CAS DataLoggers recently provided the automated monitoring solution for a wood products manufacturer whose workers were occasionally experiencing ‘Under Frequency’ alarms at their electrical substation, but they couldn’t find the cause. Meanwhile these alarms were disrupting production and proving costly over time. Maintenance staff believed that they could identify the cause if they could log their power levels, but the infrequent nature of these faults meant that they would have to wade through enormous amounts of data to find the small amount that was relevant. Ideally, the customer wanted to monitor the power levels (in kW) 10 minutes before and 10 minutes after each fault, so they required an intelligent solution capable of event-based logging.

The manufacturer installed a dataTaker DT80 Intelligent Data Logger in the substation’s control cabinet which was then connected to power transmitter sensors going out to the room’s machinery. A cost effective data logger expandable to 100 channels, 200 isolated or 300 single-ended analog inputs, the dataTaker was able to log nearly any physical value. Given that the client needed to record data 10 minutes prior to and 10 minutes following an electrical fault event, users enabled the dataTaker DT80’s ‘Archive’ function. In this way, the dataTaker was setup to store 20 minutes’ worth of data in an efficient rolling buffer where old data was dropped off as new data was collected.

Whenever an alarm condition occurred (as measured by a power transmitter), the data logger continued to log for 10 minutes before archiving the 20 minutes of data in the buffer. By waiting 10 minutes, the buffer contained 10 minutes of data before the alarm and 10 minutes following the alarm. Using this method, only the data relating to each alarm was saved to memory for later retrieval and analysis, and all superfluous data was discarded.

Users quickly retrieved the data via the local area network using either a FTP client or a web browser, which also allowed for remote access to logged data, configuration and diagnostics.  They could also query the number of events through the dataTaker’s internal web server and use a USB memory stick to manually collect new data as the events occurred.

The manufacturer soon solved its ongoing alarm problems using the dataTaker for its substation monitoring solution. By logging power levels both pre- and post-event, the datalogger tracked the intermittent faults and enabled maintenance staff to pinpoint and resolve the problem, freeing up their time. Additionally, the dataTaker’s rugged design and construction provided reliable operation under rough handling and other mishap.
www.dataloggerinc.com

Thermography provides the means by which ongoing preventive maintenance can be carried out. It enables engineers to inspect vital HVAC equipment, cooling systems, electrical switchgear, power distribution units (PDU) and other electrical devices quickly and easily. Thermal imaging, or infrared thermography, visualizes and measures infrared radiation emitted from objects. This technology can therefore be applied in any application where the performance or condition of a component can be revealed by means of thermal difference.

What an IR camera shows
The amount of infrared radiation emitted by a surface depends on both its temperature and its emissivity. Surfaces that are good reflectors (e.g. polished metal) are poor emitters, while surfaces that are good emitters (e.g. human skin) are poor reflectors. The emissivity of a surface is the ratio of energy radiated by that surface to energy radiated by a black body at the same temperature. Infrared energy makes up one part of the electromagnetic spectrum.

The naked eye cannot see infrared energy because it is emitted from objects as heat, not as light. The hotter an object, therefore, the more thermal energy it emits. Infrared thermal imaging cameras provide a visual representation of IR energy emissions. Where quantitative information is required, the thermal camera can also provide accurate surface temperature values of the object being viewed. The images generated can then be saved for later analysis and report generation.

Electrical parts that are damaged or about to fail will emit heat. The thermal camera detects any excessive heat in relation to the ambient temperature. For data centre maintenance engineers, thermal imaging technology can help:
•     check for loose or
over-tight connections;
•     identify overloaded components;
•     evaluate uneven voltage distribution; and
•     recognize failed or fatigued components within a distribution system without having to isolate circuits.

As an example, let’s look at a specific component of a data centre’s electrical infrastructure: switchgear. It is not unusual for switchgear to experience surges in current that can lead to connections working themselves loose. This problem can go undetected when relying on the naked eye to notice it. Poor connections can lead to loss of connectivity, overheating, fires and power outages—all of which would be potentially disastrous. Using thermal imaging, it is possible to identify hotspots within switchgear to detect potential problems, and allow the engineer to repair them.

The benefits of deploying thermal imaging to the data centre are significant. First, because it may be possible to avoid shutting down the facility to fix the detected problem, there is no disruption to normal operations. Second, regular monitoring with thermal imaging cameras to ensure the data centre’s power distribution boards, isolators and automatic switching panels are in working order can help the business comply with regulations.

In addition, regularly checking the system will lead to better diagnosis of any problems and enable maintenance engineers to formulate a more effective plan of action to overcome issues. Also, the use of real-time data provided from regular monitoring can extend the life of the system and result in significant cost savings. By identifying the inevitable degeneration of power equipment, replacement activity can be planned at the optimum time, avoiding major disruption.

Infrared imaging for saving energy
Along with using thermal imaging for preventive maintenance, the technology offers significant energy saving benefits. Green issues are prominent in the data centre industry. Analysts estimate that the increased shift towards cloud computing will triple the information and communications technology sector’s energy consumption by 2020.

Companies can achieve major cost savings by identifying areas where they are losing energy. Thermal imaging can provide a complete picture of a building envelope and its energy performance or, more specifically, a particular zone, room or piece of equipment. For example, it is possible to scan computer rooms to identify problems like overloaded racks and power cables, or even when IT equipment is placed backwards and is blowing hot exhaust back into a cold aisle. This can have a dramatic impact on the efficiency of the cooling system. The same can be said for when cold air escapes under a rack where a brush grommet should have been placed.

When thermal imaging is used to assess cooling systems and heat generating equipment it allows engineers to locate zones and the degree to which temperature-controlling units are actually cooling or heating the room. Systems then can be arranged for optimal performance, helping to increase the premise’s energy efficiency and lower operational costs.

Enhanced ease-of-use coupled with lower prices have made thermal imaging cameras standard equipment for in-house maintenance engineers. Where once a data centre would employ a specialist to carry out formal checks, in-house engineers can now do regular preventive maintenance and energy efficiency auditing themselves. In many cases, it only takes one problem to be identified and fixed for the thermal imager to pay for itself.

Infrared camera selection considerations
There are a number of key features to look out for when selecting a thermal imaging camera. Primarily, the quality of the image should be a major consideration. Owing to technological developments, it is now possible to find a device that delivers an exceptional high-resolution thermal image at an affordable price. Another important consideration is a detector that is fully radiometric, meaning it will capture temperature measurements over the entire image.

Image fusion allows the user to view the subject as either a digital or a thermal image, or a blend of both. By combining visible and thermal images, the user is able to get a clear image of the equipment being monitored while easily seeing potential faults.

Temperature sensitivity is also a key feature to look for when choosing a thermal imaging camera because it can affect the accuracy of the temperature measurements. The industry standard for temperature accuracy is ±2ºC.

Thermal imaging has become an accessible technology that is enabling data centres to replace traditional maintenance programs with predictive maintenance strategies. In addition, with the green agenda high on data centres’ agendas, this technology can help comply with energy efficiency obligations.

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Article contributed by Ideal Industries Inc. This was originally published in Electrical Business magazine.

Remote monitoring applications in fields like oil & gas extraction, environmental monitoring and fleet management often require attention to detail. Users need to accurately record and track several variables, including temperature, flow, strain, stress, vibration and more. Therefore, when purchasing a new data-logging solution, it’s crucial to understand the capabilities and specifications of the device.

However, the sheer variety of data loggers and data-logging systems can often make it difficult to choose the best model for your application. With this in mind, the applications specialists at CAS DataLoggers present 10 things customers purchasing for remote applications need to know.

1. The Goal
According to Pete Martin, sales manager for CAS DataLoggers, “To begin searching for the right product, always keep in mind your starting point — what do you want to accomplish? Consider whether you need a quick fix for a specific problem or a long-term solution providing a general need with room for expansion. Details such as knowing how many and what types of inputs are required are important, along with how often readings need to be taken (determining the logger’s sampling rate) since there’s such a range of options open to you. Often users believe they need to record multiple channels of data at hundreds of Hz, not realizing that this will soon exceed the logger’s available memory and require more frequent downloads.”

2. Necessary Features
Take into account whether the data logger must be equipped with external sensors or built-in sensors, or if programmed alarms are needed. Will the logger need to perform real-time calculations on the measured data? This could be avoided by installing an RTU (remote telemetry unit). Will the device need output signals? A clear initial idea of what requirements are needed and what features might become necessary in future are key factors in making the best choice.

3. Sensors
The type of sensors being recorded is also critical in the decision process. Ideally, the data logger will have the versatility to accommodate the range of sensors connected to it. For instance, if a user is planning to use thermocouples, the logger must support TC inputs. Likewise, if the application must accommodate several different inputs (including current-loops, voltages, pulses, etc.), a more flexible, powerful data logger may be required. Are you going to need a large number of inputs to adequately monitor your conditions? Are you expecting to only measure and log analog signals, or will you also need to record digital signals?

4. Ruggedness
Consider a ruggedized device that can survive hazardous working conditions that include dust, dirt and hits; and depending on the application, one may need to safely enclose the logger in a sturdy enclosure. Also decide how often you need to transport the data logger. Will the device need to be moved between jobs, which could jostle an unprotected unit and reduce its longevity? Will it be installed in a vehicle?

5. Power Source
Determine how the logger will be powered. Will you need a battery-operated device for extended operation? Again, this depends on the logger’s location, whether it’s going to be installed inside a vehicle or in a more stationary location.

6. Display
Ensure the data logger has a visible LCD display that clearly shows measurements in its given environment, whether in dim lighting, underground or outdoors. This will help when presenting the data to clients, instructing personnel in its use or when showing a project to others.

7. Value
No matter the budget, look for cost-effective options that give extensive features for an economical price. When anticipating future expansions, search for data loggers with a modular design so you can simply add other capabilities when needed.

8. Speed
Most data loggers can record at a rate up to about 1 Hz (once per second), although many faster recording frequencies are available. When speaking with a representative, it’s important to determine the right recording rates for your application. When recording from a K-type thermocouple, for example, the sensor/sample may take several seconds to change temperature, making a high-sample device give you redundant data. Depending on the application, it may only be necessary to capture a few minutes’ worth of data or you may need to store entire months of readings. This can be easily determined the amount of data storage required by multiplying the number of channels by the sample rate and recording duration.

Since model specifications vary, there may be a limit based on the total amount of internal memory, or the data logger may offer the option of using external memory to expand the available memory. Options like these can significantly cut costs.

9. Portability
Many data loggers are designed for fixed installation, but other devices are intended for portable applications, such as those commonly required for environmental monitoring. How remote is the office from where you’re collecting the data? Is the logging environment located underground? For many industrial applications, a USB memory stick serves as the fastest way to get your data, especially when the data is in unalterable format intended for clients to view. This method also lets users quickly get set up onsite and then gather all the data using USB. Communication with the data logger for setup, monitoring and downloading data can be done in many different ways, including those that continuously send the data directly to the software interface.

10. Software Features
Look for a user-friendly interface that enables fast configuration. Preferably, the software will be included free with the data logger. Martin adds, “Above all, go with the capabilities which prove the most practical for your application and analysis. If you’re looking for data trends, we recommend that you use the statistical capabilities offered by certain data loggers to summarize the data over an interval. If you’re looking for anomalies, use the triggering features in many data loggers to simply capture a window around the event.”

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This is an edited article provided by CAS DataLoggers. For more information, visit www.dataloggerinc.com.

The reliability of an onsite power system depends on the readiness of the engine generator and what it’s connected to. Understanding some basic application considerations will help users specify the right generator.

This article considers only reciprocating engine generators, those using diesel, natural gas or liquefied propane for a piston-type prime mover turning a connected alternator. In general, these generators are 10 kWe and larger.

Required Duty and Electrical Output
The first consideration to correctly specify a generator is to understand how it will be used. There are three duty types. Standby duty is when a generator is to be used in the event and for the duration of a power outage. Prime duty is when the generator supplies power in place of utility power. Continuous duty requires the generator to provide power up to its rated maximum for an unlimited amount of time. Each rating has a different effect on performance and equipment selection.

The next step is to configure the required output frequency (hertz), voltage and amperage.

In regards to frequency, some applications in Canada and the United States are 50 Hz; however, most are 60 Hz. Engine generators are constant speed machines operating at 1,800 rpm (sometimes 3,600 rpm) for 60 Hz and 1,500 rpm for 50 Hz.

Different voltage outputs can be made by alternator selection and connection. Typical low voltages are 120-600V single and three-phase and medium voltages 2,400-13,800V three-phase. There are other frequency and voltage combinations that can be generated but most of these would be for special applications and are not as common.

The total amperage output and load starting characteristics required of the generator is a huge consideration. This determines in large part the physical size of the generator and the cost. Determining the required engine horsepower and correct alternator combination is the process of sizing.

Sizing takes into account the number of loads and load steps required to be run and for how long. It is always best to have the most comprehensive load list prepared and analyzed to correctly size the generator. This load list should include all of the various electrical appurtenances (loads) organized in the order they would be started (load steps). Knowing start sequences for the loads is important. For instance, a generator for a pump house with multiple pump motors (total load) would have to be sized differently to start all the motors at once as opposed to individually (same total load, different load steps). Engine generator manufacturers have sizing software that can correctly size a unit based on this list. Certain loads require special consideration, such as UPSs, variable frequency drives and large motors. The better the load list, the more accurate the sizing.

• Fuel Selection.
The decision about what fuel to use comes down to the application and what is available at the job site.

Natural gas delivered by utility offers an unlimited supply without truck delivery to the site. There are some regional variations in BTU content so be aware of the heat value of the gas. Natural gas can be subject to supply interruption and the possibility of interruption can disqualify the use of natural gas in certain applications.

Liquefied propane (LP) gas is often used in a locale where utility source gas is not available, or prohibited from use. LP must be stored onsite so truck delivery is required, but it transports and stores well. There can be issues vaporizing enough gas off the top of the storage tank to fuel the engine in cold weather. This requires the LP be sent to the engine as a liquid to be vaporized just before entering the combustion stream.

Diesel, the most popular choice for standby duty, is a good reliable fuel for engine generators. It does require on-site storage, how much to store depends on how many hours of operation at load are required before refuel is available. Diesel does not store indefinitely: two years is its approximate storage life before it starts to settle or separate. Diesel can be susceptible to gelling in very cold temperatures. Winter grades, or fuel heaters, are available for cold climates; in tropical areas, a microbicide may be needed.

• Environmental Considerations.
Job site temperatures and elevation must be considered for generator selection. There should be provision to address any harsh conditions, such as temperature extremes, dust or dirt, humidity, sea air or corrosive environments. Consider if the job site is in a high-wind area or subject to heavy snow loads. Seismic certifications are required in certain areas.

• Enclosures.
Generators can either be located indoors in a specially designed generator room or outdoors in their own enclosure. The enclosure design should provide protection from the elements and unauthorized entry. Consider noise from the unit and proximity to distribution switchboards and transfer switches. Ensure engine exhaust will disperse away from other building openings and vents.

Generator room applications require adequate space for service access and clearances required by electrical code. There must be adequate airflow for combustion and cooling. Vibration isolators should be installed between the generator base and floor.

Outdoor enclosures are typically made of sheet metal, steel or aluminum. They can be skintight or walk in with space to allow personnel entry. The structure of the enclosure can be designed to attenuate sound. Many provisions to address harsh environments are by enclosure design and options.

• Emissions.
No other concern about engine generators is more stringently regulated than emissions. Both Canadian and U.S. environmental protection agencies set standards for allowable emissions from diesel and gaseous generators. Standards are imposed based on engine horsepower and application. There can be significant legal and monetary penalties for violating standards. Keep in mind there can also be regional or local standards that exceed federal standards. A professional should be consulted to make sure all regulations are known, the equipment being supplied is legal for the application and permitting processes are followed.

• Standards of Safety and Performance.
The International Organization for Standardization (ISO) has relevant standards for generators in regards to ratings and performance, as well as standards for the manufacturing process. Underwriters Laboratories (UL) and Underwriters Laboratories of Canada (CUL) set standards and makes a listing available for demonstrated product safety and integrity. The National Fire Protection Association (NFPA) sets fire prevention standards, establishes safety and performance standards for transfer switches and addresses the performance of emergency standby generators in critical applications. Some regions are subject to the provisions of the International Building Code (IBC) that require the generator to be designed and tested to operate after an earthquake and to withstand high wind loads. Additional sources of standards include the Canadian Electrical Code and US National Electrical Code, the Canadian Standards Association and CE mark. These are common for generator professionals to understand and your chosen manufacturer should be knowledgeable about how they apply.

Find a Professional
Good distributors and manufacturers welcome the opportunity to help you. Be prepared to discuss the duty type. Share your load list and particulars of your job site. Let them know fuel preference and how many hours you intend for the generator to run. Determine if the generator is intended for indoor or outdoor installation. Find out if there are noise restrictions and absolutely understand emissions regulations and permitting processes prior to purchasing any equipment. This should give you a good start on selecting the right generator.

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Rob Hilkemeier is the Western regional sales manager for Baldor Generators. For more information, visit www.baldor.com.

A plant engineer’s ability to diagnose, detect and monitor equipment condition issues is advancing all the time, thanks to ongoing developments with vibration, thermography (infrared), oil analysis and ultrasound tools, just to name a few.

So once you have all the fancy new tools, do you know how best to take advantage of them?

We’re here to help. Along with the sophistication of the tools available, ways to synthesize and integrate data so that maintenance teams can make immediate use of it and also monitor trend issues over a period of time are also progressing. PEM asked leading technology providers to share the latest in their condition monitoring tech developments, how best to integrate them, and where the future is headed.

Infrared
Over the last few years, infrared cameras have improved significantly in terms of resolution and now come with more options as well, says Paul Frisk, manager of the Infrared Training Center in Burlington, Ont. (the training arm of infrared camera-maker FLIR Canada Ltd.). “Infrared cameras now have the ability to incorporate wireless data from digital clamp meters and other instruments and make that all available at one glance,” he explains. “Some cameras now available immediately generate a single-page report. This summary can be transferred for printing and archiving by download to an office computer or through wifi to a plant’s CMMS system.”

Frisk says the primary value of an infrared camera is in its ability to initially determine whether a device is working properly or not while it’s running. “With some other diagnostic tools, you have to shut down the device, which obviously impacts production,” he notes. However, as with many types of detection and monitoring technology, there are misconceptions about what infrared cameras can provide.

“From watching movies and TV, people think infrared cameras can allow you to see through walls, water, etc., but they only measure released infrared energy,” he explains. “A properly trained thermographer can determine temperatures from infrared readings using conversion factors, knowing the material and so on, but infrared cameras cannot overcome the physics of all materials under all conditions.” He also stresses that infrared images can easily be misinterpreted, and proper training is absolutely necessary.

In addition to using handheld infrared cameras and connecting them with your plant’s CMMS, standalone infrared cameras can send data to the process PLC (programmable logic controller). “Based on the camera’s readings, things like process speed, fans or heat can automatically be adjusted if the material needs to be kept at a certain temperature,” Frisk notes.

With regard to the future of infrared condition monitoring technology, he foresees more improvement in resolution and smaller camera size, along with a continued drop in cost.

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Ultrasound
Ultrasound instruments have changed a great deal over the past decade, according to Alan Bandes, vice president of marketing at UE Systems. Analog detectors, which required manual entry of test results for basic trouble-shooting, have been replaced by software-driven digital systems capable of analyzing trends and reporting on a wide range of operating conditions. Newer models offer things like sound analysis, cameras, non-contact infrared thermometers, and even touch screen controls. “There are a lot of professionals that haven’t looked at ultrasound technology closely and view the instruments as basically leak detectors,” Bandes says. “Others feel, incorrectly, that ultrasound is too subjective, which is often due to experience only with older analog units.”

Bandes says it’s very easy to integrate ultrasound technology into plant processes. “Due to the sophistication of on-board software and external supportive software, users can create routes, establish baseline information and upload and download route data,” he explains. With baselines set, the software can notify personnel with low-level alarms (for example, lubrication starvation) or high alarms (failure) through headphones or other means.

Some instruments provide inspectors with the option of opening up a spectral analysis screen to analyze bearing faults, gear mesh issues and electric emissions while in the field. Recorded sound samples can be played in real-time and viewed with an image of the spectral screen. “This feature is very useful for electrical emissions as well as mechanical operations,” he notes.

Software associated with ultrasound instruments can provide specialized reporting for things like steam traps, valves and bearings. “Regarding leak surveys, downloaded test results can be converted into reports that provide important information for cost analysis and greenhouse gas emissions,” Bandes says. Regarding the future of machine monitoring by ultrasound, he believes “we are only limited by the software we can develop.”

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Oil analysis
More vendors now supply in-plant oil analysis sensors and the means to communicate with those sensors. “It's no longer necessary to rely solely on a lab for analyzing oil samples to determine fluid condition,” says Darren German, Bosch Rexroth national service manager. “In the plant, we can now get real-time results on of oil cleanliness (particle count), water content and temperature when sensors are coupled with a data acquisition device.” These devices can record and track trend parameters in real time for any given time period, but German cautions maintenance teams that monitoring equipment should be considered as a compliment to a bottle sampling program; reports from an oil analysis lab still provide the most oil condition information. The role of monitoring equipment is to provide additional protection between bottle sampling periods, he says. “If, for example, a heat exchanger ruptures and releases water into the oil the day after a bottle sample was taken,” he notes, “this will likely go unnoticed until production stops if there is no oil analysis sensors in place.”

The many oil-monitoring systems on the market range in complexity and price. “Some of the data acquisition systems also provide the ability to add a threshold or alarm which will signal the moment the results vary from a ‘baseline normal,’ ” he says. “We suggest that before investing, you should understand what it is that you want to accomplish — what parameters are important to monitor.” He recommends that maintenance groups consult with their engineering groups prior to purchasing a system, as the ability for a machine to communicate with a sensor often already exists within the machine HMI.

German predicts that down the road, the capacity to measure reliable viscosity and TAN (total acid number) will be developed, along with a sensor that can measure the amount of air in hydraulic fluid. “ ‘Smart’ sensors and wireless sensors are often mentioned as coming down the pipe as well,” he says.

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Vibration
Advances over the last few years in sensor, recording, and analysis technology have put vibration analysis within the reach of even small companies, says John Bernet, product and application specialist at Fluke Corp. “Easier measurement procedures (triaxial sensors), combined with vibration diagnosis programs (expert systems) now enable maintenance teams with minimal training and experience to use vibration to evaluate machine health and determine required maintenance,” he notes.

Bernet says vibration can identify problems before other symptoms, such as heat, sound, electrical consumption and lubricant impurities, are detected. “Measuring the vibration of motors, pumps, and other common machines can reveal valuable information about machine health or impending failures,” he notes. “However, instead of focusing on the patterns of the hundreds of faults that vibration analysis can reveal, we should focus on the four most common mechanical faults: imbalance, misalignment, wear, and looseness.” He adds that studies have found that many vibration analysis programs don’t collect all the data needed to make an accurate diagnosis — to diagnose machine condition correctly, vibration data is needed from all three axes of a rotating shaft.

The key to automating vibration analysis, he notes, is to compare new data with data from a similar machine known to be functioning properly. Automated diagnostic programs perform a sophisticated analysis, comparing hundreds of data points with the fault patterns of similar machines to give easy-to-understand results.

Bernet foresees that the benefits of vibration analysis will be expanded to the entire plant in future. “A plant’s reliability team can use high-end analysis programs on the few complex machines, while the maintenance team can use simple diagnostic tools on the basic machines,” he says.  p

Treena Hein is a freelance writer based in Pembroke, Ont.

As the world’s largest Caterpillar equipment dealer, Alberta-based Finning sells, rents and services heavy equipment and engines. Their customers run mission-critical equipment in rugged and isolated locations.

To keep customers moving, Finning’s vehicle service teams conduct ongoing equipment inspections and preventative maintenance in the field, generating large amounts of paperwork. The data is used to coordinate repairs, order parts, schedule future service and bill for labour.

Teams collect this information on paper in the field, but it takes time for the data to get back to operations, delaying parts ordering, follow-up service scheduling and billing. On top of that, manual data entry into back-end systems takes service technicians away from billable tasks. A key document process for Finning is the timesheet, as it doubles as an invoice and record of repair. Timesheets are filled out in the field and driven back to the office where they are ultimately entered by hand into Finning’s back-end system. Delayed time sheets create delayed billing and poor operational visibility to service records.

In order to digitize the information collected from the timesheets, Finning started using digital pen and paper technology by Anoto and Capturx Forms Service solution for real-time data capture. Now repair teams use the same timesheet that they’ve been using for years, but as teams fill them out, the digital pen creates a normal ink record on the paper while also making a digital copy — which it stores in the pen’s memory. Teams can use smartphones to send data directly from the Bluetooth-enabled digital pens to their back office. Data sent wirelessly from the field is instantly available in the back office in the original handwriting as well as converted text in data tables. The data can be integrated directly into other back-end systems like timecard management software to automate workflows, such as payroll and billing. PDF files with the original handwriting also contain converted text as keywords, making them easy to search, archive and retrieve.

“Finning provides a range of equipment sales and customer support services to the oil field, pipeline and other industries throughout Western Canada,” said Sam Chapdelaine, customer services manager with Finning. “Capturx helps us efficiently track the service paperwork for our planned approach to scheduled services, proactive maintenance and repairs, so customers can minimize unplanned downtime and get productivity when they need it.”

Service teams no longer take billable workers out of the field in order to drive forms back to the central office. With the extra time, service crews can spend more time on billable tasks. And with reduced lag between service repair and delivery of the service record to the central office, Finning has real-time visibility into their customer accounts and repair teams.

With immediate access to timesheet data, the office can expedite the billing process, keep payroll records up-to-date and streamline account reconciliation. There’s no more month-end scramble, invoices slipping into future months or confusion over missing paperwork.

Despite the use of “sophisticated” tools, many businesses still rely on manual data collection methods with pen and paper. Digital technology automates information in a way that is easy, reliable and requires minimal user training. As a result, organizations — especially those with a large field service staff — can continue to collect information the way they always have but now with the benefit of immediate access to operational data.

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Pietro Parravicini is the CEO and president of Anoto Inc., and Ken Schneider is the CEO and chairman of Adapx. For more information, visit www.anoto.com.

These days, it’s a whole new world for maintenance and engineering technicians. The use of mobile computing devices — allowing workers to take speedy, automatic readings, easily access asset histories and do much more — is on the rise, replacing the traditional pen and clipboard.

“Mobile solutions are a fundamental change for field and plant workers, because they provide access to the office computer, other company personnel and the internet — but also because they revolutionize the old world of manual data collection,” says David Berger, founding president of the Plant Engineering & Maintenance Association of Canada and a consultant with Western Management Consultants. Technicians are now using mobile computing power to do things undreamed of a decade ago: collect equipment performance data like pressure and temperature readings or send a picture with a message to a manager or co-worker for advice. With mobile devices, technicians can also handle work-order details more efficiently, transfer information to their CMMS database in real time, or search vendors’ websites and make direct inquiries without office support.

Early challenges with mobile computing have been overcome, and the full capabilities of hardware and software are now being realized. “The first step involved software firms providing some version of what you had in the office on a mobile device, but usage was clumsy,” Berger says. “There were issues with operating systems in that sometimes you could only view things instead of use them, you had to scroll around a lot, and the units weren’t rugged enough.” He notes that now systems are readable and usable on small screens, and workers have access a large range of powerful tools, from cameras, RFID/bar-code scanners and GPS to a scribbling function and the ability to hold a conference call.

Being connected to a company’s CMMS at all times (or most of the time using a store-and-forward function where data is collected, stored and sent when the device encounters a Wi-Fi or cell network) can result in productivity improvements of anywhere from 10 to 30 percent. “New instructions can be sent to the technician based on data the technician has sent in or a change in priorities on that day,” notes Kris Bagadia, president of PEAK Industrial Solutions. Having the data collected in real time also means workers can be alerted and respond on the spot. “An immediate reaction to a reading that’s out of the normal range can save a significant amount of money,” he says. 

Tablets offer more
Up to this point, PDA-style handhelds have been more common than tablets — and are still the number one way of collecting data, notes Florian Lenders — but their limitations have put the focus on tablets. “The small screen size of handhelds makes it hard for technicians to see the text, especially in poor light situations, and workers are also looking for more information access on-screen,” says Lenders, the vice-president at Ivara Asset Performance Management Software in Burlington, Ont.

“There is a shrinking market for cheap ($500 to $600) PDA-style handhelds with only a handful of suppliers providing ruggedized, units at a price equal or higher than the latest tablets.” He adds, “There’s also concern about the life expectancy of the current PDA operating systems, as Android and other options gain ground.”

Besides, whether you use a handheld or a tablet, both hands are needed — and while handhelds can more easily be clipped onto a belt, tablet portability has come a long way. “They’re stored and are brought out like a clipboard when needed,” says Scott Ball, the Canadian business development manager for Austin, Texas-based Motion Computing. “They can also be attached to a shoulder strap during climbing.”

The greater amount of information that can be accessed with a tablet is critical for technicians and managers. “They have the capacity to contain CAD diagrams and full electronic versions of a manual,” he observes.

The computing power of a tablet is also important, allowing things like saving multiple trips to a given area of the plant or field site. “The software supported by a tablet can analyze a given reading and determine whether, for example, an oil sample should be taken,” Lenders says. “And once the data is automatically transferred or downloaded later to your company’s CMMS back at the office, the system automatically plans the next work order, alerts the lab that an oil analysis request is coming, and so on.”

However, Bagadia points out, “As long as you have Wi-Fi and your CMMS system is web-connected, you don’t need additional programming for your mobile device. You just collect it, send it, your CMMS system does the analysis and any needed results come back.”

Tablets, beyond providing accessing to more data and providing more computing power, also provide another advantage. “To be useful to maintenance personnel, the more things a device can do, the better, and tablets can do a lot,” Ball says. “Our tablets have a bar code reader, camera, GPS, wireless capability and other things, that are now all considered standard features.” (He notes that they are all integrated into the device because attaching items to one another is a potential failure point.) He adds that outdoor-screen technology, which makes it easier to read a screen in direct sunlight, is also becoming standard.

“Most customization of mobile computing solutions for each client is therefore all about the software,” he says.

The first step is to speak to a well-established company about your needs. “You should choose a device that meets or exceeds the software vendor requirements for memory and accommodates the intended use,” Bagadia says. “Managers need to consider the benefit of enough memory to download large amounts of information to the portable device — for example, making the entire equipment or inventory available for technicians.” He adds that in order to help technicians with trouble-free data capture and recording of work progress, the device should give them the ability to choose from lists of pre-defined codes and phrases.

Costs kept low
The best news of all is that the cost of tablets has dropped enormously in the last 12 months. “The release of the Apple iPad has put a huge amount of pressure on manufacturers to lower their prices,” Lenders says. “The cost of a rugged tablet is now $1,000 to $1,500, which is 50 to 75-percent less than about a year ago.”

Bagadia says the overall price of instituting mobile computing at a company will not be as high as one thinks. “Most people have the misconception that if you have 50 technicians, you’ll need 50 mobile devices,” he notes, “but depending on factors like what your technicians are using them for and how many shifts you have, you’ll end up needing only a percentage of that number.”

Ball says service providers generally set up a pilot test with one or two devices where everything from applications to connectivity is examined. (This will also give a company a good idea of how soon cost return can be reached.) “Interference issues where the wireless signal drops off can exist in plants,” he notes, “but wireless infrastructure is not the barrier it used to be. Store-and-forward is there if you need it.”

Bagadia agrees connectivity is becoming less of an issue by the day: “Widespread wireless access is everywhere now. In the very near future, it’ll be hard to imagine anywhere, even two floors down, where Wi-Fi won’t reach.” However, Lenders is less optimistic. "Remember, most industrial plants are usually in the middle of nowhere," he says. "I have customers who still don’t have cell coverage at the plant site, and this gap is not going to be bridged easily. The cost of industrial Wi-Fi is very high and no one I know is pushing for it. The future is a wired industrial world, but it's a few years away as far as I can tell."

When asked to speculate about the future, Ball says he foresees even lighter and more rugged devices, with more battery life. “I can see more use of speech recognition too for some things, but ambient noise can be an issue with that.”

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Treena Hein is a freelance writer based in Pembroke, Ont.

Unplanned downtime caused by equipment failures costs manufacturers up to three percent of revenue every year. That’s 30 percent less profit. In an era of extreme competitiveness, no one can let that kind of money slip through their fingers.

Much of this cost can be avoided with proactive maintenance, such as measuring key indicators on critical equipment to discover impending failures and then scheduling maintenance. This practice is far more effective than waiting to perform maintenance when a failure happens, because it allows you to plan downtimes, minimize disruption and ensure spare parts are always available when needed.

Proactive maintenance programs and tools can vary from highly sophisticated processes for continuous online monitoring and automated alerts to more traditional offline programs that rely on inspection routes and manual measurements. Before looking at the tool sets needed, it is important to first establish some basic guidelines that should be support every proactive maintenance program:

• For each type of equipment, identify the potential failures and related key indicators.
• Determine what measurements can reduce the likelihood of problems.
• Determine how often equipment needs to be measured.
• Collect and track the results, watch for trends, and initiate repairs as needed.
• Integrate all of your maintenance technologies into one computerized data tracking system so they share the same equipment lists, histories, reports, and work orders.

With these ground rules in mind, we can now look at the measurement parameters and basic test tools needed when developing a proactive maintenance program.

Insulation resistance to ground testing
This test should be conducted regularly on loads and connections to detect imminent equipment failure. Ground testing line and load circuits at the starter will identify the resistance to ground of the starter, line circuits to the disconnect, and load lines to the motor and starter windings. Note that when using an insulation resistance tester for ground testing, disconnect the components or cabling to be tested from the power system.
Tool needed: Insulation resistance tester.

Temperature
Infrared thermometers are a low-cost monitoring option for quick, frequent measurements of specific components while equipment is operating. Use knowledge of the equipment to identify key hot spots to track, compare those temperature readings to operational limits and watch for upward trends. For the best measurements, get as close as is safely possible to the target, make sure the measured surface is not reflective and compensate for emissivity.

Thermal imagers are versatile tools that can play a key role as screening tools. Users can use them to quickly measure and compare heat signatures for each piece of equipment on an inspection route without disrupting operations.

Users can also quickly survey a much larger area than an infrared thermometer, and see how the temperatures of different areas relate to each other. If the temperature or thermal pattern is markedly different from previous readings, use other maintenance technologies — such as vibration, motor circuit and lubricant analysis — to assess the severity of the problem and time needed to repair it.
Tool needed: Infrared thermometer, thermal imager.

Vibration testing
Vibration is often an indication of problems with or deterioration in the condition of the equipment. If the underlying causes of excessive vibration are not corrected, the unwanted vibration alone can often cause additional damage.

Measurements are taken by placing an accelerometer near each bearing location along the drive train, using the most appropriate attachment method. It is important to ensure proper sensor placement in order to collect good data.

For consistent data over time, place the accelerometer at the exact same location each time you take a measurement. Also, be sure to take vibration measurements when the machine is running in a steady state and at normal operating temperature. (Machines tested while still cold may have significantly different vibration signatures.)

Use a vibration tester, such as the Fluke 810, to analyze the data to determine the source, location and severity of the faults, and identify potential mechanical problems weeks, if not months, prior to a failure.
Tool needed: Accelerometer, vibration tester.

Resistance
A digital multimeter (DMM) can be used to check the resistance across most connections. Before beginning, remember that resistance measurements must be made with the circuit power off. In addition, high-resolution DMMs can measure the resistance across relay and circuit breaker contacts.

Infrared thermometers can also be used to identify high resistance connections, which show up as hot spots when compared to a good connection.
Tool needed: Digital multimeter, infrared thermometer.

Current
AC and DC loads may draw slightly higher current as they age. Regularly measuring current can help you track equipment reliability. Use either a clamp meter or a DMM combined with a current clamp to measure current.

Another root cause for equipment overheating is current imbalance. A more-than-10-percent current imbalance can be a problem. Use a clamp meter or an AC current clamp with the DMM to check the current draw on each of the three legs.
If a motor isn’t performing correctly or if the circuit is tripping unexpectedly, check inrush current at startup with a clamp meter or a DMM designed to capture inrush current. Evaluating inrush current depends on comparisons of inrush measurements over time for that motor.
Tool needed: Clamp meter, CMM with current clamp.

Voltage balance
A greater-than-two-percent voltage imbalance can reduce equipment performance and cause premature failure. Use your DMM to check voltage between phases for voltage drops at the protection and switchgear delivering power from the utility and at high priority equipment. Voltage drops across the fuses and switches can also show up as imbalance at the motor and excess heat at the root trouble spot. Before a user assumes they’ve found the cause, they should double check with a thermometer.
Tool needed: Digital multimeter.

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Colin Plastow is industrial product manager for Fluke Electronics Canada. He may be contacted at This e-mail address is being protected from spambots. You need JavaScript enabled to view it . For more information, visit www.flukecanada.ca.