Condition Monitoring/Predictive Maintenance

Condition Monitoring

Condition Based Maintenance (CBM). When we purchase a machine we accept that it will not last forever. The problem isn

Improving Productivity And Reducing Costs

Oil refineryOver the past 17 years, Management of Change (MOC) has received increased attention at chemical plants and refineries due to the promulgation of new OSHA regulations. Officially designated 29CFR 1910.119 Process Safety Management of Highly Hazardous Chemicals, the OSHA PSM regulations state that any time a critical component in an oil or chemical plant changes, a formal MOC program is required to ensure that the proposed change is made safely.

However, recent analysis conducted by Gateway Consulting Group, a specialist in the design and implementation of enterprise content management (ECM) solutions for chemical and petrochemical plant environments, notes that while plant owners are in compliance with OSHA regulations, their MOC processes are not necessarily efficient. [Ref. 1]

Evidence of poor efficiency includes:Long cycle times for MOC closure; The need for, and hiring of, temporary staff to

Value Driven Maintenance

Figure 1"What is actually the added value of maintenance?" is a frequently heard question in boardrooms the world over. Even though maintenance is often critically important, few maintenance managers are able to answer the question convincingly. Especially when they are asked to express the benefits in terms of economic value added or shareholder value - the language increasingly being spoken in European boardrooms .

For this reason Mainnovation developed the Value Driven Maintenance

SPM Instrument delivers equipment for condition monitoring to Emami Paper Mill, India

Paper MillSPM Instrument India has been awarded a contract for the first comprehensive installation of online condition monitoring equipment ever in an Indian paper mill. Emami Paper Mills Ltd in Balasore, India has selected SPM Instrument to provide equipment for continuous shock pulse and vibration severity measurements on critical parts of its latest paper machine.

With its two mills, Emami Paper is one of the major domestic newsprint manufacturers in India. The Balasore paper mill has a production capacity of 110 tonnes of writing and printing paper and newsprint per day. The purchase of another paper machine in Balasore will increase the daily production to 400 tonnes in all for the two paper mills.

The SPM contract is entered into as part of an ongoing investment plan to become the number one newsprint manufacturer in India. To reach that goal, a high level of production equipment availability is very important. After installation of the SPM equipment and when optimized, the monitored paper machine is likely to be the fastest in India.

Predictive maintenance spread out

vibration monitor detects rolling element bearing failures Cost-effective predictive maintenance vibration monitor detects rolling element bearing failures and shaft imbalance conditions in four locations simultaneously.

The innovative efector octavis bearing condition monitor from sensor market leader ifm electronic is now available as a master unit which can monitor up to four seaparate locations.   These new versions make predictive maintenance efector octavis even more cost effective.

The octavis central unit can also now be programmed via ethernet. The vibration pickups, which can be up to 30m from the central diagnostic, are made in stainless steel with a IP69K rating  for arduous environments.


St Fergus TerminalTOTAL E&P UK, one of the largest exploration and production subsidiaries of the TOTAL Group has installed a 10,000 point + CitectSCADA system to provide monitoring - with full dual redundancy - of the control and safety systems for the giant St Fergus gas terminal in Scotland. The Terminal plays a key role in supplying Britain

Integrating Inspection-Based and Reliability-Based Information

Reliability MaintenanceThere are many sources of machinery health and production availability information available to an organization's maintenance and operations staff. Two of the most commonly used sources of information are scheduled inspection of machinery and condition monitoring.

In most cases, scheduled inspection of machinery has been managed through a plant

Condition monitoring:insurance against breakdowns

Kate HartiganBy using the latest condition monitoring systems and services, manufacturing companies can reduce unforeseen breakdowns. Schaeffler UK's managing director, Kate Hartigan, explains

When owning and managing high value items like cars or homes, most people are comfortable paying insurance premiums. So, surely manufacturing companies need to ensure their high value capital goods are adequately insured against unforeseen breakdowns? After all, lost production could equate to tens of thousands, even hundreds of thousands, of pounds per day. Although the cost of machine components like bearings and motors is small compared with the total machine price, the cost of production downtime and consequential losses resulting from a component failure, are often significant.

Take a steel or aluminium manufacturing plant. The typical cost of production downtime is

Lean TPM from Productivity Europe

Productivity EuropeFor many organisations today, the most important issue is how to reduce costs to compete profitably in global markets.  The two key approaches to manufacturing cost reduction are Lean and TPM (Total Productive Maintenance).Lean reduces costs by eliminating waste in the end to end process, following Henry Ford's original dictum "the longer anything is in my factory, the more it costs me".

Total Productive Maintenance reduces costs by eliminating losses in equipment based processes - once you have a lean flow, the key is to run equipment as efficiently as possible. Both Lean and TPM are based on a foundation of 5S and Continuous improvement (Kaizen) and our success is based on helping companies develop this foundation as well as applying more advanced Lean and TPM approaches.