Analytics Proof of Concept Reveals Imminent Asset Failures
While there was not initially an identified need for more instrumentation at the site, Genentech Corporate was looking for ways to explore the usefulness of applying some of the “Big Data Analytics” packages to see what value they can bring. The Oceanside site identified several Analytics software packages that could work but they required more instruments to bring in missing data. A pilot was created to test the concept behind these software solutions, which lead to the application of Emerson’s remote vibration monitoring using a WiHART field network and the Plantweb Optics platform.
Building a Culture of Reliability from the Ground Up in a New Facility
The Bel Group (aka Fromagerie Bel) is a multinational cheese marketer centered in France. Bel built a brand-new plant in Quebec, Canada. François Peloquin (Maintenance Manager) had the opportunity to participate and lead this project at the first shovel of dirt. With a very small team, he took on the challenge to build a world class facility with reliability in the fore front. Some of the challenges he had were to implement reliability from the design, accept the equipment’s from the OEM, a compact schedule and get ready for full production! François will share his story and strategy for success.
The Digital Transformation Journey of Gerdau Steel
The Gerdau plant in Petersburg is in the midst of transformative change. First, the plant transitioned from SKF to Machinery Manager to gain the benefits of Emerson's technology including PeakVue. Second, the site is moving from total reliance on route-based data collection to online monitoring of all critical equipment. This effort has already reaped the benefits of an improved understanding of asset health while increased the safety of the Reliability Team. Several "saves" will be reviewed.
Detecting Axial Movement of Tissue Roll to Prevent Unplanned Outage
This project outlines the versatility of Emerson’s existing prediction hardware and software to provide a solution to a unique request and a niche form of monitoring in the Pulp & Paper Industry. Georgia Pacific Crossett (GPC) had a problem where they needed to monitor a roll’s axial movement within one of their tissue converting units. Axial movement from this role had caused multiple failures in the past causing the entire process to go down. GPC approached John H. Carter to provide a solution that would involve connecting a non-casing sensor to their existing AMS 6500’s which would trend for analysis and trip the machine.
Cascades’ Holistic Approach to Condition Monitoring Across 70+ Plants
During this presentation we will share what motivated Cascades Corp to put in place a Center of Excellence for Reliability. The condition monitoring program is essential to move from a reactive maintenance organization to a proactive maintenance organization. We will share how the program was developed, implemented and the benefits that a corporate program implementation provided to the organization, impacting the OEE of each plant.
Advanced Diagnostic Techniques Can Prevent Unnecessary Work
This presentation is based on a client request to address a structural problem on their refrigerant compressor units. The motor was showing high vibration levels. They suspected that the base was not strong enough to support the system. Their second guess was a problem with the brand-new motor (out of balance). When we arrived to diagnose a structure problem, the client was already prepping to install thick structural support bracing to all previously installed units. The solution might surprise people as it looks like a complicated problem, but solution was to go back to basics.
And we have visual support using motion amplification as well as ODS from Emerson’s AMS 2140 to compare results.
Using the AMS 6500 on a Critical Grinder Reduced Exposure During Pandemic
John Garland with Dow in Carrollton, KY was asked to figure out ways to limit his exposure during the initial stages of the Covid pandemic. He was willing to use their AMS 2140 once or twice a week to collect route data throughout the plant. This was how he could minimize time in the plant but still keep up with his core job function. He was also able to monitor their AMS 6500 system remotely. They were able to catch a failure on a pinion bearing with the AMS 6500 remotely. John is unable to collect route data at this spot on the grinder with their AMS 2140 so the likelihood of finding this potential failure with their route program was not very good.
Reliability and Monitoring of Equipment that is Designed to Vibrate
High vibration machines are designed for various reasons. Typically, they move product along a route in a manufacturing process. How can vibration monitoring be utilized to determine health and reliability of the rotating components? This presentation provides a detailed example of such solution.
Vibration Program Successes in Pulp and Paper Industry
This factory’s reliability/route program demonstrated its effectiveness, detecting several failure modes on the various assets of the two sectors of the factory. Different technologies are used to improve reliability, but the emphasis is on the vibration route for decision making. The addition of AMS 2140s versus the AMS 2130s optimized data collection and freed up time for different analysis mandates. In this presentation we'll show examples of problem detection and correction while collecting and analyzing vibration data from different assets of production.
Best Practices for Online Monitoring of a Steam Turbine Generator
This presentation will be on problems that arose while performing an ATG commissioning for a steam turbine generator. The Turbine was completely refurbished with a new ATG machinery health protection unit. Initially we were there to just commission and monitor but the job evolved into a full blown inspection & mitigation.