Abstracts

“Transforming the Amazon Approach to Operations Maintenance”

Presented by Gail Edgar, Director, NA Reliability & Maintenance Engineering, Amazon

Operations Maintenance at Amazon has historically relied on methodologies such as Total Productive Maintenance (TPM) and Statistical Process Control (SPC) as the basis for achieving results and driving improvement. However, the advent of IOT, cloud-based computing and a growing network of sensor-enabled devices is changing the way organizations can manage their operations in real time.

This presentation will discuss the learnings and challenges as Amazon builds the analytic and control system for their fulfillment network. This session will also showcase what Amazon is doing to further empower leaders and associates with real time decision making by leveraging AI, ML and BI to drive user experience and productivity.

“Digital Disruption, 28 weeks later…”

Presented by Jose Maria Gurria, Global O&M Digital Implementation Leader, GE

A lot has been said about “Digital Disruption” but some of us have been imagining what it would look like, in my case since almost 15 years back. Actually, when I first experienced with Predictive technologies. So fortunately some people in the community, in the last 2-3 years had even adventured to write and speak about our future as M&R professionals in this new environment. Where most of the predictions threaten with thousands of jobs loss, professions transformed or even replaced by machines.

The title of this abstract, is based on a British zombie movie and the post-apocalyptical scenario that a lethal virus has left over the earth. Even if it seems under control, the thread is still alive and, as usual, a group of survivors is fighting the disease trying to find a cure, while they keep complaining and wondering how it all happened to them.

I’ll try my best to immerse you into this dark place, where we will learn, what’s this “digital disease”, what to be afraid of, what are its faces, how they are showing up, how they escalate and could end up “infecting” the whole organization.

But don’t worry, we’ll figure out how to survive “Digital Disruption” by using our Maintenance & Reliability skills, tools, knowledge, and attitude.

Good luck…

“A Practitioner’s Journey to Improving Lubrication Practices”

Presented by James Kordsmeier, CMRP, Reliability Engineer, CEMEX USA

Since 1925, Cemex’s Clinchfield, GA plant has seen many changes over the years.  As Georgia’s only operating cement plant, keeping the plant’s kiln, roller mill, and finish mills up and running requires dedication and diligence on the plant’s maintenance and reliability personnel.  With a 900,000 tons per year capacity, and a process and environment that are not kind to the equipment, steps must be taken to ensure that the equipment is running efficiently with little room for error when it comes to maintenance. This presentation will show how improving lubrication practices at a cement plant that occupies approximately 3000 acres in middle Georgia can go a long way in improving overall equipment reliability since lubrication is the “life blood” of rotating equipment.

 

“High Voltage Substation Airborne Inspections & Follow-Ups”

Presented by N.J. Lefort, CMRT, LOOP

See real life procedures and examples of how to complete the “Inspection to Repair” cycle for High Voltage Equipment and Substations. You will see actual procedures, findings and what steps were taken to ensure corrective actions and repairs.

“Ultrasound, Big Data & AI Come To Pharma Industry”

Presented by Blair Frasier, CMRP, Business Unit Manager – Reliability Solutions, Lakeside Process Controls 

A Pharmaceutical company in Toronto, ON is challenging the status quo by thinking outside the box to develop solutions to increase the reliability of their critical assets by applying IIOT, Big Data combined with Machine Learning (Pattern Recognition & Anomaly detection) technologies using Ultrasonic sensors to provide predictive analytics. In this presentation, we will explain how this was done and share some amazing results and the cost savings. This is one case study you won’t want to miss.

“The Thermodynamic, the Float, and the Bimetallic – The Chronicles of Steam Trap Maintenance”

Presented by Andrew Jensen, Utilities Manager, Louis Dreyfus Company at the Savannah Sugar Refinery

Steam traps are often a forgotten component of steam systems. There are usually several factors which play a part in this:  many times, traps fail when open and don’t affect production so nobody notices, they can be installed in inaccessible locations and they can be worked on only during outages.  Often there is a lack of knowledge about steam traps.  It is important to not forget about steam traps, because an effective team trap can reduce unplanned steam system outages, reduce maintenance cost, reduce personnel safety risks, and reduce the amount of wasted steam.

This presentation reviews the journey that the Savannah Sugar Refinery has taken to develop and implement an effective steam trap preventative maintenance program. It will highlight some of the challenges faced while setting up the program, and how those challenges were overcome.

The topics included in this presentation are:

Motivations to improve your condensate removal

Identifying/Labeling Steam Traps

Effectively using UE’s database to manage steam traps

Reviewing/modifying steam trap piping

Evaluating steam trap performance with Ultrasonic and Thermography

Standardization of steam traps

“Implementing Best Practices for Motor Greasing”

Presented by Clay Allen, Mechanical Reliability Engineer, Mosaic

An electric motor has many components that must be cared for in order to obtain reliable operation and long service life. After installation, one of the main things that must be done to achieve trouble-free service is lubricating the bearings.

This presentation will cover best practices for greasing motor bearings and how to successfully implement them.

The presentation is applicable to those wanting to start a motor greasing program because it will help create a roadmap to accelerate implementation and ensure that best practices are followed from the start. It will also be helpful to those with an established program by providing tips, tricks, and a look at some details that can help push the program to the next level.

The topics that will be covered include:

  • Motor greasing procedures utilizing ultrasonic technology
  • Purging bearings
  • Planned vs. Actual amounts of grease needed (PM vs. Condition Based)
  • How to grease inaccessible motors
  • Greasing VFD motors
  • How to prevent grease cross-contamination

“Acoustic Journey at Rio Tinto”
Presented by Gwyn Garland, Rio Tinto

In this presentation Gwyn will discuss the acoustic “journey” within Rio Tinto’s massive Australian Iron Ore operations and how, through the case studies presented, it is changing the way we work to improve safety and productivity. With targeted production in 2018 at 340Mt introducing an acoustic program across 16 mines and 4 ports spread across 505,000 km2 Pilbara region in north Western Australia has its challenges.

“Performing Ultrasonic Inspections within DOE, an Opportunity for Improvement”

Presented by Kiley Taylor, National Renewable Energy Laboratory

In this presentation, Kiley will discuss case studies of how they are utilizing ultrasound inspections to improve safety & energy use at the National Renewable Energy Laboratory. Kiley will review the various standards they follow, like NFPA 70A & NFPA 70B and the impact those have. He’ll also share how they are using ultrasound for both electrical and mechanical inspections. This will be done in a case study format and will be a great session for those looking for real life examples of how ultrasound can be used.

“Condition Based Monitoring for Random Cycle Machinery”

Presented by Michael Olszewski, President, Alignment Supplies

One of the most difficult applications for CBM is random short cycle machinery analysis.  Robots, elevators, conveyors, transfer lines, stamping presses and other types random short cycle machinery present challenges that make CBM difficult or impossible.  A comprehensive understanding of the machinery, processes, failure modes and the measurement instruments is necessary to be able to provide a solution to this high demand application.

This session explores:

  1. How to identify the requirements for various types of cyclic machinery operation.
  2. Hardware Selection.
  3. Software Consideration.
  4. Data Acquisition and Management.
  5. Considerations for vibration Analysis and Ultrasound analysis.
  6. How to define baseline values and Establish Alarms.
  7. Discussion/Q&A

“The Fundamentals of PWM Machines and the Use of Ultrasound to Detect Harmful Switching Transients,” presented by Milan Heninger, Enel Green Power North America

The effect of Pulse Width Modulating (PWM) signals on electrical motors is in most industries well understood; however technical and business constraints have in some cases led to significant (and often misdiagnosed) issues with equipment.  This presentation discusses the fundamentals of PWM machines (such as variable frequency drives and solar inverters), examines how switching transients may manifest themselves, and addresses the harm those transients may cause. This discussion develops into a case study investigating the effects of PWM signals in Geothermal and Solar applications, detailing the potentially novel use of Ultrasound to detect, classify, and reduce the risk to specialty equipment such as Electric Submersible Pumps (ESP’s), plant instrumentation, and solar power systems. This presentation is ideal for those who experience reduced run life or other problems on VFD driven equipment, as well as those who are interested in ongoing research surrounding Ultrasound in atypical use cases.

 

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