The Value of Applications Knowledge

Fonte: Bombas mundo

Industrial producers, such as paint and resin manufacturers or oil-and-gas refinery operators, estão investindo em tecnologias avançadas que irá ajudá-los a alcançar seus objetivos de negócios,,en,sistemas SCADA inteligentes pode reduzir o tempo de inatividade por meio de monitoramento pró-ativo,,en,Energia-e bomba ciente ffi tecnologia proporciona economia de custo operacional,,en,hedge contra flutuações de preços de energia e ajuda as empresas a atingir suas metas de gestão ambiental, reduzindo as emissões de carbono,,en,qualquer nova tecnologia pode aumentar drasticamente a complexidade das operações de negócios,,en. Smart SCADA systems can reduce downtime through proactive monitoring. Energy-efficient pump technology delivers operating-cost savings, hedges against energy-price fluctuations and helps companies to meet their environmental stewardship goals by reducing carbon emissions.

Contudo, any new technology can dramatically increase the complexity of business operations, at a time when cost pressures and economic headwinds threaten to curtail growth and profitability. Further, these technology investments require specialized knowledge and expertise to build, operate, and maintain. Muitos produtores industriais,,en,como a maioria das empresas,,en,restrições de recursos rosto e estão operando com níveis de pessoal mais magras do que nunca,,en,eles estão descobrindo que não possuem a in-house perícia para selecionar de forma eficaz,,en,construir,,en,operar e manter equipamentos e sistemas cada vez mais complexos,,en,e muitas vezes são forçados a recorrer a organizações de terceiros com conhecimentos especializados para suporte,,en,fabricantes de bombas, em particular,,en,juntamente com os seus distribuidores relacionados,,en,empresas de engenharia,,en,consultores e outros terceiros,,en, like most businesses, face resource constraints and are operating with leaner staffing levels than ever before. Como resultado, they are finding that they don’t possess the in-house expertise to effectively select, build, operate and maintain increasingly complex equipment and systems, and often are forced to turn to third-party organizations with specialized knowledge, for support.

Pump manufacturers in particular, along with their related distributors, engineering firms, consultants and other third parties, are increasingly stepping up to supply this critical applications expertise to their end-user customers. Properly deployed applications expertise can unlock value for industrial producers, and organizations that build superior applications expertise in their markets can gain a significant competitive advantage.


Wilden Original Series Air-Operated Double-Diaphragm (AODD) Pumps in operation at a ceramic plant in Spain.


A stainless-steel Wilden Advanced PX Series AODD Pump in use at the SABA B.V. cola- and adhesive-manufacturing facility in the Netherlands.


The challenge

Industrial manufacturers are facing an increasingly difficult business environment, one that is often impacted by these and other critical factors:

• Energy-price volatility.

• Regulatory compliance legislation and associated costs.

• Public/customer expectations for enhanced resource stewardship.

Energy-price volatility

Price volatility is defined in the energy industry as how quickly or widely electricity and/or natural gas prices change over a given time period. Prices are governed by supply and demand, where demand is impacted by factors such as weather patterns, economic conditions and consumer behaviour. In recent years, price volatility has increased in the energy market. To protect against this volatility, many companies 'hedge,' or buy a commodity at a price that is locked in over a set period of time. While this may improve peace of mind for the operator, hedging is costly and doesn’t create value for the operator beyond reducing energy-cost volatility.

The severity, and potential impact of price volatility is such that in its 2015 report titled, 'The New Normal,' the World Energy Council (WEC) opined that, “The uncertain impact of volatile energy and commodity prices…has now established itself as the number-one issue for energy leaders worldwide.” The good news is that global energy leaders have recognized this challenge and are beginning to take measures to address it. According to Francois Moisan in WEC’s triennial 2016 report, 'Energy Efficiency: A straight path towards energy sustainability,' “The introduction of energy-efficiency policies and measures has been growing fast around the world. The increasing number of countries with an energy-efficiency law…signifies a strengthening and consolidation of the industrial commitment to energy efficiency.”

The report does also indicate, contudo, that “despite the significant advances, much more can and should be done to improve the efficiency of energy production and use.” This is extremely noteworthy for industrial manufacturers because, as the WEC also notes, “industrial electric motors and electric motor-driven systems consume almost half of the total electricity and account for 70% of the total (amount of) electricity consumed in the industry.” For many industrial companies, where energy is a significant portion of operating costs, price volatility will continue to be a challenge. Essas empresas vão ser auto-serviu para avaliar a tecnologia de poupança de energia,,en,mas apenas vai colher as maiores recompensas se eles fazê-lo tendo em conta os meandros de equipamentos nas aplicações específicas em que atuam,,en,Somente através do desenvolvimento e utilizando a experiência em aplicações adequada eles vão ser capazes de identificar e escolher a tecnologia que é mais adequado para mitigar os riscos de custos associados com a volatilidade de energia,,en, but will only reap the greatest rewards if they do so by taking into account the intricacies of their equipment in the specific applications in which they operate. Only by developing and using the proper applications expertise will they be able to identify and choose the technology that is best suited to mitigate the cost risks associated with energy volatility.

Regulatory compliance

Regulatory compliance is by definition a necessity for businesses in the modern world. These laws collectively shape the environment in which businesses operate. The number of federal regulations in the U.S. has been growing steadily for several decades, requiring investments by many businesses in order to maintain compliance. De fato, a study by George Mason University shows that “the effects of federal regulation on value added to the (U.S.) GDP for a panel of 22 industries…over a period of 35 years…dampened (GDP by approximately) 0.8% per year since 1980, eliminating $4 trillion in growth by 2012.”

Two prominent examples in the industrial-manufacturing universe are the motor-efficiency regulations that have been developed by the U.S. Department of Energy (DOE) and the International Electrotechnical Commission (IEC) in Europe. A linha inferior é que os regulamentos são uma exigência inevitável para fazer negócios em qualquer jurisdição do mundo,,en,Muitos avanços na tecnologia têm sido voltados para atender as demandas de um ambiente regulatório mais rigoroso,,en,automobilismo Ahead,,en,mas será otimizado somente se eles são aplicados com a perícia aplicações adequadas,,en,a má aplicação de uma bomba,,en,incorretamente dimensionamento da bomba para a sua aplicação,,en. Advances in technology that have been geared towards meeting the demands of a stricter regulatory environment will help industrial producers to navigate the compliance realm, but will be optimized only if they are applied with the appropriate applications expertise. De fato, the misapplication of a pump (e.g., incorrectly sizing the pump for its job) provavelmente vai levar a muito maior consumo de energia do que podem ser salvos a partir de melhorias na tecnologia dos motores,,en,Uma bomba de disco excêntrico movendo carbonatadas-bebidas em uma fábrica de engarrafamento na Hungria,,en,As expectativas para Resource Stewardship,,en,Uma frase que ganhou estatura ao longo das últimas duas décadas em todas as formas de negócio é “responsabilidade social corporativa,,en,”Ou CSR,,en,que é comumente caracterizada como “práticas de negócios envolvendo iniciativas que beneficiam a sociedade.”,,en,Um artigo em junho,,en.


A Mouvex SLS Series Eccentric Disc Pump being used to transfer carbonated-beverage bases by the Coca-Cola Hellenic Bottling Company.


A Griswold 811 Series Centrifugal Pump in action during a Leased Asset Custody Transfer (LACT) operation in the Eagle Ford shale play in Texas.

Expectations for resource stewardship

A phrase that has gained in stature over the past two decades in all forms of business is 'corporate social responsibility,' or CSR, which is commonly characterized as “business practices involving initiatives that benefit society.” An article in the June 18, 2016, edição do International Journal of Business and Management intitulado,,en,“Responsabilidade e de compra do consumidor Comportamento Social Empresarial em Mercados Emergentes,,en,”Afirmou que“os consumidores agora querem que as empresas se comportam de forma ética, além de fornecer produtos de qualidade,,en,s,,en,A implicação óbvia é que as empresas que são percebidos como mordomos desatentos ou irresponsáveis ​​em relação a recursos compartilhados,,en,abastecimento de água da comunidade ou a qualidade do ar,,en, 'Corporate Social Responsibility and Consumer Buying Behavior in Emerging Markets,' highlighted that “consumers now want companies to behave ethically in addition to providing quality product[s]..."

The obvious implication is that those companies that are perceived to be inattentive or irresponsible stewards regarding shared resources, por exemplo, community water supplies, o risco de um retrocesso político e social que poderia impactar posição e capacidade de fazer negócios nas comunidades em que atua a empresa,,en,ele não deve ser surpreendente que um relatório da Harvard Business School intitulado,,en,“O impacto da Responsabilidade Social Empresarial na Recomendações de Investimento,,en,”Revelou que“pesquisas recentes mostram gastar dinheiro em responsabilidade social corporativa não é mais visto como um prejuízo para a rentabilidade de uma empresa,,en. Portanto, it shouldn’t be surprising that a report from Harvard Business School titled, “The Impact of Corporate Social Responsibility on Investment Recommendations,” revealed that “recent research shows spending money on corporate social responsibility is no longer seen as a detriment to a company’s profitability.

analistas de ações agora ver tais despesas como essencial para a marca a longo prazo da empresa e valor.”Em suma,,en,para melhorar a sua CSR pé,,en,mudança das práticas operacionais e até mesmo ajustar as estratégias de negócios, a fim de melhor amenizar as exigências-de responsabilidade corporativa do público de compra,,en,'The Dawn of a Fábrica Inteligente,,en,'IndustryWeek revista detalhou um nirvana iminente fabricação conhecido como o 'Smart Factory'. Esta fábrica do futuro será “um paraíso de eficiência e ffi onde defeitos e tempo de inatividade,,en, to improve their CSR standing, more and more companies are investing additional time and resources toward incorporating new technologies, changing operating practices and even adjusting business strategies in order to better assuage the corporate-responsibility demands of the buying public. De fato, these resources can only be optimized by developing and applying expert knowledge of the business, seus sistemas e o ambiente local em que opera,,en,As empresas que desenvolvem e usam este conhecimento vai ajudar a satisfazer as necessidades do público e alcançar resultados positivos na administração de recursos,,en,Em suma,,en,provedores de equipamentos industriais de hoje enfrentam um ambiente operacional cada vez mais difícil,,en,que inclui a volatilidade do preço da energia,,en,os custos crescentes de conformidade regulamentar,,en,e demandas públicas para a melhoria da gestão ambiental,,en. Businesses that develop and use this knowledge will help satisfy the needs of the public while achieving positive outcomes in resource stewardship.

The solution

So how do industrial manufacturers address the challenges of price volatility, regulatory compliance and resource stewardship, and still successfully achieve their business goals? Many companies are turning to technology for assistance. In a February 2013 article titled, 'The Dawn of the Smart Factory,' IndustryWeek magazine detailed a looming manufacturing nirvana known as the 'Smart Factory.' This factory of the future will be “a paradise of efficiency where defect and downtime, waste and waiting are long-forgotten issues of a long-forgotten age.” The driving force behind this phenomenon would be plant managers and chief intelligence officers who work together to create a seamless blend of data and production that will “illuminate every turn of every machine, every cut of every blade, cada movimento de cada peça em sua dança global para entregar.”,,en,Enquanto a hipérbole neste artigo é pesado,,en,a premissa básica foi ecoado em um,,en,estudo por MarketsandMarkets,,en,um editor de relatórios de pesquisa de mercado prémio,,en,Em seu artigo intitulado,,en,“Mercado de Fábrica Inteligente pela Tecnologia,,en,Componente,,en,Indústria,,en,e Geografia - Previsão Global de 2022,”os pesquisadores descobriram que o mercado de smart-fábrica,,en,em termos de valor,,en,é esperado para chegar,,en,com uma taxa de crescimento anual,,en,CAGR,,so,por cento entre,,en

While the hyperbole in this article is heavy, the article’s basic premise was echoed in a 2015 study by Marketsand-Markets, a publisher of premium market-research reports. In its piece titled, 'Smart Factory Market by Technology, Component, Industry, and Geography – Global Forecast to 2022,' Markets and-Markets researchers found that the smart-factory market, in terms of value, is expected to reach $74.8 bilhões até 2022, with a compound annual growth rate (CAGR) de 10.4% between 2016 e 2022.

“O surgimento de fábricas inteligentes pode ser visto a partir do período de mudança em direção ao controle coeso das máquinas,,en,processos e recursos com inteligência local,,en,”Ler o relatório,,en,“O foco crescente na economia de energia e melhorar a eficiência do processo,,en,juntamente com a integração de engenharia e fabricação através da adopção da Internet das coisas,,en,a ‘Internet das coisas’,,en,é esperado para promover o crescimento do mercado de smart-fábrica “.,,en, processes, and resources with local intelligence,” read the report. “The increasing focus on saving energy and improving process efficiency, along with the integration of engineering and manufacturing by the adoption of IoT (the ‘Internet of Things’) is expected to foster the growth of the smart-factory market.” While the smart-factory operating principles promise to be a boon for industrial manufacturers who implement them, they will raise the complexity of the operation, which poses its own set of unique challenges. De fato, according to strategic-management consulting firm A.T. Kearney’s 'How Much Does Complexity Really Cost?' survey of the top 30 companies in Germany, a reduction in operational complexity would boost earnings by more than €30 billion and increase earnings before interest and taxes (EBIT) by 3% para 5%.

The ultimate challenge for a manufacturer is to learn how new technologies can improve his or her operations and find the best, most efficient way to extract the benefits. This must be done while simultaneously not allowing the inherent complexities of these new systems to hinder or raise the cost of business processes. This is where the accumulation and deployment of applications expertise becomes immensely critical. De fato, Skip Giessing, President of DXP Enterprises’ Rotating Equipment Division, a company that has been supplying industrial pumps since 1908, não vê razão que a procura ea importância da experiência em aplicações não vai continuar a crescer nos anos vindouros,,en,isto é,,en,conhecimentos especializados relativos à utilização de determinados produtos em condições específicas,,en,O gráfico na próxima página ilustra,,en,Ferramentas para gerenciamento de custos,,en,ExxonMobil produziu uma Desk Dica Ajuda Técnico que estabeleceu as formas de melhorar o que chamou de “Overall Equipment Effectiveness,,en.

“I believe there will be an increased demand for outstanding supplier applications expertise as suppliers and manufacturers work together to tie technology to process-equipment networking, proactive health monitoring and reliability,", Disse ele. “A enorme redução de gastos cliente virá quando todo o equipamento chave dentro de uma fábrica está interligado e‘falando um com o outro’e ajustar a mudanças,,en,Os clientes terão de conhecer e compreender como as mudanças afetam o desempenho do equipamento e confiabilidade e como eo que fazer para manter o máximo de produtividade através de uptime de confiança e eficiência do equipamento.”,,en,Então, o que faz exatamente “aplicações experiência” significa,,en,Em seu nível mais básico,,en, etc. Customers will need to know and understand how changes affect equipment performance and reliability and how and what to do in order to maintain maximum productivity through reliable uptime and equipment efficiency.” So, what exactly is applications expertise? At its most basic level, it is specialized knowledge pertaining to the use of certain products in specific conditions. This knowledge can be used to create better business outcomes and, portanto, be the foundation for gaining a competitive advantage. As the complexity of the production system increases, the value that can be unlocked from applications expertise also increases. As the graphic illustrates (veja a Figura 1), the type of expert knowledge varies across the value chain, so there are ample opportunities for increased collaboration among pump manufacturers and distributors, and among distributors and end users, para fortalecer o conhecimento especializado e aumentar a criação de valor para todas as partes envolvidas,,en,A colaboração é fundamental em toda a cadeia de valor,,en,Ferramentas para gerenciamento de custos,,en,e ffi eficiência e e ff ectiveness,,en,ExxonMobil produziu uma Desk Dica Ajuda Técnico que estabeleceu as formas de melhorar o que chamou de “Equipamento E geral ff ectiveness,,en,utilizando a equação,,en,B = Disponibilidade x Desempenho x Qualidade,,sm,• Disponibilidade representa a frequência com que uma máquina está disponível para seu uso pretendido,,en,que pode ser um ff ete por falha de equipamento,,en,• Desempenho é uma medida da perda de velocidade,,en,• de qualidade representa a quantidade de material de sucata produzido por uma determinada máquina,,en,os produtos que não cumpram as normas de qualidade e todos os itens que exigem retrabalho toda a ff ecting qualidade geral,,en.


Figura 1: Collaboration is key across the value chain.

Tools for managing costs

Para entender melhor como experiência em aplicações pode ajudar o operador a perceber a importância de melhorar a produtividade dos equipamentos,,en,eficiência e eficácia,,en,ExxonMobil produziu uma Desk Dica Ajuda Técnica que enunciados maneiras de melhorar o que chamou de “Overall Equipment Effectiveness,,en,"Zados que,,sm,OEE é medida como uma relação entre a produção real de uma planta em comparação com saída óptima,,en,usando a equação,,en,Disponibilidade representa a frequência com que uma máquina está disponível para seu uso pretendido,,en,que pode ser afetada por falha de equipamento,,en, efficiency and effectiveness, ExxonMobil produced a Technical Help Desk Tip that spelled out the ways to improve what it called “Overall Equipment Effectiveness,” or OEE. OEE is measured as a ratio of a plant’s actual output compared to optimal output, using the equation: OEE = Availability x Performance x Quality, onde:

• Availability represents how frequently a machine is available for its intended use, which can be affected by equipment failure, manutenção não planejada,,en,escassez de material e tempos de troca,,en,Desempenho é uma medida da perda de velocidade,,en,ou o número de unidades de uma máquina é classificado para produzir por hora versus o número de unidades que realmente produz,,en,Qualidade representa a quantidade de material de sucata produzido por uma determinada máquina,,en,com materiais rejeitados,,en,os produtos que não cumpram as normas de qualidade e todos os itens que exigem retrabalho toda qualidade global afetando,,en, material shortages and changeover times.

• Performance is a measure of speed loss, or the number of units a machine is rated to produce per hour versus the number of units it actually produces.

• Quality represents the amount of scrap material produced by a particular machine, with rejected materials, products that fall short of quality standards and any items that require rework all affecting overall quality.

The conclusion is that the operator “can realize significant efficiency gains by calculating OEE for particular pieces of equipment throughout the plant.” Doing this will also make it easier to identify where particular pieces of equipment are operating to expected standards and norms for efficiency and reliability, and makes the operator aware of the areas where operational improvement will result in the greatest recovery of efficiency.

Another useful tool for operators is the total life-cycle cost (LCC) model for pump technologies. Many factory managers consider only the upfront capital cost of a pumping system in their decision process, which can end up being a costly choice for their business in the long run. According to the Hydraulic Institute’s 'Pump Life Cycle Costs: A Guide to LCC Analysis for Pumping Systems' manual, which it developed in conjunction with Europump, “the single most important factor in minimizing a pumping system’s LCC is proper pumping system design.” Other design factors that impact the pumping system’s total LCC include pipe diameters, lengths, curvas, elbows, fittings and valve types, which can increase friction loss. These factors include the correct sizing of the pump, as selecting a larger pump than necessary just ‘to be safe’ will result in the pump operating away from the best efficiency point and requiring more energy consumption; the use of throttling valves to control flow rather than pump speed; and application requirements such as flow rate head pressure and fluid viscosity. Estas são todas as áreas onde a experiência em aplicações pode ajudar o designer e instalador do sistema,,en,por esta razão,,en,muitos fabricantes olham para distribuidores terceirizados,,en,consultores ou fabricantes de bombas para ajudar na concepção do sistema e seleção de bomba,,en,fabricantes industriais podem pensar que eles estão sendo bombardeados de todos os lados quando são confrontados com crescentes demandas para melhor enfrentar e controlar a volatilidade do preço da energia,,en,atender os princípios rigorosos de legislação reguladora cumprimento expansão,,en. De fato, for this reason, many manufacturers look to third-party distributors, consultants or pump manufacturers for help in system design and pump selection.


Industrial manufacturers may feel that they are being bombarded when they are confronted with growing demands to confront and control energy-price volatility, meet the strict requirements of expanding regulatory-compliance legislation, and satisfy both the public and their customers who are ratcheting up expectations regarding improving environmental stewardship. While this can be daunting, it is also a significant, and necessary part of the cost of doing business in today’s manufacturing environment. Manufacturers must satisfy these demands while simultaneously running a profitable business. Com aquilo em mente, it’s becoming increasingly apparent that the manufacturers who will be successful in the future will be the ones who develop and utilize applications expertise, especially when selecting critical pumping technologies and systems.

To do this, industrial manufacturers and their channel partners (the distributors, consultants and engineering firms that work hand-in-hand with them) are committing to building applications expertise in their industries. This expertise, when thoughtfully applied to essential system challenges, can unlock significant value for the manufacturer and the end user alike. Portanto, companies that build superior applications expertise will create a significant competitive advantage in the market in the future.