Service has many different faces. This is especially true in the industrial environment, where a wide variety of requirements all come together: operational reliability and plant availability, plannable maintenance intervals, preventive measures and, when the need arises, fast and efficient repair. Reconciling these various tasks is no easy job – but we are in a position to do just that.
Motors need oil and sometimes petrol too. Everybody knows that. The fact that the reverse is also true, that is to say that oil and petrol also need motors, does not become apparent until one takes a closer look at a refinery. For example, the state-run Tüpras refinery in Izmir-Aliaga in Turkey. Around 2000 motors power drill and pump drives, thereby playing their part in transforming black gold into high-performance fuel and top-quality lubricants. Dozens of processes intermesh here, making it all the more important that everything is perfectly coordinated.
In 2012 Siemens faced up to this challenge and introduced a sustainable motor management system on site which includes overhaul, repair and new developments as well as the replacement of defect motors.
All of this would not be possible without a sound data basis, which is why Siemens' involvement in Izmir-Aliaga started off by seeking answers to a whole range of questions: What motors are being used? What series do they belong to? What are their serial numbers and their year of manufacture? While gathering all this data, each motor was photographed for our documentation. In a second step, the motors were subjected to a closer individual inspection. Whenever necessary, Siemens experts took this opportunity to carry out initial measures: for example vibration inspections or thermal imaging. Once the data had been gathered, the maintenance schedule was drawn up.
Fewer failures, fewer repairs
These activities helped us to considerably prolong the service life of the motors and to reduce unplanned downtimes by 67 percent. At the same time, the maintenance measures carried out by our specialists have reduced the need for repairs. This is now the second time that our motor management program has proved its worth at Tüpras. Two years earlier, we succeeded in reducing the downtimes of 1500 motors at the Izmit plant located further to the north by a staggering 83%. These are outstanding results that mark the beginning of a long-term and very successful partnership with the customer recently extending the service agreements for both locations, thereby placing its faith in Siemens' service expertise for some time to come.
Two partners, one goal, 40 percent more efficiency
One of Western Europe's largest coal-fired power plants is operated by Drax in Selby, UK. Up to seven percent of the UK's total power requirement is produced here. However, the six 660 MW turbines built in 1972 were getting on in years and so, in 2007, Drax placed an order with Siemens for their modernization. And the result is quite impressive.
It is always the people involved who turn a promising project into something special. In this case, it was mainly down to Steve Austin from Drax Power Station and Darren Davidson, the project manager from Siemens Energy Services Fossil, UK. During the five-year collaboration, numerous components had to be replaced and harmonized.
One unusual but in retrospect extremely successful aspect of the collaboration was the inclusion of Drax staff in the installation team for the modernized turbines. At first, many people believed this would not work. But those in charge asserted themselves, promoted the idea and tried it out. And it worked.
At first glance, not much seems to have changed in the turbine halls. In fact, it apparently looked exactly the same as in the 1980s. However, what the eye cannot see are the new highly efficient modernized turbines turning in the old housings. They were upgraded at Siemens in Newcastle and, not being so far away, employees from Drax were able to take a regular look at the work in progress and make some valuable suggestions.
In the end, Siemens met the very ambitious time schedule thanks to the commitment of all involved. But even more important are the technical and economic results of the project. Each turbine now generates 686 MW compared to 660 MW prior to the upgrade. And coal consumption has even gone down in spite of this improved performance. This increase in efficiency is saving the entire power plant 500,000 metric tons of coal year after year. At the same time, emissions are being reduced by one million metric tons of CO2 per year.
And, last but not least, it is also worth mentioning the newly developed maintenance plan. During the upgrade and replacement of individual components, specialists worked out a dedicated service strategy which will lead to an increase in plant availability and simplified maintenance management.
All in all, a whole bundle of fine results which are rightly a source of pride to everyone involved – as the member of a successful team.
Remote support during heart operation
In Leeds, UK, Nuffield Health runs one of the most technologically advanced private hospitals in Europe. Specializing in sophisticated surgical procedures, the hospital has been offering an extremely wide range of health services for almost 50 years. Its outstanding efficiency means that patients also enjoy short waiting lists.
To further enhance its services in the angiography sector, Nuffield Health Leeds Hospital recently installed a ceiling-mounted Artis zee. This interventional imaging system from Siemens complements the hospital’s range of services and is allowing it to now undertake various neurovascular, cardiological and vascular interventional procedures at one location.
On-the-job learning process
New equipment inevitably entails a learning phase for all those involved with it. To nevertheless meet the hospital’s own high standards and ensure maximum availability from the outset, the parties responsible at Leeds opted for support via syngo® Remote Assist.
Of course, every new piece of equipment is accompanied by a period of learning and familiarization. Nevertheless, maximum availability has to be guaranteed from the start. And with syngo Remote Assist this goal can be achieved.
Head radiography technician Kerry Kirby had already been familiar with the system for several months when there was a problem with the image quality during a heart operation one day. A fast response was necessary. Kerry requested immediate support from Siemens Customer Care Center. Just a few minutes later she was speaking to Khalid Oozeer, Senior Angiography Applications Specialist at Siemens Healthcare.
After the specialist had logged on via syngo® Remote Assist, it quickly emerged that the system was fully functional. All that was necessary to restore the desired image quality was to change just a few application parameters. Oozeer reconfigured the settings and also adapted the large monitor to Kerry’s current requirements.
Security and confidence
The radiography technician is impressed: "System availability is not just essential for our hospital but for patients too. Ultimately they depend on a rapid and accurate diagnosis. syngo® Remote Assist provides us with security and confidence in the support of expert partners. You actually get the impression that they are standing right next to you. Quite apart from the obvious time and cost savings compared with on-site support, we can also be sure that our equipment is working as efficiently and consistently as possible."
Khalid Oozeer is equally enthusiastic about the new opportunities: "syngo® Remote Assist offers us a completely new dimension in clinical applications support. In the past, Siemens Remote Service was a tool used by engineers to diagnose technical queries. Direct access to the scanner interface by our application team was not possible. Where previously a visit to site was necessary, we can now use syngo® Remote Assist to improve image quality from a remote location and clarify training queries.”
The art of making a falcon fly
40°C heat in summer, –50°C and frost in winter… Under such conditions, top quality servicing is crucial to achieve an annual performance per train of around 400,000 km. And Siemens Mobility has risen to the challenge.
Since December 2009, eight high-speed Velaro RUS trains, known as the Sapsan (Peregrine Falcon) have been operating on the 650 km route from Moscow to St. Petersburg. Siemens supplied the trains and will service them for a period of 30 years.
Delivery of the first train also saw the start of maintenance activities and the official opening of the new Metallostroy maintenance depot near St. Petersburg, where all necessary works on the Velaros will be carried out. The depot was designed by Siemens to the latest standards and built by RZD (Russian Railways).
No standby trains
The Russian national railway carrier had set itself ambitious operational goals. Instead of having up to ten percent of the fleet on standby as was previously the case, the new high-speed route to Moscow was intended to manage without any spare trains whatsoever. This is only possible if all components are carefully monitored and imminent malfunctions identified and rectified in good time. In addition, all service work has to be carried out at night, so that all trains are operational during the day. A special feature is what is known as “balanced maintenance” in which the maintenance activities are first analyzed and then divided into individual modules. Tasks that would normally take several days are therefore split up into several small jobs that can be done overnight. Although some activities like grounding the trains happen every time, maintenance intervals can still be significantly extended as a result.
Predictive maintenance model
Traditional maintenance models provide for regular checks of all components. This means that generally, a lot of time is expended on activities that are not actually necessary at that point. With predictive maintenance, Siemens is taking a different approach: tasks are only performed when necessary. So as not to compromise safety, the current condition of all components has to be known in detail. What was the voltage on a particular relay at a specific time? How long is the brake pressure at brake 7? How often was entrance door 12 opened in the last 72 hours? To answer these kinds of questions, hundreds of sensors in the Velaro gather a huge volume of data and transmit it during train operation to an IT-based system known as the Rail Remote Service Desk.
Service in high-tech depot
On the basis of the processed data it is possible to accurately assess when certain measures become necessary. Siemens specialists produce standard operating procedures and send them to the Computerized Maintenance Management System (CMMS), the centralized software for all maintenance activities. The system ensures, for example, that the necessary spare parts are available at each workstation, the teams are allocated and everyone knows what has to be done. Employees gain the necessary access to the CMMS and their assignments via terminals available all over the Metallostroy depot and via a PDA (Personal Digital Assistant).
Even more service
A figure of more than 98% availability for the Velaro RUS clearly demonstrates that the effort involved is well worthwhile. And the RŽD is also enthusiastic about the successes achieved. So enthusiastic in fact that Siemens Mobility has now also been entrusted with the maintenance for the Desiro RUS – for the next 40 years and with an order worth 500 million euros.