Rapid City, South Dakota. Not far from Mount Rushmore. Robert Mudge, a young engineer, finds himself at a career crossroad. His father, Jim, encourages him to start a business in a state where his roots are. Months later, RPM and associates is born. In typical form, RPM and associates answered a 1991 call from a long-time power customer requesting help in solving wear problems with their atomizers. This call resulted in not only solving the customer’s problems, but also in the 1996 creation of a sister-company, RPM solutions, that specializes in the repair and manufacture of flue gas desulfurization atomizer components. As their clients began to experience higher productivity, reduced downtime, and lower maintenance costs, word spread about RPM’s ingenuity. They are THE trendsetters in innovative solutions for industry. Their entire team is performing groundbreaking work that is opening their competitors’ eyes and exceeding their customers’ expectations. For more information about RPM, visit rpmsolutions.com

Rapid City, South Dakota. Not far from Mount Rushmore. Robert mudge, a young engineer, finds himself at a career crossroad. His father, Jim, encourages him to start a business in a state where his roots are. The RPM companies owe their success to a highly dedicated and motivated team of employees that work by four specific concepts:

  • Safety first and foremost.
  • Provide the highest quality products and services possible
  • Operate creative equipment and tools with reasonable effort
  • If 1-3 are performed well, a profit should be made.

All this to provide their customers with the most cost-effective solutions possible. Combine these concepts with a loyal customer base, and you have a formula for success. “You see RPM companies associated with almost every community organization here in Rapid City. Um, it ranges from wavy, to the boy’s club, to the hospital, to other organizations that do lots of good work here in Rapid City. They are THE trendsetters in innovative solutions for industry. Their entire team is performing groundbreaking work that is opening their competitors’ eyes and exceeding their customers’ expectations. For more information about RPM, visit rpmsolutions.com

RPM Solutions, Inc. Atomizer Monitoring System Overview. RPM Solutions, Incorporated has developed a comprehensive set of tools created to allow a power plant to effectively manage all aspects of maintaining an atomizer scrubbing system. The tools, collectively known as the “atomizer monitoring system”, or AMS, consists of an inventory management system, standardized procedure repository, and real-time monitoring and data collection tools. The atomizer monitoring system will save time, save money, and improve safety. It will also:

  • Effectively manage your parts inventory
  • Improve utilization and training of limited manpower
  • Obtain maximum wear life of components without increasing the risk of catastrophic failure
  • Easily maintain an accurate run-time history and maintenance history of components
  • Enhance communication between management, procurement, operations and maintenance
  • Accurately compare product improvements
  • Utilize set maintenance schedules
  • Utilize standardized procedures
  • The atomizer monitoring system is also scalable and customizable to meet your needs

The core of the atomizer monitoring system is a secure website: rpmmonitor.com. The website serves as the central repository for parts inventory, standard operating features, run-time history, maintenance completion reports, and related documentation. Computers and sensors in the plant exchange date with the website via the internet. A sophisticated application allows management, procurement, maintenance, and operations personnel to access the important information and functions. The inventory management system allows a plant to track individual parts associated with an atomizer. The system keeps track of a part’s serial number, manufacturer, current status, location, history, run-time hours, and related documentation such as certifications, inspection reports, drawings, and more. The AMS standardized procedure repository is an online system for creating, executing, and auditing, standard operating procedures for the plant. Procedures are step-by-step instructions complete with animations to guide personnel through even the most complex tasks. Steps in the various procedures are easily customizable to particular applications Procedure completion reports can be generated at the completion of each procedure to maintain an audit trail of what was done, when, and by whom. Sample procedures include assembling and disassembling an atomizer wheel, and installing an atomizer wheel on an atomizer. The procedure repository works in conjunction with the inventory management system to retrieve parts from inventory, assemble atomizer wheels and motors, and retire parts from inventory. Other features of the procedure repository include:

  • Ability to save at a given point and resume it at a later date
  • Record the “know how” of experienced existing staff
  • Automatic email and text notifications when procedures are complete

AMS realtime monitoring and data collection. Sophisticated sensors mounted directly on plant atomizers track runtime hours, atomizer location, and other key factors relating to the overall health of the equipment. These sensors transmit data in real-time to a central database located on the internet. Using a secure website, management and operations staff can utilize this data to see at-a-glance the current status of atomizers operating in the plant Data mining tools available on the website allow you to view and compare data over time, compare run-time of individual atomizers by date, evaluate run-time of devices installed in a given reactor by date, analyze unit cost of individual components per run-time hour by manufacturer. A rugged tablet PC is provided for operations and maintenance personnel Utilizing these tablets, personnel can execute standard procedures and see at-a-glance the status of equipment operating in the plant.

RPM console and sensors. For real-time monitoring and data-collection, sensors are attached to each atomizer to capture the data. Sensors connect wirelessly to an RPM console computer that forwards the data to the central website.

Scalable to meet your needs. The atomizer monitoring system is available in two base configurations: bronze, and silver. The bronze package is an entry-level system that includes the inventory management system and standardized procedure repository. The silver package includes all of the elements of the bronze package with the edition of the real-time monitoring and data collection module. The system is fully operational for atomizers. AMS also has potential application for other equipment in your plant including coal mills or pumps. Here is an example of an atomizer wheel that has been monitored.

  • Initial information – installed on July 18th at 5:45pm
  • Maximum run-time set to 2000hrs due to estimated life of the nozzles – one rotation
  • Pulled on October 17th at 11:34pm due to scheduled maintenance
  • Results – correct maximum run-time on nozzles. Wheel components cleaned and blasted. Nozzles rotated. Atomizer wheel ready for repeat service on October 18th.

Here is an example of an atomizer wheel that has not been monitored.

  • Initial information – unknown hours in the individual parts of atomizer. Unknown manufacturer and serial number of components. No work order found to state condition of wheel at time of installation.
  • Tripped at 20 mils on high vibration on October 18th at 12pm.
  • Results – total destruction of all components. Replacement costs were substantial. Disaster narrowly avoided .

Which one would you rather be? For more information, or to request a detailed quote, contact Shawn Veurink at RPM Solutions or visit our website: rpmsolutions.com