned, and eliminating
anything that might not be, we minimize
unnecessary wear and production
stoppages. This will ultimately make
our customers more profitable and our
environment more sustainable.
For further information about the
Fixturlaser NXA Geometry system and
technical details, please contact: Hans
Svensson, CEO,
hans.svensson@fixturlaser.se
Go To Contents Page Go To Last Page

Equipment, Services & People - News
News
Demand for Accurate Reporting and
Equipment, Services and People
Forecasting Drives Wireless
Sub-metering Sales Surge
HWM’s Radio-Tech brand of wireless sub-metering
products is being used by energy management service
provider Stark to provide accurate real time energy
usage and performance data to its customers. Stark
has just announced that in the last twelve months it has
added over 2,000 new wireless sub meter connections
to its energy reporting service SavenergyOnline, with
substantial demand coming from companies’ desire for
accurate financial reporting, analysis and forecasting.
Stark uses HWM’s wireless data collection system
that has been designed specifically for sub-metering
applications. Operating on HWM’s licensed 153MHz
frequency band, compact wireless transmitters and
attached sensors efficiently monitor electricity, water
and gas usage at multiple points throughout multiple
occupancy buildings, across campuses and even for
multi-site organisations. With readings collected and
processed every 30 minutes, a near real-time picture
of energy performance is provided to customers for
detailed and accurate analysis.
Thanks to their wireless capabilities and battery power,
the devices are easy to install anywhere. All devices
for each application transmit the data locally to one
of HWM’s Wi5 Data Hubs, which then uses GPRS or
Ethernet (LAN) to send all that information onwards to
either HWM’s own web-
based portal or a company’s
own data management
software – in this case
Stark’s SavenergyOnline.
This lets both service
providers and end-users
see exactly the data they
want, whenever they want
and however they want.
www.hwm-water.com
51
AMMJ May 2014
Expert Flooring Advice for
Facilities Managers
Flowcrete Australia has produced an educational eBook to
help facilities managers reach an informed decision when
specifying a new floor.
Entitled “Taking the Headache Out of Flooring Specification
for Facilities Managers”, the eBook details the key
challenges and considerations that arise when choosing
a floor for new-build or refurbishment projects in either
industrial or commercial locations.
Flowcrete Australia understands the crucial role of facilities
managers in planning for and dealing with the day-to-day
operational challenges of large-scale sites, especially if the
obstacles vary across multi-purpose, multi-unit buildings.
Therefore this resource has been designed to allow facilities
professionals to make use of advice and in-depth information
from a global expert on resin flooring, so that they can better
understand the practicalities & benefits of different solutions
when going through the specification process.
David McNeece, International Marketing & Business
Development Manager for Flowcrete, said: “Every facilities
manager wants to know how they can ensure their buildings
are up to the task they face – whether that includes
intensive manufacturing, large numbers of visitors, providing
a complex service like healthcare or allowing for highly
specialised activity such as scientific research.
“And in every situation the choice of flooring can have
significant consequences to the operational ability of the
building. Failing floors can create unhygienic, unsafe
surfaces, were as the right floor will provide a reliable
Go To Contents Page
platform which could even
add to the quality of the
environment, such as
with built in antimicrobial
additives, an aesthetic
coating or antistatic
properties.”
The new eBook includes
valuable advice on a
multitude of flooring issues,
from how to ensure a safe
and hygienic finish, understanding the problems that can
arise from chemical exposure, how to incorporate signage,
implementing a robust cleaning regime and how to get
added operational benefits from the floor.
The important considerations that decision makers need
to think through are also highlighted. These crucial details
include weighing up the cost of flooring over the building’s
lifetime and the cost of refurbishments in the case of floor
failure, what health and safety action needs to be taken
and putting effective plans in place in case of chemical
spillages.
Useful tips and techniques are included in the new eBook,
such as minimising the financial impact of refurbishment
downtime with a fast-cure flooring solution. By utilising
MMA technology floors can be trafficable mere hours
after application, in comparison to the days or weeks that
it would usually take before follow on work or productive
activity could commence.
The wide range of flooring options and the complexity of
different systems means that whilst the right solution might
be out there, it’s difficult to always identify it. Flowcrete
Australia’s eBook is the ideal starting point for any facilities
manager looking to enhance their understanding of flooring
and ultimately make the best possible decision during the
specification process.
www.flowcrete.com www.flowcreteaustralia.com.au
Go To Last Page

Equipment, Services & People - News
News
Whiting’s Passport to safety uses smart card technology
helps prevent potentially fatal wrongful use of machinery
Equipment, Services and People
AccessPoint from
Whiting Passport is an
inexpensive, easy-to-use
way to significantly reduce
the risks of equipment
misuse, which can
include death and injury,
compromising of the safety
of entire plant operations
and also causing damage and disruption that
drives up operating costs.
AccessPoint not only controls who can operate
high-value, high risk equipment, but also
records when they accessed it and for how long.
The technology enables users to employ one
system for their entire operation. The system is
administered through a secure, easy-to-use web-
based application, Whiting Viewpoint.
AccessPoint for Fixed Equipment can be fitted to
any electrically powered device, extending from
cranes, lifting and positioning machinery vital to
production, to lathes, presses, cutting and forming
equipment, CNC plant and breakout machines.
AccessPoint for vehicles can be fitted to any
vehicle with an on-off button, including forklifts,
diggers, trucks and primary production and civil
engineering implements.
“Each AccessPoint system is customized to each
specific user,” Says Whiting Passport Product
Manager Joel Phelps. “Each user has the power
to store start and stop times, to track certification
and expiration statuses and to set customized re-
certification intervals on a per user basis, as they
see fit.
“Users can remain in compliance with OHSA and
other regulatory standards because AccessPoint
52
AMMJ May 2014
gives them the ability to continuously
view how their equipment is being
used. Users can quickly address and
correct misuse patterns.
AccessPoint creates a shared culture
of responsibility that ensures the
correct use of high risk, high value plant
equipment.”
System users can view run hours of all
AccessPoint devices within range from any
Bluetooth device, or they can log into their own
personal dashboard, or Viewport, from their PC to
view usage statistics of all AccessPoint devices.
Whiting Passport dealers provide real-time
support to assist with installation and setup
and to answer customer questions. A full range
of kits are available, depending on the type of
equipment.
Features of AccessPoint
AccessPoint for Vehicles simply replaces vehicle
keys with a smart access card.
AccessPoint for Fixed Equipment works like
a power switch and interfaces with start/stop
circuits, drives, PLCs, and PC controls. It is ideal
for three-phase contractor-started machines or
single-phase switched circuit equipment where
the board can be mounted internally.
mmarkiewicz@whitingcorp.com
www.whitingcorp.com
Fluke Networks positioned in the Leaders Quadrant in
Gartner’s 2014 Magic Quadrant for Network Performance
Monitoring and Diagnostics
Fluke Networks, a world-leading provider of network monitoring and test
solutions, has announced Gartner, Inc. has positioned the company’s Visual
TruView™ solution in the Leaders quadrant of the “Network Performance
Monitoring and Diagnostics (NPMD)” report.*
The report, which is the first Magic Quadrant from Gartner on the Network
Performance Monitoring and Diagnostics (NPMD) market, foreshadows growth
in this emerging technology market. It emphasises the need for a single
integrated solution to monitor, troubleshoot and analyse networks and—even
more important—the applications and services they carry.
Market analysis conducted by Gartner noted the growing interest in the
NPMD market, also referred to as Application-aware Network Performance
Management (AANPM). Increasingly, companies are realising how essential
it is to understand their customers’ and end users’ experience with their
networks and applications. They recognise the need to proactively monitor their
networks’ performance and quickly react to troubleshoot and repair outages
and degradations that affect the experience of users and customers. Real-
time performance, historical performance and predictive behaviour capabilities
were among the criteria in the quadrant, as were flow-based data and network
packet analysis.
“Gartner’s decision to develop the NPMD report highlights the growing
importance of this market and emphasises just how vital network and
application performance management is to helping enterprises achieve their
business goals,” said Daryle DeBalski, vice president and general manager
of the Fluke Networks Visual business unit. “As one of the leading NPMD
solutions, Visual TruView helps IT professionals redefine their ability to deliver
first-rate network and application experience to end users and customers by
empowering teams to collaborate across domains and focus on service, rather
than defending their turf.”
A recent survey of network professionals conducted by Fluke Networks**
indicated that more than half do not have the tools they need to quickly
and accurately identify issues with VoIP, applications and other network
performance issues. Fluke Networks’ offering in the NPMD space – Visual
TruView – is a unified AANPM solution that incorporates five tools in one,
including real-time user experience monitoring, packet stream-to-disk, NetFlow/
IPFIX collection, device health, and VoIP QoS. TruView enables network
engineers to gather data from multiple sources, providing both a wide breadth
of visibility and the detailed forensic data required to solve the toughest
problems.
To read a complementary version of the Gartner, Inc. “2014 Magic Quadrant for
Network Performance Monitoring and Diagnostics,” visit:
www.flukenetworks.com/gartner
Go To Contents Page Go To Last Page
 Equipment, Services & People - News
News
Sky-Watch Integrates FLIR
Equipment, Services and People
Quark™ 640 into Small UAV
Sky-Watch designs and manufactures quad-rotor UAVs
for military, law enforcement, security, firefighting, and
search and rescue applications. Based in Denmark,
Sky-Watch has integrated a FLIR Quark™ 640
longwave infrared thermal sensor into their Huginn
X1 drone to give customers a thermal vision option.
Originally, the X1 was designed to manage a single
payload. But due to Quark’s compact size, Sky-Watch
has been able to design a dual-payload version that is
capable of simultaneously operating a Quark thermal
camera core and a visible spectrum camera. Necessity,
Mother of Invention.
Finding the Right Thermal Camera Core
Sky-Watch’s main customers are within emergency
management, which covers fire brigades, police,
security, and search and rescue. All of their customers
have in common the need to see at night so they
can find missing or camouflaged people. Night vision
cameras were too bulky for their platform. “Besides,”
Michael Messerschmidt, Sky-Watch Business
Development Manager, said, “for base protection and
compound protection, if you want to see somebody
who is sneaking around, thermal is much better.”
“No question about it. The reason we chose Quark
was because of size and form factor. It has a very
good centre of rotation; because our camera is front-
mounted, it was easy for us to recommend Quark,”
Messerschmidt said. “Because it’s so small, we can
actually place a daylight and thermal camera next to
each other, enabling dual sensor capability which is
unique on this small platform.”
Integrating Quark into Huginn X1
Once Sky-Watch selected Quark as its thermal
payload, they faced a few challenges integrating the
core into their system. First, they initially tried to design
their own interface board to power the core and stream
video. However, their design created too much noise
53
AMMJ May 2014
Huginn X1 Dual Imaging Payload with FLIR Quark 640
so they turned to the VPC interface board FLIR designed
specifically for Quark and found that it worked perfectly.
The second challenge involved calibration, or flat-field
correction (FFC). FFC is necessary to maintain a more uniform
thermal image. Since Quark does not have a shutter, an
FFC must be performed using an external reference source.
Sky-Watch solved this by developing a pan/tilt on the Quark
that tilts it inward to face a “flat field.” This action sends an
FFC command to Quark to correct the image. Quark initially
calibrates whenever it’s powered on, but the X1 drone
operator can initiate an FFC calibration at any time from the
user interface. An example of when this capability is most
necessary is with Sky-Watch’s fire brigade customers. “As the
drone approaches the fire, the atmosphere gets warmer, so we
empower the user to calibrate to the new environment, thereby
optimizing the output, and in turn helping the user to make
more founded decisions,” Messerschmidt said.
Once Sky-Watch plugged into the Quark VPC, they created
all the controls and software that operates the camera. From
a ground station, an operator can control X1 from more than a
mile away with the user interface. Control features include:
• Video recording via live feed on the ground station computer
• Designating a waypoint route and points of interest on the
way prior to launch
• Guide in real time based on live video feedback
Go To Contents Page
Spot control: If you want to look at a building that appears in
the right corner of the operator display, then simply click on the
building and the camera will automatically centre on that building
Flight time for a single payload is 23 to 24 minutes; for a dual
payload that time drops to about 21 minutes.
Finally, Sky-Watch added another layer of protection for the Quark
by designing the X1 with a front-mounted payload. Many small
drones have bottom-mounted payloads. When a drone with a
bottom-mounted payload lands hard or crashes, there is a greater
risk of damage to the payload. Also, when X1 lands, Quark
automatically turns upward from the ground to protect the lens.
Conclusion
Sky-Watch integrated a Quark 640 longwave infrared thermal
sensor into its Huginn X1 quad-rotor UAV and is finding
that there’s a high demand in the market for their drone. Its
combination of size, performance, and thermal capability make it
a standout in the small UAV market.
Sky-Watch worked with FLIR to integrate the Quark and get it
operational as quickly as possible. According to Messerschmidt,
“We are very happy with the collaboration. The Quark is a
very good product. All the feedback we’ve received has been
overwhelmingly positive.”
Disclaimer: Images for illustrative purposes only and may not be representative of the actual resolution of the
camera shown. Technical specifications subject to change without notice.
info@flir.com.au www.flir.com
Go To Last Page
 Equipment, Services & People - News
News
Comprehensive materials analysis in
a single benchtop unit
Equipment, Services and People
Olympus—a world-leading manufacturer of optical,
electronic and precision engineering products—
continues to be at the forefront of the development
of X-ray analysis technology which provides
fast, non-destructive qualitative and quantitative
characterisation of materials. Instruments developed
by Olympus can be used for detection, identification
and analysis of elements at a range of concentrations.
Out of this world technology
The BTX Profiler utilises the revolutionary XRD
technology developed for the NASA Mars Science
Laboratory program, where it is being deployed with
great success aboard the Martian rover, “Curiosity.”
Building on Olympus and NASA patents, the BTX
Profiler also incorporates the highly acclaimed,
award-winning, earthbound technology employed in
Olympus’ analytical X-ray instruments.
According to Andrew Taylor, Regional Sales Manager
with Olympus, the BTX Profiler can be used in a
wide range of applications. These include energy
exploration; mineral identification; ore grade control;
counterfeit drug screening; fire and explosives
54
AMMJ May 2014
forensics; and corrosion monitoring. “The BTX
Profiler can take the drudgery out of routine
analysis,” Taylor said. “With full mineralogical
and elemental analysis capabilities, it can be
used for single sample measurement or for
unattended multi-sample measurements when
combined with an integrated autosampler.”
The BTX Profiler is more efficient than
conventional powder diffraction systems. The
close-coupled transmission geometry means
that the device only requires a low powered
X-ray source and a small amount of sample.
The sophisticated sample handling technology
incorporates a patented vibration system that
enables random crystal orientation in a fixed
sample cell. The CCD detector with its smart
energy discrimination provides graphical
2-D diffraction patterns, or Ring Patterns,
and acquires more data more rapidly than
conventional XRD detectors.
According to Taylor, development engineers
are continually investigating different detectors,
filtering techniques and analysis algorithms to
improve the unit’s sensitivity and accuracy. The
Energy Dispersive XRF technology in the BTX
Profiler integrates selectable optimised beam
paths of a miniature X-ray tube and specialised
filters; a large area silicon drift detector (SDD)
for optimized resolution and detection limits;
and close coupled geometry with the sample,
allowing for a wide elemental and concentration
measurement range.
The BTX Profiler’s non-destructive capability is
of particular significance for several industrial
sectors including energy, geochemistry,
pharmaceuticals, catalysts, forensics and
education.
BTX profiler provides the advantages of XRD
and XRF testing in a fast, attractive unit that
won’t break the bank.
www.olympus-ims.com www.olympus.co.nz
Go To Contents Page
The Good Oil? Great For
Machinery but Not For Hands.
We have all heard it before:”a bit of grease never hurt
anyone”. Unfortunately, this is not true, because commonly used grease
and lubricants are capable of causing health complications that range from
contact dermatitis up to those more serious, including a variety of cancers.
Engineering oil and the oily liquids used in machine maintenance aren’t
harmless. They are chemicals, and the chemical reaction they cause can
harm workers the same as any other chemical.
Oil is a combination of many substances, including powerful neurotoxins
which can cause a range of symptoms including nausea, headache,
euphoria and dizziness. These symptoms are signs that the nervous
system of those exposed to oil is being damaged1.
“An added risk of oil exposure can be a lack of grip when trying to adjust
greasy machinery where injuries can be sustained when hands slip. When
workers are focused on getting the job done, it can be tempting to see
gloves as an impediment to completing the task”, said Ansell marketing
manager, David Nicholls.
“Even on sites where it’s mandatory for gloves to be worn, many workers
take them off, thinking that this will improve their dexterity and speed2.
However, in doing so, they are unaware that oil, dust and small, sharp
pieces of debris can be a nasty combination added to the surfaces that
comes into contact with exposed skin. Getting a firm hold on a slippery
surface can be quite a challenge but when other materials are added that
can dig into hands and make one’s grip less sure, it can protract the time
taken to complete a job3.
“Oil is used heavily in the majority of mining sites and associated
maintenance areas and wearing gloves is the best way to keep one’s
hands away from this potential skin contamination.
“The Ansell AlphaTec®58-430 and 58-435 gloves address the need for
protection against chemicals found in oils, as well as the common problem
of wet and oily grip. When discussing needs with industry representatives,
it was a common response that people wanted to improve their glove’s
grip”, Nicholls concluded.
References:
[1] National Library of Medicine, “Crude Oil”;
http://toxtown.nlm.nih.gov/text_version/chemicals.php?id=73
[2] Safe Work Australia, “Personal Protective Equipment”;
http://www.safeworkaustralia.gov.au/sites/swa/model-whs-laws/faqs/pages/faqppe
[3] Ansell, “Mining, Oil & Gas Gloves”; http://ppe.ansell.com.au/gloves/mining
For glove samples go to http://ppe.ansell.com.au/contact-us .
Go To Last Page
Articles

Stores, Purchasing, Parts and Materials. Each edition of the AMMJ will now bring you articles, news and
case studies relating to the management, procurement and use
of spare parts & materials in the world of asset management &
maintenance.
Stores Purchasing Parts & Materials

If you have any comments or would like to contribute an Article

Spare Parts Management

or Case Study or News to a future edition please feel free to
contact me directly at:
Phill@PhillipSlater.com Phillip Slater - Editor SPP & M

Stages of Excellence
Phillip Slater www.PhillipSlater.com
In almost every endeavour it is difficult to determine
what constitutes ‘best practice’ but this is especially
the case in specialist areas such as spare parts
management. Whether your key issue is reducing
working capital or ensuring parts availability (or
both) if you don’t understand where you stand right
now it is impossible to work towards achieving best
practice.
For many companies developing their spare parts
management systems is bit like starting a journey
without knowing where they are or where they are
going. All movement looks like progress!
The following ‘stages of excellence’ ladder has been
developed to help you identify both where you are
now and what you need to do to reach the next level
of performance.
LEVEL 5 –
Leader: The top rung or the ladder. Leaders
will already have in place a robust and rigorous
approach to spare parts inventory management.
Your challenge, therefore, is to focus your efforts
on continuous improvement and training to ensure
that your success is not due to the discipline of one
or two key individuals but rather the culture around
spare parts management.
55
LEVEL 4 –
Manager: At this level you have not yet fully
developed and implemented inventory management
policies and procedures or engaged fully with
all those involved in inventory management
decision making and execution. Your next steps
should be to focus on the completeness of your
policies, procedures and processes and then
training all personnel in the correct execution and
implementation of these.
LEVEL 3 –
Administrator: As an administrator you have a very
transactional approach to spare parts inventory
management. Administrators ensure that the
bookkeeping is essentially correct but usually are
not very proactive in ensuring that manage stock
levels are within their set parameters. Administrators
often do well in one or two areas and from that
convince themselves that everything is OK. You
will have lots to do to improve so you must decide
where to prioritize your improvement efforts.
LEVEL 2 –
Band-Aider: As the name suggests a Band-Aider
spends time applying corrective fixes to problems
and issues that arise but not sufficient time and
effort to affect a lasting repair. Users generally
having a low level of trust in the system and it almost
goes without saying that they will not be engaged or
accountable for their decisions affecting inventory
levels. You need to begin building trust in the system
by implementing some lasting changes that address
the frustrations of your users. This should provide the
springboard to lift you to higher performance.
LEVEL 1 –
Firefighter: This is the lowest rung so let’s be honest
here – you have a lot of work to do! Not just to reach
best practice but also to firstly establish some control
over your spare parts inventory. Start by working on
storeroom administration and control, then policy and
procedures, then inventory management process.
You may be spending most of your time, energy, and
money expediting emergency orders so you will need
to ensure that you get the right level of management
support to allocate the time and resources get some
momentum in your drive to best practice.
Identifying your position on our stages of excellence
is the easy part. The real work starts when you decide
that you are going to develop your systems to move up
the ladder!
Phillip Slater specializes in Materials and Spare Parts
Management. He is the Founder of the best practice
website, SparePartsKnowHow.com and the author of
8 books, including Smart Inventory Solutions and The
Optimization Trap. For a complimentary copy of the
e-book 5 Myths of Inventory Reduction please visit
Phillip’s personal website at www.PhillipSlater.com.

AMMJ May 2014 Go To Next Article Go To Contents Page Go To Last Page

 Stores, Purchasing, Parts and Materials
Articles
Do Process Improvements
Threaten Your Spare Parts
Stores Purchasing Parts & Materials
Management System?
Marnie Schmidt www.marnieschmidt.com
Process improvements and cost savings are a continual
expectation in this very competitive world economy. This
requires companies to be nimble, flexible and open to change.
But can process improvements actually threaten the success of
your spare parts management system?
Many companies are using lean management and Six Sigma
to reduce waste and improve their overall processes. And
this is exciting! The whole point of the lean practice of
kaizen (“change for the better” or “make good”) is to improve.
However, managing the process of change is critical to the
successful implementation of process improvements, Lean and
Six Sigma. This means that understanding the entire process
is critical for success. If improvements are made without input
(or output) to the spare parts process, the stride forward can
cost more than it saved in the first place. This is why change
management is so important.
Changes are very dependent upon people. If everyone makes
a change together, the change can be evaluated, and further
improvements can be made. If only a few team members
follow the change, the change can yield mixed results and it
may not be known whether it was effective. This is why an
effective change management process is so important. If new
parts storage, maintenance, rotation, care or replacement
practices are required, these “people changes” must be clearly
communicated, trained and implemented. Or the change can
cause more harm than good.
For example, I once worked with a company who changed
nozzles in a cooling line to improve spray coverage and overall
cooling consistency. However, as the operations people were
happy with the quality result, and the purchasing people were
happy with the cost savings, no one was aware that the nozzles
56
AMMJ May 2014 Go To Next Article
had a recommended maintenance routine which was not
followed. Several weeks later, the nozzles failed and
the line was shut down. It took several days to procure
replacement nozzles, because the old nozzles had been
a “same day turnaround” from a different vendor. The
new nozzles were special order, and no spare parts policy
had been established. Therefore, this improvement had
a negative net gain until significant additional resources
were invested to ensure the change would be successful
long term.
The best place to start creating a safe process for change
is of course, with very simple documentation. Changes
should be reflected on specifications, part drawings/
blueprints, bills of materials, work methods, operational
controls, maintenance standards, inventory management
records, etc. Your system should include a simple
change management process that requires all changes
be reviewed for their impact on these areas, and require
approval by the areas involved. It should facilitate
notification to those who are required to implement
the change, and to include the changes to the affected
documentation. This will include document control at the
engineering level (drawings), operations (control plan),
and training. Other areas such as purchasing and sales
are also almost certainly involved, but they often have
controls in place for changes. If there is a bill of materials
system or inventory management process, they should be
brought into a central system as well.
Just like with any system, the change management
process must be easy to use or it may be circumvented.
People are reluctant to do paperwork and anything that is
too cumbersome will likely be avoided. It is recommended
Go To Contents Page
that the teams responsible for the majority of improvements
and change ultimately own this process. If engineering is
most likely to launch and follow an improvement project, it is
they who are the best candidates to be the “funnel and filter”
through which changes are directed. They can develop quick
ways for themselves to evaluate and quickly disseminate
the necessary information to the affected departments to
ensure that their group’s proposed changes are implemented
successfully. Good ideas are only congratulated after they
are successfully implemented and yielding results.
Also, be sure to create something that allows a quick approval
for simple or “like-for-like” changes. And be sure that, where
more complex change management is required, it is treated
as a process that flows nicely as an input to the normal
engineering process. This will provide the best chance
at success. And be sure to consider other departments’
existing processes. As the change management process is
developed, be sure to try to tie anything else that is already
working for a department into the new system.
For example, I have worked with several companies
whose maintenance and purchasing departments work
well together. Both have their own requisition processes to
request maintenance, replacement parts, etc. But if a process
improvement is implemented without linking these processes
together, the usually successful maintenance and purchasing
processes do not do what they’re expected to do. Keeping
these areas in the loop is critical to smooth implementation of
changes and process improvements.
It is interesting that the concept of change management is a
highly regarded discipline in many engineering groups. It is
also a key element of many industry recognized management
systems such as the ISO International Standards. Yet,
effective change management continues to elude us in
practice and poke us with a “how did we forget that?” barb
when we least expect it. Connecting the dots is a great way
to start improving any system overall. This can make all
continuous improvement initiatives more successful.
Marnie Schmidt is a freelance management consultant with
Lean Six Sigma Black Belt and ASQ (American Society for
Quality) certifications. She is the author of the book, Tribal
Knowledge (available on Amazon.com) and can be contacted
via email at marnie@schmidtproducts.com or by visiting
www.marnieschmidt.com
Go To Last Page
Articles

Drones
Stores, Purchasing, Parts and Materials
Stores Purchasing Parts & Materials

4. Obsolescence costs – parts not used during useful life.

The Sky’s the In recent times there have been news reports of
various innovative uses of Drones1.
5. Opportunity costs – the costs associated with
having money tied up in slow moving spares.

Limit for MRO

Despite the scepticism around privacy, safety, MRO spares can represent up to 20% of total enterprise
reliability and technology, this science fiction dream spend and account for more than half of all indirect purchasing
is fast becoming a reality. Currently, in Europe
Spares
transactions. Many organizations limit the impact of equipment
alone, there are over 400 projects in 20 countries to downtime by storing critical spares on site. But what parts should
develop unmanned aerial vehicles for civilian use. be held and what are the costs associated with holding them
In late December, the US FAA opened up 6 sites for onsite? It’s a delicate balance between holding what you need
Jeffrey O’Brien unmanned aircraft testing in Alaska, New York, North
www.maintenanceassistant.com and limiting costs while keeping equipment running. The stock
Dakota, Texas, North Carolina and Virginia. turn metric is a good way to determine if you are holding too many
Drones are already being used for various civilian uses spares while the number of stock outs tells if you are holding the
around the world including maintenance inspections of right spares.
remote or difficult to access plant or assets, inspecting
oil and gas pipelines, etc.
Drones move autonomously using GPS, artificial
intelligence, video cameras and radar. Advances in
modern smartphone technology have helped reduce
the cost of the sensors used in drones - such as
accelerometers, GPS and magnetometers, making
them more affordable.
So in the future could we be delivering Spares using
drones?
The High Cost of MRO Spares
One of the biggest concerns facing manufacturing
organizations is having the right parts at the right
time when equipment goes down. MRO parts are
often referred to as the “MRO Monster” due to the
disproportionate effort that is spent searching for and
buying parts. The cost of MRO spares can be broken
down into 5 cost types. They are:
1. Carrying costs - rent, lighting, cooling, staffing etc.
2. Ordering & acquisition costs - creating PO’s,
payments etc.
3. Shortage costs - None in stock, urgent purchases,
loss of business or damaged reputation etc.
57

AMMJ May 2014 Go To Next Article Go To Contents Page Go To Last Page

Articles
Stores Purchasing Parts & Materials
Even if you have the part in stores, it could take
the technician an age to find it in a badly organized
storeroom. What if organizations could eliminate the
need to calculate these metrics by eliminating the
need to carry spares? Let me explain!
Parts Delivery by Air
Drones, Unmanned aerial vehicles, could spell good
news for the process and manufacturing industry; in
particular, for organizations that have cash tied up in
MRO spares onsite or have plant in remote or difficult
to access locations.
Imagine a scenario where a Third Party MRO
distributor becomes your dedicated parts and spares
warehouse. When equipment goes down, the
technician logs onto the company account at that
Third Party MRO distributor and places the order for
the part to be delivered by air.
With 30 minute delivery times expected via unmanned
drones, parts could be onsite in the same time it
would take for the technician to locate the spare part
58
AMMJ May 2014
Stores, Purchasing, Parts and Materials
in there own storeroom. The drone would park up on
the loading dock just like a delivery truck or perhaps
delivered direct to a difficult to access repair location.
The part is then removed from the UAV and installed
Maintenance Planning and
in the damaged equipment. Scheduling Handbook 3rd ed 2013
Shared Inventory System
If many organizations adopt this model, it in effect Authored by
becomes a shared inventory system where the R.D. (Doc) Palmer
MRO warehouse becomes the central parts hub Publisher
for an entire city or locale. As more companies use McGraw-Hill
the service, the MRO distributor has an increased
incentive to stock a greater range of parts that serve Written by a professional
with more than three
more customers. In many cases, access to such a decades of experience,
large inventory with 30-minute delivery could eliminate this thoroughly revised
the decision to hold stock onsite completely. resource provides proven
Questions That Need to Be Answered planning and scheduling
strategies that will take any
Obviously, there are a number of concerns that maintenance organization
need to be addressed before this could become a to the next level of
reality. What happens if the wrong part is ordered, performance.
the drone crashes, the part is delivered out of hours Maintenance Planning and
when everyone is gone home, the part is too heavy, Scheduling Handbook,
we don’t want octopods taking over the skies above Third Edition features
our cities etc.? Many of the initial concerns are valid major additions to the
business case for planning and scheduling, new case studies,
but the rate of development of this technology seems
an expanded chapter on KPIs with sample calculations,
destined to iron out these issues and make delivery
a new chapter on successful outage management, and a
by UAV part of every day life. It is just a matter of time
new appendix illustrating how to easily conduct an in-house
before MRO vendors/distributor take advantage of this productivity study. This comprehensive guide delivers the
technology. experience, advice, and know-how necessary to establish a
world-class maintenance operation.
(Ref 1 - A Drone, is the common name for an unmanned aerial
vehicle (UAV), is an aircraft without a human pilot aboard. Its flight
To purchase this excellent Handbook go to either:
is controlled either autonomously by onboard computers or by the
remote control of a pilot on the ground or in another vehicle. The
McGrawHill:
typical launch and recovery method of an unmanned aircraft is by
http://www.mhprofessional.com/product.php?isbn=0071784128
the function of an automatic system or an external operator on the or Amazon:
http://www.amazon.com/Maintenance-Planning-Scheduling-
ground (http://en.wikipedia.org/wiki/Unmanned_aerial_vehicle))
Handbook-Richard/dp/007178411X
www.maintenanceassistant.com
Go To Contents Page Go To Last Page

Research Papers and
Detailed Technical
Reports
Each issue of the AMMJ includes a section dedicated
to research and new technology in the fields of asset
management, maintenance, maintenance engineering,
reliability, condition monitoring, plant engineering, general plant
equipment, tools, energy, HVAC, plant services, bearings,
compressed air systems, lighting, training, environment, etc..
The publication of technical reports, thesis and project reports
in the fields of maintenance and reliability has in the past been
very much neglected.
The AMMJ can now provide an outlet for your work in these
fields. Each selected Paper or Report will be published in full
(as received) in the form of a Downloadable PDF.
The AMMJ does not ask for exclusivity and you are free to
publish your papers in other publications as well as the AMMJ.
To Submit your Research Paper or Technical Report to the AMMJ email
as a PDF to: editor@theammj.com
59
AMMJ May 2014 Go To Next Item
FLIR® thermal imaging cameras monitor
Download
condition and performance of cement kilns
Cement production is a complex process, in which one of the 7 Pages
steps consists of blending limestone with other components in big PDF Size 198 KB
rotary furnaces. These furnaces or kilns are a critical asset of a
cement production plant, heating their contents to temperatures up to 1,500°C.
There is however a risk of overheating, which can cause serious damage to the kiln
shell. In order to monitor this delicate heating process and prevent possible damage
to the kiln, thermal imaging cameras from FLIR Systems are used to measure
temperatures on a 24/7 basis. An advanced computer system allows cement
production operators to monitor, process and trace data from several kilns at once.
Convergence of Infomation and Operation
Technologiess to Build a Successful Smart Grid Download
Three common drivers for utilities are meeting high demand 6 Pages
growth, increased need for reliability and reduced carbon emissions. PDF Size 516 KB
Utilities have found that the newest technological advancements can
help achieve significant progress towards the requirements of those three drivers.
Some major challenges emerge in this context. The first set of challenges refers
to the adoption of these new technologies. The second set of challenges refers
to the lack of industry standards, protocols and operational guidelines. The final
set of challenges refers to the existing gap between technical operations and
business decision making within the utility’s organization. This gap reflects on the
business process, IT infrastructure and integration, workflow consistency, and
timely interaction. Basically the gap is between business applications (IT realm) and
operations and control systems (OT realm). VENTYX ABB
Infrastructure Imperatives For Australia. Download
Smart Infrastructure Facility, University of Wollongong
Australia has a good track record of ‘getting on with the job’ of 20 Pages
building infrastructure. However the time has come to better PDF Size 1.3 MB
combine our national ‘can do’ spirit with greater ‘smarts’ in the key
capabilities required by governments to meet future challenges. Foremost of these
challenges is the need to extract more value for each infrastructure dollar invested.
Meeting the expectations of the community by providing more infrastructure with
less financial resources is fundamentally important to Australia’s future.
The Green Paper identifies three infrastructure imperatives and contains 18
recommended best practice actions:
• Establish an Australian Infrastructure Market (AIM)
• Enhance Attractiveness of Infrastructure Private Funding
• Overhaul Infrastructure for Radical Innovation and Productivity Growth.
The AMMJ publishes these papers as received and does not accept
any liabilities in regards to the contents of the above papers.
Go To Contents Page Go To Last Page
AMMJ
This AMMJ you are
currently viewing is
a Complimentary
version of the AMMJ
• It is for personal use only.
• It is not for use in company
or government
departments.
• It cannot be printed nor
pages, images or text
extracted.
Become a paying subscriber
now & gain all the benefites
of being an AMMJ Member
AMMJ May 2014
WE NEED YOUR FINANCIAL HELP !!
SUBSCRIBE to the AMMJ Now
If you become a “Paying
Subscriber” to the AMMJ you
will have the following general
member’s benefites:
• Each AMMJ issue remain accessible
to you via the AMMJ website or can
be saved within your own system.
• The AMMJ will be easily downloaded,
saved to your system, easily printed,
pages/sections extracted, etc.
• You will have access to the AMMJ’s
Knowledge Centre which will contain
years of back issues of the AMMJ
and hundreds of articles and papers.
See a Listing/Contents of Back Issues at:
www.theammj.com/BackIssues.pdf
Prices are in US$ or AUD$
Download a SUBSCRIPTION FORM from:
www.theammj.com/subscribe.pdf
Go To Next Item
SILVER Membership
Annual Subscription: $120
Provides the general subscriber benefites for an
Individual Subscriber.
GOLD Membership
Annual Subscription: $180
A subsciption covering persons associated with a single
company, a government department, a library, a college/
university, a utility, mine site, etc. The AMMJ can be
loaded to the site’s intranet or Internet.
PLATINUM Membership
Annual Subscription: $460
A subsciption for any employees of major “multi site”
organisations, corporations and government bodies.
The AMMJ can be loaded to the organisation’s internet/
intranet.
Platinum subscribers will also be provided with a 10%
discount on any advertising they place in the AMMJ (for
example if publicising your Major Corporate Initiatives,
advertising for Job Vacancies, Call For Tenders, etc.).
They will also have a 10% discount on any AMMJ
seminars.
Go To Contents Page Go To Last Page
 For General Enquiries,
Advertising, Articles and News
email to the Managing Editor 3 for the price of 2

AMMJ
Len Bradshaw editor@theammj.com
Editor’s Note:
SPECIAL OFFER!!
I am just back from my annual visit to Mana
Island in Fiji. Sun, blue warm seas and
nobody mentioned maintenance. A hard 2
weeks but I survived somehow.
Maintenance
Planning &
General Information For Stores, Purchasing,
Parts & Materials Scheduling
Workshop
Send your Articles and News for
this Section to Phillip Slater
pslater@InitiateAction.com

ts The AMMJ Wants Your Articles, News, Technical

Presented By
tatemen
Mat e r i a l S
d :
ubmitte t no responsib s, features,
ep
ilit
icle
y f o r s
Reports & Research Papers. Doc Palmer
b li s h ers acc pressed in art r editorial From a half page news item to a dozen paged article or even a 100
u
The P opinions ex nd any othe He is widely recognised as one of
r a page technical report. Be a regular contributor to the AMMJ.
made o d advertising e ms for the best in the World in providing
m it t e t in g it
sub t ions.
it
se subm l is clear of an e
y training and consulting in the
n t r ib u o f t h o
co y ia
onsibilit that all mater publication in t
h area of Maintenance Planning
h e r e s p e
It is t ur
n to ens hat may affect
its and Scheduling.
pub li c a t io
ues t t restrict Published by
h t is s e s n o
copyrig h e A M MJ do r publications Engineering Information Transfer Pty Ltd
st e For every 2 delegates you
AMMJ. e p u b lication material in oth . Publication Dates:
om ur J
Unlike s publishing yo hed in the AMM pay to attend you can send a
you fromas been publis Bi-Monthly - Published in the third delegate for FREE
after it h be 1st week of each bimonthly period.
p a r t o f it may smitted
ght: o an
Copyri is c o p yright. Nal system or tr , Next Issue - July 2014 Venues
blicatio
n
a retrie
v lectronic
This pu ed, stored in ns, including e r otherwise, r Publishers Sydney 15-16 May 2014
c a o o
reprodu rm by any me ing, recording the publisher
o y f Engineering Information Transfer Pty Ltd
in any f ical, photocop permission o bscription. Melbourne 19-20 May 2014
n u
mechan he prior writte plicable to a s For General Enquiries Contact: Brisbane 22-23 May 2014
t p
without e conditions a
within t
h ISSN 1835-7903 (Online)
mail@theammj.com
Download Workshop
Advertising in The AMMJ
Download the AMMJ Media Kit From:
Brochure From:
Articles and News From Around The World of
Maintenance, Reliability, Asset Management, www.theammj.com/advertising.pdf www.theammj.com/
Plant Engineering, MRO and Stores. Readers DocPalmer.pdf
from Over 130 Countries.
61

AMMJ May 2014 Go To Contents Page Go To Last Page