PC-MAR23-PG36-37.1_Layout 1 06/03/2023 12:00 Page 36


WATER & WASTE TREATMENT


he water industry provides essential services to society and process industries by ensuring a constant supply of clean drinking water and efficient wastewater services. Demand for sustainable clean water is increasing rapidly, while water scarcity is becoming an issue in many regions. The clean water sector also faces increasing technical requirements in the areas of disinfection and desalination.


PREVENTATIVE V. PREDICTIVE T


Ideas for smarter maintenance strategies in water processing applications, by Klaus Zeller and Robert Zenoni, product marketing managers, OMRON Europe


In the water industry, continuity of operation is key. Lack of maintenance could have a catastrophic impact. Even the failure of a single component can have an impact on operations, while energy and maintenance expenses are part of the lifecycle costs of pumping systems. Keeping production lines and systems running optimally often relies on a skilled maintenance team. However, effective maintenance also involves planning and scheduling, constant vigilance, willingness to change out unworn parts, and readiness to respond to unplanned events.


Here, we look at the differences between preventive and predictive maintenance, and how automation solutions can help utility companies keep their operations running smoothly, while taking the first steps towards smart maintenance.


Water facilities that employ traditional or preventive maintenance strategies often find themselves either missing key signs of failure that occur in between inspections or prematurely replacing equipment to avoid these potential failures. These issues are two sides of the same coin, which is the lack of 24/7 monitoring of critical equipment. It is also important to keep in mind the human impact of maintenance. Traditional maintenance relies on experienced staff to identify issues. Digital solutions can benefit maintenance teams by helping relieve the pressure placed on them when there is a stoppage.


36 MARCH 2023 | PROCESS & CONTROL


While it must be accepted that no maintenance strategy can guarantee 100% machine uptime, both preventive and predictive solutions can help reduce the pressures on the maintenance teams, as fixes can be planned and undertaken during scheduled downtimes. However, when something breaks unexpectedly, the resulting unplanned downtime affects more than 75% of companies and can be very costly. Unlike preventive maintenance, which is performed according to a schedule that reflects historical events, predictive maintenance monitors asset condition in real time and prompts interventions before failures disrupt production. Advances in sensors, analytics, and communication technologies are making predictive maintenance increasingly practical and affordable. By migrating to a predictive maintenance strategy, water processing facilities and portable plants can rest assured that their equipment is being monitored around the clock and that real-time data analysis will reveal any potential issues well in advance of an actual failure.


The top 3 causes of unplanned downtimes are: aging equipment (50%), operator error (15%) and lack of time (14%). Moreover, according to a study by the Manufacturing Institute, there are more people ready to reach retirement than enter the workforce in plant maintenance: 6 out of 10 manufacturing roles are unfilled because of a lack of skilled workers. This shortage can cost companies up


to 10% of their annual profit. The first step on a predictive maintenance journey is to identify critical elements of the process. What are the major causes of unplanned stoppage historically, and where on the system do they occur? This will enable companies to create a baseline of the data collection capabilities of their systems. Retrofitted solutions are one way to modernise while keeping costs affordable. After critical assets are identified, implementing the predictive maintenance solution is straightforward. Key steps include replicating engineer knowledge for the targeted asset, establishing a baseline of acceptable conditions, retrofitting one or more sensors or monitors to the asset, and setting warning and alarm thresholds. Typical maintenance tasks at water facilities include membrane filtration water treatment systems that can be vulnerable to damage and wear caused by pressure peaks. It is important to monitor key assets, and detect any abnormal vibrations, inefficient system operation, erosion of components, and cavitation. Hydraulic hammering in the pipes may cause dislocation of the joints and weakening of the wall material, bearing wear, shaft vibration, cavitation, insulation degradation.


In one case study example, industrial recirculating pumps run almost continuously. One manufacturer used manual inspections to check a motor in its water treatment plant, but conducting accurate inspections was


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50  |  Page 51  |  Page 52  |  Page 53  |  Page 54  |  Page 55  |  Page 56  |  Page 57  |  Page 58  |  Page 59  |  Page 60  |  Page 61  |  Page 62