We invite you to download from our library of informative white papers and eBooks highlighting industry statistics, best practices and more. These whitepapers are written by industry leaders, and provide a fresh or insightful perspective on relevant topics.
Recently supply chain shutdowns have crippled companies around the globe. Ensuring existing equipment runs for as long as possible before breaking helps companies cope with reduced parts inventory and ensures continued manufacturing.
Without normal access to parts, how can a company keep its systems and production lines running? This article discusses the supply chain issue, its effect on companies, and how using reliability can help offset the limited availability of supplies now and into the future.
How often should you calibrate your instruments? Calibration is essential across industries to ensure compliance and regulatory requirements and to maintain high product quality and efficient production procedures. Learn more about calibration services in your industry and how to optimize your processes.
Terms like IIoT (Industrial Internet of Things) and predictive analytics have been buzzwords for some time. But many people seem to have different ideas of what these technologies are, how they relate to one another, and what they can achieve. To strip away the confusion, this white paper takes a closer look at IIoT and predictive analytics as well as the potential they hold for oil and gas companies, refineries and petrochemical facilities.
Terms like IIoT (Industrial Internet of Things) and predictive analytics have been buzzwords for some time. But many people seem to have different ideas of what these technologies are, how they relate to one another, and what they can achieve.
To strip away the confusion, this white paper takes a closer look at IIoT and predictive analytics as well as the potential they hold for oil and gas companies, refineries and petrochemical facilities.
Every process plant has some level of operational time-sensitivity to ensure maximum productivity. These operations need properly calibrated instruments not only for efficiency, but often to meet regulatory requirements. Instrument calibration is a specialty activity, in some cases needed intermittently and unexpectedly, and often requiring a large number of specialized staff. These and other issues can be addressed by engaging a calibration service provider to meet a plant’s calibration needs.
Edge computing brings computation and data storage closer to where it is needed, to improve response times and save bandwidth. Advantech believes that edge computing has the potential to help enterprises manage various functions and resources with Edge Intelligence (Ei). This whitepaper explores benefits and setup of Ei architecture.
Do not invest in transformer monitoring until you know which monitor is the best fit for your application. There is no such thing as “good/better/best” when it comes to transformer monitoring—only “best fit.” Read the One Size Does Not Fit All white paper to learn which is the best fit for your system… and the best investment.
What are the factors to bear in mind when defining which measuring points to include? Find out in this informative white paper!
Cooling systems in refineries and chemical plants depend on water quality analysis of recirculated water to deliver effective performance. Selecting the right instrumentation makes the difference. Discover how cooling system installations operate, what happens to the water they use, and how instrumentation can help monitor and control remediation efforts.
LG&E and KU Energy’s generation services group implemented a data technology platform to automate data collection and help the maintenance team shift focus to data analysis and finding problems before those problems threaten plant availability. Read this case study to learn how NI InsightCM is helping the generation services group support plant maintenance efforts. Also learn how NI wireless sensor technology
In this brief, Ralph Rio – Vice President at ARC Advisory Group, discusses the importance of getting business executive attention (and support) for predictive maintenance programs. Just because technology is “cool” doesn’t mean it can help turn profit. Check out Ralph Rio’s brief to get advice on ROI for predictive maintenance, setting-up projects for success, and connecting maintenance KPIs to C-suite KPIs. “Those involved in maintenance would do well to tie maintenance KPIs to executive KPIs to obtain executive approval and support for projects” – Ralph Rio, ARC Advisory Group.
The answer for most owners/operators is “way too much!” and “we’re not sure how to fix it.”
A new white paper from Lloyd’s Register on maintenance optimization shows you the steps that will leverage the strategic value of your data to increase asset performance, reduce downtime, minimize risk and maximize ROI.
It’s no secret that the power generation industry faces challenges on several fronts, one of which is asset health impact to plant uptime. This brief looks at one of the foundational elements of maintenance programs, data collection, and discusses three trends that are changing how maintenance professionals get the data they need to keep plants up and running.
The 3 trends highlighted include:
- Experienced professionals leaving the industry
- Advances in technology driven by the Industrial IoT
- Doing more with less
This summary provides an overview and then follows-up with a case study from IHS Markit Technology that shows how Duke Energy applied IIoT technologies to address their 60,000 manual data collections per month, increasing reliability demands, and need to optimize the activities of their workforce.
Precision alignment is an essential part of a proactive reliability program as it can eliminate many machine failures and defects.
This guide from LUDECA provides information for the implementation of good pulley alignment of belt-driven equipment including terminology, alignment methods, belt maintenance, storage and tensioning as well as a 5-Step Sheave/Pulley Alignment Procedure.
The Internet of Things (IoT) is transforming the way people live and work. Beyond just the smart devices you use every day, IoT is revolutionizing the way companies do business – allowing them to become faster, smarter, safer, and more efficient.
Microsoft has been at the forefront of IoT, innovating and investing as IoT continues to gain traction worldwide. The IoT Signals report was created to give the industry a holistic view of the IoT ecosystem – providing insight into adoption rates as well as benefits and challenges.
Big Data, IoT, Industry 4.0, The Cloud, Unsupervised Learning, Supervised Learning, and Hybrid Analytics: What are they?
Is unsupervised machine learning the way of the future? Is this the death knell for data analyst? How will unsupervised data interpretation affect a company’s bottom line and its assets? Is there a way to utilize all of these individual parts for a total plant management plan?
This white paper from PdMA investigates these questions and attempts to answer them and the bigger question: Will unsupervised machine learning be enough to maintain motor and plant reliability?
By now, anyone involved in the industrial sector has heard of the Factory of the Future. Those four words encompass an industrial utopia defined by increased productivity with reduced downtime, data transparency, previously-untapped levels of customization, improved safety capabilities, all boiling down to more profitable production processes. Drawing from decades of multi-technology expertise, Bosch Rexroth demonstrates how the automation technologies driving the Factory of the Future interacts with other systems to make full flexibility, individuality and scalability a reality.
Learn the basics of job training in a manufacturing workplace to help you onboard new hires more quickly, completely, and efficiently, help workers develop new skills and prepare for new jobs in their career path, and close skill gaps in your organization. This guide provides evidence-based, tested, and easily repeatable methods for improving training at your work.
In a large steel manufacturer there is a constant struggle between using veteran maintenance workers to handle the most critical issues or having them train new employees. A solution was needed to accomplish both goals. This white paper examines how this steel manufacturer used a unique combination of an online training solution and an operator troubleshooting tool to share information across all facilities, get new employees up to speed, and avoid costly production downtime.
IIoT and digitalization technologies are paving the way to increased profitability and reliability. Fortunately, capturing this opportunity does not require the full-scale digital transformation that many organizations expect.
This paper discusses how to apply these technologies where they will create the most impact, and outlines three keys to success when embarking on your digitalization journey.
Reliability engineers can’t be in two places at once. But when assets from two different plants are raising concern, how does the engineer figure out which one is more likely to contribute to an outage? Remote diagnostics help maintenance teams decide where to deploy valuable resources like subject matter experts, troubleshooting equipment, and spares.
InsightCM is condition monitoring software for reliability professionals who want to remotely diagnose equipment before deciding if an in-person trip to the asset is needed.
This white paper aims to:
• Discuss the benefits of remote diagnostics
• Introduce several key technologies in InsightCM that enable remote diagnostics
Many machines do more than just run at a fixed speed. Lots of machines speed up, slow down, adjust loads, reverse direction. In other words, they dynamically adjust to their process environments and missions. These machines are terrific! However, the very flexibility that makes machines like these so valuable in industry, also creates a unique maintenance issue. Their performance monitoring and vibration analysis can be challenging. Machinery that carry out dynamic processes require performance monitoring techniques that are just as dynamic. Order Tracking hits this dynamic monitoring nail right on the head.
Proven Strategies To Thrive In The Industrial Digital Age
Welcome to the Industrial Digital Age. Industrial manufacturers and critical infrastructure companies across the world — oil & gas, power generation, petrochemical, food & beverage, mining & minerals and the like — are joining the digital revolution. Cloud computing, big data analytics, Artificial Intelligence and other emerging technologies are powering the Internet of Things and its cousin, the Industrial Internet of Things (IIoT). This has empowered industrial companies to grow and innovate in ways never imagined even a few years ago. Along the way, these open platforms and interconnected systems have also opened new doors for cybercriminals, leading to a rise in the frequency and severity of cybersecurity attacks on the systems that control the world’s most critical and volatile manufacturing processes.
From start-up and commissioning to turnarounds and outages to daily operation, AMS Device Manager users have benefited from decision support through proactive and predictive diagnostics, resulting in millions of dollars in savings.
As maintenance staffs are shrinking and the number of work orders increases, you need powerful field diagnostic tools to fix problems quickly and correctly. Give technicians more flexibility in both the field and the workshop, helping them save time and feel more confident about the repairs and configurations performed daily. Explore how you can focus on driving asset reliability in your plant.
Choosing the wrong air compressor can cost your plant hundreds if not thousands of dollars in wasted energy and lost production time. Very often, when selecting an air compressor, the only thought given to the specification is the cubic feet per minute or CFM of airflow needed for the plant. Don’t make this same mistake.
Download this white paper to learn the primary factors in selecting an air compressor, average ten-year costs of compressor operation, how to determine if you need oil-free or lubricated equipment and how to find opportunities to reduce maintenance and energy requirements.
Bearings spall in a predictable 4-stage process. Worse wear causes higher vibration…
…but recent advances in vibration analysis let you detect damage in the early stages and alerts you to impending failure – up to months in advance.
HD technology detects bearing damage earlier and provides exceptionally clear data for quick, easy analysis. Discover how you can track the 4 stages of bearing failure to avoid costly repairs and downtime.
Many manufacturers are unaware of hidden costs of operating their compressed air system. Could this be you? With all capital equipment purchases, the initial cost is not the only expense to consider. Often there are associated costs that are not always apparent at the time of purchase that can significantly affect operational budgets.
Download this white paper and learn how to calculate the costs of your current system, how to identify potential hidden costs and examine how one company used this process to save money while providing a reliable, and quality air source.
The proliferation of smart and connected “things” in the Industrial Internet of Things (IIoT) provides tremendous opportunities for increased performance and lower costs, but managing these distributed systems is often an overlooked challenge. Explore the three necessities for successfully managing your “things.”
Does your injection-molding plant have an energy plan? If not, you could be spending as much as 30 percent more than necessary on energy. Start saving money and energy by downloading a new white paper produced for ExxonMobil: “An Energy Saving Guide for Injection Molders.” Topics include how to:
• Map energy use
• Spend time and effort where returns are greatest
• Monitor the molding cycle
• Manage resources
Lubrication of rolling element bearings is one of the most misunderstood and abused maintenance tasks in industry. How do you know when a bearing needs grease? How much grease does the bearing need? If greasing on a time based schedule is your method of operations, you need to Hear More. Download this handbook and learn how to improve reliability and save money with ultrasound by making lubrication a condition-based task instead of a time-based task.
Download the white paper to read about the challenges maintenance managers face with improving overall reliability and some of the technology considerations for implementing an online fleetwide monitoring solution for predictive maintenance.
A material handling application is generating about $1,500 per year in electrical savings rather than dissipating the regenerative energy as heat. Additional equipment life cycle savings are also anticipated as a result of the simplified electrical and mechanical designs. These benefits are realized because of the application of the U1000 Industrial Matrix Drive.
Variable frequency drives (VFDs) save energy, increase the life of mechanical systems, and offer valuable control features in a wide range of building management applications. A new VFD design includes all the advantages of conventional VFDs with the added benefit of low-to-no harmonics in a simple-to-install, cost-effective package. This white paper describes how the Matrix design achieves its added advantages, including helping to achieve IEEE 519-2014 compliance in the overall system design.
The “best laid plans” is an idiom that should not come to mind if you are describing your electric motor reliability program. When a motor fails the common question is, “How could we have missed this?” This white paper discusses the common gaps in the planning, implementation, and operation of an electric motor reliability program including mistakes in Quality Control, Trending, and Troubleshooting of electric motors.
Eliminate the risk of inaccurate data by automatically synchronizing field data with your asset database. With AMS Trex and AMS Device Manager, log and time-stamp field changes as they occur. Learn more about how the Auto Sync technology in AMS Trex helps you maintain the integrity of your asset database.
Your operation runs on critical electric motors — what happens when they are down?
• Increased Costs
• Decreased Output
• Wasted time and idle staff
Reliability is the key to keeping your operation driving revenue. Dreisilker Electric Motors offers the solution to downtime. Simply put – their repairs last longer.
What are you doing to reduce unplanned downtime at your plant? Equipment breakdowns and process interruptions are a $20 billion USD problem. Millions are being spend on new maintenance solutions, but is that even addressing the problem? Effective, earlier detection of issues would eliminate these failures. Download this white paper to learn how leading manufacturers are using big data to solve reliability problems that only a few years ago were unsolvable.
The right equipment gives technicians more flexibility in both the field and the workshop, helping them to save time and feel more confident about the repairs and configurations performed on a day-to-day basis. With Power the Loop technology in the AMS Trex communicator, technicians have more power than ever at their fingertips. Download the whitepaper to see how Power the Loop impacts three key areas of daily operation.
Whether your lube oil is designed for an engine, turbine or even an assembly line, accurate control of moisture in lubricating oils is critical to keeping your machines running at their fullest potential. Water content in oils can cause pitting, oxidation and particle contamination, which in turn lead to a decrease in machinery performance and useful life. This paper will discuss the dangers of moisture contamination, its effect on bearing life and the various techniques available for performing moisture analysis so that you are well equipped to discover, correct and prevent moisture contamination before it becomes a more serious problem.
Download the white paper to read about the challenges maintenance managers face with improving overall reliability and some of the technology considerations for implementing an online fleetwide monitoring solution for predictive maintenance.
Maintaining the highest reliability standards for electric motors is the goal of every company. Unfortunately, in an era that emphasizes lean operations, many businesses fall short and costly expenses are incurred. When issues arise, a review of maintenance and testing procedures is usually conducted to see if the problems could have or should have been detected. Is there a better way to ensure more reliable electric motors, and to do more with less?
Reliability of the power system can only happen when proper maintenance is applied to the equipment within the system.
Maintenance consists of visual inspection of the mechanical operation plus electrical tests to verify the insulation integrity and operation of the breaker. The importance of circuit breaker maintenance cannot be overstated. Circuit breakers that fail to trip properly during a faulted condition can cause fires, equipment damage and increased Arc Flash Hazards to workers performing electrical maintenance or operations.
Mobility is one of the driving forces allowing manufacturers tocompete in today’s global marketplace, by meeting customers’ demands much more quickly and with more value added. Tablets help manufacturers access and use data more easily, which can open a wide range of new options to them. When it comes to mobile devices used in complex maintenance operations, technicians benefit from the ability to use the device right where they spend the majority of their time – at the machines they are maintaining and repairing.
Find out how new technology innovations for industrial pressure guages can improve accuracy, reliability and dependability. Isn’t it time for an improvement in pressure gauge technology that meets today’s demanding industrial challenges?
Imagine supporting your reliability goals with maintenance tools you use every day. With a powerful, built for purpose handheld, you can work faster and more effectively in the field while focusing on driving asset reliability. Download this whitepaper to discover three ways to improve reliability with handhelds.
API Standard 682 focuses on seal fluid reservoirs on dual seal pumps. By measuring auxiliary pump seal flush system pressure, temperature and level, you can minimize failures, reduce pump maintenance costs and process downtime, resulting in significant payback. Find out how to:
- Gain insight into faulty seals, before the problems become more serious
- Quickly and easily replace existing switches with wireless transmitters
- Avoid pump damage and failure resulting from seal flush system faults
If you win the Trifecta of Motor Maintenance, the return on your investment is huge. This white paper discusses the winning strategies of motor maintenance, focusing on the three reliability tasks for electric motor testing and the order in which they should be applied. Following these steps drastically improves the odds of your motor reliability.
An electric motor loses efficiency several different ways, but the largest amount of loss comes from power losses caused by the resistance of current flow through the motor. This resistance not only loses power, but it also generates heat.
Infrared (IR) thermal imaging (thermography) is an effective troubleshooting tool, but many electricians who use IR cameras to spot overheated wires, connections and components may not be knowledgeable about the full range of causes that can cause such overheating, in particular issues of power quality and harmonics.
Reliability is the key to your operational integrity – if your motors are down so is your ability to generate revenue. However, what repair method will assure reliability and minimize downtime?
Read Dreisilker’s White Paper Series for an in-depth look at electric motor re-manufacturing so you can make an informed decision.
This easy-to-read eBook is for users who wish to learn how to do more with their PLC or simply refresh their understanding. It covers the basics and dives into ladder logic, PID loops, communication protocols, and motion control.
— What is a PLC
— History of the PLC
— How to Choose a Controller
— PLC Hardware
— PLC Software
— Practical PLC Topics
Plus a collection of PLC application stories to see what others are doing with their PLCs to inspire you!
Are you changing your oil too often or having machine failures? Most companies are now realizing that maintaining clean oil is one of the best investments it can make, with contamination at the core of premature machinery failure and diminished lubricant life.
Gain a better understanding how a desiccant breather can be used as a first line of defense in preventing contaminants from ruining your equipment and what the right metrics are to show a return on your investment.
In recent years, portable filtration units, often referred to as filter carts, have become a common tool in the lubrication professional’s arsenal and there are many systems where occasional or condition-based filtration is the most economical solution. However, portable filtration is not always the best solution. While portable systems will always have their place, permanent solutions offer several benefits including better average fluid cleanliness and far fewer man-hours.
A new white paper from Des-Case Corporation highlights how permanently installed, 24/7 filtration units bring you one step closer to best practices for your lubrication program.
Companies in asset-intensive industries intuitively know that enterprise asset management (EAM) is a cornerstone of operational excellence. Learn how an integrated approach to planning and scheduling that includes maintenance, production, and projects across the enterprise can help you progress from a reactive to a predictive organization, and ultimately achieve operational excellence.
Are Your New Hires Prepared to Avoid the Hazards of Electricity?
By Ron Spataro, Director of Marketing, AVO Training Institute
As your workforce continues to turn over, are your new hires prepared to avoid the hazards of electricity? As the older and experienced technicians leave the workforce, on the job training for new hires becomes a difficult proposition. This knowledge base is growing smaller, so how are you going to teach the newcomers what they need to know in order to stay safe while maintaining your equipment?
This article takes a look at the impact of having untrained technicians and the questions you should be asking when determining whether or not your apprentice program is up to par.
Is It Just Reliability?
By Richard E. Wood, AVO Training Institute, Senior Consultant
There is more to a reliability program than just Preventative Maintenance (PM), Predictive Maintenance (PdM), and Failure Mode & Effects Analysis (FMEA). The resource that is often ignored is the training of maintenance technicians and engineers. A good training program enables the technician to quickly identify the failure and return the equipment to the process, as well as keep technicians and other workers safe.
Where does safety come in? A safe environment can be accomplished through the combined effects of reliability and training. Training employees with the necessary skills to work safely will always equate to a substantial return on the investment.
Learn How to Clean Tanks Faster and Lower Operating Costs
Automated tank cleaning offers many benefits – cleaner tanks, less downtime and improved worker safety. But selecting the best equipment for your operation can be challenging because not all tank cleaning nozzles are created equal. A new white paper from Spraying Systems Co. will show you how to reduce cleaning time, minimize chemical/water consumption and improve cleaning effectiveness while avoiding common problems like clogging. You’ll also learn about key factors that will allow you to compare the cost of ownership for different types of tank cleaning equipment.
Analyzing Electrical Hazards in the Workplace
By: Timothy L. Gauthier, Project Manager/ Senior Training Instructor AVO Training Institute
Dennis K. Neitzel, CPE, Director Emeritus- AVO Training Institute
Mark Ackerson, Senior Consultant- AVO Training Institute
When it comes to risk assessment, educating leadership on all of their available options is critical.
The need for analyzing electrical hazards in the workplace has been recognized by a small segment of the industry for many years. The petrochemical industry and many government institutions have performed research on this subject for over thirty years. For the most part, however, the user level of the electrical industry has largely ignored the subject, essentially reacting to catastrophic accidents rather than proactively trying to predict and prevent them. The Arc-Flash incident that completely destroyed the front of the electricians’ shirt, along with severely burning the electrician could have been prevented if management and the worker completely understood the electrical maintenance hazards. This article will provide an overview of the three principle types of electrical maintenance hazards, along with a discussion of the standards and regulations pertaining to the subject.
New Oil Filtration
By: Harvard Corporation
As surprising as it may seem, most new oils purchased today are not filtered before being sold. Yes, the new oil is refined, looks translucent and visually appears clean, but when viewed at a microscopic level it contains unwanted particles. In many cases, the filtered oil in the equipment being replaced has less unwanted particles than the new unfiltered oil being added during an oil change.
Overall Vibration, Severity Levels and Crest Factor Plus
By: Fluke Corporation
Mechanical Vibration is a notoriously difficult subject matter to master. A quick glance at a textbook in the field shows that the advanced practitioner must master sophisticated concepts in mathematics and physics in order to accurately collect and interpret vibration data. This has caused a major problem for industrial plants—the benefits of a vibration testing program are well known, but far too many plants choose to avoid vibration testing because of the perceived complexity.
Fluke aims to solve this dilemma by developing easy to use vibration products that yield significant benefits without requiring advanced training by end-users. Fluke’s first vibration product, released in 2010, was the 810 Vibration Tester (see picture on next page). The 810 is a vibration spectrum analyzer that includes an automated diagnostic engine that identifies the four most common root causes of abnormal machinery vibration: misalignment, unbalance, looseness, and bearing faults. The 810 is dramatically easier to use than existing spectrum analyzers because the interpretation of frequency spectrum data is automated. The user simply sees a severity scale for each of the four faults listed above.
Checking Voltage Frequency Ratio on Variable Speed Drives
By: Fluke Corporation
With their unique triggering and measuring functions, Fluke ScopeMeter 190 Series II portable oscilloscopes are ideal for analyzing the voltage-frequency ratio of pulse-width-modulated variable speed drives.
Wireless Test Tools Can Cut Troubleshooting Time
By: Fluke Corporation
The automation of more and more processes and operations in today’s factories and commercial buildings is helping to reduce energy consumption and increase safety and productivity as never before. However, automation has also added a large dose of complexity for the technicians who maintain and troubleshoot the systems.