Ammj 263

AMMJ
May 2013 Issue
Asset Management & Maintenance Journal
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May 2013
Balancing Using Your

Mobile Phone
Risk Mitigation Through

Strategic Maintenance
and Reliability
12
Lifecycle Cost Analysis:

The Key to Asset
Sustainability
From Green To Gold
37
The 2013 Maintenance

Seminars
39
Does it pay to design

for reliability and
maintainability?
41
57
Equipment & Services

for Plant and
Buildings - NEWS
REPORTS AND
RESEARCH PAPERS
61
Unique Challenges of
Asset Service - Enabling
Mobile Workers in Asset
Intensive Industries
43
Determining Circuit
Breaker Health Using a
Circuit Breaker Vibration
Analysis Approach
24
44
Inspection and Condition

Monitoring Products and
Services
34
8% Operational Efficiency
Improvement at Griffins
Go To First Article
56
Thermal imaging - a great

tool for predictive
maintenance inspections
14
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52
Always In Touch Adapting mobile devices

to industrial applications
MAINTENANCE AND
RELIABILITY
PLANT ENGINEERING
AND SERVICES
Condition monitoring
protects Londons
Thames Barrier
The Humble
Stethoscope
45
Maintenance and
Reliability - NEWS
Calculating Wrench Time
For a Maintenance Crew
A Multi-state Preventive
Maintenance Policy Using
Semi-Markov Processes
62
AMMJ Information
for Subsciptions and
Advertising
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Improve the Productivity of your

Equipment and your People
BALANCING USING
YOUR MOBILE
PHONE
Ray Beebe
raybeebemcm@gmail.com
Inbalance is one of the most common causes of high vibration in machines. If

the largest vibration component in the spectra is at 1X (i.e. at the frequency
corresponding to rotation speed) then unbalance is the likely cause. Balancing is
therefore a regular maintenance activity in many workplaces.
Ray Beebe explains a method that has been successfully used on rotors large and
small, with the only instrumentation required for balancing being the stopwatch
feature of a mobile phone.
It is assumed that the severity of vibration has been assessed as unacceptable
according to sources such as the relevant part of ISO 10816 (Ref 1). Even if a
machines vibration meets such criteria, it may be causing annoying vibration of
adjacent parts.
Looseness is another of the most common causes, and a check of foundation
tightness is recommended before proceeding to balancing. If the unbalance
is due to deposition on the rotor, such as with fans handling dirty gas, the rotor
should be cleaned. In cases where a deposit is difficult or expensive to remove,
it may be expedient to balance out its effect until a more convenient time for
cleaning.
The Timed Oscillation Method
This method has been used successfully for short rotors such as overhung fans
up to 2m diameter, and for pump impellers. It has also been used on smaller fans
with two bearings that are nearer to what are considered long rotors. The rotor
must be in rolling element bearings, or set up on a mandrel and parallel ways, and
not be affected by crosswinds.
For field balancing, the usual safety precautions for opening any machine must of
course be taken so that the machine cannot be switched on while the work is in
progress.
I do not know the source of the method, but I learnt it in my first job at a power
station in the 1960s. Published in Ref 2, the equation is derived from the theory of
the compound pendulum.
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Can demonstrate the nancial value that they can add

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May 2013
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Mark numbers around the rotor, evenly spaced.

For bladed rotors, mark at the blades.
Choose a swing mass to fasten (by clamp or magnet) on the rotor, to give
to-and-fro oscillation time of about 20 seconds. (This gives some allowance for
reaction time in operating the stopwatch feature of your mobile phone)
With the swing mass fixed to the rotor at Position 1, turn the rotor so that the
mass is at one horizontal position and stationary.
Release the rotor and let it swing freely under its own inertia do not push
it in any way.
Mean Time Of Swing
Time the to-and- fro
oscillation from the
horizontal position. The
Weight
left part of the sketch
oposite illustrates
the process.
Turn the rotor so that the
mass is at the horizontal
position on the other
side, and repeat.
Position Around Rotor
Calculate the mean time
of swing for this position, and plot on a graph of time against position as shown in
the sketch. With position numbers evenly spaced, one position appears twice - at
the start and the end of the position axis.
Move the swing mass to Position 2, etc. and repeat the process.
Connect the graphed points with a smooth sine wave shape, and read off the
maximum and minimum times of swing: T and t.
Calculate the size of balance mass required from:
Balance mass = Swing mass T2 - t2
T2 + t2
Make a balance mass, and fix it on the rotor at position of maximum swing time.
The fixing must of course be sufficiently strong not to allow the mass to fly off at
operating speed. If welded, allow for the mass of the weld.
* If the correction is to be made by removing mass from the rotor,
remove it from the position of minimum swing.
* If the correction mass is at a different radius to that of the swing mass,
then calculate the mass size to achieve the same moment (i.e. Mass Radius).
If required, verify the result by repeating the swing test for three spaced points.
AMMJ
May 2013
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Supervisor
Instructions
Methods of balancing
This table outlines the several methods available.
Situation
Application to balance pump impellers

The method was developed and used for
each impeller of a high-speed 10-stage pump
of the ring-section design (where each stage
impeller is assembled in turn with its matching
stationary section). We clamped parallel ways
to the bed of a milling machine. A mandrel was
made to suit the impeller and a pot magnet
used as the swing magnet.
The correction was made on the adjacent
milling machine using an end cutter. A table
was calculated and drawn up giving the depth
of cut required in each case. The position
was marked clearly on the impeller, and it was
passed to the machinist who cut the required
mass from the back shroud.
The method gave satisfactory results. At the
time, the only balancing machine available
could only hold the total rotor assembly, and
corrections would be made on each of the end
impellers. Arguably, the impeller-by-impeller
method gave a more satisfactory result.
Balancing by trial and error
Another method that may be satisfactory does
not require any instrumentation. A story will
illustrate the method.
Among the cars that I have owned was
a second-hand 1971 Ford Falcon (in-line 6
cylinder 4 litre engine). It came with an aftermarket twin extractor exhaust system. This
gave a boy racer burble, and the salesman
explained that it was the cause of severe
vibration of the whole car that was evident at
around 90 km/h.
AMMJ
May 2013
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I tolerated this for some time before deciding

that with my growing knowledge of vibration
problem solving, and fresh from solving a
pump problem, I should be able to fix it. With
the bonnet up, I revved the engine, expecting
to see the exhaust pipes shake about when
the critical speed range was reached. To
my surprise, they did not move at all from an
equilibrium position. Then I placed my hand
on the alternator and was horrified to feel it
shaken off by its rough vibration! I should
have figured this out much earlier, because the
alternator support bracket had been repaired
by brazing, and I had replaced it with a new
one.
I removed the alternator, leaving the rotor in its
end casing bearing. When spun by hand and
allowed to come to rest, it settled at the same
angular position each time. So, I drilled holes
in this heavy pole face until the spin test
showed the position at rest to vary each time.
On reassembling and back in the car, the
vibration no longer occurred. This alternator
must have slipped through manufacturing
QC unnoticed. (When telling this story, I
usually leave out the bit about having to ask
our instrument workshop people to repair the
screw thread that I had mangled just a little!)
References
1. ISO 10816 Mechanical vibration
Evaluation of machine vibration by
measurements on non-rotating parts.
(Several parts for specific machine types)
2. Beebe, Ray S Machine condition
monitoring, MCM Consultants, 2009 reprint.
ISBN 0646250884
Rotor out of
machine
Method
Balancing
machine
Equipment needed
Balancing machine usually done by an
external service
Comments
Refer ISO 1940/1-1986(E)
for criteria
Timed oscillation Parallel ways, rotor in

Systematic method. Can
(single plane)
mandrel. Stop watch.
use on short and some
Swing mass (e.g. pot
longer rotors.
magnet for small rotors).
Trial & error
(single plane)
Parallel ways, rotor in

mandrel. Swing masses
of various sizes.
Rotor in machine Timed oscillation Rotor must be in anti("field", "in situ") Trial & error
friction bearings
Off-speed
On-speed
Sometimes cost-effective.
See above
Single plane
(sometimes
called static
balancing)
Vibration 1X and phase

angle measurement
For "short" rotors. 3 runs.

Can do in one shot with
past history data.
Vibration measurement,
no phase angle
The 4 Runs method (or

less, with 50% chance of
correct position for balance
weight). Assumes that the
vibration is predominantly
1X. (Ref 2).
Two planes
(sometimes
called dynamic
balancing)
Vibration 1X and phase

angle at each end
bearing
For "long" rotors.

4 runs using "Influence
coefficients" method. (Ref
2).
3 runs in some cases,
using "components"
method where static (i.e.
in-phase) and dynamic
(i.e. anti-phase)
components are treated
separately (Ref 2).
Multiple planes
(but in field on a
rotor often only
two are
accessible)
Vibration and phase

angles at each end
bearing
Modal balancing for flexible

rotors, rather like
components method.
Computer system is usual.
Some vibration data collector/analyser devices can have capability for field
balancing, using a phase angle reference. I think that the earlier method where a
vector diagram is drawn has the advantage of visualising the process, step by step.
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Risk Mitigation
Through Strategic
Maintenance and
Reliability
A practical case study showing the
benefits of applying a structured
approach to maintenance and
reliability techniques
Gary Tyne
ARMS Reliability gtyne@armsreliability.com
Manufacturing plants today contain numerous

equipment items that require some form of
maintenance to help deliver company output and
profit. This paper presents a practical case study from
the initial Reliability Centered Maintenance concept
using a computerised simulation approach, followed
by the detailed Root Cause Analysis on some high
consequence failure modes.
1 Introduction
The company had recognised through their internal

data management processes that a particular critical
equipment item was causing unexpected outages
resulting in a loss of business profit. It was therefore
decided by the business to embark on a continuous
improvement path that would enable them to fully
understand the equipment and how to prevent the
unexpected losses from re-occurring.
The approach taken for the critical equipment

item was to initially perform a Reliability Centered
Maintenance (RCM) study, in which all the likely and
the dominant failure modes are identified. A Failure
Mode Effect and Criticality Analysis (FMECA) model
was then populated with the consequences of
failure using the corporate risk matrix and financial
cost of failure. The outputs of the study now gave
the company the ability to optimise the choice of
maintenance tasks from both a cost and safety
perspective.
Once the optimum maintenance plan was
developed, lifetime simulations using a Monte Carlo
simulator were performed to provide a forward
maintenance budget prediction and also to assess
the effectiveness of the plan in reducing the impact
of any critical failures. Where maintenance was
not able to reduce the failure effects to acceptable
levels, they were subjected to detailed root cause
analysis in order for effective solutions to be
identified.
In conclusion, this paper illustrates how a
manufacturing plant developed a fully documented
maintenance plan with associated work instructions
for implementation through the site maintenance
management system. The RCM study addressed a

critical item of equipment within the manufacturing facility
to develop a plan to ensure safe, reliable and economical
use of the plant item throughout its life.
1.1 Reliability Centered Maintenance
Reliability Centered Maintenance (RCM) is a systematic
approach that focuses on preserving function rather
than preserving the asset. It addresses only failures that
matter using a logical process for making maintenance
decisions.
During this process, the equipment is broken down to the
lowest maintainable item. The failure causes for each
maintainable item are then identified and analysed. If
reliable failure/maintenance history is available, then this
can be used to establish the failure rate or expected life
of each failure cause. However, more often than not this
information is not readily available or its accuracy is not
very reliable.
In such cases this information can be estimated based
on technical, operational and maintenance experience
on similar machines, as well as general engineering
knowledge. The maintenance strategy for each failure
cause identified must also be derived. These strategies
may be predictive maintenance, preventive maintenance
or a run-to-fail strategy.
As part of the RCM process, the failure effect or failure
consequence is assigned to each failure cause. It
is important to identify the failure causes that have a
potential impact on the availability of the equipment so
that the equipment can be correctly modeled when the
data is transferred into a Reliability Block Diagram.
AMMJ
May 2013
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1.2 Reliability Block Diagram

Reliability Block Diagrams (RBDs)
are a tool used to carry out a system
availability analysis and produce
performance predictions. They
are made up of series and parallel
relationships that represent equipment
redundancy levels. The RBD can predict
downtime, number of interruptions
and the Mean Time Between Failures
(MTBF).
The information collated during the RCM
process can be utilised to create the
Reliability Block Diagram (RBD) model.
.
1.3 Root Cause Analysis
Root Cause Analysis is a problem
solving methodology that is aimed
at identifying the root causes of
problems or events. If the root causes
are identified and effective solutions
implemented then it would be fair to say
that we should not see the problem reoccur again in the future.
2. Case Study
AMMJ
Zinc Stripping Machine

The equipment identified for further
improvement by the business was a zinc
stripping machine. The stripping machine
is not something available off the shelf;
it was designed specifically for the
business and is unique in its operation.
The stripping machine main function is
to strip two 20 kilogram sheets of zinc
every 4 seconds with a daily target of
450 tonnes a day.
(Ref
2.1 The Analysis

The RCM study began by collating as
much information as was available,
including equipment lists and current
maintenance plans. Work order
history, and performance data were
analysed using Weibull Analysis
to determine what failure patterns
were occurring across the stripping
machine. This information was then
used to develop a Desktop Reliability
Centered Maintenance (RCM) model
using the simulation software package
Availability Workbench (AWB)1.
The asset hierarchy was built
using AWB based on the current
structure within the business
SAP Computerised Maintenance
Management System (CMMS). This
alignment with SAP was required for
future use of the AWB SAP portal and
the uploading and downloading of
maintenance plans.
With the asset hierarchy developed
the next stage of the process was to
define equipment functions, functional
failures and failure modes. This
was predominately completed using
available information and equipment
experts located within the business.
The first model developed was the
current maintenance strategy which
used the plans that were being
currently performed on the stripping
machine.
1 - Availability Workbench (AWB) is a Trade Mark owned by Isograph Limited UK)
Making RCM work with

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DATA
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May 2013
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Table 1
ID
Figure 1 Cost Criticality Pareto Chart

Cost Criticality
Busbars Dirty
Failure Mode
Prox Misaligned
Broken Switches
Light Curtain Trip

$0
$2,000,000
$4,000,000
$6,000,000
$8,000,000
$10,000,000
$12,000,000
Total Cost Contribution
Once the current maintenance plans were implemented the next step was to
assign the consequences of failure using the corporate risk matrix. The severity
levels within the table were calibrated to the companies risk matrix. See Table 1.
With the current practice AWB model complete the business was now in
a position to simulate using the Monte Carlo Simulator built within AWB to
determine the impact of the maintenance tasks on the lifecycle costs and
risk levels. The simulation results provided rapid analysis, and allowed for
further optimisation of maintenance plans to take place. Where maintenance
was not effective in either preventing or predicting a failure mode then Root
Cause Analysis was performed to determine what effective solutions could be
implemented to prevent reoccurrence.
2.2 The Results

With the AWB desktop model now complete, we needed to perform a reality
check and challenge the model results. This is carried out by first examining the
Cost Criticality Pareto chart. The Cost Criticality Pareto ranks the failure modes
based on total cost which includes any business costs associated with failure,
labour cost, spares cost and equipment cost. See Figure 1.
AMMJ
Cost Per
Occurrence
Safety
Severity
Operational
Severity
24
S&H2
First Aid Treatment
730
S&H3
Medical treatment or lost time injury
8760
S&H4
Extensive or Permanent Part Disability
87600
S&H5
Fatality (s) or permanent serious disability
876000
ENV1
No impact or measurable impairment
2500
24
ENV2
Minor effects on biological or physical environment
25000
730
ENV3
Measurable impairment on biological or physical

environment
250000
8760
ENV4
Serious environmental effects with impairment of eco system
2500000
87600
ENV5
Very serious environmental effects
5000000
876000
LEG1
Unlikely to result in adverse regulatory response
24
LEG2
Minor non compliances of breaches or regulations
730
LEG3
Serious breach of regulation
8760
LEG4
Major breach of regulation
87600
LEG5
May be considered wilful or negligent.
876000
QS1
Can easily be absorbed through normal activity
24
QS2
Consequences can be absorbed. Minor delivery delays
730
QS3
Significant event which can be managed under special

circumstances
8760
QS4
Major event with prioritised and focused management,

Customers lost
87600
QS5
Extreme event with failure to lead to failure of business. Key

customers lost
876000
STK1
Little or no stakeholder interest
24
STK2
Minor adverse local media attention
730
STK3
Attention from local media or heightened concern from local

community
8760
STK4
Significant adverse national media/public attention. Share

price may be affected
87600
STK5
Serious public outcry. International coverage. Share price

seriously affected
876000
DT1
Downtime Cost Smelter
19000
Air Gap Damaged

Flag damage
Cost Per
Hour
Report Only No treatment
Brushes Worn
Hangers Damaged
Description
S&H1
Prill Build Up
Bench Chain Worn
Consequence Table
May 2013
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Figure 2
Figure 3
Actual Cost v Predicted Cost
Safety Criticality Current Practice
Safety Criticality - Current Practice
Actual Cost versus Predicted Cost

$700,000
Emergency Stop Circuit Failure

$600,000
$500,000

Failure Mode
Cost
$400,000
$300,000
$200,000

Edge Growth Not Removed
Emergency Stop Panel Failure
$100,000
Emergency Stop Load Failure
$0
SAP Actual Year 1
SAP Actual Year 2
RCMCost Current
RCMCost Optimised
Spares
$361,520
$404,287
$354,028
$353,121
Resource
$214,507
$236,551
$241,344
$238,344
Emergency Stop Unload Failure

Emergency Stop Switch Failure
0
Now failure modes had been addressed

from a cost perspective, the next step was
to determine if the safety risk associated
to the stripping machine was less than the
acceptable business exposure threshold.
This threshold was calibrated with the
business risk matrix to align with a target
of 1. If any failure modes exceeded this
target then a safety risk exposure existed.
With the stripping machine, four failure
modes exceeded the target and showed
safety risk exposure. These failure modes
were associated to emergency stop
switches and the testing regime for those
switches.
The comparison between current
maintenance and optimised maintenance
can be seen with a reduction in safety
risk to below the target of 1 following
maintenance optimisation.
See Figure 3 and Figure 4.
0.4
0.6
0.8
1.2
1.4
1.6
Figure 4
Safety Criticality Optimised
Safety Criticality - Optimised

Edge Growth Not Removed
Emergency Stop Panel Failure
Emergency Stop Load Failure
Emergency Stop Unload Failure
Emergency Stop Switch Failure
0
0.2
0.4
0.6
0.8
1.2
1.4
1.6
Safety Criticality Target = < 1
AMMJ
May 2013
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1.8
Safety Citicality - Target = < 1
Failure Mode
Using the Cost Criticality Pareto Chart, the

high cost failure modes were examined in
detail by carrying out a validation of the
failure mode information. Once validation
was complete, the Cost Criticality Pareto
identified areas for improvement.
The type of recommendations made
for improvement included root cause
analysis (RCA), equipment redesign and
maintenance strategy optimisation.
The second method used to challenge the
model results was to examine the historical
maintenance costs and compare to the
budget prediction using AWB. The goal of
this was not primarily to ensure the budget
prediction matched the historical spend but
rather to clearly understand the reasons
for any discrepancies in the results. In
this case study, the predicted results were
within 4% of actual maintenance spending.
See Figure 2.
0.2
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1.8
Figure 5
Average Annual Cost Strategy Comparisons
Average Annual Cost - Stripping Machine

$10,000,000
With the model details validated, it was then important to recognise the comparison
between the alternative strategies on offer to the business. In this case, run to failure,
current practice, optimised and optimised with redesign strategies were compared. See
Figure 5.
Once optimisation was finalised a maintenance budget prediction was developed to
determine spares and resource requirements. Using AWB, the budget prediction could be
interrogated at many levels including system, sub-system, individual asset and individual
failure mode level. See Figure 6.
We were now in a position to determine what impact the optimised maintenance strategy
was having on the stripping machine overall availability. This would indicate single points of
failure and bottlenecks within the machine and identify further opportunity for improvement.
See Figure 7
Cost
$8,000,000
$6,000,000
$4,000,000
$2,000,000
$0
Run to Fail
Current
Optimised
Opt Redesign
$22,056,284
$3,289,972
$2,334,326
$759,258
Resource
$45,107
$241,344
$238,661
$238,344
Spares
$320,654
$354,028
$353,121
$353,121
Effects
Figure 7
Figure 6
Average Annual Budget Predictions
Predicted Availability Performances
Predicted Availability Performance - Stripping Machine
Stripping Machine - Annual Budget Prediction
99.00
$700,000.00
97.00
Predicted
Availability: 91.6%
95.00
Total Downtime: 8.4%
$500,000.00
$400,000.00
Spares
Labour
$300,000.00
Outage due
to Planned
Maintenance: 4.8%
93.00
91.00
89.00
$200,000.00
87.00
$100,000.00
85.00
Outage due to
Unplanned
Maintenance: 3.6%
1
10
Year
$0.00
10
Availability %
$600,000.00
10
AMMJ
May 2013
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Table 2
Description
Cost per Year
Frequency
Monorail
Light curtains trip
$1,107,070
Once/shift for 5 min
Side Shifter
Flag damage
$493,765
Once/week for 30 min
Solution Cost Benefit
Problem
Cost/year
Cost of Solution
Payback Days
Light Curtain Trip
$1,107,070
$34,800
11.50
11.47
$493,765
$2,880
2.17
Flag Damage
AMMJ
Table 4
Equipment
Table 3
11
Failure Modes for RCA
2.3 The Improvement Workshops

With a new maintenance strategy
developed for the stripping machine,
it was important to recognise that two
failure modes that were occurring on
the machine could not be prevented
or predicted with any form of regular
maintenance. See Figure 1 Cost
Criticality Pareto.
It was therefore decided to conduct a
detailed RCA (Root Cause Analysis)
workshop on these two failures.
The approach was taken to create a
common reality and build a cause and
effect chart that would address the
conditions and the actions surrounding
both problems using the Apollo Root
Cause Analysis Method2 .
The goal of the Apollo Root Cause
Analysis Method is to identify not
only the cause and effects but identify

the effective solutions that will prevent
reoccurrence of the problem. The
methodology is based on the four
elements of cause and effect principle:
Cause and effect are the same thing
Causes and effects are part of an
infinite continuum
Every effect has at least two causes
in the form of actions and conditions
An effect exists only if its causes exist
at the same point in time and space.
The light curtain trip identified 63 cause
and effects and 12 solutions.
The flag damage identified 22 cause
and effects and 3 solutions.
With potential solutions identified a
cost benefit analysis was carried out to
ensure payback on the cost of solutions.
FMECA Summary
Optimized FMECA Summary

Action
Number of Tasks
Use As Is
2.4 FMECA Summary

The Stripping machine FMECA analysed a
total of 1798 failure modes (see Table 4).
The new optimised maintenance plan
produced 51 Maintenance Schedules with a
total of 1466 maintenance tasks.
The maintenance strategy was categorised
into 10% Preventive Work and 90%
Inspection Work.
2.5 Continuous Improvement
With the new maintenance strategies
uploaded into the CMMS via the AWB SAP
portal, it was recognised that a periodic
review would be performed to validate
the strategy and update according to new
information and data becoming available.
This will form part of the business continuous
improvement process.
3. Conclusion
The paper has presented a Reliability

Centered Maintenance approach to
evaluating current maintenance regimes.
Once complete, the models can be used to
predict budgets, maintenance labour and
resource requirements and spares usage.
The approach also incorporated Root
Cause Analysis on high cost failure modes
that could not be prevented through the
maintenance regime.
929
Deleted
Extend Interval
54
New Tasks
471
Reduce Interval
Run to Failure
344
The paper shows through the

breadth of results available, the
benefit in applying an RCM and
RCA approach to plant strategy
optimisation. The outcomes can
help ensure that the throughput
goals are achieved at least cost
and minimum risk exposure to the
business.
References
1. Dean L. Gano Apollo Root Cause

Analysis A New Way of Thinking, 3rd
ed., Apollonian Publications, (2007).
For more information see:
www.armsreliability.com
www.apollorootcause.com
This article was originally published in the
Maintenance & Engineering Magazine
www.maintenanceonline.co.uk
(Ref 2 - Apollo Root Cause Analysis Method is a universal problem solving methodology by Apollonian Publications LCC.)
May 2013
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Lifecycle Cost Analysis:

The Key to Asset Sustainability
A Non-profit Organisation Uses A CMMS to Improve
Facility Service and to Reduce True Total Costs
Chemung Administrative Offices
www.bigfootcmms.com
Reduce, reuse and recycle are the three watch

words of environmental sustainability for saving
money, energy and natural resources. But
what can facility managers do to ensure asset
sustainability, which encompasses the costefficiency of buying, operating and servicing
maintenance and repairs?
In other words, how do you determine which
products to purchase, when they should be
replaced and how to efficiently service them to
maximize your return on investment?
12
For Adam Hungerford, facility and safety services

manager at Chemung ARC, the answer was to
use Bigfoot CMMS (computerized maintenance
management software) for comprehensive asset
management support. This CMMS is known for
helping maintenance professionals get up to speed
quickly and see results, often within a matter of
weeks.
By leveraging the softwares data and tools and
initiating an aggressive preventive maintenance (PM)
program, Chemung ARC has been able to more
effectively manage and reduce the true lifecycle
costs of his facilities assets.
With Bigfoot CMMS, we now have a clear picture of

these costs and can make data-driven decisions, said
Hungerford, whose non-profit organization provides
housing and vocational services to developmentally
disabled clients in upstate New Yorks Chemung County.
Were also much more efficient in managing our PM
program, work orders (WOs) and inventory.
Lifecycle Cost Analysis for Washers and Dryers
Hungerford is responsible for managing repair and

preventive maintenance for Chemung ARCs facilities,
including 18 residential homes and business offices.
The Agency supports around 700 clients, some in need
of constant care, others who participate in vocational
programs, and others who are employed. He also
oversees Chemungs administrative offices and a staff of
six full-time technicians and 15-20 contractors.
The CMMS has enabled Hungerford to perform equipment
lifecycle cost analyses, which have led to dramatic
changes and impressive results.
A case in point was Chemungs lifecycle cost for 40
washers and dryers.
Before we did this analysis, we were simply buying units
with low front-end costs which, we thought at the time,
would allow us to avoid expensive repairs and constant
call-outs, Hungerford said. We didnt really consider
Typical Residence
sustainability, operational costs and capacity.

These inexpensive washers and dryers were
undersized and often lacked essential features.
Since each machine ran 8-10 laundry loads each
day, they would frequently break down and repair
parts were largely out of stock because of all the
different models in use. The machines also were
operationally inefficient in their use of water and
electricity.
On average, the organization spent about $785.00
for the lifecycle of a typical washer, which included
the purchase price, installation, repair and
maintenance (R&M) costs, and disposal (but not
utility costs). Most had to be replaced in less than 15
months.
Through a CMMS cost study, Chemung now spends
almost twice as much upfront ($800 instead of
$425) for each unit but the lifecycle cost benefits are
significant:
Washers and dryers generally last six years
instead of 15 months, reducing the recurring costs
for purchase, installation and disposal.
R & M costs per unit per year dropped 30 percent
By doubling capacity of the units, Chemung cut in
half the number of loads per day and reduced
energy and water consumption by 25 30 percent
per load.
AMMJ
May 2013
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The savings and benefits have been far reaching, Hungerford said. Weve
reduced costs and downtime while improving the user experience.
Aggressive PM Processes
Using the CMMS, Chemung ARC continues to develop and maintain

aggressive PM processes. Hungerfords maintenance team checks dryer
vent ducts and lint screens each month and performs a quarterly full
exhaust tear-down and cleaning on each dryer.
We no longer have dryer R&M expenses caused by lint-related problems,
Hungerford said. The CMMS allows us to create, manage, and complete
this work. And if any repairs are needed, we can log, track, and report R&M
and operating expenses.
In addition, Chemung uses the CMMS to maintain an inventory of
commonly used washer and dryer parts as well as an inventory of spare
washers and dryers. Workers can view inventories and their storage
locations in real time.
Other CMMS Applications and Benefits
Hungerford also has done lifecycle cost analyses to create standardized

specifications for dishwashers, refrigerators, snow blowers, light fixtures,
faucets, tub controls and adaptable bathing tubs. With the PM schedule
now under control, Chemung rarely has to replace a failed appliance. For
example, the incidence of HVAC system failures has fallen 50 - 60 percent.
Other benefits afforded by the CMMS include:
Predictability for budgets, parts needs and product replacements

Compliance with health and safety regulations a PM schedule is set
to meet requirements for regular inspections and testing.
The ability to prioritize WOs -- Health and safety issues such as loss of
heat, utility outages, broken doors, broken glass windows and plumbing
leaks can be given urgent priority status
A 95 percent reduction in callbacks for repairs.
What do you do when the 5 Whys

doesnt dive deep enough?
Download our latest eBook
which reveals the benefits &
limitations of the 5 Whys process &
presents a logical framework to get
to the bottom of any problem
Download your FREE copy

ARMS Reliability are the global partners & providers of the Apollo Root Cause
Analysis Method. The Apollo Root Cause Analysis Method will help you to
solve real world problems faster, more efficiently & effectively every time.
Big Plans
Chemung has begun tracking the lifecycle costs for every item and piece of
equipment in every facility, including roofs, painting, flooring, furniture, site
and grounds work, gardens, fencing, etc. Hungerford hopes to have most of
these documented in his CMMS within the next several years.
We started small but are adding assets every few months. More
importantly, PMs from the CMMS have been completely ingrained in our
teams work habits.
13
AMMJ
Chemung ARC is a community organization committed to meeting

the needs of individuals with developmental disabilities.
May 2013
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The Unique
Challenges of
Asset Service
Enabling mobile workers in
asset intensive industries
Ventyx an ABB Company
14
www.ventyx.com
Automated mobile workforce management solutions

have been available to service organizations for
several decades. The consumer packaged goods
(CPG), parcel delivery and utilities industries were
the first to pioneer such innovations with point
solutions for merchandizing, route sales, route
delivery, meter readings, work orders, and so on.
IT organizations were quick to seize on the
opportunities presented by new technologies in
mobility, resource optimization, and knowledge
management as early as the 1980s. The result
has been a proliferation in automated field service
solutions across multiple industries.
Yet, these solutions have traditionally been narrowly
designed for field sales, field delivery and field
service workers in non asset intensive businesses.
Even those solutions deployed in the utilities
industries have been limited primarily to the
distribution end of the supply chain, for functions
such as meter readings, provisioning and
disconnects. Optimization and automated dispatch
solutions in that industry are still mostly confined

toreactive and short term activities. And even with a
degree of automation, processes in the field are still
dependent on paper.
Asset intensive industries such as mining, oil and
gas, transportation, and even utilities have been
largelyunderserved. These industries require asset
service solutions. Yet, solution providers, even
leading Enterprise Asset Management (EAM)
vendors, continue to apply field service solutions
to address asset intensive problems. While there is
certainly significant overlap between asset service
and field service, these are fundamentally two
different domains.
This paper discusses the differences between
asset service and field service. Accepting these
differences requires an understanding of the
overriding objective of any complex or high-value
asset operation: to ensure the highest possible
productivity of a given asset and thus reliable,
uninterrupted and continual service and production.
Also required is an understanding of the unique
differences in field operations in asset intensive

businesses and knowledge of the key drivers and
relative priorities in their decision making.
For those that intuitively understand and appreciate
these differences but do not see the urgency or
priority in solutions that enable their mobile workforce,
consider the following recent global trends:
Reduced revenues and sources of capital due to
the global economic crisis
Aging workforces and employee turnover
Aging infrastructure and increasing demand
Increasing cost of responding to incidents
Increasing public scrutiny forcing increasing and
changing regulation
Increasing security demands
Environmental trends and pressure to reduce
carbon footprints
New skills & workforces and knowledge required
by smart grid technologies and new green offerings
and services
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May 2013
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Traditional field service solutions cannot

address or keep up with these growing
demands. Only mobile asset service solutions
designed specifically for asset intensive
industries can pick up where traditional mobile
field service solutions stop.
Definition of an Asset Intensive

Business
15
While many may characterize utilities, mining,

and infrastructure enterprises as traditional
brick and mortar companies with large,
immovable assets with long life cycles, nothing
could be further from the truth. In reality, these
operations by their very nature are highly
mobile, remotely scattered, and virtually
managed. They rely on immediate, continual
and accurate awareness of every asset, and
of every resource required to construct, install,
operate, maintain, and service those assets.
For these businesses, any small failure or
lapse in information flow can have catastrophic
consequences resulting in tens of millions of
dollars in loss, and even injuries and fatalities
on a large scale. Reactively repairing the
failure, or picking up the pieces after the event,
is not an option.
Ventyx refers to these businesses as
asset intensive. Their objective is simple
ensure assets are productive and service is
uninterrupted. But meeting that objective is far
from easy. Consider:
How much did your last failure cost you and
your customers?
How many safety incidents did you
experience last quarter, and how much
production did you lose?
When were you last out of compliance, how

much did that cost you, and how do you
prevent it from reoccurring?
Do you know where all your resources and
assets are? Are they safe?
Are they productive?
How quickly can you identify a potential
problem before it occurs and mobilize your
resources in the field?
In a critical situation, do you know where all
your resources are, and can you marshal them
without causing or prolonging other failures?
Do your remote and mobile teams have the
tools and information needed to
effectively prevent the next
interruption in your service or
operations?
If these questions are relevant to you
and your team, then yours is an asset
intensive business.
highvalue asset operation. While one can always conclude that

customer satisfaction is the highest objective in any enterprise,
that premise can be academic in its pursuit for an asset intensive
business. Simply stated, the customer may be too far removed
from the actual or practical objective at hand to drive daily
operations in the field.
Ultimately, the pursuit of any asset intensive business is to
ensure the highest possible productivity of a given asset and
thus reliable, uninterrupted and continual service and production.
This in turn, depending on the industry and the end customer,
ensures profitability, prolongation of life, and so forth.
For the mine, this means continued flow of ore to that mines
customers, safety for its workforce, and profitability for its
shareholders.
The critical importance

of asset productivity and
reliability
For decades, asset intensive
operations have attempted to apply
narrowly-defined mobile field service
automation solutions to broader or
more complex asset service problems.
This is due, in part, to a historically
fundamental misunderstanding of
these two domains.
To understand these differences,
one first needs to understand the
overriding objective of any complex or
AMMJ
May 2013
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For oil and gas, its extracting, processing and

transporting at peak capacity over an aging
infrastructure, while reducing the carbon footprint.
For the utility, this means uninterrupted service
to its end customers, safety for the public, and
ultimately assurance that kilowatts do not go
unbilled.
For the transportation provider it can be
increased ridership on an aging infrastructure.
For the defense industry it can mean maintaining
facilities in a state of readiness to save lives
and maintain security while military budgets are
getting hit hard.
For government infrastructure, it means ensuring
the community has the foundation upon which
to conduct commerce freely and without
interruption.
Asset Service vs. Field Service
16
The domain of asset service overlaps considerably

with that of field service. The larger the enterprise,
and the more vertically integrated its business
or supply chain, the more likely it is to require
elements of both service types.
Mining operations, for example, are heavily asset
service oriented. Mine workers are thus almost
exclusively focused on operating or servicing
production assets.
The many roles within a mine itself shaft
construction, ore sampling, drilling and extraction,
shaft and utility inspections, etc. are focused
on continued operation of the mines assets and,
thus, uninterrupted production.
Yet, despite all the preventive activity, all this
infrastructure, whether it be drilling equipment,
ore movers, power generators, or ventilators, will
inevitably require repair.
This by definition is reactive repair, typically associated

with field service, whether performed internally by
the mine operator, or externally by third parties,
manufacturers or equipment dealers.
These latter parties are performing more traditional
field service-like activities, yet they are working on
complex assets. Thus the tools, systems and data
required to perform work on these assets can be just
as complex and rich as many of those used by the
mine operations.
Utilities, on the other hand, vary somewhat from
this model depending on how far up or down the
distribution chain they are.
Those that own the water source, purchase their gas
at port of entry, or generate their own electricity, have
needs very similar to those
of the mine. They or their
wholesalers might own
or lease the network over
which they then transport
their service.
In either case, preventive
maintenance of assets
is the highest priority as
any disruption can have
enormous financial and
legal consequences.
Municipal utilities or private
distributors, conversely,
are often the touch point
with the end customer
or the premise. Their
activities revolve heavily
around provisioning,
disconnection, upgrade
and repair.
As such, their service organizations typically fall into the

field service domain, and specifically into the reactive and
repair based business models. However, they also conduct
route-based meter readings, which is more consistent with
a route delivery model. In fact, they may also have a doorto-door sales force that sells energy related goods and
services.
The previous examples merely illustrate the complexity and
variation in the service continuum. They by no means fully
represent all the asset intensive industries, which include
transportation, oil and gas, public infrastructure, heavy
equipment, and defense, just to name a few.
To fully understand the difference between a field service
organization and an asset intensive service operation, we
must understand the differences in terms of What, Where,
When, How and Who.
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What is asset service?

Figure 1 represents at a high level the processes that are
primary to a field service organization vs. an asset service
organization. There is overlap, and any one large, highly
vertically integrated enterprise may actually have any
combination of these models, and in some cases all.
Unfortunately, many service organizations

make the mistake of attempting to automate
all these processes with a generic Enterprise
Asset Management (EAM) software suite
better designed to support less asset intensive
industries. They may likewise choose generic
mobile field service applications that cannot
adequately support the complex and
specific role-based needs of their assetfocused field forces.
Where are assets serviced?
Figure 1
Activities associated with field sales/services vs. asset service
Figure 2
Locations associated with field sales/services vs. asset service
17
Differences in roles and processes are

a very clear factor in distinguishing
between field service and asset service.
However, environment is equally
important. The environment where work
happens (see Figure 2) determines not
just safety requirements and key data
that must be collected and monitored,
for example. It also impacts the decision
process for planning how to optimally
allocate, assign and ultimately dispatch
resources, whether for long-term capital
projects or shorter-term activities.
Often, much of the asset service
decision-making process revolves
around getting a person or resource
from point A to point B, even in a
mine, or when a field worker may
be permanently assigned to a large
facility, where access to an asset is
only possible on foot. In such cases,
the street route optimization tools and
algorithms in a traditional field service
solution will not work. Furthermore,
tracking must be performed by LAN,
rather than by WAN or satellite.
Job length and whether the worker can travel by

automobile or must travel across regions by air
or rail, will also impact resource scheduling and
routing. The physical tools required for a job are also
affected by environment.
The worker in a mine working on a large repair will
undoubtedly have different requirements than the
worker suspended over a high voltage cable 100 feet
up, or a worker in the control room in a pump station.
All these factors add to the complexity of decisionmaking around the service activity (Figure 3).
Figure 3
Decision Compexity for field service

vs asset service events
The line between a remote worker assigned to

relatively few jobs and an apparently single location
(high degree of job process complexity), and a
highly mobile worker moving from one job site to
another (comparatively lower degree of job process
complexity) may not be seen as important in some
service organizations.
Failure to recognize the different levels of complexity
associated with these processes, and how that
relates to support mobile workers (Figure 4), often
results in attempts to solve different problems with
the same tools; the wrong tools.
Figure 4
Process Compexity for field service

vs asset service activities
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When are assets serviced?

Assets in the previously mentioned industries
typically have very long lives. For example, utilities
on average plan for 40-year life cycles. This will
vary, of course, by region, private vs. publicly owned
enterprises, and whether the utility is vertically
integrated or not.
Mining assets typically are shorter-lived but their
life cycles are far more intense and the struggle to
prolong their lives is a daily challenge. Bridges and
roads can have life cycles of 100+ years, but they
are continually evolving.
Assets with shorter life cycles do not require the
repetitive rigor and depth of service characteristic of
those with longer lives (Figure 5). Field automation
in asset intensive contexts thus requires intelligent,
process-based applications that are designed
to support and prolong the life of the complex
applications being serviced.
Optimized planning tools, utilizing this field data,

are required for scheduling all these activities, and
fitting and balancing planned and reactive work
over the life of the asset, whether project-based or
task-based.
Figure 6
Similarly, the service cycles for complex assets

are longer and more complex (Figure 7).
Exhaustive inspection and maintenance routines
and plans are required to preempt failures.
Figure 7
Figure 5 Asset life cycles characteristic of
field services vs asset services
18
The planning cycle for asset service vs. field

service is likewise far longer and more strategic in
orientation (Figure 6). It is premised on optimizing
the productivity of the asset over the course of its
life. This requires continual, relevant and accurate
data collection in the field about those assets and
the resources that service them.
Planning cycle lenght for field service

vs asset service
The time required to physically work on a particular asset

is usually considerably longer given the complex nature
and potential size and location of the asset.
Working on an excavator in a shaft, or a power line on a
remote ridge, or a high voltage track in a tunnel, requires
greater, care and preparation, and effort than field
service activities (Figure 8). Yet the pressure for timely
resolution and task completion never goes away.
Figure 8
On-site time for field service

vs asset service
The criticality of a failure, and the impact and cost can

be enormous in scale for complex assets (Figure 9).
Seconds of response time can translate into millions of
dollars, and potentially lives, saved or lost.
Service cycle Compexity for field

service vs asset service activities
This requires intelligent, process-based

applications to enable field workers with all the
steps, guides, knowledge and tools to perform
their jobs safely and effectively for each type of
activity required to service the particular asset,
with all its unique requirements.
Unlike typical field service tasks, asset service
activities can last for days, weeks or months,
with workers often having to go back and forth
between multiple assets simultaneously.
Figure 9
Criticality of response time for field

service vs asset service
The demand on automated solutions is thus greater in

an asset intensive organization. Scheduling and dispatch
solutions must work in real time.
Mobile applications must contribute to the job at hand
and not introduce administrative obstacles in the field.
The mobile worker already has too many tools and
variables to contend with while doing their job.
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How are assets serviced?
19
As previously mentioned, working conditions

are often unsafe, volatile, and remote in asset
service contexts. Comprehensive safety checks,
procedures and equipment are required before
work can even start, and very specific safety
steps must be taken throughout the entire task,
and even after the work is completed.
These can be specific not only to the asset, but
to its location and condition at the time. There
can be no guesswork. These are prescriptive
and precise actions. A simple universal form or
checklist will simply not do.
Complex assets can require multiple readings,
measurements and diagnostics. These can be
manual in nature or be electronically collected.
The results must then be processed, usually in
real-time in the field, in order to continue work on
the asset in question.
The diagnostics required often differ from asset to
asset and task to task.
An application utilizing or supporting these
results must be able to work with all the possible
permutations and know which rules to apply and
when. A monthly reading, for example, may not
be relevant or may be used different than the
same reading during a weekly inspection.The
tasks required to inspect, repair or maintain an
asset are typically decision branched.One reading
or result will often result in a unique or different
step or action than another reading or result.
Workers often can only be dispatched to an asset,
or even just a location, and once there have to
locate and identify the problem. Going back for additional

tools, information or resources may not be an option. Thus,
they require a comprehensive knowledge base in their
hands to independently and successfully complete their
work on-site.
Most often the work must be performed while the asset is in
full or partial operation, or the asset must be brought down
and be bypassed with another temporary asset or process.
The slightest failure can bring down an entire operation
and result in millions in operational production losses and
collateral damage to the rest of the physical operations.
Refineries, for example, cannot go down. A stoppage
would not just interrupt flow, but actually require a system
purge; or worse, damage a part or cause environmental
contamination.
Individual field activities can range from very mundane data
collection and simple parts runs to complex engineering
exercises and precision machining. In some operations,
field activities can be highly specialized and assigned only
to specific individuals who do nothing but that. However,
in other operations, a single individual or crew must be
able to perform multiple activities, as in the case of drilling
crews who perform maintenance and repair on the very
machinery they use.
Interdependencies between tasks and individuals are
probably the greatest area of complexity in scheduling
asset service. Internal and external resources must
very often be scheduled and coordinated in a particular
sequence to perform their work. Replacing or upgrading a
power pole, for example, may require coordination with a
government agency, construction and installation by a thirdparty contractor, surveying and engineering services, and
inspection and activation by an internal team.
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Worker Productivity
(Cost Efficiency)
Who services assets?
20
Asset intensive organizations employ

human resources with a high degree
of variability in skills, disciplines,
certifications, clearances, languages,
etc. In asset intensive organizations,
these attributes are often asset- and
task-specific. When any one of these
is scarce, individuals must be carefully
scheduled so that when those attributes
are called upon, a bottleneck does not
occur. Any one individual cannot become
the critical path for an entire organization.
But often these attributes may be entirely
absent, particularly as workforces age
and assets evolve, and for that reason,
automated solutions in the field must
provide the knowledge, direction and
tools in hand for others to pick up the
activity. Waiting for people to be certified
or trained is sometimes simply not an
option.
Lines blur between degreed engineers,
skilled machinists, certified operators and
specialized technicians. In field service
organizations there are often distinct
white-collar and blue-collar activities and
corresponding software solutions. In an
asset intensive organization, making that
distinction is typically not possible.
For example, in the heavy equipment
industry, engineers are called out to
work on state-of-the-art turbines on oil
platforms or remote desert regions. They
require software expertise and machining
skills, and may actually have to build
their workshops out of mud, discarded
corrugated steel sheets, & timber from

surrounding forests. What kinds of solutions
might this individual need in the field?
Some individuals work alone, others only
as members of a crew, and yet others
will bounce between crews and individual
assignments as needed. The more complex
the asset, the more likely it is to require a
crew with multiple individuals with different
tools, abilities and resources to get the
particular job at hand required. In some
cases a crew leader maybe the only one
recording data in the field, and in other
cases, every crew member may be using or
updating a particular piece of data.
Key Drivers for Asset Service

Organizations
The pressures and objectives of a field
service organization vs. an asset intensive
service organization are not mutually
exclusive. In fact, field service organizations
usually do service assets, whether they
are consumer HVAC units, commercial
facilities, or medical equipment in hospitals.
The factors that impact the decisions,
tools and processes are often the same.
The difference is in degree and emphasis
(Figure 10).
The relevance and weighting of these
factors varies by industry, of course; and the
field automation needs of these industries
will vary accordingly. Figure 11 illustrates
these needs for a mining operation where,
for example, ore production is the most
important driver for a precious metals
enterprise.
Asset Productivity
(Uptime/Service Life)
SLA Compliance
Regulatory
Compliance
Public Safety
Worker Safety
Social & Environmental
Stewarship
Emergency
Response
Note: Both B2B and B2C considered in relative weightings.
Figure 10
Asset Productivity
( Mines & Equipment)
Driver relevance for asset service vs field service
Maintain / Increase Rate of Ore Production
Production
Data Accuracy
Reduced Costs Associated with Under & Over reporting of Ore Production
Worker Safety
Reduced Cost of Civil Litigation, Insurance, Fines, Lost Productivity
Compliance
Worker Productivity
(Varies By Ore Type)
Reduce Regulatory Fines for Violations

Reduced Cost of Field Operations
Cost / Benefit Priority
Figure 11
Priority to business value for asset service in

precious metals mining
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Asset Service
Field Service
Go To Last Page
Figure 12
21
Priority to business value for asset service in an energy distribution utility
Figure 12 illustrates these priorities for an energy

utility on the distribution end of the supply chain.
The weightings would naturally vary for transmission
and generation businesses.
In asset intensive organizations, safety and service
obligations to the public, employees, regulatory
agencies, and other stakeholders are often a
far greater priority than in typical field services
scenarios. The vast majority of mobile solutions
fail to take these priorities into account, and focus
instead on financially-driven factors like cost of
service delivery, worker efficiency, compliance
with Service Level Agreements, and so forth. Of
course utilities, municipal governments, and other
organizations managing complex assets want to
save money but never at the cost of safety or

service quality. In precious metals mines, similarly,
the focus is on mine productivity and ore output
rather than worker efficiency and other field
service priorities.
Sample Statements
The following are sample statements that may

describe your service organization. If your
enterprise is asset intensive, it requires more than
just a traditional field service solution or mobile
technology.
What you do when you get to the job is more
important than how fast you get there
Mobile technicians maintaining geographically
distributed linear or network assets like roads
and pipelines, or complex assets in remote locations like

mine sites, etc., often travel 50 kilometers or more from
job to job. Other mobile workers operate in environments
like open pit mines where it is vital to travel at a safe,
consistent speed. Shaving down time and fuel costs is
relevant in these environments, of course, but not critical
compared to finding a safe route, for example.
Getting it done right is more important than getting
it done fast
Depending on the assets involved, KPIs for reducing
job duration potentially put quality and ultimately
the safety of the mobile worker, the public, and the
environment at risk. Maintenance and other work in
asset intensive industries often spans days, weeks, and
even months. Crews may be quite large and diverse,
and the skills required can change constantly. In these
dynamic situations faster doesnt mean better, or is
not as important as being able to work on multiple jobs
simultaneously.
Compliance is more important than commerce
For heavily-regulated, asset intensive businesses like
utilities and regional governments or local councils,
compliance with safety and environmental regulations
can vastly outweigh the commercial or financial
imperatives that drive for-profit corporations. Fines
levied against governing bodies for non-compliance
can be staggering. Operations like oil refineries, where
asset management failures can pose major safety
and environmental hazards, could be shut down for
culpability in a disaster. No efficiencies gained through
typical mobile technology applications can compare
to the magnitude of addressing these concerns by
fundamentally embedding risk management in the
mobile solution.
AMMJ
May 2013
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The quality of your asset management program

directly impacts public safety
Organizations maintaining transportation assets that
serve and convey the general public, like roads,
rail, tunnels, and bridges, are charged with a level
of quality assurance far beyond what typical field
service workers need be concerned about. Might a
bridge collapse or a passenger car derail on your
watch if your mobile workforce doesnt do its job
well?
Preventive maintenance is vital to your asset
management strategy
Some enterprises can afford to operate in a breakfix mode; others must maximize asset uptime as the
highest priority. Frequency of proactive inspection
may even be regulated. If your organizations
sole purpose is to deliver uninterrupted power or
water or transport capability with zero safety or
outage issues then you know how vital preventive
maintenance can be.
Ensuring you have the right skills, tools,
materials, and information at a job is a
significant challenge
Asset intensive service organizations might work
with tools worth thousands of dollars, and consume
items from tiny o-rings to a 10-ton generator. Mobile
workers may need on-demand access to the latest
manuals and service bulletins, as well as asset
maintenance history and other data from the EAM
system. The mobile solution must help ensure that
the right people with the right skills and the right
tools need to be at the right job site at the right time,
because making do with whats at hand isnt an
option when it may take hours or days to get to the
asset site.
22
Capturing, maintaining, and utilizing data

in the field is as important as effectively
performing the work
If youre restocking vending machines or changing
HVAC filters, youre interested in capturing
basic key performance indicators (KPIs) on how
fast you were able to deliver the merchandise
and perform the work. But if youre working on
complex assets in demanding environments like
mines, tunnels, or bridges youre much more
interested in capturing and leveraging detailed
information about the location and condition
of assets to improve the overall asset lifecycle
management process
Conclusion
Asset intensive industries have been
underserved for decades with solutions and
mobile technologies designed for field service
organizations. The following recent trends are
forcing these industries to take a fresh look and
seek mobile solutions that address their unique
pressures and priorities:
Reduced revenues and sources of capital due to
the global economic crisis
Aging workforces and employee turnover
increasing the need for knowledge-based
solutions in the field
Aging infrastructure and increasing demand
forcing enterprises to move from reactive to
preventive maintenance
Environmental trends promoting a need for field
optimization and best practices to reduce carbon
footprints
New green segments in energy-related
industries demanding new work forces, new
skill sets, etc.
Increasing public scrutiny forcing increasing and

changing regulation, particularly in developing
countries where health/safety/ compliance
previously was less of a consideration
Increasing regulation/compliance requiring
repeatable and reliable processes in the field
Growth in non-traditional business lines (for example,
consumer energy related products and offerings)
Increasing security demands Smart Grid technologies
Asset service organizations must thus increasingly seek
mobile asset service solutions that enable their field
operations to:
Detect required maintenance actions earlier, to
increase proactive work and reduce reactive work
and associated costs
Respond more quickly to events without undermining
the preventive operations
Know the locations and availability of maintenance
resources, including people in real-time
Allocate resources more effectively for quick response,
including safety emergencies
Respond more organically to changing priorities
Better enforce safety standards
Greatly reduce the risk of catastrophic asset failure
Comply with regulatory & legal requirements more easily
Prolong asset longevity
Ensure operational continuity
A mobile solution designed specifically for asset service
can pick up where traditional mobile field service solutions
stop, to fully meet the needs of asset intensive businesses.
About Ventyx
Ventyx, an ABB company, is the worlds leading supplier
of enterprise software and services for essential industries
such as energy, mining, public infrastructure and
transportation.
www.ventyx.com
AMMJ
May 2013
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Listing of Condition Monitoring

Products and Services
Apt Group
(of Companies)
The 2013 Listing of Condition Monitoring (CM) Products and Services was compiled by
Len Bradshaw (May 2013). The data given is as received from the respondents.
info@aptgroup.com.au
Web Page: www.aptgroup.com.au
Condition Monitoring Products
Alstom MSc
sales.msc@alstom.com
www.alstommsc.com.au
24
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:
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
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.
The apt Group (of Companies) has Exclusive

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 hightech 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.
SPMHD 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.
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.
AMMJ
May 2013
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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 and
pocket sized instrument for measurement and
evaluation of bearing condition. The VibChecker
provides fast and cost effective on-site vibration
measurements and assessment, whereas 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.
ALL-TEST ProTM
25
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 offline static impedance based testing instruments,
assess the condition of AC/DC motors, providing
in-depth analysis of the motor circuits - turnto-turn shorts, open turns/coils, reversed coils,
coil-to-coil shorts, connection defects, air gap
defects, rotor defects - broken bars, eccentricity
and casting voids.
Electrical Signature Analysis (ESA) instrumentation for complete on-line dynamic
Motor/Power Diagnostics.
Guide Infrared Cameras
For Predictive Maintenance; Research

Development; Machine Vision and Surveillance.
APIPro Asset Management Software &

APT Asset Performance Tools
For managing resources; scheduling activities;

tracking performance; calculating and optimizing
asset performance.
Condition Monitoring SERVICES
The apt Group (of Companies) is an

Independent Engineering Consultancy
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:
Mechanical Discipline
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.
Support Services
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.
Bearing monitoring
as youve never seen it!
...
Immediate evaluation in
Utilised in bearings operating from
1 RPM 20,000 RPM
Removes irrelevant signals
Crystal clear root cause analysis
Razor sharp spectrum and

time signal
For full specifications & product brochures visit aptgroup.com.au

or call our friendly sales team on 1300 700 002.
Technology
RESELLERS WANTED
AMMJ
Part of the apt Group
May 2013
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Aquip
Systems P/L
sales@aquip.com.au
www.aquip.com.au

PRFTECHNIKs 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 a 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.
ON-LINE: Machine protection and Vibration Analysis
26
VIBNODE, VIBROWEB XP, VIBROWEB, VIBRONET SIGNAL

MASTER :
Intelligent machine monitoring systems that can perform
measurements, evaluation, archiving & alarm warning. Very-fastmultiplexer 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.
FLUKE
Australia
sales@fluke.com.au
www.fluke.com.au
VIBGUARD
NEW 20 channel synchronous on line system. Never miss
a second of data. This system uses the new Vibguard Viwer
software and is perfect for monitoring of complex machines. It is
constantly collection data on up to 20 channels
Prftechnik 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, multi-coupling,
and bore alignment.
Intermediate and Entry Level: Because one size does not fit
all!
OPTALIGNsmart RS and SHAFTALIGN incorporate a range of
Prftechniks 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!
Aquip Systems provides expert ongoing condition monitoring

services as well as ad-hoc machine diagnosis. We provide a
range of training courses to suit all experience levels. Condition
monitoring and laser shaft alignment courses focus on
theoretical aspects and practical applications to suit the clients
site requirements. We also operate the sole PRFTECHNIK
certified service centre in Australia, and are fully equipped to
carry out services, repairs and calibration checks (calichek) on all
PRFTECHNIK equipment.
A Fluke thermal imager can save time and money by finding

potential problems before they become costly disasters.
With Flukes NEW Ti100 Series range you can efficiently
inspect an entire facility for hidden issues or monitor a
thermal process frame-by-frame.
Flukes imagers immediately make you more productive, so
you spend less time finding problems and more time solving
them. The revolutionary IR-OptiFlex focus system helps
you perform industrial, electrical and mechanical inspections
significantly faster than ever before.
Following Flukes over 60-year heritage of making the
worlds finest test tools, our new industrial imagers are the
lightest, most rugged, easiest-to-use professional imagers
on the market.
Six innovations with Fluke Thermal Imagers that make
your job easier:
IR-OptiFlex focus system
Discover issues significantly faster with Flukes revolutionary,
ultra-rugged focus system. The IR-OptiFlex focus system
gives you optimum focus by combining focus-free ease-ofuse with the flexibility of manual focus on the same camera!
IR-Fusion technology
Enjoy the industrys only point-and-shoot IR-Fusion camera.
Fluke patented technology blends digital and infrared
images into a single image to precisely document problem
areas.
Rugged one-hand operation
Experience the most rugged and reliable, lightweight
professional camera around. One-touch focus, laser pointer,
and torch. Point-and-shoot simplicity
Multi-mode video recording
Troubleshoot with the industrys only thermal imager that
records focus-free video in visible light and infrared with full
IR-Fusion capabilities. Easily download to PCs for video
viewing and analysis.
AMMJ
May 2013
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IR-PhotoNotes annotation system
Get an exact reference to your problem area
by capturing up to three digital photos per file
Electronic compass
Make sure you and others know the location
of the problem. Compass readings easily
appear in images and reports.
Take a vibration expert along
Fluke redefines mechanical 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 Fluke 810 is designed specifically
for maintenance professionals who need
to troubleshoot mechanical problems
and quickly understand the root cause of
equipment condition.
Not to mention the NEW 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.

27
Thermal Imaging and Troubleshooting Motors

and Drives training courses run throughout
the year by Fluke Australia.
FLIR
Systems
Australia
info@flir.com.au
www.flir.com/thg
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 includes:
The low cost, powerful little revolutionary FLIR i3,

producing snapshots of temperature differences
equal to 3,600 readouts from a single spotmeter with
the i5 and i7 producing even more.
The ground-breaking FLIR E-Series extends
performance and affordability with features like
Bluetooth and industry-first Wi-Fi connectivity,
3.5 touchscreen and iPhone/iPad /Android using
the FLIR Tools Mobile App. Add to this MeterLink,
the pioneering wireless connection from FLIR, that
connects your infrared camera with your ClampMeter.
The FLIR T-Series offers an optimum mix of
ergonomics and flexibility and also has class leading
features of touchscreen, Bluetooth and Wi-Fi
connectivity to iPhone/iPad/Android using the FLIR
Tools Mobile App. The T400-Series provides
advanced performance and features required by
professional thermographers. Whilst the T600Series are the best available industrial thermography
systems, which take quality of image to a whole new
level and have a long list of impressive features,
including GPS, continuous focus and the new MSX
(multi spectral imaging) feature.
FLIRs 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 FLIRs
thermal imaging camera systems can work
more efficiently and productively by utilising
the most professional camera-software
combinations.
FLIR Quality infrared viewing windows.

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 or rent an infrared camera
from FLIR, it comes fully guaranteed, and
Thermal image
with MSX
now many FLIR cameras are eligible for

coverage under FLIRs industry-leading
2-year product and 10-year detector
warranties*.
( * Terms and conditions apply )
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 FLIRs
ITC course.
The Infrared Training Center (ITC) offers
the worlds leading infrared training and
thermographer certification programs.
Thermal image
without MSX
NE
New FLIR T-Series.

Its got the X-factor.
FLIRs new top-of-the-line T-Series thermal imagers
for building, electrical and industrial have the X - factor
built in the MSX factor. Innovative Multi Spectral
Dynamic Imaging (MSX) provides exceptional real-time
thermal imagedetails.
Extremely detail-rich MSX images mean anomalies can
be detected faster. Analyses can be more detailed.
Conclusions drawn in a split second.
FLIR T-Series. High performance.
Affordable Price. X-factor built in.
FLIR Systems Pty Ltd. 10 Business Park Drive, Notting Hill, Victoria 3168, Australia
Tel AU: 1300 729 987 NZ: 0800 785 492 Email: info@flir.com.au www.flir.com
Disclaimer: Images for illustrative purposes only. Specifications subject to change without notice.
AMMJ
May 2013
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ISO No. FLIR20859

Mobius Institute
Machinery Vibration Specialists Aust P/L
mvsaust@ozemail.com.au

www.machineryvibrationspecialists.com.au
MVS Aust P/L is a specialist company
supplying products, support services and
technical training for the maintenance and
repair of rotating machinery.

SPM Instrument - AB of Sweden
28
Originator of the True Shock Pulse Method

for bearing measurement & analysis.
Innovator of the NEW SPM HD for low speed
(1 to 20,000 rpm) bearing measurements.
BearingChecker Low cost, pocket, bearing
measurement & evaluation instrument.
VibChecker Low cost, pocket, vibration
instrument to ISO 10816 with FFT spectrum.
Leonova Diamond/Emerald
3 & 2-Channel Bearing/ Vibration Analyser
with Balancing,
Laser Shaft Alignment, Bump Tests, Orbit &
Lubrication Analysis
Order Tracking and Phase Analysis. SPM HD
Bearing Analysis.
On-Line Machine Monitoring and Protection
Machine Guard -- single/multi channel with
relays, Modbus, 4-20mA.
Intellinova --- Up to 32 Channels SPM HD,
vibration, analogue in/out.
Intellinova Compact --- Units with 6,12
&18 channels very cost effective
Uses SPM HD, Very low speed (1-100rpm)
vibration, analog in, 3G interface.
All designed to monitor complex machines
such as container cranes, wind generators, rolling

mills, paper machines, cement plant machinery
and mining conveyor and crushing systems.
CEMB SpA - Italy Maintenance &
Process Dynamic Balancing Machines
True Hard Bearing force measuring machines,
horizontal & vertical.
Maintenance & Production for 10Kg to 50,000Kg.
IRD Balancing LLC - USA
Maintenance Dynamic Balancing Machines.

Soft Bearing motion measuring machines,
horizontal
Transportable, from 10Kg to 200,000Kg.
Lexseco - Motor Core Loss Testers form 10 to
300KVA.
Schmitt Balancing Systems Uk
Automatic Dynamic Balancing Systems.

Automatic dynamic balancing and process
monitoring for grinding wheels.
Support Instruments.
Rayhome Ltd.------ High quality pre-cut SS shims

in packets of 10 or boxed kits.
Hilger u. Kern GmbH ----- Laser Belt Tension
Instrument & Leak Detectors.
MVS Support Services.

Instrument and machine repair and calibration to
NMI standards.
SPM CM Software installation & Commissioning
Monitor and On-Line Startup Commissioning
On-site machine trouble - shooting bearing &
vibration problems.
Vibration, Balancing, Alignment Training Courses.
Precision Dynamic Balancing service of rotors up
to 3-5Kg.
learn@mobiusinstitute.com
www.mobiusinstitute.com
Mobius Institute offers the self-paced,

computer-based e-learning iLearn
products for condition monitoring
and reliability improvement.
Products include iLearnVibration,
iLearnAlignment, and the new
iLearnBalancing. The Interpreter
product can provide analysis assistance
by examining the spectrum on the
computer screen and identifying
patterns and suggesting fault conditions.
And if you have an iPhone or Android
phone, look for the new Mobius iVibe
application.
Mobius Institute provides vibration

training courses and certification
examination according to ISO 184362. Certification is ISO/IEC 17024
accredited. Training is provided in
Australia & New Zealand via the
Vibration Institute of Australia but is
also available in 50 countries through
licensed partners. Distance learning
courses are available through Mobius
Institute. Mobius Institute training
is unique in the world; the use of
animations and simulations make the
complex topics of vibration analysis,
alignment and balancing easy to
understand.
A fast, efficient approach

to Asset Reliability Based
Management
We supply new and revised plans in
any format you desire .docs .xls, pdfs
ready to approve and load to your
CMMS. We guarantee to slash your
project costs, meet your agreed
deadlines, outcomes and start to return
your completed plans to site in less
than two weeks.
For more info, visit our website:

www.asset-team.biz
AMMJ
May 2013
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Monitran Ltd
Sensors for Industry
katherine.alger@monitran.com
www.monitran.com
29
A leader in the design, development and

manufacture of sensors and systems for vibration,
proximity and displacement measurement.
Our products include general and special
purpose accelerometers, velocity sensors, eddy
current probes and LVDTs. They are used in a
diverse range of applications including industrial
processing, power stations, water treatment, wind
turbines, mining and the oil and gas industry. As an
OEM we can also provide a full custom design and
development service.
Sensors alone do not provide the complete answer
to measuring vibration and using the data to better
understand machine health. Monitran offers a short
range of monitoring systems that can be used not
only to measure vibration but to display values,
constantly watch the levels and take action in case
of excess and dangerous vibrations.
MTN/VM220
We recently launched our new Vibration Meter
at the Southern Manufacturing & Electronics
exhibition in 2013
The MTN/VM220 conforms to ISO10816-3 and is
ideal for detecting the early signs of component
wear or failure in machinery, motors, gearboxes,
pumps and other mechanical assemblies. The
meter includes a crisp, colour LCD display and has
the ability to store up to 100 readings (temperature
and acceleration, velocity or displacement) against
a real-time clock.
Measuring just 122 x 78 x 28mm, the MTN/

VM220 has an easy-to-grip, tough rubberised
case and a long-life rechargeable battery. It is
supplied with a probe into which is integrated
a dual-output, general purpose sensor, the
MTN/2200T, which has default sensitivities
of 100mV/g and 10mV/oC. Also included are
a magnetic base and spike (for use with the
probe), a coiled cable (0.5m nominal to 2m
extended) with a 4-pin Lumberg connector at
each end, and a universal (battery) charger; all
in a foam-lined and durable carry case.
MTN/5000
The MTN/5000 system provides a robust and
reliable method of monitoring 21 channels of
vibration and triggering an alarm when userdefined parameters are exceeded.
The system comprises of 7 triaxial integrating
sensors monitoring X, Y and Z axis vibration
at 7 points, arranged into 3 zones. Each of
these channels is sampled several thousand
times per second and mean/peak values are
calculated and logged at a specified interval
(typically 1 second).
Hovercraft
The system, designed and developed by
Monitran as a turnkey solution, employs 14
MTN/1100W general purpose constant-current
analysis sensors with AC outputs, sealed to
IP68 (submersible) and supplied with marineapproved cables. These feed into a bulkheadmounted waterproof cabinet that contains 14
MTN/8066 g-mac signal conditioning units.
Each g-mac unit provides analogue (AC)
outputs proportional to velocity and peak g,
which feed into a PCB-mounted microcontroller
programmed by Monitran to drive a touchscreen display on the front of the cabinet.
Primarily a supplier of cost effective sensors, we

are steadily increasing our portfolio of project
management clients, providing sophisticated
turnkey solutions, incorporating vibration sensors
with monitoring and display hardware to integrate
with other sensor types and customer control
systems.
Our team of expert engineers and service
specialists are always on hand to help you
integrate our products into your specific project
and develop control and monitoring systems that
are built around you and your needs.
Hovercraft Vibration Monitoring System:
We were approached with a view to providing
an integrated engine and gearbox vibration
monitoring system. The brief was to provide realtime condition monitoring direct to the pilot on a
fleet of 12 vessels designed for coastguard use.
Our development team was able to

combine microcontroller technology with
well-established and field-tested sensors
to provide a tailored solution to meet this
challenging brief.
Thames Barrier Lift Control:
We were asked to design, install and
commission a system to monitor bearing
movement and gate position. Critically, the
system had to be a permanent fixture and
would required equipment to be placed
on the outer faces of the bearings where
it would be subjected to the full force of a
tidal river.
Several elements of the project required
custom-built equipment and, additionally,
we needed to assemble a team of skilled
engineers trained and certified to work in
confined spaces and on floating platforms.
helps build on success
To find out more visit www.monitran.com

Call us on +44 (0)1494 816569 or email info@monitran.com
AMMJ
May 2013
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www.ashcomtech.com
MaintiMizer CMMS/EAM Solutions

NVMS Measurement Systems
info@nvms.com.au
www.nvms.com.au
30
AMMJ
Noise & Vibration Measurement Systems

PTY Ltd (NVMS) represents only the
worlds leading manufactures - GE Bently
Nevada, Brel & Kjr S&V, Hottinger
Baldwin Messtechnik (HBM), Sensear,
FLIR Systems all available individually or
within our turn-key project engineering to
international standards.
SYSTEM 1 software platform: A unified
platform and user interface providing you
with a window into the condition of every
asset in your enterprise, regardless of
whether online or offline data sources
are used. Supports all Bently Nevada
monitoring hardware solutions.
BN 3500 machine protection and monitoring
system: Providing continuous, online
monitoring suitable for machinery protection
applications of the highest demands and is
designed to fully meet the requirements of
API 670 standard. This is our most capable
and flexible system in modular rackbased
design and is the monitor of choice around
the world for all critical machines. In
2012 the 3500 is at the 3rd generation of
hardware.
TRENDMASTER PRO DSM monitoring system

Provides online condition monitoring for all
essential machines where a safety system (incl.
relays) is not required, or where an existing
safety system is already installed. Trendmaster
Pro DSM is a cost effective way to bring highspeed online condition monitoring data into
your System 1 platform for local and remote
access to your machinery health data. Supports
also Modbus.
SCOUT; is the latest combination of vibration
Analyser, data collector and balancing and
recently added to GE Bently Nevadas product
offering. This unit is favoured by many for its
ease of use, cutting-edge features and easy
integration with System 1.
HBM Hottinger Baldwin Messtechnik: HBM
German based company is well known for
60 years experience in manufacturing strain
gauges and providing highest reliability in data
acquisition solutions.
HBM offers an extensive knowledge and
product range for structure analysis and
monitoring from Sensor to Report. This includes
also transducers like pressure, force, torque,
load cells plus a huge range of measurement
products like data loggers and amplifiers for
laboratory and field applications.
HBMs recently introduced fiber optic
strain gauges which can be used in harsh
environments from subsea, Civil Engineering,
Mining Industry plus O&G for pipeline
monitoring - even in hazard areas.
SENSORS and Accessories: for the various
diagnostic & monitoring tasks we have over
1000 products available including a large range
of transducers: accelerometers, velocity

sensors, displacement probes, microphones,
strain gauges, torque sensors, load cells etc.
Thermal imaging cameras
Flir: The world leaders in thermal imaging.
Get a GRIP on Your

Maintenance Department

At NVMS we have developed our service
and project support reputation through close
partnerships with our highly valued clients
and suppliers.
Each customer has unique requirements, so
the one size fits all concept simply doesnt
apply here. We provide extensive full circle
service and support packages that closely
match the specific requirements of a wide
range of industries and machines, and these
can be easily fine-tuned to our customers
specific application. We are listening!
Instrumentation for machine protection and
conditionbased monitoring
Support and implementation of predictive
maintenance strategies
Engineering and design
Project management
Performance monitoring solutions
Installation and commissioning support
Test and measurement solutions for
structure analysis and durability
Service and products in all industries
including O&G, Power, Mining.
Industry recognised and certified training
courses tailored to your requirements in our
own training facility in Perth.
NATA accredited calibration laborator
Whats Missing in
Apps-One
Pty Ltd is your
Your Tool Bag?
one-stop Australian
engineering app shop
The team at Apps-One have

developed an engineering
app designed to run on
iPad, iPhone and Andriod
systems.
A simple smart phone and
iPad app for technicians to
use remotely in the field.
www.apps-one.com
May 2013
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www.pwc.com.au/assetpartnership
PWC
Asset Partnership
Simple, effective
condition
monitoring
Full Page Advert
PwCs The Asset Partnership

Stephen.young@au.pwc.com
www.pwc.com.au/assetpartnership

Artesis MCM is a new approach to
condition monitoring, providing all the
benefits without the high complication
and cost of traditional systems.
Artesis MCM monitors the condition of
equipment driven by an electric motor,
effectively using the motor itself as a
sophisticated transducer. It requires only
connection into the motors electrical
supply, avoiding the need for specialised
sensors. Because Artesis MCM is
permanently installed, it provides
continuous fault monitoring and does
not depend on expensive manual data
collection. Artesis MCM uses advanced,
NASA-developed technology to provide
a self-learning capability in a compact,
affordable, panel-mounted instrument.
It automatically teaches itself about the
normal operation environment of your
equipment so that it can accurately
identify and diagnose faults long before
they become a threat. This greatly
reduces the specialist diagnostic skills
required of the user, making the benefits
of condition monitoring available to

many groups who have considered it
too difficult in the past.

Two services are provided:
Option 1
Is to purchase the Artesis MCM unit
and install. We provide installation and
commissioning support and training to
ensure you obtain the best result from
the installation of the equipment.
Option 2
Enables a complete outsourcing of
the condition monitoring of selected
equipment. Under his option, the
selected equipment is monitored
24/7 from our office and we provide
a monthly executive summary report
on the condition of your equipment.
In the event a problem is identified
we immediately contact the owner
of the equipment with warning of
the impending problem and advice
upon the urgency of action together
with a detailed report on the fault or
impending fault condition.
Artesis MCM is a new approach to Condition Monitoring,

providing all the benefits without the high complication
and cost of traditional systems.
Simple to install and use
Continuous monitoring and fault detection
Reliable automated fault diagnosis
Connects with other systems
Cost effective for widest range
of equipment
We Want Your Articles, News & Research Papers

NA
GY
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DEV ELO
May 2013
Contact: Stephen Young | PwCs The Asset Partnership

(+61) 2 8266 0442 | stephen.young@au.pwc.com
T EC HNO
AMMJ
ED
31
From a half page news item to a dozen paged article or even a

30 page research thesis. Be a regular contributor to the AMMJ.
Send to mail@maintenancejournal.com

SKF Australia
R.S.Senthil.Vel@skf.com
www.skfcm.com/reliability
32
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
SKFs On-line surveillance systems complement the use
of periodic data collection instruments, facilitating a roundthe-clock monitoring of machinery that collects data 24
hours per day, 7 days per week from permanently installed
sensors.
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 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.
6. 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.
7. 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.

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
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.
AMMJ
May 2013
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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. 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.
33
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 SIUIs NDT products,
including their CTS-4020E Flaw Detector,
SUPOR Phased Array Flaw Detector, CTS703 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.
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 - express shaft alignment system.
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-Meters 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.
C-Cubed Vibration Meters
C-Cubed manufactures and supplies a
complete range of low cost, high performance,
easy to use vibration analysis tools for
maintenance engineers. The Vib Meter 320
is a simple to use, low cost vibration meter
that records, analyses and displays vibration
signals at the push of a button.
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
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
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.

Vitech Reliability provides the following service:
Product, VA and Alignment Training (class room
& customised on site)
Installation & Commissioning of systems
Do you run a complex erp but still

publish Data in a spreaDsheet?
mainstaysoftware.com.au
AMMJ
May 2013
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8% Operational Efficiency
Improvement
at Griffins
The Analysis:
Ganesh Natarajan Business Manager

SKF Asset Management Services
www.skf.com.au ganesh.natarajan@skf.com
SKF deployed the assessment process SKF CNA-AM to

initiate the analysis. The process analyses 40 unique aspects of
Asset Management and compares the site to industry averages
and industry best practice. Depicted as a spider chart, the
process facilitates identification of key deficiencies and enables
formulation of a targeted improvement plan.
Griffins, Papakura embarked on an Asset

Management Improvement journey with
support and assistance from SKF Asset
Management Services. The site achieved:
Engineering Downtime reduction of
4.0% and
OE improvement of 8% [65% to 73%]
Return on Investment for the project
was 860% [or 1.25 months].
Key deficiencies were identified from

the SKF CNA-AM process and were
analysed for suitable solutions. Identified
solutions were further prioritised based
on the expected impact and ease of
implementation.
Solutions that were assessed to have a
high level of impact and required lower
level of implementation effort were
assigned a higher priority. This low
hanging fruit approach provides quick
wins and generates support and traction
for the improvement project
The Holistic Solution Package

A range of aspects need to be effective
and functional for a Maintenance driven
Reliability/OEE enhancement program to
succeed.
As a minimum this will require the
right task to be executed at the right
frequency with right skills and knowledge,
procedures, documentation, specifications,
fits, tolerances and the right methods,
spares, tools, etc.
Further robust and functional work
management, planning, spares
management and skills management
systems and processes are essential to
support this outcome.
The Requirement:
34
The low hanging fruit
Griffins Foods is a Food & Beverage

manufacturer based in New Zealand. Griffins
tracks Operational Efficiency [OE], which is
the product produced against the theoretical
maximum production rate (TMP) the line is
able to produce at 100% speed.
In mid 2011 Griffins, Papakura expressed a
clear requirement to reduce their unplanned
Engineering downtime, reduce waste and
enhance OE. SKF Asset Management
Services was engaged to assist and support
them in this process.
AMMJ
May 2013
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For Griffins, Papakura, based on the SKF

CNA-AM analysis, the phased holistic
solution package was made up of the following
initiatives:
Phase 1
Maintenance Strategy review
RCFA Training & Mentoring
Phase 2
Technical Training
Task Documentation
Task specific Tools
Task specific Training
Mentoring
Optimise Work Management
Optimise Planning Process.
Phase 3 (potential)
Operator Driven Reliability
SPARO - Spares Rationalisation &
Optimisation
The Business Case, ROI
35
AMMJ
Site data was analysed to estimate investment

required for successful implementation of the
holistic solution package and potential gains
from the same.
The achievable gain was estimated at 5.1%
improvement in OE. Through application of
business metrics this was translated into
financial gain.
The estimated ROI for the project was 500%
[or 2.0 months].
The ROI % is calculated as
(Gain Investment)/Investment.
Investment/Gain X 12 provides ROI in months.
Griffins approved the project based on the
business case.
The Delivery and Implementation

Elements of the approved holistic solution
package were delivered in a phased manner.
1. Maintenance Strategy Review:
SKF SRCM process was applied to
generate the Asset Management Program.
This streamlined RCM process, while true to
the fundamentals of classical RCM, is able
to significantly optimize the effort required to
deliver similar results.
SKF AMST software tool was used to
conduct the analysis. With its builtin
templates for Failure Modes, Effects and
Tasks, the tool further reduces the effort
required to complete the analysis.
This unique combination of process and tool
delivers a quality solution at optimal cost.
Asset Register:. Collate existing
information on site, address gaps, populate
information as required, set up and establish Asset
Register
Criticality Matrix: Discuss with Griffins and identify
key business risk areas, domains, and associated
severity descriptors. Design Criticality Matrix based on
the same in SKF AMST tool.
FMECA: Assess and assign Failure Modes, Failure
Effects, and Asset Criticality for all assets and Failure
Causes for critical assets.
Maintenance Program: Generate Maintenance
program based on a structured analytical process for
critical assets and an empirical process for non-critical
assets with input from SKF application and industry
experts and site maintenance teams as required.
Process Review & Submission: Review criticality
assessment and Task assignment with site team.
Discuss and agree on anomalies. Update Maintenance

program as required. Submit in a suitable format for
CMMS upload.
2. RCFA Training & mentoring:
A combination of Ishikawa and 5-whys processes was
introduced on site. Site teams were provided awareness
training on the same. Selected Reliability Engineers
were further supported through one-on-one mentoring
sessions to conduct RCFA.
3. Technical Training:
Site team members were taken through a technical
assessment using the SKF TNA process. The process
queries the candidates on 8 aspects of Maintenance
execution and provides each candidate with their
personal skill profile. This profile is compared to a trade
profile average [e.g.: Fitter] as well as industry best
practice.
May 2013
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Skills and knowledge deficiencies were identified

through this process. Targeted technical training
programs were developed and delivered to the site
teams.
4. Task Documentation:
The output of the MSR was analysed. Similar/
repeat/complex tasks were identified and standard
Job Plans were developed for selected tasks.
The Job Plans typically address Pre-start checks
including Hazards, JSA/WMS, Isolation, Permits,
PPE, etc. Further the Job Plan provides detailed
Work procedure with specifications, fits, tolerances
and spares & tools required to execute the job.
5. Task specific Tools:
Tasks were assessed for any special tools required
for effective execution of the task were identified
and procured. Site teams were trained on proper
use of these tools.
6. Task specific Training:
Site team was further provided with Task specific
training addressing the use of right methods, tools
and information in executing the task.
7. Mentoring:
Team members were mentored by walking the
task with them, more than once, to ensure that the
task can actually be performed, the new methods
are well understood and the undesirable legacy
practices have been discarded.
8. Work Management & Planning Process
Optimisation:
Progressing through the project, deficiencies in the
Work Management and Planning process became
evident. The predictive and inspection tasks
from the maintenance program were effective in
identifying emergent work. But these work requests

were not being effectively processed through the
system.
The work management and planning processes
were analysed in depth, workshopped with key
stakeholders and the process and structure optimised
to bridge identified gaps.
The Outcome:
As the project progresses a snap shot of Griffins,
Papakura status, as of March 2013, indicates the
site tracking at 73% OE; up from 65%. The site has
experienced a
Engineering Downtime reduction of 4.0% and
OE improvement of 8% [65% to 73%]
Return on Investment for the project was 860%
[or 1.25 months].
Acknowledgements
The author wishes to acknowledge the contributions
from SKF and Griffins teams without which such
a positive outcome on such a challenging project
would not have been possible.
In particular:
Adrian Coleman, Group Engineering Manager,
Griffins Foods Ltd., for his vision and courage of
conviction in embarking on this journey.
Steven Hall, Reliability Engineer, SKF Asset
Management Services, for his passion and
dedication in making it happen
36
AMMJ
May 2013
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Len Bradshaw is
available to present
these seminars
anywhere in the
World
The Seminars are presented by

Len Bradshaw
Len Bradshaw is a specialist in
maintenance management, maintenance
planning/control and asset management,
with over 35 years of experience in these
fields.
As the Publisher of the AMMJ he keeps
in touch with World leaders in the
fields of Maintenance, Reliability and
Asset Management. He has worked in
Maintenance and Plant Engineering in
Europe, Asia, Africa and Australasia.
Len has a Masters Degree in
Maintenance Management from
Manchester University (UK), he helped
create the Maintenance Management
programs at Monash University
(Australia) and also was a member of
the panel for the Australian Maintenance
Excellence Awards.
37
AMMJ
For your company,

or government
department.
or
Add one or both of
these seminars to your
Conference
For example in April 2013
Len Bradshaw presented, to
a group of 39 attendees, the
Maintenance Management
Seminar at the Beyond
Maintenance Conference in
Malaysia.
The Remaining
Public Courses In Australia
Adelaide
Darwin
Gladstone
Maintenance
Seminars
Planned Maintenance
The Why, What, How & Who Of
Maintenance
Moving towards better asset
performance, better maintenance,
better reliability
& asset management.
13 - 14 May 2013
16 - 17 May 2013
20 - 21 May 2013
Download the full Maintenance Seminars Brochure from
www.theammj.com/MaintSem2013.pdf
Who Should Attend:

Maintenance & Reliability Engineers, Managers
and Contractors. Maintenance Planners
Maintenance Supervisors, Technicians.
or Email:
mail@maintenancejournal.com
May 2013
Go To Contents Page
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Why, What, How & Who Of

Maintenance
1 Day Seminar
This seminar introduces the wide range of Maintenance Management activities

and techniques that may be applied within your organisation and the contribution
Maintenance can make to improved service, performance and profitability. It is
important to have an understanding of what can be done and what can be achieved.
Why good maintenance is so important, What different ways we can do

maintenance. How we plan and do maintenance. How we monitor machine
condition. How we organise parts and materials. Who does the planning, the
maintenance work, the reporting and history - and the skills required.
1 Consequences of Good or Bad
Maintenance
The direct & indirect costs of Maintenance.
The real cost of failures & cost of Downtime.
Identifying/recording real maintenance costs.
Short term and long term impact of
insufficient resources in Maintenance
2 Maintenance Activities
Emergency, corrective, preventive,
predictive, condition based, and Proactive
maintenance.
Fixed time replacement of components.
Understanding failures in maintenance.
The different failure types and how they
affect what maintenance should be used.
What maintenance is needed. Basic rules in
setting inspection and PM frequencies.
Introduction to maintenance plan
development.
3 Maintenance Planning
Maintenance Planning and Control
Coding, inventory and asset registers.
Asset technical databases. Rotables.
Asset and task priority or criticallity.
Maintenance requests. Quick work request.
A PM becoming a Corrective task.
The small job.
Backlog and frontlog files.Opportunity
maintenance. Backlog file management.
Planning PM routines and corrective work.
Determining the weekly workload
Maintenance planning coordination meeting.
Work order issue, work in progress.
38
Feedback & history.

Performance measures.
Who should be the planner. Responsibilities
and duties of the planner.
3 Computerised Maintenance Management
Systems
Working with a CMMS
The move towards Asset Management
Systems and beyond the basic CMMS.
GIS, GPS, Internet, Web based systems.
* Mobile maintenance and mobile CMMS.
4 Inspections & Condition Monitoring
What inspection and preventive/predictive
techniques are available in maintenance.
A look at the wide range of inspection and
condition monitoring techniques
Visual inspections, oil analysis, vibration
monitoring, thermography, acoustic
emission, boroscopes, fibre optics,
alignment techniques, residual current, etc..
5 Maintenance Stores
Store objectives and stock control.
Impact of maintenance type on stock held.
Who owns the stores? Who owns the
parts? Maintenance of parts in the store.
Location of the stores.
6 Maintenance People and Structures
The different organisational structures used
for maintenance activities.
Restructured maintenance, flexibility,
multiskilling and team based structures.
Maintenance Outsourcing/Contracting
1 Business & Organisational Success Via

Better Maintenance
The key role that maintenance plays in
achieving business success. Maintenance
as a profit creator.
Maintenance in Good or Bad business
times. Proving your worth. Reducing Direct
or Indirect maintenance costs.
Maintenance Impact on Safety, Insurance
and Legal Costs. Risks of poor or under
resoursed maintenance.
2 Achieving Better Maintenance
Common features of the best maintenance
organizations in the world.
What is Maintenance Excellence.
2.1 The Best People:
Leadership, recruitment, training, flexibility,
motivation, teams, TPM, performance,
rewards, core skills and outsourcing.
Matching people and structures to your
organisation. The rise of the super
contractors.
2.2 The Best Parts Management:
Stores management, stores objectives,
vendor and user alliances, internet spares,
parts optimisation, improved parts specs.
automated stores, stores personnel.
2.3 The Best Maintenance Practices:
Moving through Preventive / Predictive to
Proactive Maintenance. Earning time to
develope new techniques for improved
asset management.
Download the full Maintenance Seminars Brochure from
AMMJ
May 2013
Go To Contents Page
1 Day Seminar
Seminar
3 Maintenance Strategies
For The Future
Setting Strategies: From Policy Statements,
Audits, Benchmarking, Gap Analysis and
Objectives through to Maintenance
Performance Measures.
Examples of Maintenance Objectives and
Performance Measures.
4 Analytical Methods
In Maintenance
Maintenance Plan Development and
Optimisation Software.
Example of how to collect, use, and
understand maintenance data.
Using downtime data to minimise impact of
downtime.
Using failure data to optimise maintenance
activities using techniques such as Weibull
analysis.
Fine tuning PM activities.Can we use
MTBF? Timelines, Histograms, Pareto
Analysis, Simulation.
5 Asset Management
Asset Management & ISO 55000. How much
do I really need to know about Asset
Management
Plant Design considerations that improve
reliability, availability and maintainability.
Introduction to life cycle costing of assets.
Plant replacement strategies;software tools.
Better maintenance specifications of
machines.
www.theammj.com/MaintSem2013.pdf
Go To Last Page
Does it pay to design

for reliability and
maintainability?
Ramesh Gulati, Manager of Asset Management and
Reliability Planning, Arnold Air Force Base,USA
39
When Hyundai Motor America began offering

100,000/miles, 10 year warranties, on their cars many
predicted that this offer would bankrupt the company.
However, the companys sales continue to climb, with
sales of Hyundai Motor America vehicles in 2011 up
20 percent over their 2010 record-breaking year. This
relatively newcomer to the automotive market is now
competing with industry giants like Toyota, Honda,
Ford, etc. How are they doing it?
Design for reliability (DFR) is an emerging discipline
that refers to the process of designing reliability,
maintainability, safety, etc., into products towards an
objective of improved availability, lower sustainment
costs and maximum asset utilization during product
life. Typically, the first step in the DFR process is to
establish the systems availability requirements.
For example, is our application mission critical like a
pacemaker requiring 100% reliability, or can the asset
be safely and cost-effectively down for an extended
period of time should it fail? During system design,
top-level reliability requirements are allocated to
subsystems by design engineers, maintainers and
reliability engineers working together
Over 80% of the total cost of ownership

of an asset is fixed during design, before
it is even put into use or operation.
As asset owners, operators and maintainers, we
often hear that it costs too much to design for
reliability (and maintainability).
How do we refute this claim?
Are we upholding our responsibility in educating
our capital project, acquisition and finance
managers on life cycle cost management?
Are we clearly and succinctly communicating the
total life cycle costs of our equipment assets?
Most of our assets are surpassing their design life
of 25-30 years. How will this affect the bottom-line
of our organizations?
While some organizations, like the United States
Department of Defense (DoD), do a good job
at considering total cost of ownership when
designing weapon systems, industry in general,
while beginning to pay attention to this subject,
still has a long way to go.
Lets review some basic terms such as reliability,
maintainability, availability, life cycle, and
operations and maintenance (O&M) to provide a
clearer understanding of DFR.
Generally speaking, Reliability (R) means something you can

depend upon, i.e., no (or fewer) equipment/asset failures, and
is usually measured by mean-time-between-failure (MTBF.) Do
you remember the Maytag appliance repair commercial with the
service man waiting for repair calls that never came? Thats the
equipment reliability we dream about.
Maintainability (M) is ease of maintenance. If an asset goes
down, how quickly are we able to bring it back to operation?
It also means easy access to equipment, availability of the
right tools and spares, adequate training of operators and
maintainers, proper documentation, etc. Maintainability is
usually measured by mean-time-to-repair (MTTR.) In my
experience, this is the first area where cuts are made if money
gets tight.
Figure 1 is an example of where poor asset design can
significantly impact MTTR. How will this motor be removed to
repair a leaky hydraulic hose, and what will be the associated
costs in doing so?
Figure 1
Hydraulic system maintenance challenge
AMMJ
May 2013
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Figure 2
Life Cycle Expenditures and Cost Commitments
Availability (A) is defined as a function of reliability and maintainability.

A = Uptime / (Uptime + Downtime)
or A = MTBF / (MTBF + MTTR).
While the criticality of equipment availability can vary depending on the process
or application, one thing is for certain, every organization wants to be pushing and
pulling the levers controlling it, and not vice versa.
What are the costs associated with uncontrolled availability? While it is readily
understood that unplanned events lead to costly lost production and potential,
unacceptable safety risks, organizations often fail to consider the costs associated
with angry customers, idle employees and bad publicity.
Life cycle costs (LCC), also referred to as total cost of ownership (TOC),
represent the aggregated costs from asset concept, design/development,
building/manufacturing, operations, maintenance and disposal. Operations
(O) and maintenance (M), major contributors to total cost of ownership, are
fixed during design, before assets are even put into use or operation (See
Figure 2).
In application, this means that the design of our assets determines a variety
of asset-related costs including the number of operators necessary to
operate the asset, what our energy/utility costs will be, asset failure rates
based on selected components, etc.
As asset owners/operators/maintainers, we like to take it for granted that
our assets will perform as needed. However, the reality is that we generally
have to make improvements/modifications to make them work efficiently
and effectively. And, the necessary actions (reliability and maintenance) to
assure their availability represent significant, unnecessary costs.
From a balance sheet and safety perspective, it would cost our organizations
much less if reliability, maintainability and safety were designed into
our assets, and users were properly trained on them prior to their
commissioning.
We need to become involved much earlier in the design process and insist
on building reliability, maintainability, safety and sustainability into our assets.
While it may increase acquisition costs, these increases will be more than
offset by the significant reductions in the total cost of ownership.
The reliability of an organizations equipment assets (including
maintainability and safety) can make or break an organizations ability to
produce the products or services necessary for their survival a precept
Hyundai seems to be successfully taking to heart, and the bank.
About the author:
Ramesh Gulati is the Asset Management and Reliability Planning Manager
with Aerospace Testing Alliance at the Arnold Engineering Development
Center (AEDC), Arnold Air Force Base, Tennessee.
First published in October 2012 issue of the meridium APM Adviser
www.apmadvisor.com
40
AMMJ
May 2013
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Thermal imaging cameras

are a great tool for predictive
maintenance inspections
Gunther Willems, Coservices, Netherlands
Thermal imaging cameras from FLIR
Systems are increasingly used in industrial
environments for predictive maintenance
inspections. Thermal imaging is the fastest
growing predictive maintenance technology
on the market today. It is simply the only
technology that allows you to immediately
see whats wrong.
41
AMMJ
Gunther Willems, Technology Manager at one of

Europes largest condition monitoring consultancy
agencies Coservices said that Coservices perform
inspections at regular intervals so that we pick up
faults as they develop, so repairs can be planned
accordingly, allowing companies to fix issues before
they disrupt the production process.
Without predictive maintenance inspections
companies are forced to use a method called
preventive maintenance, explains Willems. This
means that parts of equipment are replaced at regular
intervals to prevent breakdowns. But in many cases
parts are replaced beforetheir time, just to be on the
safe side.
PM inspections using thermal imaging
technology save money
With the PM inspections using thermal imaging
technology we perform for such companies, we can
accurately determine whether a part or piece of
equipment needs to be replaced or not. This is

important information for these companies, for
the continuity of production is guaranteed without
unnecessary part/equipment replacement,leading
to cost savings of thousands of Euros, claims
Willems.
Stop guessing, start seeing
The service provided by Coservices is not limited
to thermal imaging alone. For the maximum
effect we combine several technologies: vibration
analysis, ultrasonic tests, oil analysis and
inspections using thermal imaging cameras. The
main advantage of thermal imaging is that you
can locate mechanical and electrical problems
very quickly and accurately. With thermal imaging
you will be able to immediately see which
component is causing the problem.
Thermal imaging speeds up the inspection
Thermal imaging cameras are also crucial to allow
swift inspections. In some cases there are also
simply too many pieces of
equipment or equipment
components to test using
vibration analysis or other
methods. If a production
plant features a row of
conveyors the fact that
you can walk along this
row of conveyors and
swiftly scan them with the thermal imaging camera is a mayor

time-saver. The same goes for electrical equipment: if you are
inspecting an electrical
This roller bearing is overheated
cabinet with thirty
and should be replaced.
fuses, you dont want
to go and check each
individual fuse using a
spot pyrometer to find out
which one is going to fail
first.
And according to
Willems for some types
of equipment thermal
imaging really is the only
technology you can use.
With refractory linings,
for instance, thermal
imaging cameras are the
only practical condition
monitoring tool available.
So what Im trying to
say is that a company
that provides condition
monitoring services
cannot be complete
without thermal imaging
technology.
May 2013
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42
Why FLIR?
One of the reasons why Willems opted
for thermal imaging cameras from FLIR
systems is the ergonomic design. If you
use a piece of equipment as often as we
use the FLIR thermal imaging cameras
ergonomics and ease of use are crucial.
All FLIR thermal imaging cameras are
relatively compact, lightweight and easy
to use.
Another important factor is the optics.
The interchangeable optics of the
FLIR T-Series are very important
to us, because it is very difficult to
do everything with just one lens.
Sometimes theres not enough room to
take a step back to capture a piece of
machinery in one image, so you need
to change to a 90 wide angle lens. And
in other cases you cannot get too close
due to safety hazards, for instance, and
you need to switch to a 7 telephoto
lens. Being able to make these switches
in lens gives the operator much more
flexibility.
The importance of training
The fact that thermal imaging technology
is visible and intuitive also makes it very
easy to learn for new employees. That
can also be quite deceptive, however,
according to Willems. The thermal
imaging cameras from FLIR are so
easy to use that you might think that it
is just a matter of pointing the camera
and pressing the right button. It is very
important, however that you know what
AMMJ
youre doing. You need to know how

to accurately correct for emissivity and
reflection, for instance. Otherwise you
might draw false conclusions.
FLIR Systems therefore not only provides
top of the bill thermal imaging cameras,
but also good training in co-operation with
the Infrared Training Center (ITC), Willems
explains. We make sure that all of our
maintenance consultants have at least
followed the level 1 ITC training course
and preferably also the level 2 course as
well.
Software
Another important factor in the use of
thermal imaging cameras is the software,
according to Willems. It goes without say
that the reports we produce are of vital
importance to us, for that is what the client
will receive. And I must say that Im very
pleased with the FLIR Reporter software.
The fact that it is completely compatible
with Microsoft Office is an important
advantage for us. We have tailor-made
Word templates for each of our clients,
so the fact that we can import the thermal
images in Word & alter the level and span
right there in the Word file is a major plus.
There simply is no other thermal
imaging supplier that delivers the same
combination of image quality, good design,
service, training and software, concludes
Willems.
info@flir.com.au www.flir.com
The thermal image shows faulty pipework insulation.

This can disrupt the production process and cause dangerous accidents.
This electromotor is overheated and needs to be inspected

and repaired before a failure occurs.
The refractory on this ladle shows signs of wear and if it degenerates further needs
to be replaced. Thermal imaging cameras are the only practical tool available for
refractory inspections.
May 2013
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Condition monitoring protects

Londons Thames Barrier
Andy Anthony
43
Monitran
www.monitran.com
UK
Operated by the Environment Agency, the

Thames Barrier is Londons main defence against
flooding. It became operational in 1982 and
protects parts of the city against abnormally high
tides and tidal/storm surges. Understandably,
the barrier needs to be maintained to ensure it
can protect the capital when needed. Indeed,
during its history about a third of its 400 plus
closures have been necessary, the rest being for
maintenance purposes.
The barrier divides the Thames into four nonnavigable spans (closest to the rivers banks) and six
navigable spans; of which four are 61m wide and two
are 30m wide. The non-navigable spans have falling
radial gates, in that they lower into the water to form
a barrier, whereas the navigable spans have rising
sector gates which, in their open positions, lie flat
with the river bed.
Each of the four main gates weighs more than

3,300 tonnes and presents a 20m high barrier
when in its defence position which can hold back
loads of up to 9,000 tonnes.
To adopt their defence positions the main gates
rotate through about 90o, and the maintenance
position requires a further 90o of rotation. The
bearings of the main gates have, since the early
1980s, therefore only ever experienced quarter
and half turns; and any wear will reflect this life of
partial rotations.
The Challenge
As the Thames Barrier approached its 30th

anniversary, and under a contract awarded by
the company responsible for its maintenance
& upgrade projects, Monitran was tasked with
designing, installing and commissioning a system
to measure bearing movement & gate position. In
addition, the system had to be a permanent fixture
and would require some equipment to be placed
on the outer faces of the bearings, and therefore be

subjected to the full force of the tidal river.
Established in 1986 and based near High Wycombe
in the UK, Monitran is an OEM of sensors
and systems for vibration and displacement
measurement. At the time the company was
approached about the Thames Barrier project,
Monitran had only recently started undertaking
turnkey projects, and developing complex monitoring
systems from the sensor up. The project therefore
represented a considerable opportunity for the
company. One not without its challenges.
The system Monitran developed uses four eddy current
probes, per bearing, to make distance measurements as
the gate/ bearing rotates through 180o. Positioned at 90o
intervals around the end of the bearing (see Figure 1), the
probes were optimised for maximum sensitivity over a 10mm
displacement range and positioned a nominal 5mm away
from the chamfered face of the end of the inner bearing. In
addition, the bracket seen at 6 oclock in Figure 1 also holds
a pressure sensor, used to derive tide height.
The cables for the pressure sensor and eddy current probes
terminate in the junction box, seen at 10 oclock in Figure 1.
This box, which is stainless steel and sealed to IP68, also
contains an inclinometer for recording gate position.
A single cable then feeds through the centre of the bearing
and into the inner trunnion support structure; and then on
into a GRP junction box enclosure that contains the eddy
current probe drivers. In addition, the inner face of each
bearing is fitted with an accelerometer in order to measure
vibration levels; and those of the larger gates also have
water leak detectors.
AMMJ
May 2013
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Maintenance Bits
Figure 1 - Pictured above, the outer bearing of

one of the Thames Barriers navigable gates.
Not shown but a circular plate normally covers
the outer face of the bearing. However the seal
is not water-tight so the sensors, junction box
and wiring are all rated to IP68.
44
All signals and power lines to and from the

sensors converge at a single cabinet (on
one of the barriers decks). The cabinet
has six displays which, between them,
show the displacements measured by the
48 eddy current probes, the outputs of the
12 pressure sensors, the gate positions
(as either 0, 90 or 180o) and the status of
each of the eight water leak detectors. In
addition, BNC connectors make available
the accelerometers outputs for vibration
monitoring or analysis.
Service Plus
The importance of the Thames Barrier
project warranted far more than just the
provision of standard or even custom
products, and Monitran assembled a team
of skilled engineers and put them through
training in order to work in confined spaces
and on floating platforms.
Accordingly, there was a relatively

steep learning curve - but this was
offset by many things Monitran did to
reduce risks during the installations.
For example, as much circuitry as
possible was wired, enclosed and
pressure-tested at Monitrans HQ
in High Wycombe. In addition, a
complete installation was made,
and commissioned, on a single
bearing before any of the others were
tackled. Doing so not only enabled
the company to develop an optimum
process for working on the remaining
bearings but it also resulted in the
early detection of a problem with
a water-tight bulkhead; giving its
manufacturer time to devise an
alternative method of construction.
Monitran has since undertaken a
variety of other turnkey projects
which, although not on the scale of
the Thames Barrier project, have
also been developed from the sensor
up. For example, Monitran recently
developed a system for continuously
monitoring the vibrations caused
during construction work at a school
in London. In another instance, the
company developed a condition
monitoring system for Griffon
Hoverwork; for installation on
hovercrafts ordered by the Indian
Coast Guard.
Both of these case studies can be found here:
www.monitran.com/services/project-management/
The Humble
Stethoscope
By Joe Conyers
In todays digital world, using an analog

device might seem like taking a step
backwards. Using a stethoscope to
diagnose machine problems might seem
silly with all the advanced vibration
technology and signal processing available
today. But in some cases, less is more.
The bag house in a cement plant is the
place where finely crushed cement is processed into individual consumer-sized bags.
Not only is the area deafeningly noisy, its a very tough place for bearings - dirty and
dusty. The environment often leads to severe abrasive bearing wear, which can be
difficult to diagnose with standard vibration technology.
In one case involving several bearings and multiple shafts, the vibration was so
severe, the problem bearing was difficult to localize. The techs at the plant had
already tried cheap doctors-style stethoscopes and found them ineffective: they
couldnt hear anything with the surrounding high noise levels.
When they tried a more advanced stethoscope, they accidentally found a great
tip. Since the area was high noise, the tech was already wearing ear plugs and
ear muffs. When they swapped ear muffs to use the stethoscope with built-in ear
defenders, they had to increase the volume to get a better signal-to-noise ratio from
the device.
This allowed them to easily find the bad actor bearing and replace it. Otherwise,
they would have had to shut down and examine each individual bearing for damage,
exposing all the bearings to even more contamination, and wasting valuable
production time.
The SKF Stethoscope comes with a CD of damaged bearing sounds and more tips
on best practices to promote expert use. Sometimes, taking a step back is exactly
the right step to take.
To help you find out best practices and other interesting information about
maintenance issues, why not visit the blog Maintenance Bits authored by Joe
Conyers.
AMMJ
May 2013
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Maintenance
& Reliability
News
BPSE, UGL Limited Continue Track Record for
Railway Success
Ultra Group Selects Apptricitys Smartfleet

& Asset Tracking
45
Apptricity, provider of the Jetstream suite of supply chain,

e-procurement and financial productivity solutions, announced
today that the Ultra Group of Companies has selected Apptricity to
automate asset tracking and boost efficiency in its service fleet.
Ultra, a diverse organization that covers a wide spectrum
of industries, from amusement gaming to technology,
telecommunications and real estate, last year asked thought leaders
for ideas on tracking parts and equipment. Those conversations led
Ultra Group to Apptricity for in-depth discussions on the companys
need for efficiency through organizational transparency.
Apptricity Jetstreams award-winning asset tracking automates the
asset life cycle to improve efficiency and reduce costs. Features
include asset assignment, chain-of-custody management and
monitoring of asset availability, depreciation and repair schedules.
Ultra also chose Smartfleet, Apptricitys transformative new way to
increase field technician efficiency and reduce costs. Smartfleet
delivers the competitive advantage of wireless work order, inventory
and asset tracking to vehicle-based businesses.
Field technicians have full access to real-time data through any
tablet or smartphone using iOS, Android or Windows mobile
platforms.
Smartfleets powerful features made it a clear choice to enable Ultra
Group to improve its level of client service. With Smartfleet, field
technicians and other mobile users can ensure that vehicles are
properly stocked, get optimize routes and receive turn-by-turn driving
directions. They also receive alerts of new and updated work orders
with detailed instructions, time estimates and required materials.
We are proud to partner with Ultra Group and help them gain
greater control over their assets at client sites, said Timothy Garcia,
Apptricitys CEO. SmartFleet gives them a state-of-the-art means
of managing technicians time in the field, increasing efficiency and
cutting costs.
www.ultragroupinc.com
Consulting Experts Go Live with Fully Operational SAP

ECC 6.0 System in Record Time
Project Rail Map

Industry:
$16B+ railway transportation
Client:
UGL Limited
Leads:
CEO, SAP IT Team
Version:
SAP ECC 6.0
SAP Solutions: Solution Manager, PLM,

CS, WM, MM, FICO, COPA
Integrators:
BPSE Consulting, BluLeader
Securing the Backend that Powers Australias
Railway to the Forefront
Australia commands global attention with an advancing
market and outstanding standard of living, both fueled
by high growth, low inflation and low interest rates.
Supporting a population of more than 22 million, 70
percent of which is gathered around 10 geographically
dispersed cities, Australias economic development rides
on the strength and reliability of the modern railway.
Australias rail services are a hotbed for expansion, with
a 2012 freight industry valuation of nearly $8.9 billion
and passenger revenue close to $7.5 billion. While the
fundamentals of railway design have, for the most part,
remained the same, the technology driving this evolving
transportation industry has become its own intricate
system of tracks and switches. As steel is the backbone
of railway equipment, SAP is the foundation on which
much of the industrys data center is built.
UGL Limited (ASX: UGL), a global leader in outsourced
engineering and construction, property services and
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 PDFs or Word Docs.
Images and photos welcome.
Maximum news word limit is normally 600 words
but larger news items will be considered.
mail@maintenancejournal.com
asset management and maintenance, is a major leader in

Australias railway equipment manufacturing industry. Its 2012
revenue was nearly $4.8 billion. UGLs Rail division, which
includes a 20 percent stake in Metro Trains Melbourne, offers
rail customers an integrated solution for design, engineering,
manufacturing, maintenance, refurbishment and asset
management of locomotives, passenger cars, trams and
freight wagons.
In December 2011, UGL renewed its Main Train maintenance
and logistics contract with RailCorp, an Australian government
agency that delivers public transportation services in New
South Wales as well as interstate passenger rail services.
Under the new seven-year, $1.4 billion contract, UGL
would continue to provide heavy maintenance and logistics
management services on 1,050 passenger cars.
To service the contract, UGL joined forces with Unipart Rail,
an engineering and logistics consultancy, to create the joint
venture UGL Unipart. UGL had an SAP ERP system in place
that covered financials, asset management and project
management, but realised a new system must be established
to support the new RailCorp contract.
BPSE Consulting Climbs Aboard to Lead SAP
Management
UGL Uniparts SAP system had to be full steam ahead in
less than four months. Having been an existing customer for
more than six years, UGL looked again to BPSE Consulting
to conduct the transition to the new contract in SAP ECC 6.0.
BPSE Consulting collaborated with SAP solutions integration
partner and customer service and asset management expert,
BluLeader, to further extend its delivery of services.
AMMJ
October
May
2013
2012
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Maintenance & Reliability News
46
BPSE Consulting and BluLeader provided UGL Unipart

with unmatched enterprise asset management and rail
logistics expertise. Together, they would deliver an SAP Plant
Maintenance and Repair, and Customer Service solution that
enabled UGL Unipart to commence operations on day one,
with improved cost capture capabilities.
It was important that UGL Unipart have an accurate picture
of expenses at a much higher level of detail than in the
past, explained Marco Formaggio, managing director for
BluLeader. Not only was it a technical SAP challenge, but
there was also a business impact that changed the way UGL
Unipart functioned and captured data.
The Nuts and Bolts of UGL Uniparts SAP Transition
As BPSE Consulting and BluLeader began to peel back
the paint, they found that the transition was highly involved.
In addition to utilizing SAP Solution Manager to capture all
requirements, design, configuration and testing, the most
pressing priorities included:
Moving existing functionality into the new company,
Implementing new billing processes and the rules that
applied to the new rail fleet maintenance contract,
Establishing inventory management at the RailCorp
depots, and
Integrating SAP into a third party advanced planning
system.
The new environment would incorporate the following ECC
6.0 modules:
Plant Maintenance and Repair (EAM),
Customer Service (CS) with contract billing, fixed
price billing and enhanced resource-related billing,
Warehouse Management (SCM/WM),
Purchasing (Procurement)
Logistics (SCM) with complex stock planning and
materials requirements planning, and
Finance and Controlling (Financials).
In addition, a number of new contract requirements
were required to be met including shifting fixed prices,
implementing fleet configuration management and interfacing
with RailCorps legacy system. As a joint venture, UGL
Unipart was also responsible for managing the supply chain.

Accurate and expedient stock management had become a core
focus area. These, and many other technical and business
requirements had to be supported by the new SAP system.
BPSE Consulting had to consider integrating the RailCorp depots
into the solution without introducing overhead, explained Alandre
van Vuuren, managing director for BPSE Consulting. To ensure
that requirements were met, the consulting teams worked very
closely with key business stakeholders.
Given an SAP project of this magnitude, an extremely tight budget
and timeline posed great challenges. UGL Uniparts new SAP
environment had to be fully functional by 1 July, 2012, leaving
BPSE Consulting and BluLeader with less than four months to
assess, integrate, develop, test, migrate and go live.
BPSE Consultings rail industry expertise, and proven track
record of outstanding service and familiarity with UGLs systems,
strengthened the collaborative effort with BluLeader. Together, the
teams quickly mobilised to help UGL define business requirements
and get things rolling.
Both veteran, technologically savvy consultancies, BPSE
Consulting and BluLeader quickly integrated business
knowledge and processes. Utilising highly skilled staff allowed
for a smaller implementation team that reduced resource costs.
A unique, agile approach reduced timelines and enabled a sixmonth+ project to be efficiently and effectively compressed into
4 months.
On Schedule as UGL Unipart Leaves the
Station for Go Live
BPSE Consulting and BluLeader collaborated to deliver UGL
Uniparts SAP ECC 6.0 system on time and minimal disruption.
This enabled UGL Unipart to commence operations for RailCorp
without service interruption, a successful milestone that trickled
throughout NSWs passenger railways.
within a tight timeline and documenting the process and

approvals to satisfy corporate governance. This challenged the
organisations to respond to the call for action.
As business operations leader for maintenance solutions in
earlier implementations of SAP within UGL and as project
leader in this joint venture transition, I truly understand the
benefits that both BluLeader and BPSE Consulting have
brought to the implementations and adaptions of SAP into our
asset management solutions.
Kevin McCarthy,
General Manager passenger projects and tenders
Featured Client: UGL Limited UGL Limited (ASX: UGL) is a
global leader in outsourced engineering and construction, property
services and asset management and maintenance
www.ugllimited.com
About BPSE Consulting BPSE Consulting has extensive
experience working with, designing, implementing and improving
logistics business processes using SAP software, we provide bestfit solutions to our customers.
www.bpse.com.au
About BluLeader BluLeader is a leading SAP implementation
partner.
www.bluleader.com.au
Given the extremely tight time frames required by our RailCorp

customer in the management of a transition, project success
was always going to be dictated by the skills of the individual
members of the team that were engaged to lead and assist
this project and the ability of the individuals to work as one
integrated team. BluLeader and BPSE Consulting brought the
perfect mix of these capabilities into the joint venture transition.
Together we found the most appropriate way of executing
AMMJ
October
May
2013
2012
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Fixturlaser NXA - a digital laser based
shaft alignment tool
47
A revolution in usability says Elos Fixturlasers CEO Hans

Svensson about the new high-end system for precision shaft
alignment, the Fixturlaser NXA. The new laser based shaft
alignment tool utilizes the latest technology in digital signal
processing. It aims to provide the user with a fast and simple
operation, as well as having access to advanced functions and
capabilities.
The new alignment system consists of a display unit, a 6,5 inch
diagonal touch screen, with a video game realistic graphic user
interface and a new set of sensors. By introducing a gyro-powered
OmniView function, the screen will always show the machine to
be aligned from the same viewing angle as where the operator
is positioned, i.e. the system knows where it is in relation to the
machine.
The new sensors use a 2nd generation CCD technology with
increased capabilities and reliability. Also the sensors have builtin gyroscopes to provide a quick and reliable measurement of
vertically mounted machines. They have the smallest form factor
on the market, with built-in batteries and Bluetooth communication,
which provide for easy access on machines in limited spaces.
The system operates, at continuous measurement, for more than
10 hours between charges. An advanced charging technology
gives the display unit
6 hours of operation
after only one hour of
charging. The sensors
can operate for more
than 24 hours without
charging.
If we can provide the
ultimate shaft alignment
system when it comes
to usability, we will help
thousands of companies
worldwide to become
more efficient, but also
reduce waste of both
components and energy. We believe strongly that if

all rotating equipment in the world were aligned within
its specifications, we would have a much healthier
environment. An alignment system that is as easy to
use as the Fixturlaser NXA will pave way for this. says
Hans Svensson.
hans.svensson@fixturlaser.se www.fixturlaser.se/
New-format Fluke VT02 Visual Infrared

Thermometer fills the gap between
thermometers and thermal imagers
Fluke Corporation has introduced the Fluke VT02

Visual IR Thermometer, a troubleshooting camera
with an infrared heat map.
Until now, electricians and industrial, HVAC and
automotive technicians have had to choose
between single-point infrared thermometers and
high-resolution thermal imagers (infrared or IR
cameras). The Fluke VT02 Visual IR Thermometer
fills the gap, for when a single-spot temperature
reading isnt enough and a high-resolution thermal
image is more than users need. One tool combines
the visual insight of a thermal imager, the visual
images of a digital camera, and the point-and-shoot
convenience of an IR (infrared) thermometer.
Conducting inspections for electrical, industrial,
HVAC/R and automotive applications is faster with
the VT02 than an infrared thermometer, which
requires multiple readings and manually recorded
results. The VT02 instantly detects problems using
blended thermal and digital imagery. It will display
and save images as full visual, full infrared, or in
three blended modes (25, 50, and 75 per cent).
Markers pinpoint hot and cold spots indicating the
hottest temperature with a red box and the coldest
with a blue box. A temperature reading is provided
at the centre point. Images are saved to the micro-SD

card, eliminating the need to write down single or multiple
measurements.
Developing a tool that is easier to manufacture than
traditional thermal imagers required significant innovation.
Using hyper-thin pyroelectric technology, engineers
discovered a way to push the limits of the technology,
pioneering an array dense enough to create an infrared
heat map.
Affordable, compact, and intuitive, the VT02 operates
with focus-free simplicity, expanding the user base
from senior to junior technicians and broadening the
applications for in-house staff as well as creating new
business opportunities for service contractors. Images
from the VT02 can be imported into SmartView analysis
and reporting software, included with the VT02, to
produce professional reports that document problems
detected or repairs made for management and customer
review. www.fluke.com.au.
New book on: Building Information Management

for Facility Managers
The International Facility Management Association (IFMA)

and IFMA Foundation are proud to announce publication of:
BIM for Facility Managers, edited by Paul Teicholz.
The book is published by John Wiley and Sons.,
Addressing building owners, developers, and managers,
this text covers how building information management (BIM)
complements facility management (FM) systems to achieve
significant lifecycle advantages. It includes coverage of the
guidelines for BIM in FM as developed by owners such as the
General Services Administration, the COBie2 (BIM document
standard) used to collect and communicate facility equipment
information, and a list of software for BIM/FM integration. It
also offers six real-life case studies including the Texas A&M
Health Science Center, the USC School of Cinematic Arts,
and the State of WI Facilities.
IFMA is the worlds largest and most widely recognized
international association for facility management
professionals, supporting 23,000 members in 85 countries.
TFor more information, visit www.ifma.org.
AMMJ
May 2013
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Delta Electricity software pilot to deliver fewer

plant outages and significant cost savings
48
A new software application being piloted at Delta Electricitys

Wallerawang Power Station Australia) will allow maintenance
engineers to make faster, better decisions to reduce the
frequency and duration of plant outages.
The Delta Electricity Information Gateway will be available
on mobile devices and desktop computers, making Delta
engineers significantly more productive.
The project is a collaboration between the Cooperative
Research Centre for Infrastructure and Engineering Asset
Management (CIEAM), the University of South Australia,
Queensland University of Technology, and enterprise asset
management software provider Mainpac. Delta Electricity is
sponsoring the pilot, which commenced in March, 2013.
I have seen similar projects in power stations in other
countries, but the combination of high cost and development
and implementation times that stretched over a number of
years made them too onerous for our purposes. Through
discussions with CIEAM and their commercialisation partner
Mainpac, I realised we could produce a solution at a fraction
of the cost within six months said Steve Saladine, General
Manager Production at Delta Electricity.
After a few weeks of discussions with CIEAM and Mainpac,
Mainpac demonstrated a prototype thats when I knew we
had an exciting project on our hands.
Mainpac Executive Chairman James Kirk said the main
aim of the Information Gateway is to assist engineers in
decision making, allowing them to quickly assess all factors
relating to an incident, including the assets history and the
possible implications of a variety of alternative decisions.
The Information Gateway will bring together complex data
from numerous existing in-house applications and external
data providers, providing instantaneous analysis and
presentation.
The pilot comprises of a number of deliverables including
rapid incident diagnosis, comprehensive decision support,
and asset-related business intelligence. After successful

deployment, further enhancements are earmarked for the
Gateway with the incorporation of predictive maintenance
modelling tools from Queensland University of Technology.
The Information Gateway will act as a funnel, offering the
engineer a very wide selection of information at first, then
refining that selection until it is detailed and specific enough
to allow the best decision to be made. It is expected that
the Information Gateway will reduce the risks and costs
associated with plant outages as well as reducing the
frequency, impact and duration of outage events, James
said.
The disparate data sources are correlated and integrated
using tools and techniques developed by CIEAM and the
University of South Australia. Analytical information is
presented using Mainpac Asset Intelligence software, which
facilitates the broader objective of the Information Gateway to
support production and maintenance KPIs.
This is an important pilot from our perspective because the
benefits will ensure that we live up to our mission, which is to
generate electricity safely, reliably and competitively, Steve
said.
For example, we anticipate that the reduced severity and
duration of plant outages will allow us to improve electricity
supply. We will be able to increase worker safety by providing
staff with relevant information in real time via their smart
phones and tablets. Because they immediately have all the
relevant data they will be able to make better decisions as a
result of the application, well see reduced operational costs
and improved plant reliability.
Put simply, well be able to improve both service levels
and worker safety two very important outcomes for Delta
Electricity.
To effectively identify, risk-assess and resolve plant incidents,
engineers require concurrent access to real-time event
information, historical maintenance records and rich content
such as drawings, isolation and rectification procedures.
Retrieving and viewing all of the required information
from the various sources can add days to the process.
The Information Gateway is designed to drastically reduce
this time by putting all of that information in one place at the

engineers fingertips. This allows them to make the best decision
faster and get started on the repair or replacement work
sooner, Steve said. Intuitive access to information will also
significantly reduce training and induction time for employees
and contractors.
The Information Gateway pilot will take place at Delta Electricitys
Wallerawang Power Station, located near Lithgow, New
South Wales. The power station has a total capacity of 1,000
megawatts provided by two generating units of 500 megawatts
capacity. The Wallerawang power station was chosen because
it has high maintenance requirements and the data is configured
by plant areas which enables the data to be grouped logically.
The pilot is expected to confirm that the Information Gateway
saves time and cost, resulting in best decisions faster. The
application will be rolled out broadly across Wallerawang
and subsequently made available to other power generation
enterprises following the completion of the pilot.
www.mainpac.com.au
NEW book on Facilities Management Managing Maintenance for Buildings & Facilities
This book by Joel Levitt covers the essential role and

responsibilities of the facilities manager as it pertains to building
maintenance.
If youre a newcomer to facilities management, you will find
this book an excellent introduction to managing maintenance.
Already an established professional? Youll be able to brush up
on the latest technological and regulatory trends affecting how
complex facilities should be successfully maintained by way of
risk assessment.
The book contains ample, ready-to-use assessment forms
and resources for extended practical information. Highlights
include: Coverage of key components of facilities maintenance
management including risk management, building safety,
operations and purchasing, staffing, and more; Guidance on new
trends including lean building maintenance and Green Building
specs (Green Spec) like LEED; Guidance on legal contracts,
safety regulations, energy efficiency, and more; and Specific
management guidance by building type including apartments,
office buildings, hotels and resorts, government buildings,
schools, transport facilities and many others.
www.MaintenanceTraining.com www.momentumpress.net
AMMJ
May 2013
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SKF introduces an online network
developed to solve maintenance problems
49
SKF today launches the SKF Maintenance Network,

a web site that enables maintenance professionals
to connect with other maintenance experts globally
and get their feedback on specific problems and find
potential solutions. The SKF Maintenance Network is
a unique, fun and rewarding way to solve problems.
In todays ever challenging business environment,
increasing uptime in manufacturing operations
can make the difference between staying
competitive and struggling to survive. Consequently,
maintenance departments play a crucial role in
finding fast answers to equipment breakdowns and
thereby minimizing downtime.
Every hour of downtime is costing a lot of money
to the company and causes high stress levels. In
many cases the fix is a partial solution that allows
production to go on and the real problem is not
tackled until the next maintenance shutdown. But
then a more long lasting solution needs to be found,
and it is here that the new SKF network service may
be able to help.
The SKF Maintenance Network offers an incentive to
the participation of solution providers by rewarding
them with points. These points can be used to obtain
various prizes at the networks web store.
The web site includes discussion rooms where
people can discuss hot topics as well as specific
problems and take advantage of the available
expertise and solutions around one specific
maintenance topic. SKF will regularly introduce
different hot topics where maintenance experts can
post their problems and/or help other peers. At the
end of every such topic, top solution providers will be
announced.
The web site can be accessed at:
www.mapro.skf.com/maintenancenetwork
SPM wins prestigious test

done by Boliden
During 2012 Boliden performed an evaluation of several suppliers of condition

monitoring systems. Boliden is one of the
major mining companies in Sweden. The
test object was an autogenous mill placed
in Garpenberg mine. During the test period of about 8 months all suppliers measured condition of motor, gearbox and gears
to the mill.
During the test, Boliden was able to test
both functionality of the systems and also
the service organization from the different
suppliers. After an evaluation of all final
reports have been made Boliden project
team decided that SPM Instrument AB has
delivered the best results.
Concentrator at the Boliden mill in
Garpenberg, Sweden.
Image source: Boliden AB
The Project Manager Anders Stenberg

says - The project team agreed that the
SPM system has delivered very clear
measurement results where all interesting
signals from the machines was clearly
visible and has shown great commitment to
the task. The system combines Intellinova
shock pulse technology SPM HD and
vibration analysis in the same unit which
gives a possibility to choose the best
technology for the different measuring
points.
This means future delivery of both online
systems and handheld instruments for most
of Boliden facilities. The mine in Garpenberg
is right now in the middle of a large project
with new concen-trator where all machines
that are classified as critical for the
production will be equipped with the online
system. The investment for the new plant
amounts to SEK 3.9 billion and will increase
ore production in Garpenberg
from the current level of 1.4 to
2.5 million tonnes of ore per
year.
The new facility is expected
to be operational in the first
quarter of 2014.
SPM look forward to even more
cooperation with Boliden and
are very proud to be Bolidens
first choice for condition
monitoring.For technical details,
please visit:
www.aptgroup.com.au
info@aptgroup.com.au
Get a GRIP on Your

Maintenance Department
www.ashcomtech.com
MaintiMizer CMMS/EAM Solutions
Whats Missing in
Your Tool Bag?
Safeng provides OH&S services

that include OH&S WHS
Auditing, Safety Procedure
Writing, Worker and Workplace
Assessments, JSA Task Writing,
Safety Presentations, Training,
Auditing and Surveys.
Safeng Pty Ltd is licensed and
accredited for sales and
facilitation of the Safety
Commitment Survey.
www.safeng.biz
AMMJ
May 2013
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SPM Instrument presents Leonova Emerald
SPM Instrument, Sweden, today announces the launch of

Leonova Emerald, a new data collector in the Leonova
line of portable instruments and sibling to the Leonova
Diamond released in October, 2012.
Leonova Emerald comes with the patented and awardwinning SPM HD measuring technique for condition
monitoring of rolling element bearings. Capable to
reliably measure machine condition in the 1-20.000 RPM
range, the method brings to light machine problems
which are impossible to monitor with traditional vibration
measurement techniques.
Alongside SPM HD, Leonova Emerald also offers highly
sophisticated vibration analysis capabilities. The instrument
boasts an excellent signal-to-noise ratio and provides
razor-sharp spectrums even where signals are weak and
low in energy content. The 0 to 20 KHz frequency range
covers most needs in practical vibration measurement. For
corrective maintenance,
dynamic balancing
can be added to the
instrument as an optional
module.
Stefan Lindberg,
Managing Director
of SPM Instrument,
comments on the
introduction of the new
instrument: Leonova
Emerald is a data
collector engineered for
performance. The full
range of sophisticated
measuring tech-niques with supporting diagnostic and
troubleshooting capabilities makes it the perfect frontline
tool for industrial maintenance.
For technical details, please visit:
www.aptgroup.com.au info@aptgroup.com.au
More new features examples:

Measuring point imaging connects images or photographs
to measuring points, and can be displayed in various parts of
Condmaster, e.g the Alarm list, Graphic Evaluation, Colored
Spectrum Overview, etc.
Highlighted measuring points - measuring points of particular
interest can be highlighted in the Measuring point tree and
displayed in a separate window, making it easy to keep an extra
watchful eye on them.
HD Order tracking algorithms produce spectrum with
exceptional detail and without smearing problems.
Vocal comments comments to measurements can be voice
recorded (in .wav format). When a measuring point has a voice
comment, it can be played back in Condmaster.
For technical details, please visit:
www.aptgroup.com.au info@aptgroup.com.au
SPM Instrument presents Condmaster Ruby
The new release of the Condmaster condition monitoring

and predictive maintenance program Condmaster
Ruby continues to enhance the software with powerful
new features and usability improvements. Among them
is advanced functionality for the recently launched
instruments Leonova Diamond and Leonova Emerald.
One example of the new features is Publishing of trends
and alarms on the Internet, which offers the possibility to
publish trend graphs and alarms on the Internet, enabling
users to view them via most mobile devices with Internet
connection (such as smartphone, tablet and computer),
without access to Condmaster. This enables you to easily
monitor critical machines or machines with deteriorating
condition when you are on call or on the go.
50
AMMJ
May 2013
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iReliabilityTM Joins IBM PartnerWorld
To further enhance iReliabilitys compatibility with
select Computerized Maintenance Management Systems
(CMMS) and Enterprise Resource Panning (ERP) systems,
iReliability has joined IBM PartnerWorld, making
iReliability the clear choice as a targeted bolt-on solution
with an easy-to-use use interface and a safe IT selection.
The Maintenance and Reliability community has seen
firsthand how powerful the iReliability toolkit is and how
much it simplifies their role within their plant. The challenge
has been, without the IT seal of approval, clients often could
not get access to the tools or had to suffer double data
entry - entering data into both Maximo and iReliability.
iReliabilitys participation in IBM PartnerWorld offers
the opportunity to create a secure path for iReliability or
Maximo analytics to be passed back and forth safely.
By becoming part of the PartnerWorld Community of
Practice, we will have a view into new data structure and
functionality changes planned for Maximo to better
anticipate how we can even further enhance functionality...
delivering more effectiveness and efficiency to our clients.
www.iReliability.com
Portable Data Acquisition System from Elsys

Enables Precision Measurement in Rugged,
Remote Environments
51
AMMJ
New TraNET PPC captures multiple data points

simultaneously on up to 24 channels
Elsys Instruments, a leading manufacturer of custom and
standard fast, high-precision data acquisition systems, now
offers its highly accurate transient recorder technology in a
portable, ruggedized system for in-the-field measurements.
Available with up to 24 channels and sample rates up to
240 MS/s, the flexible TraNET PPC enables precise data
acquisition from multiple points simultaneously.
The new system combines Elsys high-speed, LANcontrolled instruments with a robust industrial PC for flexible
data acquisition in a number of harsh and mission critical
environments, including power plant maintenance, electric
traction engine testing, ballistics and explosive testing.
The LAN connectivity enables reliable, standalone

operation in remote applications as well, such as
structural health verification on bridges and buildings,
seismic activity monitoring or stray voltage detection from
defective power lines.
Channel
configurations
of 4, 8 and 12
are available in
addition to the
24, depending on
application needs.
Each channel
provides up to 128
MB of acquisition
memory.
Different Elsys PCI/PCIe-compatible TPCX and TPCE
digitizers comprise the heart of the TraNET PPC,
depending on specific application needs. The modules
offer a typical measurement precision of 0.03% with
transfer speeds of up to 2.5 GB/s on the PCIe-compatible
modules.
These advanced digitizers offer many sophisticated
features such as single-ended and differential inputs,
large input voltage and offset ranges, advanced trigger
capabilities with an external trigger, programmable antialiasing filters as well as ICP input for piezo sensors and
digital inputs.
The new TraNET PPC offers several different recording
modes to address specific data requirements. Scope
mode, Continuous mode, Block mode, The most
sophisticated mode, Event Controlled Recording (ECR),
provides intelligent streaming for troubleshooting and
long-term monitoring applications. ECR uses smart trigger
logic that allows adjacent channels to overlap ensuring
all relevant data is captured and eliminating dead time
between triggers. In addition, every channel can acquire
waveform data independently on trigger command as well
as synchronously with associated channels.
www.elsys-instruments.com/products/tranet_ppc.php?
Nolek Launches Game Changing

Portable Leak Detector
In the past five years Nolek has spent considerable sums
and time on the development of the proprietary SniffIT
Technology. First an analogue
version of the product was released
in the marketplace in 2010. Since
that time, Nolek has been working
on the digitalization of the product,
the refinement of the measuring cell
and other improvements based on
customer feedback. The product
is now ready to be launched in the
marketplace.
The new SniffIT Digital series of
portable leak detectors are truly
redrawing the map of the leak detector
marketplace. The SniffIT Digital leak
detectors are the most accurate high
sensitivity mobile sniffers in the world
today, yet they are the lowest priced
leak detectors in the given sensitivity range.
The technology leap that Nolek has made with these sniffers
can easily be visualized by comparing the difference between
the first car-mounted cell phones to the modern-day iPhone. We
have taken a product that the market generally knows as a big,
expensive, heavy box with a hose connected to it into a product
that is truly mobile, i.e. not bigger than a human hand and that
weighs almost nothing in comparison. At the same time, the
SniffIT Digital series of leak detectors have higher sensitivity
and can measure leaks faster, better, and with various additional
functions that the old stone age technology cant offer.
We are extremely proud of our new SniffIT Digital series of leak
detectors and we know that our customers will be happy to take
this technology leap together with us. We have already gotten
feedback from the marketplace that is truly remarkable and
we look forward to offering this revolutionary product series to
both new and existing customers world-wide Comments Pr
Thomaeus, Sales Manager of Standard Products at Nolek.
www.nolek.com
May 2013
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Plant Engineering and Services Article
Always In Touch
Adapting mobile devices to
industrial applications
Mobile devices like the Apple iPad are being used efficiently in industrial settings.
Wa Fredrik Alfredsson, Jonas Bronmark, Magnus

Larson, Elina Vartiainen ABB Corporate Research
Petter Dahlstedt, ABB Process Automation, Control
Technologies
Sweden
52
Mobile devices have great potential to increase

the efficiency, productivity andsatisfaction of plant
personnel in industrial settings: People could work more
independently; there could be feer errors as personnel
access information on their mobile devices rather than
relying on other people or ones own memory; systems
could be updated on the spot; and decision makers
could be contacted directly anytime.
Mobility could considerably increase the efficiency of
field workers as they could access real-time information
away from their work stations or control rooms,
enabling greater independence.
And yet, despite the obvious gains to be had, mobile
devices in industrial settings are not being utilized
to their fullest. But ABB is working to change that.
Its researchers have been identifying the challenges
of using mobile devices in traditional production
environments as well as identifying theneeds of
personnel in those settings. ABB is defining mobile
device concepts that will help empower plant personnel.
Today, mobile devices are an essential part of

peoples daily activities, enabling them to keep
in contact through calling, texting, emailing and
social media. Mobile devices are also used to
create media (includingphotos and videos) that
can be shared with others. Moreover mobile
devices are more than just communication
devices: They can be used as a music player, a
navigation device or a gaming platform, enabling
a very powerful combination of technology that
can be leveraged for industrial automation. The
interaction techniques people use to control
mobile devices (for example, touch, voice and
gestures) have also evolved at a fast pace during
recent years. For example, the introduction of
well-designed touch-enabled devices changed
the smartphone market completely, and the
voice recognition (for example, Siri on the
iPhone) and gesture recognition are finally at
an acceptable level. These possibilities enable
efficient interaction between the user and the
mobile device even in situations where hand/eye
interaction is not possible.
Challenges for mobile devices
The challenges of introducing mobile devices in industrial

environments include network capability, current work
practices, IT infrastructure, environment and safety
equipment.
Network capability
An industrial plant may not have network infrastructure
for mobile connectivity. This might be quite obvious in an
underground mine, where the rock makes it very difficult
to build a network that would provide good signal strength.
Yet open-pit mines might not have good mobile network
coverage either since they are often located in sparsely
populated remote areas, which therefore have no need for
commercial or proprietary mobile networks.
Current work practices
In many plants radio phones (ie, walkietalkies)
are still an important means of communication between
workers. Factories are often divided into many areas that
use different radio frequencies for communication to prevent
information overload. In some factories workers carry both a
mobile device and a radio phone, as the mobile device has
not been able to replace the functionality that radio offers.
AMMJ
May 2013
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a mine or walking around a plant. Yet todays workers

spend less time in dangerous areas, as they more often
stay in control rooms or other office locations. Therefore,
safety equipment is becoming less of a challenge in
certain areas.
Assessing needs
Figure 1
53
ABBs Extended Automation System 800xA supplements mobile device usage.
IT infrastructure
Industrial IT systems usually contain a lot of legacy
software as they have been developed over several
decades, and it might be difficult to integrate mobile
devices to the existing process systems. For
example, the mobile solutions introduced by the
customers might not be specifically designed for
mobile devices but rather copied from a desktop
environment.
Industrial processes also require extremely secure
IT systems, which external persons are not able to
access. Companies are concerned about utilizing
mobile devices as they could introduce more
complexity and risks into their IT systems. The
IT department might value system security more
than providing mobile solutions that could improve
efficiency. Understanding this tradeoff is crucial
when designing mobile solutions for industrial
automation.
Environment
The multitude of different industrial environments
also affects mobile device use. Some have
impurities such as dust or dirt which can affect
the touch abilities. Other environments might
have large temperature variations affecting the
battery function and possibly making the mobile
device work slower with longer response times.
Others might have humidity. Light conditions can
also differ, thus impacting the color scheme and
lighting in the device to achieve the best contrast.
Safety equipment
Industrial environments require personnel to
wear protective gear. The type of gear can vary
based on the safety level of the process, but in
general, safety boots, vests, helmets, gloves, ear
protection and safety glasses are commonly used.
Often protective gear is mandatory in certain
areas; for example, when moving in tunnels inside
ABB has identified specific needs for mobile devices to

be used in industrial environments. Understanding these
needs is essential when designing mobile solutions to
create more efficient operators and field workers.
Through its research, ABB has discovered that rugged
mobile devices are not wanted in locations where sparkfree equipment is not a requirement (as, for example, in
oil or gas platforms). Users prefer to replace broken or lost
devices with new ones rather than pay extra for rugged
options. Users want well-designed backup solutions that
will keep the device content safe in case of an accident.
The backup solutions would automatically save the
content of the mobile device to a secure server to prevent
information from getting lost in case of an accident.
And of course, security must be very high since any
break-in to the system could be disastrous. Yet the level
of security should not affect the availability of the system:
There is no use for mobile solutions if the information
cannot be accessed anytime, anywhere.
Another important criteria is that the mobile device should
fit into a pocket; otherwise, the device might stay on the
work desk and not be carried along during assignments at
the plant.
The ability to type with a full keyboard is not considered
an issue since the mobile device is not meant to replace
a desktop computer it is just a tool when a field worker
is on the move. ABB has installed Extended Automation
System 800xA workstations in plants for workers to
access the process automation system remotely. These
stations have a keyboard and a big screen and can be
used when the capabilities of a mobile device are not
enough (Figures 1 2).
AMMJ
May 2013
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54
Learning to cope with certain limitations of smartphones

(for example, the need to charge the phone daily)
is also not considered an issue since the phone could
be charged between ones shifts together with other
equipment that also needs to be charged eg, lamps.
Thus, special devices with extended battery durability
might not be necessary.
Current mobile devices that have been specifically
designed for industrial environments do not include
the latest available interaction technologies such as
multitasking or multitouch, nor are they equipped
with sensors for measuring the orientation (gyro,
accelerometer), proximity of other objects, and
light conditions. However, the latest smartphones
in consumer markets offer these capabilities and a
superior user experience. Workers in industrial settings
have the same expectations of mobile devices when
used as a work tool.
The main advantage of a mobile device in an industrial
setting is the real-time access to all information
independent of the workers location. The information
includes the process data as well as manuals,
blueprints, and descriptions. Up-to-date information is
vital for accessing process information. Today, this is
accomplished by communicating via radio or phone
with the operator in the control room (see Table 1).
For a mobile solution to work, it is important that
everyone is included in mobile communication. All
personnel should have a mobile device in order
to be reachable. Otherwise, other communication
methods are needed, which in turn add complexity
to the communication. In an ideal case, people could
contact anyone at the plant according to, for example
their availability, responsibility area or expertise
without needing to know the actual phone number.
The communication method (for example, phone or
video call, text messages, or chatting) could

also be chosen according to the work task and
availability of participants. This could minimize
the operators being overloaded as they could
answer some of the questions asynchronously.
Mobile devices would also enable private
communication, which is not possible with radio
phones.
At times personnel in industrial settings use
their work or even private mobile devices to
take pictures or videos of issues encountered
for documentation or to consult with their
colleagues. However, they do not have any
support for this task from the system or tools
provided by their employer. Therefore, industrial
mobile devices need to make it possible to
collect and share information about the status of
the industrial process more directly.
Application development
The rapid development of Web and mobile
applications is very different from the traditional
release cycle normally used for industrial
systems. Mobile applications have adopted a
release cycle of weeks and months, adding new
functionality and features as they are updated.
The mobile app Angry Birds, for example, has
constantly been adding more levels and new
characters into the gameplay since it was
released in late 2009. Similarly the Facebook
application for iOS has also constantly been
adding functionality over time instead of
releasing a version that does every requested
feature from day one.
Such a method for software development
(ie, adding functionality in small but frequent
Figure 2
System 800xA on a mobile device
installments) is necessary in the mobile domain as the

hardware and software is shifting so rapidly. That is,
the top-of-the-line hardware today will be considered
old and replaced by something else tomorrow. These
quick software release cycles are something that the
industrial sector will have to adapt to by releasing
updates as frequently as any other apps for the mobile
devices instead of releasing super versions that include
every requested feature but with the price of a very long
development phase.
Furthermore, with a shift toward quick development cycles
it is possible to develop and release software for the
industry that solves the most critical use cases, where
mobile solutions will make a huge impact. Continuous
updates to the industry applications will then improve
and add requested features. Also, rapid prototyping and
mobile app development on mobile devices is inexpensive
today, which makes the smartphone platforms attractive
for industrial domains as well.
AMMJ
May 2013
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What lies ahead

The continuous progress in mobile technologies
related to user experience and interaction
techniques raises the need to allow existing
human-machine interfaces (HMIs) to evolve so
that personnel can use these techniques when
interacting with ABB products. Future HMIs should
utilize the best parts of these new inventions
(including depth-sensing, gestures, voice contro
and new display technologies) and enable users to
interact with systems more efficiently, and safely.
ABB research shows that with custommade apps
for well understood scenario and use cases, mobile
device usage in industrial automation can be taken
to a completely new level. New developments such
as augmented reality, pico projectors and sensors
for detecting the environment can make mobile
devices even more powerful in several ways.
Augmented reality shows a live view of the reality

through, for example, a camera view of a mobile
device. The view is then augmented by computergenerated content (eg, graphics). Augmented
reality could benefit, for example, maintenance
engineers to show more equipment-related
information. For instance, the system could
visualize important information related to a device
(eg, the water level in a tank).
Pico projectors are small, handheld projectors
that can project full-size images onto any surface.
When these are attached to mobile devices (some
mobile devices already include one, for example,
Samsung Beam), any surface can be used as
a display. Then, a maintenance engineer could
use his pico projector to project, for example,
instructions related to maintenance work directly
on top of the device that needs repair.
Mobile devices already include sensors such as

a gyroscope and accelerometer to detect the
orientation of the device. In the future, mobile
devices will probably include more sensors such as
infrared cameras or smell detectors to record data
about the environment. This information could be
used to check if there are abnormal gases in the
air or if some equipment has overheated. The gyro
and accelerometer could be used to detect where
the maintenance engineer is pointing, and identify
the device in question to give him more information
related to the device.
ABB continues to look toward the future, to analyze
the impact of emerging technologies, and explore
efficient utilization and the reasonable combination
of existing and emerging technologies related to
mobile device enhancement.
Three of ABBs customers have introduced a mobile solution that utilizes the remote desktop capability of System 800xA: Boliden in Gllivare, Tarkett
in Ronneby and Alcro Beckers in Nykvarn. The Boliden mine was using an Android app on a smartphone and Tarkett and Alcro Beckers had tablet
computers. All of the mobile solutions used the remote desktop to access System 800xA in a similar way as for PC clients. Therefore, the mobile solutions
in use were not specifically designed for mobile devices with smaller screens and touch user interfaces but were directly transferred from the PC solutions
without significant rework. The customers commented the benefits of their mobile solutions as follows:
Through the mobile client we can access all the systems:
we can control processes, produce electrical drawings and
functional descriptions, and access the maintenance system.
It is very valuable to be able to be at the process site and
troubleshoot without the help from the control room. Earlier
without the phone we had to work in pairs: the other one was
in the control room and checking the screens and the other
one was at the site.
Mikael Burck, Electrical Department Manager at Boliden Aitik
55
It is an enormous advantage for the maintenance

engineer to have all relevant data easily accessible. The
tablet computer with remote desktop connection to our
System 800xA makes his work much more effective as
he now can operate the process, view real time values
and historical data during the trouble shooting.
Ted Evaldsson, Electrical Department Manager at Tarkett
Table 1
I use 800xA from my iPad through the remote

desktop to start new sets of batches, to monitor the
process and to make adjustments to the process. It
has proven to be a really efficient and accurate tool
as now I can observe the tank and its content while I
am making the adjustments.
Mats Johansson, Process operator at Alcro Beckers
Satisfied Customers
First published in ABB Review Issue 4/12
AMMJ
www.abb.com/abbreview
May 2013
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From Green
To Gold
Rod Ellsworth
56
Global Asset Sustainability
Infor
www.infor.com
Legislative measures instilled by the Emissions Trading

System (ETS), and CRC Energy Efficiency Scheme are
enforcing a reduction in energy consumption for the largest
users across Europe, with the UK focused CRC tasked with
cutting consumption by 1.2 million tonnes per year by 2020.
However for the millions of organisations which are
currently too small to be impacted by these initiatives,
reducing energy consumption is being driven primarily by
the need to stem spiralling energy bills.
The costs of energy and fuel have soared by 40% in the
last five years and are set to increase by a further 40% in
the next five years according to experts.
Of course, companies can do little about the long term
market price of fuel. And as a result, they often view
their energy bills as a fixed cost - a necessary evil which
they have little control over. However in reality this is not
the case. When one considers that on average, energy
accounts for 70% of an organisations Operations and
Maintenance (O&M) budget, and that up to 80% of energy
consumed is actually wasted, the cost benefit of cutting out
energy waste within an organisation to reduce bills, comes
into sharp focus.
While some organisations are starting to take measures to
reduce their energy consumption, attempts are often limited
in what they can achieve. Typically, companies tend to start
by looking at a utility bill and set objectives to reduce the
total figure at the bottom. Some might even combine this
figure with supply chain costs such as warehousing and
transportation to get a more comprehensive figure to work
from. However, while this might sound like a logical place
to start, this figure represents only a crude measure from
which to instigate the process.
Any objective to reduce energy wastage cannot be achieved

by just measuring the energy usage by a commodity, but
must focus on how that commodity is consuming energy.
This energy bill down approach does not include the
detailed energy consumption patterns of individual plant
assets which can identify when and where most wastage
occurs. Without this detail, there is no way of knowing
how much of the energy consumed is being wasted, and
therefore what can be eliminated without impacting the
running of day to day operations.
As with any business change, a shift in both culture &
processes are central to making improvements. In order
to reduce energy bills, the following questions must be
answered:
1 Our commitment to improving energy consumption?
2 Where is the majority of our energy consumed?
3 How much energy should we be consuming?
4 How much wastage is involved?
With the exception of (1), most organisations are unlikely to
be able to answer the above questions fully and accurately.
The old adage that you cant manage that which you
cant measure is true; if a company does not know which
assets are inefficient, it is impossible to act to improve the
consumption of energy.
Having committed to the concept, it is technology which
presents the real opportunity to deliver cost savings, as the
necessary actions simply cannot be undertaken manually.
Unfortunately no spreadsheet, no matter how sophisticated,
is capable of capturing and processing the millions of pieces
of data necessary to effectively monitor, measure and
analyse the energy consumption and performance of the
broad range of machinery, air conditioning and transportation
involved in running a manufacturing plant.
Organisations tend to assume that once an asset is installed
the biggest cost has been expended - when in fact it is the
ongoing running costs which far outweigh the initial outlay.
More over there is a belief that plant equipment will continue
to operate as efficiently as it did on day 1. In fact machinery
which utilises compressed air represents one of the largest
culprits of waste as the pressure involved in the operation of
the machine means that leaks are more likely.
However, these leaks are often left to continue without

question. The problems inevitably get worse as
the equipment ages, but again, the extent to which
consumption deteriorates is often impossible to track.
Advanced asset management systems harness data from
a number of sources to assess how efficiently a machine
is operating on a continuous 24/7 basis. They show the
actual energy being consumed in the course of production,
and the units, parts or processes which are consuming
disproportionately more energy than they should. Such
systems also provide warnings when consumption gets too
high and present red flags when maintenance, routine or
otherwise, is required.
Sub-meters are also crucial, as they measure energy
consumption at the asset level in order to feed asset
management software. However many pieces of equipment
are now being fitted with built in smart-metering at the point
of manufacture. Microprocessor chips fitted onto assets
can provide information on consumption levels, uploading
information to asset management software directly.
The level of information provided by asset management
systems can facilitate the action required to remove
inefficient processes, parts and machines which are
disproportionately energy-hungry, and the lifecycle of an
asset can often be extended through evaluation of its
running costs against efficiency levels. As the escalating
number of pressures facing manufacturers continues, any
potential to strip out costs must be exploited - particularly
where expensive energy wastage is occuring.
An increase in energy bills seems inevitable, and while part
of the cost is fixed, a large part of it is not.
Asset management software, in conjunction with sub or
smart metering, can reduce energy consumption by an
average of 30%, which for a typical plant running a large
number of machines, air conditioning units and transport
involved in supply chain operations, equates to big figure
savings year on year.
Of course, long term targets & legislative measures
are integral to reducing carbon footprints. However in
an economy which remains tough for the majority of
manufacturers, the cost savings associated with substantial
reductions in energy consumption & wastage, are very
compelling in the quest to be both green & lean.
AMMJ
May 2013
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Equipment & Services

for Plant & Buildings
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plant equipment, tools, energy, HVAC, plant services,
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Bentley releases OpenPlant

V8i (SELECTseries 5)
57
Bentley Systems, Incorporated, the leading company

dedicated to providing comprehensive software solutions
for sustaining infrastructure, has released OpenPlant V8i
(SELECTseries 5), the emerging pacesetter in information
modelling software for multi-discipline plant teams. OpenPlant
V8i is being widely adopted by leading plant engineering,
procurement, and construction (EPC) contractors and owneroperators who have confirmed it as the most practical system
for plant design, engineering, construction, and operations in
terms of fastest return on investment and the most scalable.
Through its use of iRING/ISO 15926 as an intrinsic data
model, OpenPlant V8i enables users to coordinate and share
information across multiple disciplines and the infrastructure
lifecycle, as well as among third-party systems all with full
fidelity, while also empowering them to easily migrate from
other vendors legacy systems.
CEO Greg Bentley said, At Bentley Systems, our commitment
and our hallmark is to accomplish software superiority in both
practicality (that is, quick ROI) and scalability for the largest
projects and the largest challenges in particular, the work
sharing and global sourcing required in plant creation today.
With the SELECTseries 5 release of OpenPlant V8i, I believe
our users agree that we have understood their priorities, to hit
this mark.
NEWS
He continued, Reinforcing the emerging market leadership
of OpenPlant is its selection by Siemens Industry Automation,
officially announced earlier this week, to augment its offerings
in the process industries for information mobility across
CAPEX and OPEX. Ive enjoyed observing the enthusiasm of
Siemens and Bentley colleagues, and of our joint users and
prospects, as weve demonstrated this week at Hannover
Messe in the Siemens exhibit our OpenPlant working
smarter, together with the Comos engineering software
solution from Siemens to deliver this breakthrough.
OpenPlant Provides Information Mobility with Data Integrity
OpenPlant V8i (SELECTseries 5) provides enhanced
information mobility across project team disciplines and the
infrastructure lifecycle through its use of not only iRING/ISO
15926, but also i-models containers for open infrastructure
information exchange. In addition to using i-models to share
information among the broad range of Bentley applications,
Bentley provides tools to create i-models from third-party
systems, such as SmartPlant, PDS, PDMS, and Revit, for
integrated review with OpenPlant. This information mobility
is secured by Bentleys ProjectWise system of collaboration
servers and services underlying OpenPlant ModelServer.
The OpenPlant V8i (SELECTseries 5) Offerings
The SELECTseries 5 releases of OpenPlant V8i include the
following product offerings:
OpenPlant Modeler V8i, providing:
- the ability to work stand alone or synchronised with the
rest of the team in a distributed environment;
- 2D/3D comparison tools with OpenPlant PowerPID V8i,
enabling data to be shared between the P&ID and the
model, speeding the design process and facilitating
consistency checking across tags;
- KKS workspace for users working on projects requiring the

classification system used by power plant operators
throughout Europe (available as a separate download);
- persistent point-clouds, enabling users to interchangeably
maintain and interact directly with both point clouds and
geometry in hybrid models, made practical for even the
largest plant projects through point-cloud streaming from
ProjectWise Point-cloud Services;
- support for over 80 new component types, including the
Lindab HVAC catalog;
- a custom component builder, catalog editor, and dynamic
slope placement;
OpenPlant ModelServer V8i, featuring new automation tools to
create and manage i-models across the design project, and
new tools to provide more granularity around the checking in
and out of components; together, these provide more robust
access control and management, along with greater visibility
into project status;
OpenPlant Isometrics Manager V8i, delivering a simple user
interface to quickly create isometrics styles for each project,
eliminating the complexity and extensive time typically needed
to configure isometric production using other plant design
systems; with this new functionality, projects can start up faster
and address the needs of each project with less administrative
overhead.
visit www.Bentley.com/OpenPlant.
Fluke Calibration 9190A Ultra-Cool Field

Metrology Well delivers best-in-class stability
Fluke Calibration, a leader in precision calibration
instrumentation and software, introduces the 9190A Ultra-Cool
Field Metrology Well, a small, lightweight, and accurate dry-block
calibrator with best-in-class stability.
The 9190A is ideal for pharmaceutical, biomedical and food
processing applications that demand strict quality control and
regulatory process compliance. This includes on-location
validation and calibration of RTDs, thermocouples, thermometers
and other temperature sensors.
The 9190A conforms to EURAMET cg-13 guidelines for best
measurement practices for temperature dry-block calibrators.
This means its specifications for accuracy, stability, axial
(vertical) uniformity, radial (well-to-well) uniformity, loading and
hysteresis have been thoroughly and carefully defined & tested.
AMMJ
October
May
2013
2012
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Equipment & Services for Plant & Buildings News
The 9190A has a wide temperature range

(-95 to 140 degrees Celsius) to cover the
coldest and warmest temperatures required
in pharmaceutical, biomedical and food
processing applications. Operating at ultra-cold
temperatures is not typically available with a
calibration bath. The 9190A uses no bath fluids,
which keeps clean rooms clean, makes it easier
to transport and delivers faster heating/cooling
rates. It offers best-in-class temperature stability
(plus-or-minus 0.015 degrees Celsius) for
consistent and accurate results.
The 9190A with process option features 4-20
mA connectors, a reference thermometer input
and a 4-wire PRT/RTD input with an accuracy
of plus-or-minus 0.02 degrees Celsius. It also
has a reference sensor control to minimise the
effects of the axial gradient when a reference
PRT is aligned with short sensors.
www.flukecal.com/9190A
FLIR Raven: Real-time Interactive

Security Site Planning Tool
58
Copy: Ever wanted to see exactly how your

security application plan would perform before
it was installed? Know exactly how far the
thermal imaging cameras will see? Find any
black-spots
and be able to
fine-tune the
entire system
even before
installation?
Now you can.
Introducing
FLIR Raven
the free
web-based
tool using
Google Maps
that allows
you to design
your entire security application and camera

layout using the FLIR Raven Site Planning
Tool.
Raven is an interactive thermal security
site planning tool for FLIR security and
surveillance thermal imaging cameras.
It can handle up to 50 cameras at a time
and conveniently displays both range and
location for each camera specified.
It will show you the area of detection
coverage, allowing you to plan which
cameras you need to have installed and
where. It is now very easy to quickly
determine areas of vulnerability within your
security network.
Using Raven, you can choose from a
complete list of all thermal imaging cameras
currently available in the FLIR security and
border security product range.
Raven online users guide:
An updated users guide is available online
at www.raven.flirops.com - here you will
also find a direct link to a video tutorial with
screen shots and audio. This will show
you exactly how to get the best use out of
Raven. Raven is available free of charge via
the FLIR website.
www.raven.flirops.com
Clear-VU EZ Connect Filter

Distinctive Clear
Replaceable Filter
Following a year of development, testing and
product evolution, Industrial Specialties Mfg.,
(ISM) is excited to introduce the Clear-VU
EZ Connect Filter, an in-line filter specifically
designed for convenience in most pneumatic,
vacuum and fluidic applications. There is a
customer demand for this type of product in
the marketplace and weve developed a very
unique filter. This in-line filter represents the
next generation of in-line filtration, with the
use of the finest quality filter elements coupled
with the convenience of John Guest pushin connections. said James Davis, ISM
president.
The Clear-VU EZ Connect is a push-toconnect filter that features a clear plastic
housing with a color-coded filter element on
the inside. The colored filter element frame
indicates micron rating of each filter. Push-in
connections allow for quick replacement of
the disposable filter without having to cut or
replace the tubing.
Current Clear-VU EZ Connect product sizes

include 6mm and 1/4 push-in connections
with filter options covering the following range:
10, 48, 65 or 250 micron. The filter has a
maximum pressure rating of 125 psi. Other
sizes are now available on a special order
basis.
www.industrialspec.com
SkillsTech Australia welds a

better future for USA workers
SkillsTech Australias expertise has helped
it win a contract to develop and deliver
customised training solutions for workers at a
global supplier of engineering products in the
United States of America.
The move comes on the back of the Hays
Global Skills Index 2012 that described a
world-wide economic paradox in which
many countries are suffering a combination
of high unemployment and chronic skills
shortages, with the USA being one of the
worst affected.
SkillsTech Australia Corporate Solutions
Manager Gordon Elledge said geography
was a non-issue when providing high quality
and responsive training solutions to meet
clients needs, especially during a time of
global decline in skilled labour.
Bradken is an international supplier in the
resource sector and SkillsTech Australia has
been their national training provider of choice
for the past two years, Mr Elledge said.
We recently delivered a three-week welding
program, specifically developed to upskill
Bradken employees in Tacoma USA, in an
effort to maximise individual performance
and support productivity.
The training program entailed both
theoretical and practical aspects of welding
specialised castings using exotic materials,
allowing them to meet growing production
requirements.
The manufacturing process of these
products used in large industrial power
stations and by the US military can take
anywhere up to 12 months.
This is another great example of SkillsTech
Australia providing tailor-made solutions to
support industry productivity which in turn
boosts Queenslands economy.
http://skillstech.tafe.qld.gov.au/trades/
manufacturing-and-engineering/index.html.
AMMJ
October
May
2013
2012
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FLIR Systems launches the K-Series handheld thermal
imaging cameras for firefighting applications
Siemens and Bentley extend

collaboration to the process industry
59
Extension of interoperability between Comos and

OpenPlant
Integration of 2D/3D data across the entire plant
lifecycle
Leveraging ISO 15926/iRING
The Siemens Industry Automation Division and Bentley
Systems announced today at the Hannover Messe
that they are stepping up their strategic collaboration,
focusing on the process industry sector in fields
such as chemicals, energy, pharmaceuticals, and oil
and gas. Both companies are targeting increased
interoperability between the Comos engineering
software solution from Siemens and Bentleys
OpenPlant 2D/3D system for plant design and
construction.
One of the aims envisaged by the collaboration is for
both companies to work jointly on a system that will
allow the capture, exchange and further utilisation of
data and information spanning the entire plant lifecycle,
from engineering through to plant operations across all
disciplines. Along with a cohesive connection between
Comos and OpenPlant, this collaboration also seeks
to afford users access to supplementary disciplines
supported by the Bentley portfolio such as heating,
ventilation and air conditioning (HVAC), construction
simulation, cable and raceway management, conveying
technology, steel construction and laser scanning.
By increasing the interoperability of our fully integrated
2D engineering software solution Comos with Bentleys
open 3D system OpenPlant, we will be generating
exciting new potential for users, based on the global
standard ISO 15926 and iRING, explained Andreas
Geiss, Vice President of Comos Industry Solutions,
Siemens. This will benefit both plant engineering and
operation.
Comos provides unique industry-specific solution
concepts spanning the entire plant lifecycle on
a standardised, object-oriented data platform.
Consistent and reliable data exchange is guaranteed

from the engineering stage through to maintenance,
with plant documentation that is always up to date.
Comos bidirectional data exchange between graphics
and database prevents inconsistencies and provides the
guarantee of an up-to-date, as-built depiction of the plant at
all times.
The interoperability between Comos and OpenPlant
extends the scope of these benefits to now span plant
design, engineering, procurement, and construction.
This breakthrough is a validation of our organisations
interoperability strategies, and a great return on Bentleys
investment in ISO 15926 and iRING. It brings our joint
users information mobility across CAPEX and OPEX that
is, from design and construction through operations and
maintenance, said Ken Adamson, Bentley Vice President,
Building, Electrical, and Plant Products. As in our ongoing
collaboration with Siemens Industry Automation Division
to unify product and production lifecycles for discrete
manufacturers announced last year, its both rewarding and
stimulating for us at Bentley to work with Siemens in the
process manufacturing sector. For instance, in leveraging
technologies such as Siemens SIMATIC environment,
we can together further enable the ultimate in industrial
information mobility from plant design through real-time
automation.
Monica Schnitger, principal analyst at Schnitger
Corporation, said, Weve long believed that much of
the value created in the design and engineering process
is lost in the handover to operations. By using the ISO
15926-compliant i-model to connect OpenPlant and
Comos, Bentley and Siemens are coupling 2D and 3D, the
conceptual design of a process through to the controlling
instrumentation of an operating plant. This project, an
extension of a collaboration announced last year for the
discrete manufacturing industries, promises to deliver
significant benefit to EPCs and plant operators in the
process industries. Its an exciting development and well be
watching with interest to see industry adoption.
More information on Comos and OpenPlant is available on
the internet at: www.siemens.com/comos and
www.bentley.com/openplant
Thermal imaging cameras are finding their way into more and more
industries. As the world leader in thermal imaging cameras, FLIR
Systems wants to serve every market that can benefit from the
technology of thermal imaging by developing thermal imaging cameras
specifically tailored to suit the end use. Firefighters benefit enormously
from thermal imaging cameras. Not only do thermal imaging cameras
produce a crisp image in total darkness, they also have the ability to
see through smoke, assisting firefighters to find people in smoke-filled
rooms, as well as helping them navigate their own way in through
smoky environments. They help save the lives of both firefighters and
those caught in a fire. Thanks to the ability of thermal imaging cameras
to measure temperatures, firefighters can ascertain whether a fire is
burning behind a wall or door. Being armed with this knowledge helps
them to avoid dangerous backdrafts.
These cameras
also allow the user
to find hotspots in
extinguished fires.
Imperceptible to the
naked eye, hotspots
need attention in order
to prevent a fire from
reigniting. Thermal
imaging cameras are
an instrumental tool in
ascertaining whether
a structure is safe to
re-enter once a fire
has been extinguished. Thermal imaging cameras can also be used
for other forms of search and rescue missions in which firefighters and
emergency services are often involved. FLIR K-Series FLIR markets
more thermal imaging cameras than any other manufacturer. Thanks to
economies of scale FLIR Systems can market the FLIR K-Series at an
extremely inexpensive price meaning that every firefighting truck can
afford to have one.
Easy to use, even with gloves on An intuitive and simple user interface
allows firefighters to focus on the job at hand. The FLIR K-Series is
controlled by just three large buttons on top of the unit, making it ideal
for a firefighters gloved hand. More about FLIR Systems and our
products can be found at www.flir.com
AMMJ
October
May
2013
2012
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Its finally HERE - intrinsically Safe iPad

Case is transforming industries
A West Australian mobile company, SEE Forge announces the

release and certification of a new intrinsically safe and rugged
iPad case for oil and gas, and underground mining.
These cases are highly specialised, engineered and certified
for Class 1 Division 2 and ATEX Zone2.
The intrinsically safe iPad case covers the entire iPad so
that employees that work in hazardous sites use their mobile
devices to complete their paperwork without having to worry
about intrinsically safe regulations.
The cases are designed to resist shocks, vibrations, dust
and water within indoor or outdoor environments, enabling
employees to use iPads in classified hazardous environments.
The intrinsically safe iPad case allows employees to connect
securely to through Wi-Fi, 3G or 4G. This allows employees
to use SEE Forges technology to capture issues and report
in real-time so that the information can easily be reviewed,
tracked and resolved.
Intrinsically safe cases for iPads have not previously been
available to industries such as oil & gas and underground
mining before today. With these new certified cases,
employees will have the opportunity and flexibility to work and
report while they are in areas that were previously restricted.
60
This is an exciting opportunity

for companies to boost their
productivity, explains James
McDonough, co-founder and
Managing Partner at SEE
Forge Mobile Solutions.
This newly release product
is available for immediate
use in Australia at SEE
Forges website. For further
information in regards to the
product and its specifications, please visit www.seeforge.com.
Innovative solution integrates low-cost laser

scans with modern cPLM to enable
state-of-the-art management of plant
information at existing facilities
Intergraph has released SmartPlant Fusion to specifically
tackle the challenges faced by plant operators and
engineering, procurement and construction (EPC) companies
in accessing, organizing and managing unstructured legacy
engineering information of an operating plant.
Concurrent engineering projects, turnarounds, equipment
changes and even plant acquisitions flood operators with
information in multiple formats, often distributed around the
organization, potentially duplicated and inaccessible to support
critical decisions.
SmartPlant Fusion crawls through all these information
formats and locations, automatically reads and extracts
meaningful content and assembles a highly organized plant
record that can be simply navigated via an intuitive photorealistic web portal. This as-is repository can be purged
of duplicates, thus highlighting the true master information.
Inconsistent tag naming and numbering, often the result
of different engineering projects, can be aliased and
harmonized.
SmartPlant Fusion captures High Definition Surveying (HDS),
combined laser scan point clouds and digital photography,
and integrates it with the as-is documentation to present a
digital and physical record of the as-exists plant. This can be
used for maintenance and safety planning, remote engineering

design using integrated point cloud and 3D, as well as
operating configuration capture where the true as-built state
of the plant is demanded.
Patrick Holcomb, Intergraph Process, Power & Marines
executive vice president of Global Business Development
and Marketing, said, SmartPlant Fusion marks Intergraphs
first foray into brownfield legacy information acquisition
and also extends our information management capabilities
for greenfield projects. This new solution leverages
technology from Intergraphs SmartPlant Foundation and
Leica Geosystems TruView Integrator for SmartPlant
Enterprise to provide owner operators with a unique direct
comparison between the as-is information and as-exists
condition of a plant. It provides a quick and easy starting
point of the evolution of unstructured content, enabling owner
operators and engineers to extract tremendous value from
legacy information, and allowing them to verify the operating
configuration of the plant, at a much lower cost than ever
before possible.
Rick Standish, Intergraph Process, Power & Marines vice
president of Information Management and Integration, said,
Developed in partnership with our key owner operator
partners, SmartPlant Fusion is a proven solution to organize
and contextualize the information in an operating asset
to allow our clients to quickly realize the true value of the
information locked away in disparate data stores.
SmartPlant Fusion is the fastest and smartest way to make
legacy information available for decision support. It integrates
many leading information organization and visualization
technologies, enabling intuitive navigation with an accurate
representation of the way things are really connected, thereby
transforming unstructured and unintelligent information into an
intuitive solution for all plant personnel.
For more information about SmartPlant Fusion, visit
www.intergraph.com/go/fusion/.
A case study about the decision by Woodside, the largest
operator of oil and gas production in Australia, to utilize
SmartPlant Fusion to rapidly capture, organize, manage and
reuse unstructured information for a brownfield offshore project
is available at
www.intergraph.com/assets/pdf/Woodside_CaseStudy.pdf
AMMJ
October
May
2013
2012
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Calculating Wrench Time
Research Papers and

Detailed Technical Reports
John Yolton,
SKF Reliability Systems
Download
7 Pages
PDF Size 66KB
USA
This article discusses the value of wrench time as a key performance indicator
for maintenance. An organized method for accurate and consistent calculation
of wrench time within a maintenance crew is presented. The article includes
data from a real study undertaken in a U.S. paper mill.
info@aptitudexchange.com
Determining Circuit Breaker Health

Using a Novel Circuit Breaker
Vibration Analysis Approach
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: mail@maintenancejournal.com
Download
18 Pages
PDF Size 1.32MB
John Cadick, PE (Cadick Corporation) and

Finley Ledbetter (Group CBS Inc.)
info@circuitbreakeranalyzer.com
This paper discusses a new Vibration Analysis method that is being used
successfully for determining the mechanical condition (and thus the electrical
performance) of circuit breakers. Using a marriage of compact and modern
communications equipment, internet data transfer, and sophisticated Condition
Base Maintenance Algorithms.
Circuit Breaker Analyzer Inc. (Addison, TX), a GroupCBS company, has developed the
CBAnalyzer app for iPhones, iPod Touch, and industrial tablet to simplify vibration testing, analysis
and documentation of electrical circuit breakers and other common industrial equipment.
A Multi-state Preventive Maintenance

Policy Using Semi-Markov Processes
Download
Dang, L. V.; Luong, H. T.

Asian Institute of Technology, Bangkok, Thailand
haidang_math1804@yahoo.com
10 Pages
PDF Size 330KB
The purpose of this study is to derive a multistate preventive maintenance

policy for industrial systems subject to deterioration and failure. The system
condition is modelled by a Semi-Markov decision process. Maintenance
policy is a set of predetermine activities including preventive and corrective
maintenance. The model and mathematical formulation is developed in order
to determine optimal preventive maintenance policy that maximizes system
availability.
The AMMJ publishes these papers as received and does not accept
any liabilities in regards to the contents of the above papers.
61
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AMMJ
Asset Management and

Maintenance Journal
ISSN 1835-7903 (Online)
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and Reliability. Readers from Over 130 Countries.
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May 2013 Issue

Asset Management & Maintenance Journal

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Balancing Using Your

Risk Mitigation Through

Lifecycle Cost Analysis:

From Green To Gold

The 2013 Maintenance

Does it pay to design

Equipment & Services

Inspection and Condition

Thermal imaging - a great

Always In Touch Adapting mobile devices

Calculating Wrench Time

For a Maintenance Crew

Improve the Productivity of your

Inbalance is one of the most common causes of high vibration in machines. If

Can demonstrate the nancial value that they can add

For an obligation free discussion about how we may be able to help

Perth: (08) 9474 4044

Mark numbers around the rotor, evenly spaced.

LogbooksOnline is a result of over a decade of research across all industry

Application to balance pump impellers

I tolerated this for some time before deciding

Timed oscillation Parallel ways, rotor in

Parallel ways, rotor in

Vibration 1X and phase

For "short" rotors. 3 runs.

The 4 Runs method (or

Vibration 1X and phase

For "long" rotors.

Vibration and phase

Modal balancing for flexible

ARMS Reliability gtyne@armsreliability.com

Manufacturing plants today contain numerous

The company had recognised through their internal

The approach taken for the critical equipment

management system. The RCM study addressed a

1.2 Reliability Block Diagram

Zinc Stripping Machine

2.1 The Analysis

1 - Availability Workbench (AWB) is a Trade Mark owned by Isograph Limited UK)

Making RCM work with

Software for Seamless Integration,

INITIAL MAINTENANCE PLAN

NORTH / LATIN AMERICA

AUSTRALIA / ASIA / NEW ZEALAND

P: +1 512 795 5291

P: +61 3 5255 5357

ONGOING MAINTENANCE PLAN

P: +44 122 445 9362

P: +27 10 500 8232

Figure 1 Cost Criticality Pareto Chart

Light Curtain Trip

Total Cost Contribution

2.2 The Results

First Aid Treatment

Medical treatment or lost time injury

Extensive or Permanent Part Disability

Fatality (s) or permanent serious disability

No impact or measurable impairment