INDUSTRIAL MAINTENANCE Combining tradition and technology
MACHINERY MAINTENANCE Through lubricant health
SCIENCE, TECHNOLOGY AND KNOWLEDGE
ZAYER AND ILINE MICROSYSTEMS Latest collaborating organisations
JULY 2015 | No. 102 ENGLISH EDITION
Introducing our new digital identity
www.tekniker.es
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INTRODUCTION
Three years have passed since we refurbished our facilities. At that time it signiďŹ ed a great step forward in IK4-TEKNIKER’s image. Now we are taking another step forward: we are renewing our digital identity by incorporating more and better information about the activities that IK4-TEKNIKER undertakes not only in its processes to generate knowledge but also in those involving the transfer of technology to industry. We do hope you will like it!
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INDEX © ORONA
THE EXPERTS’ VIEW
C04 Industrial maintenance: combining tradition and technology
INTERVIEW
C06 “Service excellence through maintenance”
NEWS
C08 The new IK4-TEKNIKER website C11 Zayer and iLine Microsystems, new collaborating organisations
PROJECTS
C12 Coating for parabolic cylinder collector pipes in solar power plants
C14 Machinery maintenance through lubricant health
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THE EXPERTS’ VIEW
Industrial maintenance Combining tradition and technology The expert’s view: by Jorge Alarcón, Head of Industrial Maintenance at IK4-TEKNIKER
JORGE A RCÓN
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Due to the global economic situation in recent years, many industrial sectors have, in one way or another, been through a kind of reconversion of their business models. Even though the processing of materials continues to be an active part in the industrial chain, a high percentage of funds as well as companies have shifted their attention to the maintenance of assets in service, a field that has seen ongoing growth in recent years. By defi nition, maintenance is about all the necessary actions that aim to preserve or restore the state of an asset so that it performs the desired function.
cessing. This llastt conceptt comes within the fframework i Thi ithi th k off IK4-TEKNIKER’s Smart Asset Management (SAM) line.
Transfer to the industrial sector and IK4-TEKNIKER’s role
From the start of the industrial revolution up to the most advanced state of production today, maintenance has played and will continue to play a highly critical role, because the activity of industrial business depends on it.
For a long time, IK4-TEKNIKER has been an international benchmark in many spheres relating to maintenance tasks, such as the analysis of industrial oils and fluids, product dependability, monitoring and information acquisition, and support in decision-making and management, among other things.
Industry has a long list of actions geared towards maintaining the state of its assets; the actions were gradually modified in line with the design of new and more modern components and were coupled with the actual advances in the available tools. Despite this, with the current availability of technology, many maintenance actions are still carried out within the threshold of not knowing and without making any contribution at all to the business activity or with the orientation focussing on maximising results.
The technological integration of these spheres in accordance with the aims of advanced specialisation and, at the same time, with market goals constitute a significant challenge for any company. This is the new role of IK4-TEKNIKER’s SAM line: to achieve the complete integration between traditional maintenance and the currently available technological tools. To achieve better productivity and efficiency in manufacturing processes based on avoiding the replacement of equipment in accordance with the “4.0 Industry” report.
Today more than ever these actions require a holistic view covering the asset, its environment and integration with communication technology, analysis and data pro-
The scope of this maintenance vision is broad and can be easily adapted to single critical equipment on a plant going right up to the analysis and processing of fleet data.
Processing fleets
Incorporation of online sensors and oil analysis
Analysing operating and maintenance data
Data processing of fleet operation and maintenance with the aim of determining common fault patterns over time; the result is the maximising of maintenance tasks on the basis of the condition of the components.
It is becoming increasingly common that equipment in remote or highly critical locations should have at least one type of sensor to monitor their state. Current technology has enabled a new, powerful suite of online oil sensors (Atten2) to have a place within this framework, thus making the immediate availability of certain indicators of the state of the oil or the component possible. In this respect, the sensor does not replace the lab, nor the other way round; both in an integrated way maximise the information by making more precise programming and planning margins of tasks associated with maintenance possible.
A large percentage of equipment in remote or highly critical areas generate a vast amount of information; in many cases, making all this information available poses a problem rather than an advantage when it comes to using it properly. The proper processing of it by using analysis tools adapted to each detection, diagnosis or prediction phase makes it possible to align the data processing with the optimising of the operation and maintenance of the equipment.
CASE STUDIES
SAM tools not only allow the global diagnosis of the equipment to be optimised, by applying methodologies such as machine learning or clustering data geared towards the prognosis of situations prior to breakdown have also been obtained.
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INTERVIEW
© ORONA
© ORONA
Most companies have traditionally based themselves on the sale of the product, but in recent times we’ve been seeing the growth of models in which the sale of services is more important in the income statement. How important is maintenance at Orona? The service business has always been a source of revenue for Orona, although the origin of the company has more to do with the industrial and production sphere. You have to bear in mind that Orona has been on the market for over 50 years and the evolution has been slow, starting with a mainly production profile and moving towards a services profile, which right now is the predominant one.
“Service excellence through maintenance” Alberto Maritxalar, Head of Orona’s Technological Innovation in Services Alberto Maritxalar is in charge of technological innovation in services at Orona, a company that designs, manufactures, installs, maintains and upgrades lifts, escalators, ramps and travelators. In this interview Maritxalar speaks from his own experience about the importance of maintenance in offering a better service.
Within the services business, maintenance activity is very important. It is worth pointing out that Orona is a services company on a European level, and each country presents a different context both in the market situation and in the legislative aspect. If we focus on the Spanish market and on the current economic context, maintenance activity is the most important one right now. Why is this commitment to maintenance important? How does it help to differentiate Orona’s offer with respect to that of its competitors? You have to remember that lifts are systems that transport people. Therefore, Orona has always been committed to a quality service that guarantees the maximum safety for travellers, and the operational readiness of the installation through proper preventive maintenance. We strive to guarantee a time for dealing with notifications and emergencies that fit the customer’s needs, and we also advise on the improvements that can be made to the installation with a view to improving accessibility for all types of people as well as cutting the energy consumption of the installation with the resulting economic savings. What is more, in view of the fact that the company is a co-operative, Orona has a highly committed human team that is fully geared towards the needs of the customer.
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© ORONA
Maintenance calls for an intensive commitment to R&D&i, and in this respect, work in conjunction with R&D centres is normal. What is Orona’s sphere of collaboration with IK4-TEKNIKER? Would you like to highlight an example of this collaboration?
Orona Fundazioa (Foundation) has also been set up and from there Orona Ideo has begun to work with the aim of opening the company up to society. But there is still a lot to do. Orona Ideo is an open project with an important road ahead of it to be covered. We’ve only just started and we have to go on building the mechanisms that will enable us to boost the benefits of this “innovation ecosystem”, by taking on more collaborators and boosting the synergies among all the players.
Along this path towards excellence in service, Orona has the advantage in being able to influence the various elements involved in this context. Firstly, by developing innovative products, for new installations as well as for existing ones. Secondly, by designing optimised processes and services geared towards the customer. And lastly, by providing ourselves with the infrastructure and systems that enable us to make the most of all this, thus improving communication and the availability of information.
How is Orona approaching its near future with respect to maintenance? What kind of proposals will it be working on to provide the customer with greater value?
Traditionally, products, systems and processes used to be worked on separately yielding good results, but we have seen that the greatest potential is obtained when we consider the three aspects together. This is not simple, because it forces departments to work in a coordinated way with each other when traditionally they used to work in an autonomous way, but the result is spectacular.
The results we are achieving with the current lines of work are very positive and the transfer of results to Orona is taking place very rapidly indeed. This is reinforcing us so that we can go on being committed to the same line; from this line we are expecting increasingly greater results arising out of the knowledge acquired and the stability of the working teams.
For example, we can use the information that reaches our Contact Centre through certain automatic communication systems, draw conclusions from it and make it available to our maintenance network through mobility tools.
We are developing a new generation of products that are being born already prepared for this context, and we will go on developing our systems and processes to make the most of them.
For a long time IK4-TEKNIKER has been helping us in this work involving a global approach by providing the necessary theoretical knowledge; what is more, the centre is endorsed by its practical experience in other sectors.
All this will enable us to know, for instance, when a component in the installation is nearing the end of its useful service life and to programme the maintenance of it or replace it at the most appropriate moment and before it causes the customer problems. We will also be able to make available the necessary information and knowledge to our field personnel to guide them in their work on the basis of historical information and the use of the installation in question, and also on the basis of the experience built up by all the professionals who carry out similar tasks.
Orona’s commitment to R&D become clear for example with Orona Ideo, an innovation city where companies, R&D centres, university, etc. converge. What phase is this project in at the moment and what is it going to contribute? Orona Ideo is already running in terms of the teaching, business and technological aspects. We have infrastructure which a few years ago we couldn’t have even imagined. It is the second academic year for the university, and there are also R&D centres with their working groups.
At the end of the day, always designing a more efficient service of greater quality, bolstered by supports that enable us to strengthen our commitment to the customers, is something that has always characterised us.
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NEWS
The new IK4-TEKNIKER website It has a simple, attractive design and provides a complete showcase of value content
IK4-TEKNIKER launches its new corporate website and takes a qualitative leap forwards in the way it offers its users value content. IIK4-TEKNIKER began the month of June with a grand première: its new website. It is a key tool showing the R&D centre’s activity from a range of perspectives. The new corporate website has opted for a simple, attractive design and offers the user a complete showcase off value content, thus projecting IK4-TEKNIKER’s knowledge and its application in various sectors. The website is thus consolidated as the R&D centre’s main channel off communication. The new arrangement of content, which is now better organised and more usable, makes it possible to inform the market more effectively about the various fields off research and R&D solutions that IK4-TEKNIKER brings
to the various industrial sectors it works with. What is more, the new items such as success stories, scientific excellence and unique equipment considerably enrich the projecting of its activity. IK4-TEKNIKER has committed itself to responsive design for a range of devices, to the incorporation of visual elements and multimedia content as key items for transmitting its messages, and to providing the potential visitors to its website with distinctive information. Two new sections stand out in particular: Case Studies and Communication, which provide an exhaustive list of successful projects and all the R&D centre’s current affairs: events, news, projects and collaboration. Social media continue to be an essential part in the web ecosystem of IK4-TEKNIKER in order to increase interaction with its public and to consolidate a growing community.
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NEWS
News FRESADORAS CNC Y CENTROS DE MECANIZADO
Zayer and iLine Microsystems New collaborating organisations The R&D centre is consolidating its programme of advantages for collaborating companies The IK4-TEKNIKER R&D centre has incorporated the companies Zayer and iLine Microsystems as collaborating organisations with the aim of developing joint, high added-value projects. The Alavese machine-tool company Zayer, S. A., which specialises in milling machines and CNC machining centres, and the Gipuzkoan company ILine Microsystems, which specialises in the development and manufacture of systems for in-vitro diagnostics, have joined the IK4-TEKNIKER R&D centre as collaborating organisations. The aim is to combine the knowledge needed to drive forward the development of innovative products and services. Zayer is one of the Basque benchmarks in the machine-tool sector. Firmly committed towards R&D&i, the company exports over 70% of its output, has a sta of 165 people and facilities for addressing challenges like building machines up to 13 metres high. With the new agreement, IK4-TEKNIKER and Zayer are reinforcing an R&D bond going back several years, since among other areas for collaboration the R&D centre will be able to accompany the company in specifying its strategic plan for R&D&i by acting as an expert and technology watch agent.
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iLine Microsystems, located in the Science and Technology Park of Gipuzkoa in Miramón, develops Point-of-Care in-vitro diagnostic devices to monitor oral anticoagulant therapy with a high degree of innovation and reliability. The aim of their alliance with IK4-TEKNIKER is based on developing R&D strategies together, promoting collaborative projects, and driving forward the design of high addedvalue products with a highly innovative component. Programme of benefits The agreement signed opens the door that will enable both Zayer and iLine Microsystems to join the programme of advantages for IK4-TEKNIKER’s collaborating companies; this programme boosts the strategic relationship among the various players and enables a relationship of co-operation in R&D&i that is stable in time to be achieved. The incorporations of Zayer and iLine Microsystems into IK4-TEKNIKER’s group of collaborating organisations now number among other similar alliances the centre has set up with various companies. With the incorporation of these companies, the R&D centre’s Collaborating Organisations now number 21.
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PROJECTS
Coating
for parabolic cylinder collector pipes in solar power plants THIS COATING IS ABLE TO WORK AT TEMPERATURES OF 600ºC IN SOLAR THERMAL POWER PLANTS
IK4-TEKNIKER has developed a coating for parabolic cylinder collector pipes in solar thermal power plants that is able to work at temperatures of 600ºC with high absorptivity and low emissivity.
However, currently, the existing selective absorbers are degraded at temperatures above 400ºC.
Parabolic cylinder collector technology for solar thermal power plants plays a key role in the field of renewable energies, given that it accounts for more than 1,500 MW of operational capacity worldwide.
To overcome this issue, a multilayer functional coating was developed on actual 4m length pipes. The coating consists of a metallic, infra-red radiation reflective layer, an absorbent cermet type visible radiation layer composed of metallic particles in a dielectric matrix and an anti-reflective layer formed by a low index refractive oxide.
To increase the competitiveness of this technology, it is necessary to increase the plant efficiency. This increased efficiency implies an increase in operating temperature above the existing 400ºC.
This coating is able to work at temperatures of 600ºC without showing any degradation in accelerated ageing tests, shows high absorptivity and low emissivity for high temperature solar thermal power plants.
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A multilayer functional coating was developed on actual 4m length pipes.
This coating is able to work at temperatures of 600oC without showing any degradation in accelerated ageing tests.
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PROJECTS
Machinery maintenance through
lubricant health IK4-TEKNIKER has an advanced laboratory offering a comprehensive service with the capacity to analyse and establish diagnoses of at least 400 samples per day and provide a customised response within 24 to 48 hours.
Industrial maintenance to prevent potential breakdowns in equipment Carrying out exhaustive monitoring of the physico-chemical, thermal and tribological properties of fluids for industrial purposes is essential to guarantee the properties of these substances. But it also contributes towards checking the overall state of the machinery, towards diagnosing possible defects and towards designing preventive maintenance strategies that are specific to each piece of equipment.
The IK4-TEKNIKER R&D centre has an advanced laboratory offering companies in the industrial sector a comprehensive service with the capacity to analyse and establish diagnoses of over 400 samples per day and provide a customised response within 24 to 48 hours. The R&D centre’s premises allow a predictive maintenance-based diagnostic analysis to be made for heat transfer fluids (HTFs) and molten
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IK4-TEKNIKER has an advanced laboratory offering comprehensive service to analyse and establish diagnoses of over 400 samples per day and provide a response within 24 to 48 hours.
The R&D centre is capable of developing and improving industrial fluids through the selective incorporation of additives, such as nanoparticles and ionic liquids.
salts, and also for dielectric fluids, lubricants, greases and coolants used in a whole range of applications, such as air conditioning systems, solar thermal plants or heat exchangers.
What is more, IK4-TEKNIKER is capable of developing and improving industrial fluids through the selective incorporation of additives, such as nanoparticles and ionic liquids as well as the design and fi ne-tuning of advanced characterisation techniques to handle the new fluids coming onto the market. The R&D centre’s techniques and initiatives have been validated by leading groups like AENOR and subjected to comparative studies with other laboratories.
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PARKE TEKNOLOGIKOA APDO. DE CORREOS 44 CALLE IÑAKI GOENAGA, 5 20600 EIBAR · GIPUZKOA · SPAIN TEL: +34 943 206 744
www.tekniker.es
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