Demm Engineering & Manufacturing May 2012

NZ’S LARGEST ABC AUDITED CIRCULATION TO THE ENGINEERING & MANUFACTURING SECTORS May 2012 $6 INCL GST

• CONTENTS

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14 25 Editor's

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note

More from less What do drinkable water, fish, minerals and oil have in common? Demand for all those natural resources increases

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the United Nations, the population will attain 8.2 billion in 2030 and growto 9 billion in 2050. There are going to be more mouths to be fed, thirsts to be quenched, cars to be fuelled and homes to be heated. Consequently, one of the five

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less’. It has become paramount to manage our available

20 Motors and Transmissions

resources more efficiently.

On 17 June 2011, at the launching of the newISO50001 energy management standard in Switzerland, ISOSecretaryGeneral Rob Steele told the audience: “Energy is no longer

We help you take the tension out of belt tensioning.

25 Automation and Control Dad’s Pies uses cutting edge automation technology to cater for pie lovers nationally and internationally.

a technical issue, but a management issue with an impact on the bottom line and the time to address the issue is now.”

He also pointed out that “most energy efficiency in industry

28 Pumps and Valves The latest developments in the world of pumps and valves.

Includes a look at how hose pumps can decrease costs.

is achieved through changes in howenergy is managed in an industrial facility, rather than through installation of newtechnologies”. The newISOstandard provides a framework for industrial plants, commercial facilities or

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energy use.

We kick off our Energy Efficiency feature on page 14 with an

39 Electrical Technology This time it’s all about lighting and what you can get out of swapping to energy efficient technology.

article on what an energy management system looks like.

Maybe your company can soon report a success story similar to the one of Cook Composites and Polymers Co. (CCP) in

Maintenance Matters This feature includes an article on how good maintenance helps avoid corrosion of assets.

entire organisations to manage energy; it is estimated that the standard could influence up to 60 percent of the world’s

Energy Efficiency Discover how your business can save money and learn how the EECA Award finalists do it.

megatrends identified by CSIRO(Commonwealth Scientific and Industrial Research Organisation) is entitled‘more from

Product Watch A round-up of technologies and services designed to increase the productivity, efficiency and safety of the engineering and manufacturing sector.

steadily while supplies deplete incessantly. According to

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Coming Events

Houston, Texas. After implementing ISO50001 principles, the Texans achieved the following results: 14.9 percent energy savings in 24 months and savings of $250,000 per-year. The capital investment required was $0.

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COPYRIGHT:

DEMM Engineering & Manufacturing Magazine has a copyright and may not be reproduced in whole or in part without the written permission of the publisher. Neither editorial opinions expressed nor facts stated in advertisements are necessarily agreed to by the editor or publisher. Whilst all efforts are made to ensure accuracy, no responsibility will be taken by the publishers for inaccurate information, or for any consequences of reliance on this information.

Advertising Frank Atkinson, Email: frank@adrenalin.co.nz Publisher: Cathy Parker, Email: cathy@adrenalin.co.nz Editor: Stefan Richter, Email: editor@demm.co.nz Designer: Email: Rob@adrenalin.co.nz Circulation Manager: Kim McIntosh, Email: kim@adrenalin.co.nz

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Supported by:

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• PRODUCT WATCH

New respirator systems provide integrated protection

The new Versaflo respirator systems from 3M are designed to protect workers in a wide range of industries and applications helping them work comfortably for long periods.

The Versalfo product range has three modules: an air delivery unit, a headtop and a breathing tube that can be combined into

dozens of configurations to deal with changing environments, hazards and comfort preferences.

Versaflo S-Series head covers and hoods can be comfortably worn by more users due to new sizing and adjustment options.

Users also benefit from the comfortable, quiet airflow, the reduced fogging and the wider

field of view. Versaflo M-Series face shields and helmets provide integrated protection from multiple hazards. They are lightweight, compact, wellbalanced, easy to use and easy to maintain. All Versaflo headtops provide a direct comfortable stream of flowing air to where workers need it most: the head

Edit o choi r's ce and face. The moving airflow can make hot environments more tolerable while greatly reducing visor fogging. Versaflo TR-300 powered air respirator is a lightweight, slim, easyto-use air delivery unit for environments with particulate hazards. All Versaflo headtops are cross-compatible with Jupiter powered air respirator and Versaflo V-series supplied air regulators. With Versaflo respirator systems, pressure on the face, breathing resistance and heat build-up are all greatly reduced when compared to nonpowered tight-fitting face pieces, creating all-day comfort for the user. Flowing air supplied to the wearer reduces the additional breathing effort required, in comparison to half and full face respirators. Go to www.demm. co.nz/enquiry quote: D120502

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Digital humidity and temperature sensor A brand new design of the humidity meter for wall mounting application with a humidity range from five percent to 98 percent RH, and temperature range from -20 to +80°C, has been released

by Bestech Australia. The

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May 2012

new Almemo humidity sensor provides a user choice of output signals of two channels with either 0-10VDC or 4-20mA. The MH8D46 humidity transmitter requires a power supply of 9-30VDC (nominal 12VDC or 24VDC). The

features that make this humidity probe versatile include the easy setting up procedure and later changing of settings. This is facilitated by three on-board push buttons with matching digital displays that also show the ‘live’ data when required.

The ease of in situ replacement of the humidity sensor elements with competitive pricing ensures simple and low-cost maintenance and a long-life installation. Should there be a power failure, all characteristics, settings and adjustment data are automatically saved into the non-volatile memory of the humidity sensor.

The user can choose any two simultaneous outputs from the choice of the four atmospheric variables including

temperature, relative humidity, dew point and mixture ratio.

The rugged IP65 rated diecast case of the humidity sensor enables it to be mounted

safely in most industrial, medical and commercial environments. Also, the humidity meter itself, with its stainless steel case, can be mounted separately from the main enclosure if needed.

Alarm limit relays may be added if required, and a wide range of other options are available to meet most application requirements. Go to www.demm.co.nz/enquiry quote:

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D120502a

• PRODUCT WATCH

A safe way to avoid arc flash

The new Flir IR windows have been rigorously tested by reputable labs to international safety standards for enclosures that house dangerous electrical and mechanical parts. This includes the following: • Testing the seals when installed on a flat panel.

• Ensuring that mechanical forces (vibration, impact, and load) don’t enable access to live electrical components.

• Testing the strength of the installation system.

• Testing frame integrity during common equipment failures (arc flash, mechanical breakdown).

• Effect of climate on frame and seals.

• Long-term integrity of frame and seals.

Flir says its IR windows meet end application safety requirements for medium and high voltage switchgear (above 600V ). Opening electrical cabinets to perform IR and visual inspections of live components is dangerous work, exposing technicians to the risk

of a hazardous arc flash incident. Now users can put the added safety of new Flir IR Windows between them and energised equipment and eliminate the need for opening enclosures. The IR windows are compatible for all thermal cameras. All of them feature a secure, permanently-hinged cover that opens easily with one

hand, which means there’s nothing to remove, drop or lose. Flir’s broadband crystal lens allows cameras to capture visible light pictures as well as thermal images. It also allows LED and laser illumination to pass straight through for clearer visual assessments.

Go to www.demm.co.nz/ enquiry quote: D120503

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MetalFix

®

Waterbased Primer For Heavy Rust

A single-pack water-based rust converting etch primer, for application over rusted steel. The product converts the rust layer into a metal phosphate and simultaneously cures into a tough abrasion-resistant skin, which is impervious to further rusting.

MetalFix® * * * * * *

Water wash up (no solvents) Protects rusted exhaust systems Safe for hazardous areas (e.g. fuel depots) Fire retardant properties Operates from sub zero to 900 C+ Repairs rusted holes (e.g. water tanks)

MetalFix 1000®

* * * *

Imparts a resistance to fire Non toxic in the dry state May be used safely in confined spaces No sandblasting necessary, the paint has a quick recoating time

KT KemTek for details visit: www.kemtek.co.nz

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• PRODUCT WATCH

Rubber beats metal in process and manufacturing applications Rubber springs have long been attractive for industrial applications because of their reliability, light weight and basic simplicity. But to obtain the load requirements for many applications, solid rubber springs were either too large physically, or became unstable laterally when made long enough to provide good isolation characteristics. The concept of stacking rubber springs answered the latter problem, but introduced the need for complicated mechanical guidance systems to control the lateral stability problem.

A rubber spring design that solves this basic problem is the Marsh Mellow spring from

Firestone Industrial Products, represented in New Zealand

by Bridgestone New Zealand.

Marsh Mellows provide a new and unique way to make use of the many advantages of rubber as a suspension and isolation

Power Transmission “PACKAGED” To Suit Your Needs

Worm Gear Motors and Worm Gear Reducers

• Modular design with ISO standard flanged input together with output flanges, torque arms, plus simple connection of multiple staged reductions • 100% compatible with ISO flange mounted motors • Lightweight aluminium design • Available in 10 sizes with power ratings .09kW - 15kW and ratios of 7.5:1 to 6,400:1

RR Fisher & Co Ltd R PO Box 23293 Auckland

Auckland Ph: 09 278 4059 Fax: 09 279 8286 Christchurch Ph: 03 377 0025 Fax: 03 377 0086

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May 2012

element in major applications, including vibrating screens, conveyors and particularly corrosive processing and manufacturing environments that may damage metal springs.

The basic construction of the springs includes a solid rubber core with a hollow centre, reinforced covers and specially designed tapered ends.

“The controllable variables of this construction are the secrets to the extreme design flexibility the spring offers,” says actuation and isolation specialist Jim Hine, Product Manager, Bridgestone New Zealand Ltd. “Changes in taper, rubber durometer (or hardness), or changes in cord angle or bias result in dramatic changes in operating characteristics of the products.”

The characteristics of the Marsh Mellow design facilitate a constant natural frequency and variable spring rate to provide constant isolation over a wide range of loads.

Compared with traditional rubber springs and steel coil springs, Marsh Mellow offer: • High degrees of vibration isolation, as well as lateral vibration isolation and consistent vibration isolation with changing loads.

• Low natural spring frequencies to provide excellent isolation of forced frequencies in the range of 13-20Hz (8001200 cycles a minute).

• Compact overall size with high load capacity and increased stability at higher percentages of compression, • Greater allowable deflection and greater length-to-diameter ratios for machine design flexibility and simplicity.

• Long life durability and corrosion resistance to eliminate downtime and potential damage to machinery.

• Low cost and maintenancefree performance with effective noise reduction.

Marsh Mellow springs can be an effective isolator in virtually any application where an air supply is not available for traditional air springs. Their outstanding performance – and a maximum load range now extending from 1.4kN up to 88kN (on special order) – makes them particularly suitable for vibration isolation applications beneath such equipment as bin hoppers, compressors, crushers, blowers, motors, HVAC installations and vibrating screens. Go to www.demm.co.nz/enquiry quote:

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D120504

• PRODUCT WATCH

Screw compressor benefits CNC processes Industrial Air Systems NZ claims to bring benefits to CNC machining processes that will reduce the risk of an expensive breakdown and result in higher productivity while saving on operating expenses, through the installation of their RC integrated rotary screw compressor and aluminium air reticulation system.

The company’s director says too often companies are installing expensive CNC machine tooling for highly productive or precision machining work, completely overlooking the need to provide a matching reliable, dry and clean compressed air supply that these machines are so dependent on. A substandard or insufficient compressed air supply can lead to the spoiling of the machining process or, worse still, the breakdown of the CNC tool itself, leading to very expensive repairs and costly downtime, when ultimately these units need to be kept in constant production for maximum yield and fast payback.

He says why risk coupling an old, worn out $1000 piston compressor to an air system that supplies air to CNC machinery worth $50,000, when it is such an integral part to its operation? You are asking for trouble and it’s like driving a Lamborghini performance car on worn out retread tyres.

At the end of the day the vehicle will only go as far as the worn out tyres do and most probably have an accident in the meantime.

Industrial Air Systems recommends that the simple installation of their quality rotary screw compressor and dryer package will not only safeguard the system against any potential air contamination, but improve machining productivity while decreasing the compressed air operational costs. The RC screw compressor brings a win-winwin benefit and an investment that CNC operators will not look back on. The renowned RC screw compressors offer the advantage of having a direct driven motor/ air end transmission system – usually only found on much larger models, which greatly enhances its operating life saving on energy and maintenance costs.

With an oversized air-end and spinning at less than half the RPM of conventional belt-driven screws, this unit runs cooler, quieter and cleaner than most other models in the industry and with less moving and wearing parts these compressors can be very easily serviced by the operator. A smaller oil reticulation

system enables the screw compressor to run in stop/start or continuous on-load/ off-load modes, depending on the going workload, for optimising energy efficiencies and reducing unnecessary wear. This means the compressor’s operational programme can be customised to suit every compressed air environment within its output capacity.

Go to www.demm.co.nz/enquiry quote:

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D120505

AADEMM20110916

save your energy...

Efficient, Compact, Maintenance Free, Aurora make us part of your process www.aurora-nz.com

0800 55 77 33

DIMPLEFLO ENERGY RECOVERY HEAT EXCHANGERS FOR TRADE WASTE & SLUDGE HEAT RECOVERY Compact Configuration with Large Dia Tubes Versatile Modular System for Expansion Low Maintenance & Self Draining Ultra-High Heat Resistant Efficiency Fouling Resistant

sales@aurora-nz.com

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• PRODUCT WATCH

Quality protection and maximum comfort Protecting your hands while working with hazardous chemicals is vital, which is why Honeywell Safety Products offer a range of gloves that provide quality protection and deliver maximum comfort. The Viton unsupported gloves offer excellent chemical resistance to chlorinated and aromatic solvents. They have a high resistance to PCBs and can be used in water-based solvents without dissolving. With a curved finger and hand design, the gloves provide a better fit for greater wearer comfort.

With 100 percent nitrile content, the NitriGuard unsupported nitrile gloves offer high resistance to cuts, snags, abrasions and punctures. Free of latex proteins, the gloves are suitable for workers who suffer from irritating latex allergies.

They are available with

unlined or flocked interior and comply with USDA and FDA regulations, 21 CFR, for use in food processing.

Flexible and sensitive, the Butyl unsupported gloves provide the highest permeation resistance to gas and water vapour, which enables greater worker protection. The curved finger and hand design allow for a better fit, helping workers stay comfortable for longer periods of time. The gloves are also available with a “Grip Saf ” palm for wet applications.

The Nitri-Knit gloves provide high manual dexterity and comfort while protecting hands from temperature extremes.

With a unique texture finish, the gloves provide an excellent grip on oily, wet and dry objects and have an interlock knit liner for strength, as well as comfort. The true dip

The Butyl unsupported gloves provide high permeation resistance to gas and water vapour.

coating with a permanent bond of nitrile to the inner liner ensures that it won’t peel apart like glued-in liners and the comfortable elastic sleeve ensures the gloves stay put during hazardous tasks. Perfect for workers who suffer from allergies to latex, the gloves are free of allergy-inducing latex proteins, while the high nitrile content offers superior resistance to cuts, snags, abrasions and punctures.

The strong material also outperforms natural rubber,

neoprene and vinyl gloves when exposed to solvents, caustics and animal fats and won’t swell, sag or weaken after absorbing fats. Suitable for conditions up to 150°C for long periods of time, the Nitri-Knit gloves can even be used for most autoclave applications. With the hand portion treated with a permanent anti-bacterial and anti-mildew agent, the gloves stay clean and dry and can be laundered for extended use.

Go to www.demm.co.nz/enquiry quote: D120506

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High cycle, high reliability ReCoila’s range of automation reels are specifically designed to supply hydraulic oil from fixed to moving points on cranes, truck mounted cranes, forklift trucks and other materials handling equipment. Compact, efficient and reliable, the AG & A4 series features superior-quality bearings and components that offer high cycle rates and high life expectancy in the most demanding of applications and environments. Superior design and construction allow these reels to handle the constant repetitive unwind/rewind motions of crane arms, telebooms or forklift truck lifting mechanisms ensuring reliable operation. These reels are designed to accommodate up to six hoses, with the addition of hose and cable combinations and working pressures up to 300 bar. ReCoila also offers a range of models in 316 and 304 for marine and food processing applications. Go to www.demm.co.nz/enquiry quote: D120506a

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May 2012

• PRODUCT WATCH

New low-noise exhaust fans

Fantech has added two new models to its TD Silent Series of efficient, low-noise exhaust fans. Fantech Engineering Manager Kerry Dumicich said the TD Silent 250mm and TD Silent 315mm models were high-performance, highcapacity fans that were quieter than any other fan in their

class. “This breakthrough in noise reduction is due to a technically-advanced design and internal construction.

Sound waves produced inside the fan are captured by a sound-absorbent internal membrane resulting in an efficient low profile fan that operates very quietly.” Mr Dumicich said the TD Silent

BUILD IT Exactingly right – Every time –

Series was extremely quiet and a real advance in acoustic technology.

At three metres, the TD Silent 250mm has a sound pressure of 42dB(A) in low speed and 47dB(A) in high speed. The 315mm has a sound pressure of 44dB(A) in low speed and 50dB(A) in high speed. “The smaller fans produce even less noise, making the TD Silent Series suitable for hospitals, apartments, hotels, and offices.” According to Mr Dumicich, the engineers of the TD Silent had looked at all sources of noise and provided clever adaptations in these two new models such as its specially designed aerodynamic inlet to improve

air-flow performance and further reduce noise. “The larger fan body of the TD Silent 250 and TD Silent 315 can be easily separated from the ducting for cleaning and maintenance by removing four screws at each end of the fan.” The 150mm and 200mm models have a sleek body manufactured from reinforced injection moulded polypropelyne plastic. The larger 250mm and 315mm models are constructed from durable sheet steel finished in a protective epoxy polyester paint to provide strength and help minimise the fan’s dimensions. The larger models also feature an external terminal box which is rated at IP55. Go to www.demm.co.nz/enquiry quote:

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D120507

• Motors • Brake motors • Servo motors • Geared motors Gear units • Control Technology

Quality European Manufacturing • Motors • Gear Components • Control Technology

Final test.

High voltage motor test.

Painted to customer application requirement.

Individual components selected to specification for the gear unit.

Finished products ready for delivery.

Fast, customised assembly at purpose designed workstations.

New Zealand Assembled

When you deal with SEW-Eurodrive, you are dealing with the `manufacturer’. • Fast, customised assembly for every Our huge range of quality European manufactured componentry is held in drive requirement stock at our Auckland & Christchurch plants, ready for fast turnaround customised assembly. In tight economic conditions, getting it `right’ every time, is even more crucial. Contact us for advice, planning and drive calculations.

AUCKLAND 82 Greenmount Drive, East Tamaki. Ph: (09) 274 5627. Fax: (09) 274 0165 PALMERSTON NORTH Ph: (06) 355 2165 CHRISTCHURCH 10 Settlers Crescent, Ferrymead. Ph: (03) 384 6251. Fax: (03) 384 6455 Email: sales@sew-eurodrive.co.nz • Web: www.nz.sew-eurodrive.com

24/7 Service backup

E&M212

Components for the motor are quickly order picked to each customer application requirement.

INDUSTRIAL DRIVE TECHNOLOGY

• PRODUCT WATCH

Robust multi-gas monitoring solutions Wormald is now distributing the Scott Safety Protégé multi-gas monitor. Ideal for industrial workers in hazardous environments, the robust and easy to use hand-held device is designed to monitor the breathable atmosphere within a confined space.

The Protégé monitor can measure up to four gases including oxygen, combustible gases, hydrogen sulphide and carbon monoxide. Simple sensor change-outs allow for detection of up to five different combinations. The compact and portable unit weighs just 213g, yet its robust construction means it can survive drops.

The Protégé is also IP67 rated which makes it suitable for use where dust, electrostatic shock or water is present. Peter Payne,

product manager with Wormald said, “The Protégé device is suitable for a range of applications where employees are exposed to hazardous situations or working in confined spaces. As it is easy to use, operators will require little training and can concentrate on the situation in hand rather than on operating the equipment.” For noisy and harsh environments, the Protégé uses a tri-alarm warning system alerting users through a dual bright red LED visual alarm, piercing audible alarm and a vibrating tactile alarm. It also offers an alarm for peak readings, battery charge, short term exposure limits and time weighted averages. Protégé software allows users to set parameters that are specific for their situation, and the device has significant data logging capabilities. The optional Protégé Masterdock station enables users to automatically calibrate and bump test the monitor and download information to a text file. Up to 7,000 significant events can be captured for analysis. Go to www.demm.co.nz/enquiry quote: D120508

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Tested and ready to stand the pressure As advanced hydraulic systems are designed and engineered into more and more high-powered, high-pressure equipment, the importance of high-quality, flexible, durable hose assemblies that won’t fail has never been more critical. Gates has developed an integrated solution to meet the needs of today’s hydraulic systems – and tomorrow’s. The manufacturer meets the needs of high-powered, high-pressure hydraulic equipment with its MegaSys line. As part of an integrated solution, the

hydraulic spiral-wire and wire-braid hose and coupling products offer a combination of technology, performance and flexibility that is, according to Gates, unmatched by anything on the market today. The company says the products have been tested at 1,000,000 impulse cycles and above maximum working pressures to stand up to even the most demanding applications. The MegaSys line of constant pressure hoses can be bent up to one-third SAE specifications.

Combined with innovative couplings

specifically designed to crimp on these hoses ,leak-free performance is guaranteed by Gates up to a maximum working pressure as high as 8,000psi. MegaSys products save time, space and money. Coloured laylines and constant pressure ratings through all sizes make hose identification and selection easier and faster. Go to www.demm.co.nz/ enquiry quote: D120508a

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Working capital is the lifeblood of the manufacturing industry… need a transfusion?

Lock Finance is New Zealand’s leading independent and business finance company offering a fully integrated combination of trade finance, working capital, debtor finance and factoring since 1889.

Freephone 0800 ASK LOCK (0800 275 562) lockfinance.co.nz LOC 6898 A

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May 2012

• PRODUCT WATCH

Footwear for firefighters and emergency services Oliver Footwear has released two new firefighter and emergency services boots. Designated as the Oliver Footwear 66 Series, the boots meet the AS/ NZS Standard 4821:2006 and are officially designated as the Oliver style number 66-360 as a 180mm, or seven inch, Type 1 Wildland Firefighting Footwear. The second choice is Oliver style 66-395 a 230mm, or nine inch, Lace Up Structural Type 2 Firefighting Footwear.

Both Oliver 66 Series boots feature high quality, black

water-resistant and flameretardant leather uppers.

The soling material is heavy duty dual density nitrile rubber with two layers of expanded rubber cells which provide a soft midsole that cushions the foot, with a high density hard-wearing outsole reflective of the demanding conditions in which they are likely to be worn. The outsole is resistant to 300°C of surface contact with the sole also resistant to mineral and organic oils and acids. The sole also has high cut, split and crack resistance and an

Halcon 11 announced MVTec Software has announced the release of the new version Halcon 11. For machine vision users, Halcon 11 provides many innovations and enhancements. As a unique feature, the software presents the ‘sample-based identification’. With this innovative technology, trained objects can be recognised only by characteristic features like colour or texture, thereby eliminating the need to use bar codes or data codes for object identification purposes. Furthermore, Halcon introduces new technologies and enhancements for 3D vision like ‘3D surface comparison’, registration and triangulation of point clouds, and improved photometric stereo tools for superior 3D surface inspection capabilities. The new version extends its data code reading functionality by supporting Aztec and Micro QR codes. Moreover, classification tasks are greatly simplified by using the ‘automatic feature selection for classification’. Furthermore, the usability of Halcon’s integrated development environment (HDevelop) is improved thanks to new features like the Profiler Tool and a new OCR assistant. The speed of Halcon 11 is significantly improved by 16 additional operators supported

by GPU computing and various faster algorithms. On top, many new market- and user-orientated code examples as well as detailed documentation are included. The new version now supports the Mac OS X operating system making Halcon’s technologies available to Apple users for the first time. Go to www.demm.co.nz/enquiry quote: D120509a

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excellent slip resistant pattern.

Wearer comfort is afforded by the Oliver Comfort cushion which uses a combination of cellular urethane and Poron for protection of the heel and foot with the constant impact absorption helping to reduce

foot, leg and lower back fatigue. Both styles have a lightweight Oliver Hi-impact composite Nature form wide profile Type 1 protective toe cap that is non-metallic.

Go to www.demm.co.nz/enquiry quote: D120509

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VIKING NEW ZEALANDS MOST COMPREHENSIVE RANGE OF DUST EXTRACTION AND SPRAY BOOTH SYSTEMS.

SPRAY BOOTHS • Kit set open face booths • Auto spray lines • Heated spray and bake booths • Heated drying rooms • Paint work stations

DUST EXTRACTION • Reverse pulse bag filters • Camfil Gold series collectors • Cyclones and static filters • Fans and rotary valves • Design build, project management • Sheet metal and general engineering

• V-Duct modular ducting • Welding and fume extraction T: (09) 835 4090 F: (09) 835 4070

www.vikingltd.co.nz

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• PRODUCT WATCH

Versatile infrared thermometers Ircon has introduced the Modline 7 series of infrared thermometers. Combined with Ircon ModView Pro software and a variety of accessories, the Modline 7 series provides sophisticated solutions for demanding industrial environments. The Modline 7 is a rugged, IP65 (NEMA 4) sealed sensor system with the flexibility to meet nearly any continuous temperature monitoring and control requirement. The thermometers

are used in a wide range of industrial applications, including semiconductor manufacturing, metals processing, furnace refractory, primary and secondary glass, as well as

plastics thermoforming. They offer exceptional versatility with extended temperature ranges (-40°F to 5432°F/3000°C), high-resolution optics and fast response times. The thermometer’s sensing head can operate as a stand-alone sensor, providing simultaneous analogue and digital outputs of process temperatures. Motorised focus control and both throughthe-lens and laser sighting are standard on all units. The new thermometer’s intuitive

sensor design – with integral water-cooling in a stainless steel enclosure or high-temperature water jacket – reduces installation and setup time. The water jacket is intended for use in ambient temperatures up to 599°F/315°C with an integrated air purge capability. An optional air purge collar accessory enables the lens to be cooled and kept free of debris in hot dusty environments.

Go to www.demm.co.nz/ enquiry quote: D120510

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More freezer capacity for the same footprint With its GEA MaxiStack, GEA Refrigeration Technologies presents its new spiral freezer model – which is highly convincing owing to its great freezing capacity on a small footprint. These new freezers are available for freezing output up to 3500kg/h.

Its compact size is possible as a result of its self-stacking, patented GEA Q-belt conveyor belt, which makes unnecessary the slide rails that are used with low-tension spiral freezers.

This means more conveyor belt surface area with the same external dimensions. The new model is available in various numbers of tiers, thereby

enabling the user to adapt his freezers to the product being processed.

According to the company, the Q-belt system outperforms conventionally designed self-stacking conveyor belts as a result of its rugged construction.

For example, the belts – stacked one over the other – interlock on a large surface area and employ enhanced interlocking, which enables stable stacking.

This structural design also positively influences the durability of the conveyor belts. The other components are likewise designed for ruggedness. GEA Maxi-Stack uses the latest advanced features

from the GEA freezing product range: e.g., the fully welded modular insulated floor and stainless steel structure, and a fully welded stainless steel enclosure as an option. All these design features enable the GEA Maxi-Stack to be cleaned efficiently by a CIP-System (clean-in-place). The evaporator is manufactured in-house with stainless steel tubes and with 0.6mm aluminum fins.

GEA Maxi-Stack offers special benefits when a greater throughput of frozen products is desired on a given equipment footprint – or when compact building dimensions are being planned as criteria for the

production floor. The option of a snow-removal system allows extended operating time between interruptions for defrosting. The recirculating CIP option offers highly efficient cleaning and saves water and detergent. Go to www.demm.co.nz/enquiry quote:

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D120510a

GEA Freezing GEA Freezing 356 Church St, Penrose, Auckland, New Zealand

systems. The design of our Spirals, Tunnels and Carton Freezers has

PO Box 12479 Penrose, Auckland 1642

evolved from more than 30 years’ experience in the food processing

Phone: NZ +64 9 526 3344 · Fax +64 9 526 3345

industry. Our food application, engineering and manufacturing teams

Phone: AUS +61 3 9770 8832 · Fax +61 3 9770 8839

ensure the freezers or chillers fully meet your processing needs.

www.geafreezing.com

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Offers a wide range of energy efficient freezing and cooling

May 2012

TC0179_DEMM

GEA Refrigeration Technologies

• PRODUCT WATCH

Efficient cooling system platform launched

Rittal has successfully launched a new cooling system platform based on the Rittal Liquid Cooling Packages (LCP). This way, cooling output is increased, product selection is made easier and clearer, service simplified, and the need for accessories in storage is reduced. In addition, Rittal has optimised the products’ energy efficiency. The Rittal LCP cooling system platform of the Blue E generation is made up of four different climate control systems: the Rittal LCP, the Rittal LCP Inline, the Rittal LCP T3+ and

the Rittal LCP LWWT. They all share a common architecture and interchangeable components. For example, all systems can use the same type of ventilator. This means that fewer accessories must be stored. The costs of servicing are also cut: Because service engineers need to deal with fewer versions, maintenance and repair work can be carried out routinely and so faster. The Rittal LCP models offer an extended power range, from 10kW up to 60kW. They can be scaled in steps from 10 to 20 or to 30kW, or from 40 to 50 or 60kW. This is a benefit if heat losses in the enclosure rise, for example, due to the use of additional servers. The efforts for increased energy efficiency were a high priority of the Rittal LCP developers: All versions have improved fans that consume less electricity. The LCP LWWT even works without any ventilators at all.

With the Rittal LCP platform of the Blue E generation, despite the standardised construction, completely different customer requirements can be met. Consumers of high levels of computing power – such as research

institutes – generally cause high power losses. That is why they often place special requirements on the climate control system.

These are met by the rack-based LCP, which Rittal offers with 30kW up to 60kW. It’s different with the LCP Inline. It cools all the rows of racks by blowing cold air to the front in the partitioned cold aisle. The LCP Inline is available with an output of 30kW and as much as 60kW. The LCP T3+ has a similar construction as the LCP. It ensures higher fail-safe rates, as the cooling water and electrical supply are designed in a redundant manner. The LCP LWWT has an output of 20kW and operates without using any fans at all. The energy saving version of the LCP Next Generation has a passive air-water heat exchanger in the rear door of the server enclosure. The LCP DX (direct expansion, direct evaporation) is especially suited for smaller applications where space is limited. It uses a refrigerant instead of water. This way, the climate control system can be installed quickly and easily. Go to www.demm.co.nz/ enquiry quote: D120511

•

Design for every application Engineering Ltd

Integrators of specialised robot systems Phone: (64) 9 826 0580 Web: www.carbines.co.nz

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May 2012

HOW TO STOP YOUR FANS SUCKING PROFITS OUT OF YOUR BUSINESS Improving the energy efficiency of your pumping and fan systems can save thousands of dollars a year.

But too often these savings aren’t realised because the opportunities are not obvious. An energy audit can show you where you can make improvements – and lock in savings. When a world-leading manufacturer of Medium Density Fibreboard engaged an EECA Business approved provider to audit their fan systems, they identified a great opportunity. The energy audit recommended an upgrade to motor controls which resulted in a 51% reduction in energy use, equating to a cost saving of around $127,000 annually, and a two year payback. What’s more, the project reinforced the company’s reputation for sustainably developed products.

And because production was not impacted, management gained the confidence to pursue further energy efficiency initiatives resulting in more cost savings. EECA Business is offering funding towards pumping and fan system audits and grants to help implement energy efficiency projects.

Arrange an audit by contacting an EECA approved programme partner today and see what you can save. Visit www.eecabusiness.govt.nz

Ogilvy/EEC2294

• Energy Efficiency

A standard for energy excellence Skyrocketing energy prices, dwindling fossil-based energy resources and increasing competitive pressure motivate politics and society to fundamentally reconsider the way we deal with energy. Legal guidelines and regulations lend further impetus. Numerous investigations and studies show that, in many cases, there is a considerable savings potential of up to 30 percent and more. Energy management systems based on the ISO 50001 help tap this huge potential.

ISO 50001 Energy management systems – Requirements with guidance for use, is a voluntary international standard developed by ISO (International Organisation for Standardisation). This standard establishes a framework for industrial plants, commercial, institutional, and governmental facilities and entire organisations to manage energy. Targeting broad applicability across national economic sectors, it has been estimated that the standard could influence up to 60 percent of the world’s energy use.

The general aim of this standard is to support organisations in the set-up of systems and processes to improve their energy efficiency.

Systematic energy management leads to the reduction of energy expenditure, energy costs and greenhouse gas emissions. An energy management system (EMS) determines the energy situation in the organisation; helps redefine the energy policy of a company based on concrete data and improves the energy efficiency. Furthermore, factors that influence energy consumption must be identified in order to continuously monitor and measure them. The energy manager of a company is responsible for pursuing the defined goals and continually improving the results achieved.

The decisive component in an energy management system is an effective and continuous energy controlling control circuit. A control circuit of this type consists of four stages: data acquisition, energy analysis,

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May 2012

energy efficiency measures and inspection.

Continuous data acquisition A first step to escape the financial trap is the precise acquisition of all energy data, electrical and power quality parameters. First of all, the operating, consumption, and cost data (e.g. power, gas and district heating invoices) must be acquired and recorded by qualified personnel during the data acquisition phase. To make a detailed evaluation of an organisation and to create a basis for relevant energy efficiency measures, the energy flows must be further resolved from the supply side all the way down, which means major consumers or company units must also be measured and sub-measuring points are required.

Because larger companies have many measuring points, often even hundreds of measuring points, automatic acquisition of the energy consumers must be provided. Significant points for the configuration of such a data acquisition system include the decision about the data required (which electrical and energy parameters), data resolution (different data requires different averaging times), query intervals and the communication architecture (e.g. TCP/IP (Ethernet), Bacnet, Profibus, Modbus …). Modern energy measuring technology provides the necessary transparency in the field of building energy supply.

Continuous data acquisition is recommended in order to react speedily to changes in operation

The decisive component in an energy management system is an effective and continuous energy management cycle. Source: Janitza

while also documenting the results achieved.

Via corresponding communication architectures, the acquired data is transmitted to a central location, stored centrally in high-performance databases and made available for further processing in an architecture that is as open as possible.

Attention must also be paid to simple integration in higher-level systems, e.g. SCADA systems, building control technology or PLCs, as appropriate.

Energy analysis The energy analysis is based on the data of the automatic measurement data acquisition system. The energy analysis provides the basis for the concrete goals of the enterprise with regard to energy consumption and energy cost reduction (e.g.

10 percent energy savings a year). In addition, the energy analysis results are also the significant starting point for an ABC analysis of the loads, the development of a catalogue of measures, evaluation of specific measures, prioritisation of the energy efficiency measures and

creation of a detailed plan of measures.

Planning of measures The results of the energy analysis flow into the planning of measures for reducing the energy consumption and energy costs.

The measures can be divided into four groups: Planning: Examination of energy use, optimisation of operating times, machines with high efficiency, peak load optimisation, heat recovery, etc.

Organisational measures: Area of acquisition (e.g. putting emphasis on the life cycle costs), changes to the workflow, in the area of regulation/control, the conduct of employees, during maintenance and repair, training and motivation.

Technical measures: Use of more energy efficient motors (more than 95 percent of the life cycle costs of an electrical drive are energy costs), changing to frequency inverters, use of heat recovery, leakage reduction in the compressed air network, optimisation of the regulation and control of systems, optimisation of steam generation, intelligent use of

• Energy Efficiency

peak load optimisation/energy storage etc.

Load management: Load (peak demand) management constitutes a special measure.

Optimisation of the power load profile does not primarily bring energy savings but, depending on the power supplier contract, leads to substantial cost savings.

This measure also stabilises the energy supply.

Checking and correction After integration of an energy management system in the company, it is important to rigorously continue and further develop it. In other words, an EMS is not a unique or shortterm project, but a continuous process. It is important to repeatedly check that the set goals have been achieved and to introduce improvements where necessary. The goals must also be inspected at regular intervals to check that they are still sufficient and updated if need be. Only with automatic data acquisition can goals – both achieved and future – be discussed and redefined on the basis of the relevant data. Or else the comparison (e.g. with the previous month) indicates

trends (e.g. capacity utilisation of the operation) and identifies errors in time (e.g. leaks in the compressed air, mains feedback effects causing high neutral conductor currents or even posing a fire risk).

Energy efficiency measures can be monitored and documented after implementation of automatic data acquisition, comprising all kind of energies, such as heat meters, gas meters, network analysers and multi-function measuring devices, for example.

Benefits of an EMS • Identification of ‘energy wasters’ and introduction of measures results in the reduction of power and energy costs (kWh, peak load costs, reactive power costs).

• Reduction of climate killing carbon dioxide (Green IT, Zero carbon offices, Kyoto etc.).

• Stabilisation of processes (improvement of the power quality).

• Lowering maintenance costs by pro-active maintenance and reduced stress factors.

• Avoiding power failures, e.g. due to harmonic currents or resonance problems, voltage sags

Via communication architectures (here the Janitza system architecture), the acquired data is transmitted to a central location, stored centrally in high-performance databases and made available for further processing.

or transients.

• Raising awareness of employees with regard to energy savings and climate protection.

• Fulfilment of legal framework guidelines, energy tax reduction.

• Cost centre management enables consumption-oriented cost allocation.

• Cultivation of environmental protection and corporate image.

The power bill is usually the gauge for the cost calculation of operational plants, buildings or infrastructural facilities.

However, this bill is only the visible part of sometimes much higher costs, taking a ‘dirty’ and unreliable energy supply into account. Next to the direct electricity costs, the effective capacity utilisation of energy distribution systems and facilities as well as a reliable energy supply also play an important role in economic efficiency. As these costs are not so obvious, they are also referred to as ‘hidden costs’.

With an integrated, integral energy management system, you can also centrally monitor and compare (benchmark) branches at various geographical locations, for example. The power consumption, reactive power monitoring, water and gas consumption, the availability of electrical energy and the power quality can be collected, evaluated and analysed in the company headquarters’ database.

This can also increase energy efficiency as saving potentials are revealed by cost comparison.

Practically at the push of a button, the relevant software can be used to prepare the various data and create statistics and tables in the desired format, which are then made available to the financial controller, the energy manager, the purchasing department or facility management. In the area of property management, this also means an improvement of the preciseness of power consumption accounts and convenient, automated, customer-

Modern energy measuring technology: Janitza UMG508 power analyser

specific accounting (cost centre management), for example.

End-to-end energy management systems create network transparency on the various network levels, which allows the identification of possible ‘sinners’, uncovering inefficient processes and initiation of corresponding energy efficiency measures. Many energy efficiency measures can be achieved with low financial investments. And even with real capital investment, a return of investment can often be expected within six to 18 months.

ECCA funding Would you like to reduce your energy use and costs while building your brand? If you would like to improve your building’s energy use but haven’t got the capital, a Commercial Project Grant from EECA could fund up to 40 percent of the cost to help your project ‘over the line’.

Commercial project grants may be used for: • Upgrading or replacing equipment e.g. lighting, refrigeration, heating and air conditioning.

• Continuous commissioning systems that adjust energy use in line with demand.

• Monitoring and targeting systems that monitor energy use and target areas for improvement.

Article by Michael Welzel, Direct Control Ltd. The Auckland based company is one of the Programme Partners of ECCA and supports the ISO 50001 with integrated building automation and energy management solutions. Go to www.demm.co.nz/enquiry quote:

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D120514

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• Energy Efficiency

EECA Award finalists showcase excellence in efficiency Some innovative manufacturing and processing sites have been shortlisted in the 2012 EECA Awards – with a diverse range of projects making the finals. or processing sites among the finalists, spread throughout the regions from Whangerei to Christchurch, and demonstrating a diverse range of projects.

EECA chief executive Mike Underhill said the 2012 Awards judges were particularly impressed with the standard of entries. “Although many businesses are still dealing with the impact of the recession, there are many taking a longer term view and proactively improving energy use. This helps future-proof these organisations against price rises, and strengthens their ability to compete on the international stage. It also helps our national energy security and promotes the shift to a lower carbon economy – all of which boosts the competitiveness of New Zealand Inc.”

Heat recovery delivered savings for Life Technologies

Heat recovery exchangers were installed on the two main freezer refrigeration compressors at Life Technologies in Christchurch.

Energy efficiency is taking firm root in New Zealand’s manufacturing sector, if the 2012 EECA Awards finalists are any indication. Unveiled in April, this year’s finalists account for $60 million

worth of energy savings, or renewable energy generated. And unsurprisingly, several trailblazing manufacturers, across a range of sectors, feature in the line-up.

This year there are five manufacturing

Shortlisted in the Small to Medium Business category is Life Technologies’ protein-separation unit in Christchurch.

The unit started its sustainability drive in 2008, aiming to reduce energy, water use and waste sent to landfill. After an energy audit, the company carried out a number of initiatives including installing variable speed drives on air handling units, and introducing heat recovery.

Cleaning and sanitising of its ultrafiltration (UF) plant was a major water and energy user. Waste hot water is now recovered during the rinse step, stored in a 30,000 litre tank and reused in the tank cleaning process. This has cut diesel use, and brought savings of more than one million litres of water per year. Late last year, the company installed a system to collect waste heat from its two main freezer refrigeration compressors. At current performance, this is on track to save more than 100MWhrs of diesel per year by preheating incoming water supply to the hot water boilers. Across all its initiatives, diesel use at the Christchurch site has more than halved.

Nelson Pine tackles heat plant and motor efficiency Shortlisted in both the Large Business Nelson Pine Industries’ process engineer James Cameron by the plant’s fibre-forming line.

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May 2012

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• Energy Efficiency

Steam needed for paper production at SCA Hygiene, Kawerau, is now provided by clean geothermal steam.

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and Energy Management categories is Nelson Pine Industries, the largest electricity user in the top of the South Island. As such a large consumer, any efficiencies the company achieves benefit the region through easing pressure on supply. With a close eye on the sensitivity of its MDF manufacturing process, the company commissioned a site-wide energy audit then introduced the recommendations in careful stages.

First it tackled heat plant efficiency by improving furnace control, reducing dryer airflows, and automating its pre-steaming control. Combined, these measures reduced its wood fuel bill by $800,000 a year. Optimisation of its motor systems started in early 2012 and was carried out in four phases. By July that year it had installed variable speed drives to control air flows on 18 fan lines, and continued to fine tune and optimise the systems to gain further efficiencies. Electricity savings are now worth $500,000 a year and are expected to improve even further. The project has also had a spin-off benefit of reduced maintenance costs.

Dominion Salt boosts production and improves efficiency Dominion Salt and Aurecon New Zealand are joint finalists in the

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May 2012

Innovation category thanks to a vacuum plant upgrade that has boosted plant capacity by 63 percent and allowed the simultaneous production of food and pharmaceutical grade salt, compared to previously where the plant had to switch between production runs. The project has improved overall energy efficiency by 48 percent – natural gas used per tonne of product is down 33 percent from 4.25 GJ to 2.84 GJ, and steam use and carbon emissions have also reduced by around a third. At current production levels the upgraded plant is saving the company more than $500,000 per year in energy costs which is expected to increase further when it reaches full plant capacity of 76,000 tonnes of salt production per year. As well as allowing Dominion Salt to keep up with expanding export demand, the upgrade has given the company a competitive advantage by lowering input costs.

SCA Hygiene cuts CO₂ emissions with geothermal Award finalists aren’t showcasing just energy efficiency – there are also groundbreaking renewable energy projects on display. SCA Hygiene, the manufacturer behind common household brands such as Purex and Tena, is a finalist for the Large Business award.

It replaced natural gas boilers used to produce the steam required by paper machines at its Kawerau site with direct clean geothermal steam. SCA’s new geothermal-powered plant generates 16barg of clean steam, 24 hours a day, 363 days per year. This change alone cut the plant’s CO₂ emissions by 39 percent, and has enabled further energy savings. For example, after use, the clean geothermal steam is turned into condensate (clean, warm water) which is also used in the paper mill. This cuts down on water use, and also the energy used to heat it. Using geothermal steam as an energy source has a number of benefits for SCA Hygiene: it’s reliable (being available 24/7) and is accessible, being right under the plant. It’s also highly efficient as there is no energy conversion, and the price is stable.

SCA buys its clean steam from Ngati Tuwharetoa Geothermal Assets, a wholly-owned commercial subsidiary of Ngati Tuwharetoa Settlement Trust. This means most of the revenue generated stays in the Kawerau area.

Biofuel replaces coal at Golden Bay Cement Golden Bay Cement is another example of a large operation tapping into an innovative renewable energy source to cut its CO₂ emissions. The company has been increasingly substituting coal burned at its Whangarei facility with wood fuel, mainly sourced from local construction and demolition waste.

It’s now substituting, on average, 30 percent of coal with biofuel. This has delivered annual energy savings worth $3 million, and reduced CO₂ emissions by 58,000 tonnes per year. Golden Bay Cement’s entire biofuel-substitution system was designed specifically to suit the company, and in-house ingenuity reduced installation costs significantly.

International experts costed the system’s design and supply options at around $5 million – but after an in-house review, the company found a way to achieve it for a fraction of the cost, including using re-used material. As well as lower energy costs, Golden Bay is paying less for its raw materials, as it needs less high-grade limestone for production, thanks to the lower ash content in the wood fuel compared to coal. Go to www.demm. co.nz/enquiry quote: D120516

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• Energy Efficiency

How to increase compressed air efficiency Compressed air preparation is not exactly a hot topic for plant operators. As a result, carelessly maintained compressed air systems waste energy and result in premature wearing of high-quality pneumatic valves and drives.

Festo is now launching a push for greater compressed air efficiency.

Once it gets into the service units, this contaminated compressed air results in faster wearing of seals, oiled-up valves in the control section and dirty silencers. This decreases the availability of the machines and the service life of the pneumatic components and systems and increases the energy costs due to leakage and maintenance effort. Help is available in the form of diagnostic tools, safety functions to ISO and ready-to-install system solutions that Festo combines in a customised and energy-efficient package as appropriate to the requirements of the compressed air systems. Even a few small tricks can together increase the efficiency of the system. These include switching off the air supply when

the machines are at rest, when shifts end or during breaks. If greater pressure is needed at specific points in the compressed air network, it is often enough to use a pressure booster at this point instead of operating the entire network with a higher working pressure.

Installing a decentralised compressed air preparation system directly at the system reduces the risk of components being contaminated. Users should clarify the following questions when designing a decentralised compressed air preparation system: What is the maximum flow rate required?

What connection sizes are required?

Do all consuming devices need the same compressed air quality?

What compressed air quality does the compressor actually provide?

Intelligent service units such as the MS series from Festo integrate flow and pressure sensors that detect unnecessary consumption in good time and enable preventative

maintenance. They can also be remotely adjusted and monitored. Pre-assembled solutions for compressed air preparation save users a lot of time and money. These individual solutions with their one part number simplify the design and purchasing process and are supplied ready to install directly at the system.

Compressed air system accessories such as tubing and fittings also deserve attention: tubing materials appropriate to the environment prevent chemical, physical and microbial damage. Festo tubing can be hydrolysis-resistant, flame-retardant, heatresistant, antistatic or suitable for use in the food industry. When it comes to tubing, it is important to have the correct lengths and diameters to minimise pressure losses as well as to cut them to length using suitable tools.

Fittings with modern sealing rings and support functions ensure leakproof and reusable screw connections. Go to www.demm.co.nz/ enquiry quote: D120519

•

CRC 5.56 Industrial is a high performance variant of CRC 5.56. It is fortified with PTFE to provide additional lubricating performance and is non-flammable making it safe to use in industrial applications.

CRC 5.56 Industrial leaves a thin film that clings to surfaces providing multiple benefits; Effective lubrication, penetrates through corrosion to free rusted components, inhibits corrosion by forming a continuous protection barrier and displaces moisture.

crc.co.nz www.crc.co.nz

CRC_3242_DEMM

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• motors and transmissions

All the Tools You Need for Embedded Measurements and Control, in one rugged box.

Black gold and extreme motors Petroleum is the black gold of the earth – to get to this treasure, innovative and modern technology for recovery of petroleum and natural gas is required. The materials used in deep drilling are subjected to extreme conditions: Up to 200°C, vibrations and very high pressures. Motors by maxon motor are used for many tasks, such as operation of the valve controllers, as well as for triggering mechanisms and measuring devices.

More than 85 percent of the global energy consumption is based on fossil fuel sources, i.e. oil, gas and coal. But to get to these valuable resources of our planet, it is necessary to drill deeper and deeper – no easy enterprise. Deep drilling technology (called ‘downhole drilling’ in the field of oil and gas exploration) makes it possible to recover oil and

The inside of the EC22 HD motor with the special coil

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Graphical Software

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Sensor Connectivity

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Signal Analysis

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Control Algorithms

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Custom Timing

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Custom Triggering

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Actuator Connectivity

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Embedded Storage

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Industrial Networks

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Expansion Systems

The NI CompactRIO hardware platform can handle your embedded measurement and control applications, and do it in a way that outperforms other off-the-shelf systems so you don’t have to spend time developing a custom solution. The range of high-quality measurements, coupled with an extremely rugged design and the ability to modify the hardware using NI LabVIEW system design software, gives you all the benefits of customization with the convenience of an off-the-shelf platform.

>>To

learn more about CompactRIO, visit ni.com/compactRIO

0800 553 322

©2012 National Instruments. All rights reserved. CompactRIO, LabVIEW, National Instruments, NI, and ni.com are trademarks of National Instruments. Other product and company names listed are trademarks or trade names of their respective companies. 05551

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May 2012

gas from depths of more than 2500m. By combining downhole drilling with directional drilling (dynamic position alignment of deep drill), previously unreachable oil reserves can be opened up, with drilling depths of currently approximately 5000m and drill lengths of up to 11,000m.

All drilling operations have one thing in common: The requirements on the materials used are very high. The drill heads, in particular, have to withstand extreme conditions. The temperatures and pressures at these depths, combined with the strong vibrations that occur during the drilling procedure, present unique challenges to the use of electronic drives. The conditions several kilometres below the surface of the earth are anything but technology friendly.

Robust materials that remain 100 percent reliable even at the high temperatures of up to 200°C that are required.

The EC22 HD (heavy duty) from maxon motor fulfils all requirements for these extreme ambient conditions. The electronically commutated motor, which has been designed for the exceptionally high requirements in the field of deep drilling, can withstand harsh conditions in which ‘normal’ motors would fail.

The constant development of electronics and motors today makes it possible to better monitor and control many functions throughout the entire drilling procedure. For example, the turbine in the drilling tool is driven by mud flow. Through the use of magnetic coupling, motors become generators and supply the electrical energy for various drive functions. Thanks to this self-contained system, no expensive, polluting lithium batteries are needed. With the aid of the EC22 HD, the position of the drill head can be measured and aligned dynamically during the drilling process (MWD, measurement while drilling). This measurement is performed by means of accelerometers, inclination sensors and other instruments that allow precise recording of the position of the drill head. But how do the measured values get to the surface? To this end, the

• motors and transmissions MWD technology converts the data to pulses that are sent to the drill platform. This system is driven by electromagnets or HD motors. Diverse deep drilling tools also use the hydraulic valves or flaps that are operated by electromechanical drives.

A matching gearhead for the EC 22HD is also available: the GP 22HD. Many applications, especially in the field of deep drilling, require a robust gearhead that accurately fulfil the requirements.

Most underground applications require very high torques, sometimes for only very short durations (valve control, moving flaps). A special property of the gearhead is the integrated drill holes that are necessary for an unhindered oil flow, because the gearhead, just like the motor, can be operated in oil. The different versions of the EC22 are optimised either for operation in air or for operation in oil (flooded in hydraulic oil).

The motors are constructed without adhesives and do not have a mechanical commutation system. This enables the motor to withstand extreme temperatures and also ensure constant performance under ultra-high vacuum conditions. The power rating depends on the surrounding medium and amounts to 80W in air and, due to the much larger heat dissipation, 240W in oil. The motors have been designed for ambient temperatures of more than 200°C and atmospheric pressures of up to 1,700 bar. If the motors are cooled with oil, they can even withstand temperatures up to +240°C. Other requirements on the motors, which have a diameter of up to 22 millimetres, are resistant against vibrations of up to 25 Grms, as well as against impacts of up to 100 times the gravitational acceleration of the earth (100 G). In comparison, Formula 1 race cars reach 2 G and fighter jets up to 13 G. A human can withstand approximately 10 G, in other words ten times his body weight.

However, these are peak values and only astronauts and pilots can cope with such high physical stress for a certain period.

In addition to its very high resistance to the extreme ambient conditions at great depths, the maxon HD motors also have a very high efficiency. An efficiency of up to 88 percent is reached in air and more than 70 percent oil. With these properties, the EC22 can be of benefit in countless other areas of application – for example under the extreme conditions in outer space. With their detent free running properties, the motors have excellent control characteristics and are therefore optimally suited for high-precision positioning tasks in outer space, even at low rational speeds. In the future, the motors will also be used on Venus – NASA is planning a space flight with this destination. However, there the motor will have to withstand temperatures of up to 480°C. The further development if precision motors for extreme conditions will therefore continue.

Go to www.demm.co.nz/enquiry quote: D120520

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Article by Anja Schütz, maxon motor

A matching gearbox for the EC22 HD: the GP22 HD

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• motors and transmissions

Taking the tension out of belt tensioning A transmission belt that doesn’t need re-tensioning – the Germanmanufactured Optibelt Red Power V-belt makes this dream come true. Editor Stefan Richter talked to the sole NZ Optibelt agent about the features and advantages of this maintenancefree belt which is being released in its third generation.

3

According to the German manufacturer Optibelt, insufficient belt tension is one of the main reasons, along with misalignment, for premature transmission belt failure. V-belts rely on tension to transmit power by creating friction on the grooves of the pulley. Too little tension and the belt loses its power transmission capability, starts to slip and quickly wears out. If the tension is too high the belt suffers from excessive stretch plus putting an additional load on bearings, couplings and

Transmission Products shafts. “Optibelt estimate that Mechanical it to aPower workshop with a dozen GERMANY over 90 percent of premature belt fitters, and you asked them to failures are caused by installation tension the belts as they normally issues; usually the belts are being would, probably nine out of tensioned incorrectly,” says Neil the 12 fitters would apply an Baudinet, Director of Tranz insufficient tension. That’s clearly Corporation Ltd. “Most fitters an issue; fitters generally don’t use tend to apply gut feeling when tools to accurately measure belt it comes to tensioning belts. tension. SPZ-profile belts with a We have a ‘demonstration rig’, top width of 9.7mm will require consisting of two small twinconsiderably different tension groove SPA pulleys and belts figures to SPC-profile belts that mounted on a frame. If you took have a 22mm top width. Very often the recommended retensioning after the initial run-in From From turn and insulation, to to high voltage turnground and ground insulation, high voltagemachine machine period doesn’t take place either, coil insulation, hasitto Motor Transformer coilitinsulation, itOBA hasOBA to be OBA FabricatedAccessories. components. coil insulation, hasbe to be Motor Transformer Accessories. resulting in poor belt life, wasted energy and excessive downtime.”

Tranz Corporation Ltd pride themselves on being a specialist power transmission Capacitors and automation company.

Motor Start Capacitors Quality Fabrication Motor Start Besides importing and stocking www.oba-ic.co.nz Capacitors Start Switches www.oba-ic.co.nz Motor Run Capacitors Start Switches Services ForFor further information, contact your www.oba-ic.co.nz Motor Run well-known brands of mainly further information, contact your Motors Transformer Board nearest OBA Branch.

Fans and Bushes nearest OBA Branch.

For further information, contact your Motors Transformer Board European origin, such as Value Added Services Fans and Bushes nearest OBA Branch.

Preformed NOMEX ® Anti-Condensation Wedges Heaters Lenze and Vogel gearboxes, Preformed NOMEX ® Anti-Condensation Switchboard Wedges DMD Performed Heaters Thermistors Insulation Wedges they are also Optibelt’s sole Performed DMD Wooden Thermistors Wedges Microtherms Motor Insulation New Zealand agent. Optibelt Wooden Microtherms Steel Wedges - Special Slot Sticks is a privately-owned German Transformer Laminations Insulation SteelSteel Laminations Wedges - Special company specialising in Laminations Printer Circuit Board Materials manufacturing transmission Steel Laminations E & I laminations Ballast E, E & I laminations U, Tube Manufacture belts and are now celebrating U & Bar laminations Strip laminations Choke laminations EE their 140th anniversary. “A Gate laminations considerable amount of research and development goes into their products, for example the Red Rower wedge belt, which still remains a unique product,” explains Neil. “With this top-quality product we target the industrial market, Ph 0800 526 5533 working mainly with the primary email: orders@oba-ic.co.nz industries. Many of these

Fabricated Motor/Transformer Motor/Transformer Components Accessories Accessories

Slot Sticks

E & I laminations Ballast E, E & I laminations U, U & Bar laminations Strip laminations Choke laminations EE Gate laminations

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May 2012

companies value reliability and performance. They recognise that if they pay a little more for a premium product they not only get their investment back but actually add value to their business.” The director admits that selling products like the German V-belt sometimes takes some convincing. “It’s a higher-cost product, because of the R&D, the superior quality of the materials used, the sophisticated production processes and stringent quality assurance standards that are in place. However, the companies that utilise Red Power belts appreciate the advantages and they enjoy the resulting superior performance.”

To address the problem of ongoing maintenance and shutdown costs associated with regular re-tensioning, Optibelt introduced the first generation of Red Power belts in the late 1990’s and after further refinement, the second generation in 2003. “The third generation, the Red Power 3, will be available progressively during 2012 and offers one of the highest power transmission capabilities in the industry.

All three belt generations are maintenance-free; you fit them once, using the correct set-up procedure, and then you can forget them. “You don’t need to go back to re-tension them for their entire service life,” says Neil. “This is what is meant by maintenance-free.”

A typical V-belt consists of several load-carrying tension cords which are embedded in a transverse fibre compound and covered with an abrasionresistant cover fabric. “When a standard V-belt is fitted and runs for the first time, it heats up and the tension cord stretches, making it necessary to re-tension it after the running-in period. If re-tensioning does not occur, the

• motors and transmissions belt will continue to lose tension to a point where the efficiency of the drive is reduced,” explains Neil. “Optibelt have specifically designed and patented the Red Power polyester tension cord so that it only expands minimally during the settling-in period.”

Once a set temperature is reached, the tension cord locks and the belts retain their tension for the rest of their service life.

Optibelt design their belts to have a service life of 25,000 hours. Although this service life is under laboratory conditions, there are many examples of Red Power belts operating in arduous industrial environments achieving close to this high service life. To enjoy these benefits, engineering staff need to follow some simple guidelines regarding alignment of pulleys and accurately measuring belt tension. To assist with this important process, Optibelt produce a range of easy to use

CMGNZ_DEMM_1112_01_OUTLINED.indd 1

and competitively priced service tools. “The initial loss of tension is a normal part of the runningin process. We provide the fitter with the exact initial tension figure that is required, so that he can measure it. There is no guesswork involved.”

With all Optibelt V-belts over 1.2 metres long, belt matching when using multiple belts on a drive is a practice of the past. The ISO standard used by most other manufacturers allows for lengths variations of ±1 percent. While this may sound like a small amount, such a tolerance on a 5000mm belt would allow for belts to be produced as short as 4950mm or as long as 5050mm, giving a total length variation of 100mm. To get around this problem, the industry norm has been to “match” belts of a similar length using matching codes on the belts.

By contrast, Optibelt has an in-house standard for belts up

to 5000mm length of ±2mm.

This is achieved on a high volume production basis due to the unique “rotary vulcanising” process that cures belts while under tension. Any Optibelt product that has the marking “S=C Plus” (this includes all generations of Red Power) comply with this standard. A set of “S= C Plus” belts are in effect “factory matched” and the load will be evenly carried by all belts on a multi-belt drive. This will lead to longer service life and drive efficiency.

“Compared to an Optibelt standard type SK wedge V-belt, the Red Power II belts display a dramatically improved performance; the Red Power II provides up to 42 percent more power transmission capability, and the Red Power 3 up to 50 per cent,” says Neil. “This higher performance means that in some multiple belt drive installations a lesser number of belts can be

used. Such an example would be going from eight standard wedge belts to perhaps five or six Red Power belts. This means narrower, lighter and less expensive pulleys resulting in less overhung loads on bearings and shafts”.

Optibelt market their Red Power belts with a drive efficiency of up to 97 percent.

This is not only the efficiency on start-up but one that is ongoing due the ability of the belt to retain its tension. In order to achieve this outstanding result, best engineering practices should be followed. Improper belt tensioning, worn pulley grooves, angular and axial misalignment not only reduce the overall efficiency, but also compromise the belt’s service life. “There are a lot of variables when it comes to efficiency,” says Neil, “but care taken during the installation will be rewarded with a longer service life and higher drive efficiencies

13/12/2011 11:06:01 AM

23

• motors and transmissions

with lower operating costs.”

To assist in the installation process, Optibelt produce a range of service tools that includes simple devices accompanied by a reference chart for belt tension to more sophisticated hand-held electronic devices that are extremely accurate. Profile gauges are the easiest way to determine wear in pulley grooves and a compact laser tool with calibrated marker posts will accurately measure axial or angular misalignment.

With the help of Optibelt’s CAP drive calculation program it is quite simple to design functioning and optimally tuned drive systems. “Our customers advise us the important parameters such as motor speed, shaft diameters, engine power, required output speed etc. The software provides a recommendation, stating details such as number and lengths of belts, centre distance, diameters of pulleys, taper-lock bush sizes and shaft loads. There is also a recommendation for the correct belt tension and shaft loads to enable the bearing ratings to be checked,” explains Neil. The sophisticated software is also of assistance when it comes to troubleshooting faults on existing drive systems. “Equipped with this software and the service tools previously mentioned, our experienced and well-trained staff can go onto an industrial site, identify

the cause of a problem and make suggestions for improvement.”

Sometimes, especially with larger industrial sites, you can find a whole raft of different belts in use. “When there is a problem or pulleys are worn and need replacing, we use this as an opportunity to check and, where appropriate, re-engineer the drive utilising another size of belt that the customer is already using elsewhere within the plant,” says Neil. “That way they can cut down their inventory. In some cases replacing a special diameter or uncommon section pulley than is worn requires a custom build. This could be more expensive than redesigning the whole drive using new pulleys and belts of a more conventional profile. In each case we strive to work with the customer to find a solution that gives us credibility by solving the customer’s problem and adding value to his business.”

There has been a trial at a North Island pulp and paper site in New Zealand to quantify the energy savings achievable with the Red Power II belt. This belt and a competitor product were used to drive a storage tank agitator over a complete cycle of 109 hours.

First the competing belt was fitted, the motor energy consumption was monitored and the percentage of full load current being used was graphed. Then the belts were swapped and

the Red Power II was assessed under identical conditions. The Optibelt product showed an energy saving in excess of 10 percent.

During another trial the Red Power II and its rival faced off directly. The purpose of this trial was to prove to the customer that the Red Power belt would not require further tensioning. This happened at a board mill site in New Zealand, where a set of each belt type was installed to the drives of slash deck saws.

After being tensioned and aligned the drives operated continuously (for approximately 920 hours). Upon shutdown, the tension of both belt sets was measured. The Red Power II showed a small loss of tension which is associated with the settling period and this was in line with the figures given by the Optibelt.

The competing belt set had a 54.4 percent loss of tension and would have required regular re-tensioning to continue operating efficiently.

Because of the continuous operating nature of these saws, belt tensioning cannot be carried out at regular intervals and Red Power was designed to provide the optimal solution to overcome this problem.

This trial demonstrated that there is a significant ongoing performance and energy efficiency advantages offered by Red Power that are evident within the first fiven percent of its service life. Go to www.demm.co.nz/ enquiry quote: D120522

•

Process performance motors. The time has come to look beyond the ordinary.

ABB’s process performance motors have what it takes to reach new levels of efficiency in demanding processes. Combining the best available materials with superior technology and uncontested expertise, they are prepared to meet the most demanding expectations. Helping you to achieve the most reliable production process, ABB’s process performance motors are prepared to answer any reliability, availability and energy efficiency challenge, both now and in the future. For more information visitwww.abb.co.nz/motors&generators

ABB Limited Tel: 0800 GO 4 ABB (0800 46 4 222) Web: www.abb.co.nz

UShalfpage.indd 1

24

4/15/2012 11:46:29 PM

May 2012

• automation and control

Cutting-edge automation technology for good old-fashioned pies From their fully-automated production plant in Silverdale, Dad’s Pies caters for pie lovers nationally and internationally. Editor Stefan Richter took a tour of the high-tech facility. making equipment to customer specifications. We utilise a total of four Rademaker lines in the different areas of our factory.”

How Dad’s Pies are made

Every year 7.5 million pies leave Dad’s pies’ fully automated production plant in Silverdale.

Have you ever, after filling up your vehicle’s tank at a BP service station, felt the urge to also fill up your stomach there?

Then you might have already savoured one of Dad’s Pies’ baked delicacies without knowing it. “We offer our products – classic and gourmet pies, sausage rolls and savouries – both chilled and frozen. The chilled products primarily go to BP’s Wild Bean Cafes and 2go stores,” explains Marketing Director Michael Welch.

The relationship to BP dates back to the year 1988 when Eddie Grooten, the Dad’s Pies’ Managing Director, supplied the first BP service station with pies. “We still supply BP with our products,” says Michael, “and we are now their exclusive supplier in New Zealand. But we do not think of stopping at this point and have also started expanding internationally.” This doesn’t sound too bad for a company that started as a small beachfront shop 31 years ago.

In 1981, Eddie Grooten and his wife Erika, both of them Dutch immigrants, bought a small shop called Dad’s Pies, which was located on the shore at Red Beach. “Eddie would bake fresh pies every day, load them into his van and deliver them to all the dairies and schools in the local area,” relates Michael, “but he finally realised that the future lies in wholesaling pies rather than just operating from one retail shop.” The visionary shop owner very quickly grew his business. An initial 60,000 dollars turnover skyrocketed to 360,000 dollars annual turnover just two years later. In 1987 Eddie moved into new premises located only two streets away from the current factory, where he purchased the local bakery. Within two years he then took over two buildings next to the factory. In order to set himself up for national and international expansion, Eddie finally had a new facility built in Silverdale in 2001, and also took over the building next door in 2008. Now equipped with enough space to meet future production demands, he decided to invest heavily in state-of-the art automation technology for mass production rather than maintaining his old, manual pie lines. “Eddie started to source and purchase special equipment, especially from the Dutch company Rademaker, who specialises in designing and building pastry

During a tour of the busy production facility, Michael gives an insight into the automated mass production of pies. The pastry dough for the pies is made in an automated mixing line from VMI, a French company. “The control system of the mixing machine is preprogrammed with all the recipes for the different types of pastry we use. The machine automatically deposits the correct amounts of flour and water in the mixing bowl, only margarine and re-work pastry have to be added manually,” explains Michael, “This process step could also be automated, but it only requires operator intervention every ten minutes for only a moment or two. The machine stops and waits for the operator to add these ingredients through a set of automated doors and then carries on with the kneading process.” After the preset mixing time has elapsed, a lift automatically deposits the pastry dough in the hopper which feeds the laminating line.

The laminating line is one of Dad’s Pies’ four Rademaker machines and extrudes the ready-mixed dough into a dough sheet and reduces its thickness from approximately 150mm thickness down to 30mm, utilising three reducing stations with a pair of gauging rollers on each. A so called lapper, a vertical oscillating transport belt, builds up layers of dough on a moving belt and thereby creates the puff pastry's typical layered structure. “We can adjust the process to achieve up to 20 layers,” says Michael. “Then an operator adds two folds by hand and feeds the puff pastry dough to a second reduction line, which is also from Rademaker.”

This final process step in the dough production reduces the puff pastry sheets to the desired width and thickness. “As we grow our capacity we have the ability to add an additional step to the laminator which will connect directly from the existing laminator onto the second reduction line. We can then also include an

The pastry dough for the pies is made in an automated mixing line from VMI.

25

• automation and control

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Incremental encoders, linear potentiometers or sinusoidal output.

Motion coordinator for single or Multi axis motion control.

Servo motors and control for single or Multi Axis machine control.

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26

May 2012

Christchurch 080037 38 39

The packing station marks the last step in the pie production process.

automated resting station to reduce the resting time down to 40 minutes. At the moment the pastry sheets are put on racks by an operator to let them rest overnight.”

In order to be able to produce customer-specific pies, Dad’s Pies has maintained some small production lines that can make small batches in a manual, labour-intensive process. “When you bring in automation on the scale we did, it becomes very expensive to customise individual products for customers,” explains Michael, “So we still utilise some of our older, smaller machines which rely heavily on manual labour, but are far more flexible.” Because these smaller machines do not have automatic feeds for the pastry, two operators run a dough sheeter which will take the finished puff pastry dough, reduce it to size and put the dough sheets on pins. A cutting/stacking line from Rademaker takes the pins of pastry, cuts the dough sheets to the desired shape and stacks them automatically. With the help of a pie machine manufactured by the Australian company Simple Simon, four operators fill the pies which, after being baked in rack or rotary ovens, are immediately transferred to the spiral freezer. “To increase the production volume of this line in the future, we can replace the dough sheeter with a direct connection to automatically supply the cutting/stacking line with pastry.”

The fully-automated mass production at Dad’s Pies takes place on a Rademaker pie line which is automatically supplied with ready-to-use pastry from the reduction line. A pneumatic suction system deposits aluminium foils in the machine, these are filled with pieces of dough, and the first of two four-ton-presses shapes the dough in the form of the foil. Then a pneumatic depositing system fills the pies, and, after the top pastry layer has been applied, the second press shapes this top layer and adds the necessary decorations. Finally an egg wash mixture is sprayed on top of the pies – to give them a nice golden brown colour after baking – and a conveyor belt transfers them to the oven.

“This fully automated line is our most efficient one in the whole factory,. It has the capacity to produce in excess of 9000 pies an hour, with a team of 4-5 operators,” adds Michael. The pie line for mass production is controlled by Allen-Bradley PLCs and Rockwell Automation software from one single touch screen.

Three years ago Dad’s Pies installed a serpentine oven from Auto-Bake in Australia and automated the transfer of the products from the pie production line to the new oven and from there directly into a spiral freezer. “This gas-powered serpentine oven was one of the first installed in this country. It is a revolutionary technology which replaces the traditional tunnel

• automation and control

ovens. The vertical oven process requires only 30 percent of the space of a tunnel while offering the same baking capacity,” says Michael, and adds, “The oven uses 20,000 dollars’ worth of grease every single year. At times we run temperatures in excess of 300 degrees, which requires the use of highly specialised grease.” After the baked pies leave the oven, they are directly transferred to a cooling conveyor, where they are cooled down prior to entering the spiral freezer. “We reduce the core temperature of the pie from 90 to two or three degrees Celsius in about 90 minutes. This time can be adjusted if necessary.”

When the chilled or frozen pies finally come down from the spiral freezer, an automated conveyor system transports the products to an X-ray machine and a metal detector, where the pies are checked for foreign bodies. Some of the pies are additionally wrapped into plastic foil before they end up in cardboard boxes to be transported to hungry customers nationally and internationally. “The cartons are taped and labelled automatically, and the wrapping machine uses only one kind of wrapping material. After selecting the product, all the relevant information is printed onto the plastic wrap,” explains Michael. “However, the pies are still put into the cartons by hand.

Every pie differs slightly in shape, size and weight, and these variances render an automated handling and packaging of pies impracticable. We use this manual process step as an opportunity to conduct a final visual check of every single product.”

Into the future Dad’s Pies’ production facility has been set up with growth in mind. “The equipment we have installed is based on meeting future demand,” says Michael. “We are only running at 25 to 30 percent capacity at the moment. This allows us to guarantee to meet our customers’ demand at all times without first purchasing more equipment to expand production. The high degree of automation in our factory also allows us to guarantee consistent product quality and appearance. The manual production process causes greater variances: You can put two pies coming from the same line on the same day next to each other and they won’t even look the same.” There is also enough space available for spatial expansion. “We have secured the lease on the building next door.

Currently we operate a 600 pallet bulk freezer in there, which handles our entire frozen product for national deliveries. And we sub-lease the rear of the building to another tenant,” says Michael.

“I think we will be able to utilise our current premises for at least another 15 years before we run out of space.”

Dad’s Pies’ brand is becoming more internationally known.

“There are some very prestigious customers in Dubai, but it is still a new market for us. We are proud to supply Emirates Airlines with pies for their first and business class passengers, and our products are available at events such as the Dubai Rugby Sevens and the Dubai Golf Open. We also supply a company called International Fine Foods in Hong Kong and have just secured the contract for the Hong Kong Rugby Sevens. This event has become a very good avenue to introduce our product. Our products are also sent to Korea, Singapore and Japan. In Canada we have a number of possible interests, but we are not supplying anyone directly yet.” Fortunately you don’t need to fly to these faraway places to savour one of Dad’s Pies’ delicious products. A short trip to the next BP station does the same trick. Go to www.demm.co.nz/enquiry quote:

•

D120525

27

• pumps and valves

Hand pumps increase productivity and safety

Enerpac has announced its new Ultima series of steel hand pumps, designed for easier and safer operation, as well as extended life. These versatile steel hand pumps are ideally suited for rugged applications, where durability is of utmost concern. The series now features an innovative design that provides greater ease-of-use. Handle effort is reduced by up to 20 percent in the Ultima steel hand pumps without compromising speed or performance. The pumps’ innovative bypass system further reduces loads often created by two-stage pumps.

28

May 2012

By incorporating the new Power Push handle grip and linkage design, loads are better distributed further reducing felt load while pumping – minimising operator fatigue.

Enerpac Regional Manager, Australia and New Zealand, Mr Tony Brooks says the high pressure pump is ideally suited to a huge range of compact and portable high-pressure cylinders and tools used for diverse tasks. These include lifting, cutting, clamping, pressing and forming as well as diverse bolting and fastening technologies, such as hydraulic torque wrenches

and tensioners. Incorporating a vent-free reservoir, these hand pumps eliminate performance deficiencies from forgetting to open a vent as well as spillage resulting from a vent left open.

For additional ease, the fill plug is conveniently located on the top of the hand pumps, enabling them to be quickly, cleanly, and easily refilled.

Plus, the pump contains an integrated carrying handle for durable and hassle-free mobility, and the Sure-Grip release knob enables simple gripping and handling, with or without gloves, for superior control while releasing pressure.

“By further improving

including a reservoir over pressurisation system and a wider footprint. The reservoir over pressurisation system releases excess pressure, which could otherwise create an unsafe condition. The wider footprint further increases safety by improving stability, reducing the potential for pump tips or slips, while the vent-free reservoir prevents unsafe spills.

In addition to ease-of-use and safety, Ultima steel hand pumps are also constructed for superior durability and longevity. The solid steel construction can withstand significant onthe-job abuse. The reservoir

Enerpac’s already proven line of hand pumps, we demonstrate our dedication to manufacturing products that not only increase productivity, but also maximise worker safety,” said Tim Ebner, Global Product Marketing Leader at Enerpac. “We deliver easy-touse products that are combined with advanced safeguarding features, providing users with the most effective and long-lasting hand pumps.” To ensure superior safety along with dependable performance, the Ultima series is equipped with various safety features,

features thick-wall steel tubing, while the pumping head and base are cast from steel that is sculpted to reduce weight. The tie rod design allows it to be effortlessly disassembled for maintenance or servicing. A chrome-plated plunger protects the pump from wear and withstands contaminants, while a wiper ring cleans the plunger, preventing contamination from damaging the piston. The vent-free reservoir prevents contaminants from entering the pump through the opening.

Go to www.demm.co.nz/enquiry quote: D120528

•

• pumps and valves

Vacuum pumps for high performance in demanding processes The new Dryvac DV450 from Oerlikon Leybold Vacuum now complements the already existing variants of Dryvac pumps and systems. This new pump also combines dry screw technology with a very compact design and additional customer benefits such as extreme silent operation, low ambient temperatures and minimal cooling water consumption.

The DV450 is the ‘smaller brother‘ of the Dryvac DV650, with an optimised drive for suction speeds of 450m3/h and an also optimised engine efficiency with only 5.3kW power consumption at final pressure.

The integrated frequency converter leads to reduced installation efforts for customers with full pump protection and a large variety of interfaces. Another benefit for demanding processes is the operation at very low

screw-rotor temperatures, which predestines the pumps for applications such as solar lamination, eliminating possible layers to be built-up. All combinations with a Ruvac roots pump are possible. Arranged vertically in a standard mode, the overall plant footprint is reduced, while with a horizontal arrangement the pumps can be placed underneath the plant’s manufacturing systems. The company’s offering of sturdy and reliable roots pumps is now complemented by the new Ruvac WH2500 featuring highest flexibility and pump protection via operation with frequency converter. Furthermore it offers smallest footprint in an advanced design. Lowest power consumption and minimised noise and heat emission meet the requirements of innovative customers. Due to the compact-size and the reduced weight, the

The vertical standard assembly with a Ruvac blower pump saves footprint.

pump can be directly mounted onto properly sized backing pumps of Oerlikon Leybold Vacuum. This saves additional costs and reduces installation space. The full product range of WH2500 is already available. The range includes three types of different drives with internal frequency converter, external frequency converter and direct net operation.

In addition, the pump is available with two different oil fillings – either synthetic oil or PFPE oil. The new WHU2500 with bypass valve features a new motor concept which helps to reduce pump down time in short cycle applications dramatically. This improves throughput in time critical processes. Go to www.demm.co.nz/enquiry quote: D120529

•

Namur solenoid and manifold solutions Rotork Australia’s Fluid System division, introduces the Bifold Group range of direct mount solenoid valves, manifold and accessories for general valve actuator applications. These valves are available in 3/2 or 5/2 5/3 port configurations. Compact in its design, the solenoid valve features a Namur mounting pattern according to VDI/VDE 3845 designed to mount to any Namur valve actuator thus reducing actuator response times, space requirements and also negating the need for a back plate.

Installation costs are lower as the need

for tubing; fittings, brackets and assembly labour are greatly reduced. All mounting screws and seals are included with the valve.

Rotork says that what differentiates the Bifold design to any other on the market is the unique patented mounting/spacer block which is free to rotate through 360°.

This feature avoids the solenoid housing from coming into contact with the switch box and ensures the filter regulator remains upright at all times. This range of products also includes the manifold option which incorporates the Namur interface kit based

on the ‘Axis’ system, allowing the direct mounting of filter regulators, check valves, flow control valves, pressure relief valves and manual valves etc. The multifunction rotating system includes inlet/exhaust flow control valve and high flow quick exhaust valve and optional fully rotational filter regulator. This robust design is manufactured from 316L stainless steel with an operating temperature range of -60°C to +180°C and worldwide approvals Ex d, Ex ia, Ex emb and explosion-proof. Go to www.demm.co.nz/enquiry quote: D120529a

•

Soltions that save you time & money Pumping

FREEPHONE 0800 482 747 | info@primepump.co.nz 29

• pumps and valves

Continuous flow without pressure regulator recreational vehicles and marine applications. There is a significant market each year for a compact twelve volt powered pressure pump for liquids or water transfer or powering smaller capacity spraying equipment. Newly developed in the USA, the key feature of the Smoothflo pump is the constant pressure technology from the pump when turned on, to prevent uneven pulsation. This effect is important where a twelve volt powered pump is part of a system for spraying so that the application pattern is uneven.

Silvan Selecta spokesman Greg Everett says that the Smoothflo is a positive displacement pump that is ideally suited for spot spraying or smaller boom spray type applications. “It achieves a

Silvan’s Greg Everett with the new Smoothflo 12 volt pump that offers constant flow technology without the need for a pressure regulator.

Silvan Australia’s Selecta Division has been appointed the sole Australasian distributor of the compact new Smoothflo 12 volt pressure pump that offers continual flow without the need for a pressure regulator. The pump is ideal to use with spraying equipment and also for mobile homes,

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•

Ideal for use in transferring hydraulic oil from xed to moving parts on cranes, forklifts, telebooms and other automated equipment

•

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www.recoila.co.nz 30

May 2012

QUALITY CONSTANT IMPORT TENSION

maximum pressure of 690kPa or 120psi and a maximum open flow of up to seven litres per minute. Typical maximum power draw is 9 amps while the Smoothflo has an electric motor with quality roller bearings at each end of the shaft and is sealed to give an IP55 rating.

“The Smoothflo 12 volt pump is manufactured with Viton valves and a Santoprene diaphragm while its internal design regulates the flow under pressure to maximise the volume under higher pressures.

By design it is a positive displacement three chamber diaphragm pump with a built-

in auto-bypass which includes a quality Honeywell on-demand pressure sensing micro switch for on demand spraying or other transfer applications.”

The new pump is compact in shape and while weighing only 2.6kg the Smoothflo is self priming and has all inlet and outlet fittings in standard 3/8 inch BSP profiles. Mr Everett says, “the Smoothflo pump is designed for continuous flow without the need for a traditional pressure regulator and is supplied with a common footprint mounting plate requiring only four screws to fix in place.” Go to www.demm. co.nz/enquiry quote: D120530

•

Functionally reliable and easy to maintain The new Hirschmann fieldattachable GDM series valve connectors can be used to supply power to components such as solenoid valves, pressure sensors and temperature sensors, or to connect them to a data network.

Circuit protection ensures that downstream circuitry cannot be damaged by excess voltage or electromagnetic fields. Versions with built-in LED status indicators (with or without circuit protection) are also available, making maintenance considerably easier. Depending on the version of the valve connector, additional features include the industrial protection class IP68, an operating temperature range of -40° to +90°C and high shock and vibration resistance. They play an important role in implementing reliable solutions for mechanical and plant engineering that enhance the productivity of machines and systems, even under harsh environmental conditions. These type A connectors, also available with integrated strain relief conforming to UL 2238, are easy to connect thanks to their greater height. Depending on the connector version, cable diameters of between 4 and 14mm with a conductor size of up to 1.5mm2 can be used. The housings are characterised by features such as acid resistance or biodegradability. The easy-to-grip housings ensure safe handling.

The connectors are available with black or transparent housings, depending on the circuitry, and with two or three poles plus PE. The rated voltage is between 12 and 250VAC/VDC, depending on the version, and the rated current between 1 and 10A. Go to www.demm.co.nz/enquiry quote: D120530a

•

• pumps and valves

Peak performing hose pump decreases cost Decades of experience and knowledge have combined with closely scrutinised customer feedback to deliver Apex, three new hose pumps from Bredel, part of the Watson-Marlow Pumps Group. Designed to suit all dosing, metering and transfer applications from 2.8 to 1200 litre/hour across a broad range of applications, the new Apex pumps are now, according to the manufacturer, the first choice for processing plants worldwide.

Users of the Apex pumps will benefit from extremely low maintenance requirements, giving extended uptime and therefore process continuity. With a cast aluminium housing providing superior heat dissipation, robust direct-coupled technology, and precision-machined hose elements, Apex provides decreased cost of ownership, reduced operating costs and low inventory stocking.

Among the many benefits of the new pumps is ease of scalability. While Apex offers optimum performance for low flow transfer applications, should process

requirements change, easy upgrades are achievable without having to buy a new pump. This is because Apex models are three pumps in one, with a single pump body adjustable for three hose sizes (10, 15 and 20mm) when production volumes rise.

Such scalability to higher flows provides future-proofing that cannot be matched by competitor pumps, says the manufacturer.

Offering the best performance available on the market for pressures up to 8 bar, along with reliable and stable flow up 1200 l/h (with 20mm diameter hose), makes Apex an interesting choice for ongoing, precise dosing. This is boosted by a new generation of long-lasting hoses

Almost 1000m³ blow-off volume When the pressure in technical gas systems is to be kept constant, special safety valves are used, these blowing off gas at even the smallest pressure increases. To this end, the German manufacturer Witt has developed the new AV919 with a previously unavailable performance spectrum. Even the smaller AV619 version is impressive. It blows off unwanted overpressure in a very low range from 5 to 500mbar with the greatest reliability and consistency. As a comparison: Standard valves corresponding to the Pressure Equipment Directive 97/23/ EEC applicable for this product group often only respond after an overpressure a hundred times greater. The new AV919 also masters these low setting pressures, while keeping a blow-off volume ten times greater at 967m³/h under control. The opening pressure of the new development, still very compact despite being around 90 x 170mm larger, is set precisely at the factory. The manufacturer can provide a TÜV (Technical Inspectorate Authority) test on request.

This component weighing only around 1500 grams can be used with all technical gases in a wide temperature range from -40° to +300°C. Safety valves with an opening pressure below 0.5bar are regarded as a technical challenge with the result that many systems work less accurately as the pressure decreases. Yet reliable functioning is not only crucial for economic viability but also for safety: Sensitive and expensive systems as well as their tanks and pipes for gas supply are relieved prior to reaching their operating limits, should the gas pressure rise unexpectedly. Go to www.demm.co.nz/enquiry quote: D120531a

•

that also supports repeatable accuracy when dosing additives, while continuous pump speeds up to 100 rpm provide a wider capacity range in comparison with alternative hose pumps.

The all-round performance of Apex models means they are suited to applications ranging from lime dosing and slurry transfer, through to handling food and beverage products. Along with a two-year warranty, customers purchase safe in the knowledge that Apex pumps are manufactured by Bredel, the world’s largest manufacturer of hose pumps with more than 100,000 models in operation around the globe.

Unlike other pump types, hose pumps have no expensive wearing components such as seals, valves, membranes, stators, rotors or glands. Subsequently, they are ideally suited for handling ‘difficult’ fluids – abrasive, corrosive, viscous, shear-sensitive, crystallising or even fluids presenting a combination of these properties. Go to www.demm.co.nz/enquiry quote: D120531

•

Peak performance from the market leader • Higher productivity, lower cost of ownership • Scalability from 13 litre/hr to 1200 litre/hr flow • Robust and compact direct-coupled design

09 273 3166 enquiries@wmbpumps.co.nz www.wmbpumps.co.nz

31

• MAINTENANCE MATTERS

Good maintenance helps avoid corrosion of assets Awareness of the potential for corrosion developing in the building service industry is slowly improving. However, building service engineers should update their understanding of modern corrosion control techniques to ensure that corrosion is avoided by good design and proper maintenance.

Article by Les Boulton.

Corrosion is the process that occurs when materials (metals and non-metals) interact with the environment in which they are operating. The result is that materials degrade and expensive plant and equipment exposed to the environment may no longer be fit for the intended purpose. The deterioration of ferrous metals produces rust, whereas other materials are said to corrode (from Latin corrodere – to gnaw away). Corrosion of materials costs developed countries about four percent of the annual GDP, of which about 25 percent is avoidable by employing well-known corrosion control technologies, such as good design, protective coatings and cathodic protection. The estimated cost of corrosion in New Zealand is about $2000 for every single person in the country, every year, so we are all paying an ongoing rust tax.

Corrosion of the plant

Corrosion at badly designed steel valvecopper pipe joint in waste pipe of high-rise building.

Severe galvanic corrosion of the steel at a valve-copper piping joint.

that comprises building services is not unlike an asset assassin because the result of serious corrosion in buildings can be devastating for owners. Corrosion of any key building asset including heating, ventilation and air conditioning equipment (HVAC), presents the most potentially damaging loss to a building next to the threat of fire. Insurance claims and litigation can ensue from

corrosion of building assets which ramp up the cost of a corrosion failure for the asset owner. Corrosion-damaged air conditioning coils and heating plant cannot process air and heat efficiently as intended by the designers. This introduces operational issues including increased power usage and increased maintenance costs as the building services have to work harder. Factors such as these can also result in

problems for commercial building occupants such as lower comfort levels which affect productivity at work.

The effect of corrosion of building services is to greatly increase costs with possible loss of commercial income for the building owners. Some owners are prepared to ignore the risk that a corrosion tax would apply to their building assets if corrosion occurs. Failure to consider the potential for corrosion during the design of building services will eventually

Corrosion due to dissimilar metal contact in a water system: copper pipe-steel flangestainless steel valve.

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May 2012

• MAINTENANCE MATTERS increase costs, introduce safety hazards and could also have an environmental impact. It is surprising to note the low priority given by architects, designers, constructors and maintenance engineers to corrosion prevention on building assets such as HVAC plant. The situation can sometimes be accounted for by lack of awareness of the damage that corrosion can have on building services and the serious consequences of asset failures.

Consequences of corrosion The corrosion of building services and other equipment within a building envelope can have far-reaching consequences.

The structural soundness of the building and building service equipment may be severely affected.

If a metal component is embedded in another

building material, corrosion products can expand and cause distortion or cracking of the other material with serious consequences.

Failure of the material due to corrosion may lead to entry of water into the building envelope, causing hidden corrosion of structural elements.

Unsightly corroded surfaces may be produced with visible weeping of rust which downgrades the building aesthetics.

Manufacturing defects or design deficiencies may produce localised corrosion which can lead to corrosioninduced cracking of structural building elements.

Corrosion can be inadvertently designed into the building system and avoidance relies totally upon good maintenance to ensure that corrosion control is operational.

There are building water piping

designs that include connection of dissimilar metals which introduces galvanic corrosion issues. Astute building system designers are aware of the potential for galvanic corrosion and they recognise the threat that inadequate corrosion control may impose.

Nevertheless, circumstances can still arise that contribute to unexpected corrosion problems.

The pictured corrosion cases illustrate building services corrosion problems.

A number of the corrosion failures are due to poor design – these are often just straight corrosion blunders. Some corrosion failures are due to poor (or non-existent) plant maintenance and others are associated with the ingress of water into a building.

The most common situation that causes corrosion in structures is the joining of dissimilar metals which causes

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Failure of paint coatings on steel piping and fittings in building services plant room.

galvanic corrosion of the less noble metal. Some of the illustrations show cases of severe galvanic corrosion due to poor design practices in commercial building designs.

Connecting steel to copper in the presence of water (the electrolyte) always results in severe galvanic corrosion of the steel and it is seen all the time in building services.

Designers must be aware of the likelihood of galvanic corrosion in order to ensure a long service life for the

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BOLTING  Hand torq. wrenches  Torq. multipliers  Heavy duty sockets  Hyd. torq. wrenches  Nut splitters  Backup spanners  Calibration HYDRAULIC  Pumps  Hoses  Cylinders  Toe jacks  Heavy lift jacks  Crimping tools  Load cells  Chain cutters  Pullers

Web: hytoolsnz.co.nz 33

• MAINTENANCE MATTERS

structures they are designing.

Good industry practices recommended In order to mitigate corrosion in building services, good industry practices are recommended.

Externally located air conditioning condenser units with copper or aluminium fins should be washed regularly with fresh water to ensure that deposited salts and grime are removed from metal surfaces susceptible to atmospheric corrosion.

If metal surfaces are not well-protected with good paint coatings, then additional protection against corrosion should be applied to metal surfaces, for example, using aerosol-applied corrosion prevention compounds.

Consideration should be given to coating fin-fan condensers with a good coating to insulate any dissimilar metal

contacts, particularly if a damp environment prevails.

Good-quality coatings should also be applied to the internal cabinet surfaces of heat pumps and air conditioners.

A detailed understanding of water treatment requirements in a building, based upon water quality, equipment design, construction materials and operational practices, is essential to ensure cooling plant reliability.

Effective water treatment servicing and monitoring programs designed to minimise corrosion, deposition, and microbial problems can have a positive impact on system performance which is important for cost-effective operation of HVAC plant.

Les Boulton, Les Boulton & Associates Ltd, Materials and Corrosion Consultants, Auckland Go to www.demm.co.nz/ enquiry quote: D120532

•

VACUUM LIFTERS/JIB CRANES A complete range of lifting units for every application. ➧ Steel/Aluminium Sheet ➧ Cartons, boxes and sacks ➧ Finished Product

SOLUTIONS FOR ALL YOUR LIFTING REQUIREMENTS Vacuum lifters-Jib Cranes-Electric Hoists-Spring balancers

Tel 09 263 7725 FAX 09 262 0970 10 Oak Rd, Manukau City 2241 Email sales@stratalign.co.nz 34

May 2012

Effective, intelligent and safe vacuum lifting Stratalign Limited are New Zealand sales and service agents for two brands of European Vacuum lifters. Vaculex Vacuum Systems from Sweden and Fezer Vacuum Lifters from Germany are both among the world leaders in their fields.

Vacuum is increasingly being recognised as the ideal method of lifting almost any item in a safe, gentle and effective manner.

Steel sheets, timber panels, glass, bags/sacks, cartons, drums, and every other conceivable item, airtight or porous, can be moved around the production area single handedly with ease.

The wide range of vacuum and mechanical gripping tools offers application-oriented systems and individual handling solutions for different goods. Because no up/down buttons are required for the balance function, the user has prefect control of the handling process without any physical effort. This increases productivity and also helps to maintain employee’s health.

As a solution to a long standing challenge, Cabtec Ltd purchased a Fezer vacuum lifter from Stratalign, for processing sheets of board through a CNC machine. Prior to the purchase, the process had required manual handling, which in today’s environment, is not a sustainable option. More than one option for this solution was investigated by Cabtec with the decision being a vacuum lifter as the winning choice. Cabtec’s Peter Burgess recalls, “Vacuum lifter options were then investigated and an approach was made to Stratalign. Cabtec selected Stratalign as the winning supplier, based on their ability to provide the technical and professional advice, along with what Cabtec considered, a ‘top quality product for a competitive price’. This great investment has served Cabtec well and we would recommend these very good quality lifters to any prospective buyer. The ‘ease of operation’ is facilitated by the very smooth running bearings and movement points, integral to this structurally sound piece of kit.” Peter continues, “From the day the order was placed, the Stratalign team kept us updated with progress, to the day the machine was installed. The installation process was organised in such a way, by Stratalign, that it caused absolute minimal disruption to a very busy working environment during normal working hours.”

Fezer’s range of units is broad. The VacuPowerlift tube lifters come with 5–150kg capacity and are suitable for steel, plastic, glass, sacks, cartoons, and finished product. VacuBoy lifters were designed for the horizontal transport, swiveling, and turning over of loads up to 2000kg, e.g. steel sheets/plates, aluminium sheets, glass. The VacuGiant is capable of horizontal transport up to 40 tonnes and swiveling up to 15 tonnes. The VacuCoil lifter handles paper and steel coils. The lifter series VacuPoro and VacuWood are suitable for porous workpieces and planks and gluelam beams respectively.

Vaculex’s tube lifters are designed for lifts between five and 200kg. Since the suction foot is always dimensioned in accordance with the vacuum lift tube, the user does not risk dropping lifted items that are too heavy. If the weight is too much, the tube lift will simply not lift the article. This reduces the risk of personal injury and damaged goods.

Go to www.demm.co.nz/enquiry quote: D120534

•

• MAINTENANCE MATTERS

Hydraulic equipment for hire

Plant and equipment maintenance is an ongoing task throughout all industries.

If you are planning any maintenance or have unscheduled maintenance within your company and have a requirement to hire any hydraulic equipment then pay a visit to Hytools NZ in

Auckland, as they will probably have a solution for your tooling requirements right on their shelves. When it comes to hiring needs, Hytools NZ has an extensive hire range available from hand torque tools, torque multipliers, and some of the largest hydraulic torque tools available. In addition to this,

they stock a large hire range of impact sockets suitable for most applications. They even hire a range of striking wrenches.

Hydraulic cylinders and pumps covering a large tonnage range are available. Cylinders range from five tonne right up to 600 tonne and are available in a variety of different models for various applications. Hollow cylinders, pancake jacks and lock ring cylinders make up some of the range available.

Hydraulic pumps of various sizes and reservoir capacities as well as hoses and manifolds are also available. Some of the more specialised tools available are stressing jacks, nut splitters, cutters, crimping equipment, pullers, pipe benders and toe jacks. All of their tooling available is sourced from

reputable and well-known suppliers. All of their hire equipment is maintained by their in house service department, and in addition to the wrench calibration department Hytools can even calibrate jacking systems if required. Go to www.demm. co.nz/enquiry quote: D120535

•

Maintenance Best Practice - 5 Day Course. A bottom up approach to maintenance that will improve workplace culture and increase reliability.

Maintenance & Reliability - 5 Day Course. Learn how to analyse and monitor plant to make positive changes to your maintenance practises.

Planning & Scheduling for Planners - 5 Day Course. This course gives your planners the tools they need to increase productivity and reliability across the workplace.

Introduction to RCM and HAZOPS - 1 Day Workshop. Learn what these processes are all about and how to lead and manage teams to implement them.

May 21-25 Planning & Scheduling for Planners

May 28 Introduction to RCM & HAZOPS One day workshop

Auckland

Tauranga

June 11-15 Maintenance & Reliability

July 9-13 Maintenance Best Practice

Auckland

Tauranga

Download the full course calendar from the Skills4Work website www.skills4work.org.nz

p.hurford@skills4work.org.nz 027 488 6446

35

• MAINTENANCE MATTERS

Keeping the well of experience flowing Many core industries are well aware that a wealth of knowledge is held between the ears of their more experienced staff; however the danger these industries are facing is an ageing work force that is taking this knowledge with them when they retire. On-the-job training and onsite micromanagement of new and lesser skilled staff can create disruption to the workflow and production of any business, and often places the responsibility of passing on experienced knowledge in the hands of those who may be great practitioners, but may not be the best communicators.

Thanks to the committed vision of Peter Vause, an oil and gas industry veteran of more than 30 years, a purpose-built training facility is now available

to all industries to ensure that essential skills and experience can passed down to the next generation. The Vause Training Centre lies in the heart of New Zealand’s oil and gas production region, New Plymouth.

For any industry to grow, passing on essential skills and experience needs to be done in a focussed learning environment by skilled and effective trainers. These resources are few are far between in the Asia Pacific region, and the inability to have access to both classbased learning and essential site-based instruction in the same location often means high travel costs and extended time away from the job. That’s where the Vause training centre comes into its own.

Practical, high-touch skillsbased learning is catered for on-site with an engineering workshop featuring cutaways of drilling equipment and other components – essential to understanding the oftenunseen mechanics of the industries’ tools. This is coupled with modern lecture and examination rooms for learning knowledge skills such as management, leadership and best practices. A fulltime staff support member is available who can help with course administration, accommodation and transport facilitation, and there are also catering facilities on-site.

But what really adds value to the Vause Training Centre is the installation of a 1000ft well, where potentially

hazardous well pressures are safely simulated using water and air. On top of this sits a working “Christmas tree” giving trainees valuable hands on experience controlling potentially volatile situations.

Offering not only individual placements in existing courses, but also the hire of the centre for larger groups to run their own courses, Vause Training Centre has the flexibility to upskill your staff members with little disturbance to your on-site production and ensure that the next generation in your industry carry on the knowledge passed down from skilled practitioners and instructors. Go to www. demm.co.nz/enquiry quote:

•

D120536

your Complete Hydraulic Provider - system design, sales, service, installation, certification, preventative maintenance and fault finding - NZ Wide.

With an average over 15 years experience per sales and technical team member, Hyspecs can confidently handle any project that is presented from clients. Full turnkey systems, in conjunction with service division personnel, can be designed, quoted, and installed in any part of New Zealand. Our sales team is available to consult directly with customers in our offices or on site. Sales trips are regularly taken to all parts of New Zealand and our representatives are always contactable.

Hyspecs has application experience in a wide range of industries including: Forestry Machinery, Marine (Pleasure and Commercial),

Agricultural Industries, Industrial Plant, O.E.M Machinery, Transport and Construction Machinery.

Hyspecs also offer hydraulic training seminar programmes for customers and interested parties. Seminar programmes are normally carried out in both offices, but can be customized to suit client requirements. Custom seminars are also available to suit specific or specialist requirements.

Talk with one of our sales engineers today using the numbers below, drop us an email or check out our Website for more information.

Industrial Mobile Access Equipment Servicing Marine Forestry Construction OEM Design Agricultural

FLUID POWER ENGINEERING

Auckland 0800 497 732 • Taupo • Nelson • Christchurch 0508 476 937 •hyspecs@hyspecs.co.nz • www.hyspecs.co.nz

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May 2012

• MAINTENANCE MATTERS

National engineering diploma available now Competenz, the Industry Training Organisation (ITO) for the Engineering Manufacturing sector, is accepting enrolments now for the new Level 6 New Zealand Diploma in Engineering Practice, or NZDEP. The NZDEP is achieved in conjunction with the New Zealand Diploma in Engineering (NZDE) – an academic qualification that can be completed at an accredited Polytechnic. Together, the two qualifications provide a structured career pathway for aspiring mechanical engineering technicians.

This new qualification recognises both practical work-based skills as well as the theoretical expertise engineering technicians need to succeed. The qualification will help qualify people in the skill and knowledge sets that industry needs most right now – to bridge the gap between qualified engineering tradespeople and degreequalified engineers.

Candidates can either study full-time to achieve the NZDE and then enrol in the NZDEP when they start work, or work towards both while on-the-job in an industry cadetship. Graduates of the NZDE/NZDEP are eligible for Certified Engineering Technician (CertETn) registration and Associate Membership of IPENZ, the professional body for engineers. The New Zealand Board of Engineering Diplomas developed a Unified Diploma system and this qualification as part of the National Engineering Education Plan (NEEP) to create more seamless career pathways for both vocational and academic engineering learners. Competenz representative on the Board, Bill Sole, says the knowledge and practical experience covered in both Diplomas will prepare candidates to meet the skill needs of industry.

To enrol in the NZDEP for the mechanical engineering sector, or to find out how your business can offer the on-job cadetship option, contact: Bill Sole – Competenz, Phone: 09 5399 832, Mobile: 027 777 4405, b.sole@competenz.org.nz.

Compact weightlifter in the red zone

A groundbreaking ‘spider’ crane is delivering big productivity gains for engineering company Texco Steel Ltd as it carries out earthquake strengthening works in Christchurch’s ‘red zone’. The Unic URW295 mini crawler crane supplied by Cranes Sales New Zealand can fit through standard door frames and can run on petrol or three-phase electricity. The crane is saving Texco time and manpower as it installs large steel bracing in DMC House – the old Smith City building on Colombo St. Texco Steel Ltd has the contract to install new steel bracing frames on all four floors of the building. Operations Manager Chris Roberts says the spider crane has already delivered a 30 percent plus improvement in productivity.

“It is so compact we can navigate it through standard doorways and into tight locations but it can still lift almost three tonnes. We are using it at maximum capacity to lift sections of steel frame.”

The Unic URW295 is just 600mm wide, 1375mm high and 2690mm long. But when its legs are fully extended, it can lift a maximum 2.9 tonnes and has a maximum working radius of 8.41 metres. “Using the spider crane, we need fewer staff and the installation times are now accelerated. That’s a big advantage for these contracts which usually have tight timeframes.” Before the company purchased the Unic mini crawler, staff had to use skids, chain blocks and lots of manpower to erect this type of steel frame.

Go to www.demm.co.nz/enquiry quote: D120537

•

SKF Reliability Systems Excellence in Reliability Solutions

SKF Integrated Condition Monitoring SKF Reliability Systems hardware and software components are specifically designed to make it easier to collect, analyse, use and share machine condition data.

From hand-held to hard wired to wireless, SKF has a complete, fully integrated range of condition monitoring tools and technology to help our clients.

• Basic hand-held tools • Portable Data Collectors and Analysers • On-line Surveillance and Protection • @ptitude Asset Management System • Baker Electric Motor System diagnostics • Thermography • Laser Alignment and Geometric Measurement

Other SKF Services available: • Reliability Training Solutions • Maintenance Strategy Design • Asset Management Services

• Proactive Reliability Maintenance • Engineering Solutions • Remote Diagnostic Centre

For further information contact your local SKF Authorised Distributor or email marketing.skfnz@skf.com

www.skf.co.nz 37

• MAINTENANCE MATTERS

Engineering change

By Craig Carlyle.

That’s it; summer’s gone. It is no use sniffing about our lost summer. Time now to focus on all those uncaught snapper who will only get bigger for next year!

Years ago I wondered how much more change is required before we finally got it right. Now I realise that change is the only constant. Change and stress is a difficult but constant force in industry; show me someone without change stresses and I will show you someone who stagnated and died on the job years ago, but doesn’t recognise it yet.

Engineers and electricians tend to be technically minded, so the concepts of people, processes and change are somewhat foreign to us. There is a good and bad side to that mindset; we tend to push back against change (unless we can see the benefit) but that in turn can leave us

ARE YOUR STAFF NOT ‘GETTING’ IT? IS MAINTENANCE MANAGEMENT OR HEALTH AND SAFETY GIVING YOU A HEADACHE? Unlock your staff’s potential with either of our inspiring and informative short course training sessions: •Maintenance Management Basic Training or •Health and Safety Made Simple From only $220 + GST per person check our website for details and session dates

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May 2012

offside with change agents. Often what we need when faced with change, is to have the consort of other engineers, hear direct from our peers about their experiences and validate or dispel our unease about new ways of doing things.

This is where the Maintenance Engineering Society proves its worth, providing the forum for engineers and electricians to compare notes, listen and talk. The society does this with regular regional networking forums and its annual national conference.

Regionally, the next forum off the block is back in Auckland, this time at Stevenson’s Engineering in East Tamaki on the evening of Wednesday 23 May. The relatively informal evening is based around a tour of the host’s facility, followed by a light supper. If the Stevenson’s facility shows half the promise of their exhibition stand (and their branded BBQ sauce) then the evening is guaranteed to be a winner! There is no cost and MESNZ membership is not a prerequisite for attendance, so contact Barry Robinson (barry@safegroup. co,nz)or Larry Wiechern (larry.wiechern@ manukau.ac.nz) if you would like to attend.

Be quick though as these evenings are oversubscribed.

While the society puts a lot of background work into organising these evenings, they are only a primer to the big daddy event; the SKF National Maintenance Engineering Conference. This annual event, supported by official media sponsor DEMM Magazine, is a full-time task for the event managers, and even though the November 2012 Rotorua event might seem months away, it is a hive of activity in the event management office. Exhibition

space is close to full and registrations are now coming in as attendees make sure their places are reserved.

The conference event provides an opportunity to put expert speakers in from of attendees, whist still sticking to our ideals of supporting maintenance engineers in their real world environments. Using my topic of change as an example, respected speakers such as Ann Andrews can show us not only how to cope with change and difficult people, but how to harness the positive opportunities. All while learning to enjoy the ride!

It’s not all touchy-feely though, and the organisers have made a black art out of mixing holistic topics such as team management with burning line management topics such as health and safety and HASNO, while not forgetting traditional preventative maintenance, electrical and technical topics.

Because the SKF National Maintenance Engineering Conference is run by the non-profit MESNZ, it is entirely focused on returning value to engineers and proudly boasts the cheapest attendance of any two day+ event in the southern hemisphere. So cheap (at NZ$440 to 680 pp plus GST,) that it is viable to fly in from the northern hemisphere and attend, and still have change left over!

The November 2012 Rotorua event, teamed with the Maintenance Engineering Trade Expo, will be bulging with attendees, exhibitors and speakers, all responding to the theme of “Lifting The Game”. Registrations are open for exhibitors and attendees and can be found on the website (www.mesnz.org.nz\nmec\) or by contacting Event Manager Leanne Powley on (09) 296 1333, conference@mesnz.org. nz. Details of all the MESNZ activities are available on the society website, www.mesnz. org.nz. As a resource for maintenance engineers, you would agree MESNZ is a busy little society, but not too large that we do not welcome your call to listen to your issue or ideas. Email, call, or better still, see you at the National Conference!

Meanwhile, I’m off to feed the fish.

Craig Carlyle Secretary MESNZ

Seeing daylight and saving money It dawns on more and more businesses that by swapping their existing lighting for more energy-efficient solutions they can save some serious money.

But there are more benefits in store for those who swap, as editor Stefan Richter learned from Grant Simpson, PowerSave Light Company’s Director.

Night or day the PowerSave highbays improve efficiency and safety at CourierPost depots.

Being able to spot the personal hygiene habits of trespassers might not be the first thing that comes to mind when talking about the advantages of various lighting products.

“The daylight colour of our lamps constitutes a big benefit for the utilisation of CCTV systems,” explains Grant Simpson, Director of the Albany-based company. “In fact one of

our customers, who had previously installed some of our floodlights, told us that they had had an intruder on their premises, and that the images of this unwanted visitor captured by the surveillance camera had been so sharp they were actually able to see he hadn’t had a shave in the morning. This report might have been a little exaggerated, but they basically

wanted to let us know the object definition of their CCTV-generated footage has improved big-time since utilising our lamps. And that’s why they had ordered our products in the first place.” To the majority of PowerSave Light Company’s customers, however, another benefit of the highly energy-efficient industrial and commercial lights and fittings is probably far more important: the massive electricity cost savings of up to 50 percent and more.

“Since my partner Warwick Wilkinson and I took over the company six years ago, we’ve kept our product range quite narrow,” says Grant. “We mainly focus on industrial lighting, and also offer some products for commercial applications such as schools, hotels, retail and offices. Our approach is to be able to provide customers with all the types of lighting that can be found on an industrial

Lighting consumes about 40% of the electricity in a typical commercial building.

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To find out how Wattstopper can reduce your energy bills contact Eurotec today on 0800 111 990 for a free copy of the Wattstopper Control Six brochure - it's the bright way to a better future.

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39

• lighting site.” This includes highbays and lowbays for factories and warehouses, floodlights for security, signage illumination, car parks and loading bays, bulkheads and self-ballasted lamps. The latter are suitable for both new installations and replacement of conventional HID and incandescent lights. “PowerSave Light Company covers about 98 percent of the lighting which is necessary to outfit industrial applications. We provide either a completely new product or the lamp and control gear to retrofit into existing highbay, lowbay and floodlight fittings.”

Since the economy has become more challenging for businesses, Grant has been observing a growing focus on finding ways to reduce costs and expenses. “All a lighting system does is illuminate an area and enable a company’s staff to do their work productively and accurately. The question is: Why not cut the cost of doing that in half? Many of our customers are quite surprised when they learn how much they can actually save by using our energy-efficient products and still get a similar light output,” says Grant. “Our main business in NZ is replacing existing 400W highbays.

A 400W lamp including control gear runs at about 450W, whereas the PowerSave unit only consumes 200W. At an industrial site that operates 24/7 you can save around $330 dollars per light, per year.”

Cutting the power bill Among the many companies which have tapped the huge energy saving potential is New Zealand Post. When the lighting at the North Harbour courier depot was upgraded, PowerSave 200W high intensity fluorescent (HIF) highbays replaced the conventional 400W HID lighting and turned out to consume less than half the energy. As a result there has been a roll-out across the depots countrywide. Another example is Metal Skills, a leading contract manufacturer of sheet metal products. Because the company had already made good experiences with PowerSave Light Company’s highbay fittings in their previous East Tamaki building, they wanted the same system in their new premises. Metal Skills’ director Graeme Bartlett reports, “The end result is our lighting will use less than half the power of a typical factory/warehouse. For us it means we can redirect the $30,000 saved into other areas that will add value.”

Money can also be saved by replacing conventional floodlights with more energyefficient units. “A 65W compact fluorescent light, or CFL, will typically replace a 250W high-intensity discharge (HID) lamp, and the 120W CFL will replace a conventional 400W

40

May 2012

metal halide or 500W halogen lamp,” explains Grant. “In both cases the CFLs will return electricity savings of better than 70 percent.

The (separated) electronic ballasts used in our EnergySaver floodlights are also extremely efficient with a start-up draw of just 0.5 Amps compared to 4 Amps with conventional wirewound ballasts.”

AHI Roofing’s lighting upgrade encompassed not only floodlighting, but also new aluminium highbays, prismatic highbays retro-fitted with PowerSave components, new and retrofitted lowbays. Martin Bliss, Roof Tile Group project engineer reports around $35,000 in annual savings and adds, “The theoretical payback period for power savings has been around two years including the installation costs. If all our lights were running 24/7 the payback period would be even less on average.”

PowerSave Light Company’s Grant Simpson is convinced that a 24h operating business can achieve a payback period as low as seven or eight months. “We find that our clients consider payback periods of less than two years a good threshold that justifies the change to our energy-efficient lighting.”

Swapping to PowerSave lights is also very quick and therefore inexpensive. Highbays for example come with a power cord and plug and merely require a chain to attach to the hanging hook before plug and play. A scissor lift trundling down a warehouse aisle requires ten minutes to swap a highbay.

Feeling more comfortable That the quality of the light produced by the energy-efficient lighting is beneficial for the use of CCTV systems has already been mentioned.

Grant: “PowerSave lamps come with a colour temperature of 6400K, and that’s the quality of light you have on a sunny day. This can have an amazing impact on staff ’s well-being.”

“With the white colour of the PowerSave lights, the inside of the building actually looks like it is daytime, even at night, and I know this helps cheer the guys up when they get to work for the night shift,” says Metal skill’s director Graeme Bartlett.

North Harbour CourierPost depot operations manager Tony Su’a says staff were initially surprised by the lamps’ white daylight colour but soon realised it created a brighter effect.

“This is a great result because parcels are easier to read and handle quickly which is what we do. Staff are also finding the light easier on their eyes and more comfortable to work under.”

Another example comes from the food industry. Grant Simpson: “One of NZ’s largest meat producers installed our flood lights and highbays in their new production area. And

they tell us our products are excellent, they can see the blemish on the meat clearly, which is important for staff working with knives.”

Improved staff safety PowerSave lights also restart within seconds, a fact which can not only improve the safety at an industrial site, but also save additional money.

Graeme Bartlett says he is “pleased that our lighting has improved staff safety. PowerSave’s lights restart immediately, so if there is a ‘brown out’, the machine operators are much safer than with normal lights.”

Grant Simpson reports another example, “Because conventional HID lights take several minutes to cool down before they come on again, the staff in the meat processing industry must leave the cutting floor after each power outage, which means that they must rescrub all their equipment. They typically lose 15 to 20 minutes production, resulting in several thousand dollars lost production each time that happens. And it happens reasonably frequently.”

According to AHI Roofing’s Martin Bliss, the lights’ rapid start “makes it easy to switch areas on and off without having to wait ten minutes for normal light levels to return.” Users don’t need to leave the lights on all the time, but only switch them on when needed, and maybe use a motion sensor to do that.

Site Safety PowerSave highbays operate at 0.85 amps compare to over 2.0 amps for conventional 400 Watt highbays and are also high power factor.

Removing such large amounts of current from the system results in less system stress and deterioration and less heat through circuits and switchboards. Many fires originate at switchboards and insurers are acknowledging by taking out this amount of current from the site substantially reduces the risk of fire.

The newest product from the Albany-based company has been enduring tests for three years. “Our new reflector for recessed proffers in the ceiling will reflect more than 90 percent of the light that hits it. In a normal troffer you have three tubes, and a lot of that light is lost inside the fitting on account of very poor reflection. We remove one tube and put a reflector over each of the remaining tubes. We still get the same amount of light, but consume one-third less power,” says Grant. “We are able to supply lighting solutions for the factory and the warehouse, for security applications, and now also for the office.” Upgrading on energy-efficient lighting saves money, improves staff well-being and safety, and also reduces the carbon footprint of a company. “You can only win with it, it’s a real no-brainer.” Go to www.demm.co.nz/enquiry quote: D120539

•

• lighting

Excited by magnetic fields Induction lighting is commonly less-known than LED lamps, but has what it takes to outperform the latter especially in industrial applications.

In fluorescent lamps electrically excited mercury vapour emits UV radiation which is finally converted to visible light by the phosphor coating of the bulb. Induction lighting generates light in a similar fashion, except for one important difference. “An induction lamp is essentially a fluorescent lamp without electrodes,” says Phil Fuller, Company Director of Infinity Lighting Limited.

“In this advanced technology the lamp relies on magnetic induction to ignite the gas fill rather than electrodes, which are the components that burn out in a typical fluorescent lamp. Frequent replacement is the consequence. LEDs and induction lighting have many features and benefits in common, but the latter has been around a lot longer with a proven track record.

Induction lighting actually offers twice the Benefits of induction lighting

Long lifespan, up to 100,000 hours.

High quality white light.

High colour rendition.

High efficacy.

Low glare.

Wide operating temperature range: -30 to +50°C. Cost effective.

Virtually maintenance free.

Instant re-strike – no warm up time.

Lamps run a lot cooler than metal halide and high pressure sodium lamps.

Depreciation of light output is only 30 percent over ten years.

suggested lamp life of LEDs. That’s about 100,000 hours instead of 50,000 hours!

And often LED solutions have high glare issues whereas induction lighting is much easier on the eye.”

Infinity Lighting has spent many years looking around the world for a reputable supplier of industrial induction lighting product and is now the New Zealand agent for Everlast Induction Lighting, a division of Full Spectrum Solutions USA. This company was founded in 1997 and is based in Jackson, Michigan. Full Spectrum Solutions was originated on the principle that people who spent the majority of their day indoors needed healthy, full spectrum light in order to lead a productive and happy life. The company has quickly become a leading manufacturer of energy-efficient lighting solutions for residential, commercial and industrial applications. By working with renowned research partners and testing facilities, including the California Lighting Technology Centre at UC Davis and the Enhanced Spectrum Lab at the University of Michigan, Full Spectrum Solutions, Inc. offers more than 200 lighting solutions marketed today under the names BlueMax, UltraLux and EverLast. Infinity Lighting’s products are on a list of preferred lighting products for Fonterra.

Huron aluminium highbay

History of induction lamp technology In 1890 Nikola Tesla demonstrated that it is possible to wirelessly transfer power to electrodeless fluorescent lamps. The Serbian-American inventor and engineer applied for patents on the system, and in June 1891 Tesla was granted a US patent to cover an early form of induction lamp. Since that time lighting firms worldwide have tried to transfer Tesla’s findings into an efficient and commercially viable product. In 1967 John Anderson, a professor and employee of General Electric, developed the first reliable electrodeless lamp. General Electric attempted to patent the system. Phillips introduced their QL lamp in 1990. This lamp can be considered the first lighting product to utilise induction technology.

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• lighting

¾

launched the Genura System in 1994 (based on John Anderson’s lamp), and Osram introduced the Endura System two years later. EverLast came out with an induction system capable of step dimming in 2006.

The early problems with induction lighting – high cost, EMC interference with electronic devices and radio signals, limited range of wattages and limited

number of applications – have now been successfully dealt with. Induction technology is much more affordable nowadays, the electronic ballast in modern products has taken care of the EMC interference, and the user can now choose between various types and styles to match their specific needs. The following industrial fixture types are now available: aluminium high bay fixtures, acrylic

high bay fixtures, gum drop style high bay fixtures, aluminum low bay fixtures, bullheads, floodlights, streetlights and IP65-rated wet location fixtures. You can chose between rectangular lamps, circular lamps and mogul based lamps and various wattages between 40W up to 400W. Go to www.demm.co.nz/enquiry quote: D120541

•

LEDs deserve better power supplies

Facing dramatic climate change and soaring energy prices, governments around the world are beginning to list some high energy consuming products as prohibited products, and incandescent lamps are on top of the list. Banning the use of incandescent lamps first began in the European Union (EU) and Japan, followed by other countries. Based on the timeline of the worldwide ban on incandescent light bulbs, it is suggested that most countries have set 2012 as the deadline of banning incandescent light bulbs, which also marks the rise of LED lighting.

To comply with the global trend of saving energy, Wellforces continuously introduced various high-quality LED power supply products and accessories from Mean Well to the New Zealand market. Mean Well’s LED drivers have been designed for higher efficiency and lower heat dissipation and are in compliance with the latest lighting regulations all over the world. Wellforces stocks

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May 2012

the complete range from low-cost plastic models to high-end metal casing up to five years warranty.

Most importantly, Mean Well has made this range of products very reliable in order to match with the long lifespan of LEDs. Not only distributing these quality power supply products, Wellforces also provides product selection and customisation services, as well as LED circuit design for lighting manufacturers. They offer complete and reliable LED lighting solutions. Wellforces’s LED power supply products have been widely used for street lighting, architectural lighting, embedded lighting and LED sign boards. The robust design with high protection level against dust and moisture makes them suitable for all kinds of indoor or outdoor installation of LED related applications.

LED street lighting for example has many advantages; in particular it offers unmatched energy-saving potential and environmental friendliness compared to

traditional street lamps. As green environmental protection becomes a global theme today, it has won extensive support from governments and industries. When its technology becomes mature, its strength in eco-friendliness will be more salient. Nowadays, the LED industry is one of the most promising industries, where the speed of technological advancement has gone beyond imagination and industry standards are being established.

When the LED street lamp has a stable quality, long lifetime, and intelligent control, its cost will then lower to an acceptable range, and LED street lamps will ultimately replace the conventional ones.

Mean Well does sense the rising demand of LED street lamps accompanying the technical enhancement and price decrease in LED chips. Among Mean Well LED power products, the CLG and HLG families for street lamp applications have been bestsellers, and the sales figures continuously achieve new records.

The HLG-240 series, with an efficiency reaching 94 percent, has penetrated the market aggressively; many streetlamp manufacturers in Taiwan and China requested for testing samples, and this series now has been designed into the latest version of LED streetlamps among numerous customers. The high efficiency of the HLG series helps increase LED street lamp system efficiency, and lower its cost by enabling system designers to choose lower-end LED chips.

This might be the main reason that accelerates the process of LED street lamps replacing traditional street lamps. It has been estimated that there will continuously be a big increase in the demand for LED street lamp power supplies, and Wellforces is well prepared for this opportunity with Mean Well’s new high efficiency products of 40~320W HLG40/60/80/100/120/150/185/320.

Other LED applications such as general illumination and decorative lighting have already shown strength over traditional lighting, and will continue to be a replacement solution for incandescent and fluorescent lights over the next few years.

Since LEDs are also electronics, controlling these devices becomes easier. However, this transition is rendered pointless if the LED driver fails easily and before the actual LED failure. Wellforces has kept this in mind and is dedicated to only offering the customer the highest quality Mean Well LED power supply products. Mean Well’s LED power supplies also come with constant voltage, constant current or 3-in-1 dimming function, which ensures that the products suit any kind of lighting application during this period of technology transformation. “LEDs deserve better power supplies,” concludes Lenny Peng, Wellforces Limited.

“And we are here to offer reliable solutions for LED applications.”

Go to www.demm.co.nz/enquiry quote: D120542

•

• lighting

Commercial sector offered subsidised lighting controls

Businesses looking to reduce their electricity bills are to be offered subsidised lighting controls under a programme announced recently. The Energy Efficiency and Conservation Authority (EECA) Commercial Sector Efficiency Lighting Programme aims to reduce over-lighting and increase

the uptake and usage of lighting controls.

Building owners and tenants will be able to obtain subsidised lighting controls from a number of lighting suppliers. The subsidy varies between the different technologies.

Lighting in commercial buildings such as food stores, offices, hospitals, retail, schools, hotels and motels accounts for approximately 20 percent of total energy consumed by the commercial sector. Efficient lighting controls such as daylight harvesting, where lights automatically adjust in response to the amount of daylight in a space, offer substantial savings.

“Reducing this energy use by just 20 percent through the use of more efficient lighting and controls could save New Zealand over $40 million of energy every year,” said EECA’s Lighting Programme Manager, Bill Brander. “There have been significant advances in commercial lighting controls so we are encouraging commercial property owners and tenants are encouraged to take

another look. “Lighting represents one of the easiest savings for a tenant and payback on the technology is typically less than three years.” The programme was developed after research showed that there is a significant lack of knowledge and understanding of the opportunities to use lighting control systems to reduce energy costs.

Eight companies have been appointed to help businesses in New Zealand cut their lighting bills. The suppliers selected are: • Architectural Intelligence Ltd • Electrical Supply Corp • Energy Light Ltd • Eurotec Ltd • Philips New Zealand Ltd • Thorn Lighting (NZ) Ltd • Evolve New Zealand Ltd • Advanced Lighting Technologies NZ Ltd For more information about EECA business programmes, go to www.eecabusiness.co.nz.

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43

Changes in electrical regulations and standards Currently there are a number of amendments to the Regulations and Standards in progress for electrical legislation used by the electrical industry.

The details that follow are the position as at 1st April 2012.

New Zealand Electricity (Safety) Regulations 2010 + amendment 1 There is an amendment 2 under preparation, to cover changes required for the certification review that comes into force on the 1st July 2013. This amendment is under preparation by Energy Safety.

Previous press releases to the electrical industry have detailed the general intent of the Electricity (Safety) Regulations 2010 amendment 2.

Electrical Standards cited by the Electricity (Safety) Regulations 2010.

It should be noted that normal operational procedures for standards requires that all draft standards or amendments to existing standards are released for public comment before the new or amended standard is permitted to be approved for publication. The public comments for draft standards or for amendments to existing standards received are considered by the standards drafting committee before publication and if satisfactory for inclusion, are incorporated into the draft or amended standard before publication.

Draft standards for public comment are placed on the Standards New Zealand website, www.standards.co.nz; the public comment files are located in the “public comment tab on the standards home page. On the public comment page select “NZ Standards” for NZS standards or “Joint standards” for AS/NZS standards. Each entry for standards for amendment describes how to make public comment, the usual method to make public comments, is by an online submission. A progress report of amendments in progress follows.

AS/NZS 3000 + amendments No. 1 and A Wiring Rules Amendment (no. 2) has been under development for some time, and it is expected to be released in April 2012 for public comment.

AS/NZS 3001 Electrical installations Transportable Structures (also known as connectable installations in NZ) Public comment for amendment No.1 closed late March 2012 and the public comment received is being considered by the drafting committee.

It is expected that amendment No. 1 will be

published May 2012 following the Australia and New Zealand Electrical Regulatory approvals.

Note: The AS/NZS 3001New Zealand only Amendment A is being incorporated into AS/ NZS 3001 amendment No. 1.

AS/NZS 3003 Electrical installations – Patient areas A new fully revised standard was released in 2011. The main changes are the electrical requirements for patient areas in hospitals and in domestic installations where it is permitted for some patient treatment to occur. There are three classes of medical equipment permitted in domestic installations, each with different residual current ratings and the location of the RCD, refer to AS/NZS 3003:2011 for details.

AS/NZS 3004 parts 1 and 2 Electrical installations – Marinas and pleasure boats It is proposed to carry out some amendments to AS/NZS 3004 parts 1 and 2 during 2012/2013, but is awaiting approval for the revision to commence.

AS/NZS 3008.1 series Electrical installations – Selection of cables It is proposed to carry out some minor amendments to AS/NZS 3008.1 series during 2012/2013, but is awaiting completion of cable performance testing and approval for the revision to commence.

AS/NZS 3010 Electrical installations – Generating sets Approval to carry out a major revision is held to amend this standard; revision work has commenced but has been held up due to the AS/ NZS 3000 amendment No. 2 revision.

AS/NZS 3012 Electrical installations – Construction and demolition sites It is proposed to carry out some minor amendments to AS/NZS 3012 during 2012/2013, but is awaiting an independent option on a provision in the standard being obtained and approval for the revision to commence.

In the photovoltaic (PV) installation standards, there is major revision work in hand, details are as follows: • AS/NZS 5033 PV arrays Has been open for public comment late 2011 and early 2012, consideration of the public comment received is almost complete and publication of the revised standard is expected mid-2012.

New Zealand Electrical Institute Inc. PO Box 64-258, Botany, Manukau 2163 Phone: 09 271 1901, Mobile: 021 613 448.

Email: nzei@xtra.co.nz

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May 2012

• AS/NZS 4777 parts 1 and 2 Grid connect systems Drafting of a major revision to both parts is nearing completion, and is expected to be released for public comment mid-2012.

General 1. The above details the amendments of major standards used for electrical installations, the amended or revised standard do not come into force until listed in schedule 2 of the Electricity (Safety) Regulations 2010.

2. If you find an area of an electrical standard which is unclear or needs to cater for new applications, use the “Keeping Standards up-todate” process, details of this process is contained in every standard.

Allan Hill National Secretary New Zealand Electrical Institute Inc.

AGM/Conference and extraordinary meetings The New Zealand Electrical Institute Inc. held their AGM/Conference and extraordinary meetings from the 16th to the 18th of March 2012 in a vastly different format than previous years. The Friday, day session was a technical session with speakers from: • Electrical and Telecommunications Electro Technology & Telecommunications (ETITO), Mr Paul Hollings.

• Electrical Workers Registration Board (EWRB), Mr John Sickles.

• Energy Safety, Mr Peter Morfee.

• Mr Alan Blee (Past President) Spoke about the Restoration of the One Mile power station.

• Mr Joe Heappey (Past President) spoke about some of the Electrical Facilities at SkyCity, Auckland.

•The AGM was held on friday night. The extraordinary meeting was held on Saturday morning to discuss the future of the NZEI Inc. The general meeting of the NZEI Inc. was held on Saturday afternoon with the investiture of council in the evening.

Election of Offices for the NZEI Inc. Mr Alan Blee, the Vice President of the Institute, was elected unopposed to the position of President of the Institute. Alan is

a Registered Electrician with advanced trade certificate, REA 1989 and was Registered Electrical Inspector 2002. He joined the NZEI Central Otago Branch in 1983, holding committee, secretary, and Presidents positions until the Branch membership was transferred to the National Branch in 2010. Alan was elected to Council in 1992, having roles with the membership and publicity committee.

Alan was elected to Vice President 1995-96, and National President 1996-1998. Alan was re-elected to Council in 2010. He is currently employed by Electrical Inspection Training and Communications, working as an Electrical Inspector, and a presenter of refresher courses and other training courses for electrical workers.

Mr John Brothers, the Vice President and Secretary of the Auckland branch, was elected unopposed as Vice President of the Institute.

He was born in Christchurch in March 1957 of NZ and Cook Islands heritage. John joined the institute in the late 1970. He left then rejoined four years ago. John served in the RNZN from January 1974 to retirement March 1994, he was a Chief Petty Officer Electrician for the last nine

years of his service. Approximately eight years prior to his retirement he worked part-time for various large electrical companies to gain his land-based skills and upon retirement went to work for one of those companies. John has worked in most areas of the electrical industry from basic domestic to heavy industrial and hazardous areas. In 2002 John decided to go it alone and started up his own small electrical company with two apprentices. Currently John is tutoring at M.I.T. up-skilling Marine Engineers, refrigeration students, and EAS/ EST students. John has been involved with ESITO, and Trades Up courses, plus the odd refresher courses run by M.I.T. Mr Bill Burn, a residing council member of the Institute was re-elected to council. Bill is a registered electrician with advanced trades certificate and is currently employed with a local contracting firm in Invercargill and is mainly involved with domestic commercial and industrial repairs and servicing. Bill joined the NZ Institute of Electricians Southland Branch in 1970 and has since held all positions in the branch. A tenure of note is that of twenty eight

years past service as branch secretary/treasurer, organiser and newsletter editor. He is currently the Branch President. Initially elected onto the Institute’s national council in 1979, he served a four year term and years later was re-elected back onto council in 1988. Bill became National President in 1992 and had the distinction of chairing a large gathering at the Blenhem conference the next year which saw the start of major changes in the electrical industry. A considerable part of Bill’s earlier working life was spent at the Tiwai aluminium smelter where he was initially involved with the construction phase and later the smelter company which saw him take on various job roles including plant maintenance electrician (on shift), electrical foreman, maintenance supervisor, technical officer and maintenance development engineer involving PLC automation before leaving the company in 1997. Bill is married to Mary with a grown up family (all married) of two daughters and one son and six grandchildren and is also a member of a local Lions service club for over thirty years.

•

A.W. Gooder Award presented to Mr Stephen Crocker Mr Joe Heappey presented the NZ Electrical Institute’s A.W. Gooder Award (2011) to Mr Stephen Crocker on 19th February 2012 at his home in One Tree Point, Northland. Also present were his wife Diane, two of their children and his parents.

The certificate and bronze medallion were earned

by Stephen for achieving 99 percent in the EWRB Electrical Inspectors Exam in the 2011 round. The NZEI Education Trust cheque for $200 is the icing on the cake for a truly excellent result.

Stephen is currently employed by South Pacific Industrial Ltd (SPI) as a hazardous area inspector under an Employer Licence at Refining NZ Ltd at Marsden Point.

On leaving Whangarei Boys High School in 1992 with School Cert and 6th Form Certificate Stephen studied at Northland Polytechnic for Electrical Engineering Stage 3 through 1993, then worked in a bike shop carrying out hands-on repair work before gaining a training position at Golden Bay Cement Company in 1994. Through his electrical apprenticeship at Portland he gained experience on HV equipment, such as motors, switchgear, and transformers as well as work such as PLCs through to electric motor maintenance and repairs.

His marks were always “fairly” high with 90 percent First Qualifying, 92 percent Regulations, 88 percent Trade Certificate. At the end of his training position in 1998 he was on the road servicing petrol pumps and fuel depots for Oilcon Ltd working on installation and maintenance

from Gulf Harbour to north of Kaitaia.

In 2001 he struck out on his own and started trading as Crocker Powertool Services carrying out appliance testing and repairs before expanding to Stephen Crocker Electrical. In this later self-employed situation he carried out domestic, industrial, and commercial installation and servicing including work back at Golden Bay Cement on switchboards and control panels. Other work that he undertook included industrial electrical construction at dairy factories for Industrial Controls South Canterbury. Other leading-edge work involved alternative power systems such as wind, solar, generators and invertors. In 2008 Stephen became employed at the refinery by South Pacific Industrial as an electrician on electrical and instrumentation construction work then on to do hazardous area inspections under the refineries employer.

“With respect to the refinery, it has been a huge learning curve for me.

They have a big focus on safety with all work in the plant controlled by a ‘permit to work’ system. A couple of things about working in a hazardous area which are quite different is that all equipment (motors, control panels etc) must be independently certified for the zone in which is installed and that the user is very limited in their ability to modify equipment as this will usually invalidate its certification certificate making it non-compliant.” As a consolidation of his work he took a two-week block course at Manukau Institute of Technology, by Marius Schmidt, as study for the EWRB’s Electrical Inspector Exam. His mark of 99 percent caused his mother to remark “what did you get wrong?”

Stephen ascribed his success at the exam to good teaching but that is typical of his modesty as he discusses doing “all right” at his exams. His intention is to work towards gaining the relevant unit standards and completing his qualification as a hazardous area inspector. The New Zealand Electrical Institute wishes Stephen well in his career and his undoubted pursuit of excellence.

•

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• SINGER

“I love it when a plan comes together” Singer continues its run of attracting top talent as its ‘Powerful Solutions’ deliver across-the-board to clients. By Kevin Kevany Over the last few months, we have reported on Singer’s broadening its application of new technologies to meet the industry and particularly clients’ needs thereof, as well as a particular focus on upskilling at the top end to drive the company’s commitment to delivering ‘Powerful Solutions’ to its many long-standing and growing number of new customers.

This month we look at Singer Generation Services which has just clocked up its first birthday. A year on and it would not be surprising to find Singer Group CEO, Jeff Mclaren being likened among his colleagues to Colonel John “Hannibal” Smith – “I love it when a plan comes together” – as a number of new clients and projects come on-board and the leading power generators in the country prepare for a partial listing on the NZSE. In April 2011, the company, rapidly approaching its 60th year of operations, announced the formation of Singer Generation Services, and appointed the broadly-skilled industry veteran, Ian Brothers, a long-term Singer manager, who returned to the company as Business Development Manager, after leaving in 2007 to pursue other options. Brothers was charged with developing and growing existing clients in NZ – which already included Genesis Energy and Contact Energy – and to plan future offshore opportunities to exploit the company’s skills in thermal and hydro processes.

“We also set out to grow the skills we could offer the local generators at the very top end of our skills pyramid, since we have always had compelling strength in the middle to lower-top-end and have, over the last decade, grown a powerful mechanical contracting offering which none of our opposition can compete with.

“Ian has not only pursued and achieved his external targets but has become familiar with the major advances we have achieved in skills and personnel in diverse areas like thermal imaging and automation – and there will be more in that sector in the months to come – which he now knows he can offer our power generation clients and others, with confidence.

“I am also particularly pleased that after a series of three-ways discussions, Ian and I were in a position to be able to bring a Kiwi thermal generation talent back to New Zealand from his sojourn in the United States, by appointing Reg Soepnel as

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Ian Brothers (Left) and Reg Soepnel

Manager, Singer Generation Services, with immediate effect.

“Reg has gained a lot of experience and learnt a good deal during his eight years in the US power industry. He even had the privilege and the challenge of working for the legendary financier, Warren Buffet, whose Berkshire Hathaway company had a significant stake in the company he worked for there, along with the very prominent industry ‘names’, CEO, Gregory Abel and onetime Buffet heir-apparent and chairman, David Sokol.

“Ian and I, of course, got to know him well as he worked his way up the Genesis Energy ranks to GM before he left. We regard this appointment as a step-change in Singer’s offering at a time of great opportunity and change in the local power generation industry.

We are also flattered that he chose us against many competing opportunities, because of our potential for further growth, both personally and as a team-player, something he is particularly passionate about.

Reg has proven technical ability and broad industry experience, combined with the leadership and interpersonal skills to apply these effectively. Importantly, he is an excellent communicator and motivator, who has successfully achieved business objectives – through periods of major change. The timing of his arrival is just perfect,” Mclaren says.

Brothers, who like Soepnel worked at Huntly power station during its construction, takes-up the story. “Because most of us come from a contracting background, it’s also a great fillip to our offering that we now have someone who has proven himself over many years, at home and abroad in senior management roles, for the asset owner – an important difference requiring different skills. He is especially welcome, and will be an additional asset to call on for senior management in existing and future client companies.”

Soepnel, a modest and self-effacing professional, has the pedigree to back-up the enthusiasm shown by Mclaren and Brothers.

Initially appointed Unit Manager/Operations Manager at MidAmerican Energy, in 2004, he rapidly advanced to a MD role at the Hunter & Huntington plants of their Utahbased PacifiCorp Energy acquisition before being appointed a GM role at MidAmerican’s Mississippi River Energy Center. Later he was promoted to their Neal Energy Center as GM before leaving in January this year.

“I’ve learned a lot about the importance of true customer service and the business approach needed of an investor-owned utility at MidAmerican, which is recognised as a leader in the industry. In addition, they had a strong emphasis on ethics and principles in their ‘six pillars’. Along with their primary

• SINGER one of customer service, they also had employee commitment; financial strength; environmental respect; regulatory integrity and operational excellence.

“As a consequence, I intend ensuring that everything Singer Generation Services does for any customer, existing or new, will be ‘put under the microscope’ to see what benefit/s they, the customer, will derive from that particular service,” says Soepnel, who has chalked up a trade ticket; an advanced trade certificate; technician’s certificate, NZCE qualification; right up to a Management Graduate Diploma, via the tough combination of night classes, correspondence and day release, during his sparkling career.

Like Brothers, he ‘confesses’ to an ‘emotional attachment’ to his former employer and significant Singer client, Genesis Energy, where he rose to be GM Thermal Generation, responsible for the Huntly, Kinleith and Tokaanu power stations, and also worked on the integration of Huntly, Tongariro and Waikaremoana Hydro, prior to moving

to the USA. “I’m looking forward to sharing the experience I have gained as an asset and operations manager, both locally and in the US, especially since while that particular market is very similar to ours in the mix of plant and equipment – and the challenges are quite similar – they use a wider range of strategies and techniques which could apply here too.

“Obviously, there are more than can be covered in one article, but I believe, particularly in the areas of innovation and Health and Safety, I have learnt a great deal of value in the last five or six years.

“It is the tremendous opportunity presented by the significant changes in our local power generation industry – along with the lifestyle and being ‘back home’ – that persuaded me the time was right to join the Singer team,” says Soepnel, who has clearly settled back into the Waikato, and is chuffed that one of his two lads has brought his American bride back to Hamilton.

Singer Generation Services deliver Singer has provided services to the Power Generation Industry for the past decade, ranging from day-to-day Site Services and Maintenance Trade Teams. The company prides itself in managing additional resources for major plant overhauls, by assisting clients with experienced resources to meet the plant needs and shutdown time-frames.

There is a strong focus on training to improve the performance of all employees deployed within the generation services industry, now and into the future. Singer Generation Services extend into the thermal, geothermal, hydro and gas sectors.

Proven skills and experience are brought to bear to assist existing and new clients with plant modifications, upgrades or extensions. From planning and project management to installation, Singer provides turnkey ‘Powerful Solutions’ for both electrical and mechanical CAPEX. Design becomes a working reality.

Whether it be a full maintenance solution, support for a customers’ maintenance teams or skills necessary for planned outages, the company has the knowledge and innovation to safely assist in maintaining and ensuring the reliability of assets.

PMs or defects are repaired, recorded and fed back into your Maintenance Management System.

Control and monitoring are the essential elements for providing flexible generation in today’s market. As plants expand and technology improves, Singer can assist with modifications to existing systems or provide new, stand-alone systems which are compatible with existing infrastructure.

The company carries a full complement of engineers, project managers, planners, resource coordinators, health and safety management, administrators, turbine / generator overhaul supervisors, quality control monitors, plant auditors, team leaders, mechanical fitters, electrical fitters, instrument technicians, electrical protection technicians, mechanical fitters, workshop machinists, welders, electrical fitters, electrical and mechanical trainees, scaffolders, coal plant assistant pperators, mobile plant operators, overhead crane operators, riggers, laggers, lube technicians, trade assistants and labourers.

0800 474 643 www.singergroup.co.nz

47

“Even better than expected”

Nationwide distributor Pudney & Lee represents some of New Zealand’s leading consumer electronics accessories – so when building a new office complex to accommodate their expanding company, they wanted the latest in lighting technology. “I’d been reading a lot about the efficiency and benefits of LED lighting, so I was very interested in seeing if we could incorporate it into the new office fit out as a way of making the building more energy-efficient,” says Graham Pudney, Managing Director Pudney & Lee. According to the government’s Energy Efficiency and Conservation Authority (EECA), switching to energy-efficient lighting provides one of the best returns on investment for companies looking to reduce their energy use.1 “Getting the lighting right is more important than

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most businesses realise. It makes up around 30 percent of their building’s energy use, and Philips’ research has found that investing in good workplace lighting can contribute to greater employee well-being and performance by reducing employee stress, absenteeism and industrial accidents,” says Ken McDonald, Project Manager, Philips Lighting.

How did they do it?

A number of Philips LED solutions were presented to Pudney & Lee, who selected the Philips Smart Panel. Philips then compiled a lighting design incorporating the Smart Panel for Pudney & Lee’s open plan office space, meeting rooms and corridors. These energyefficient LED luminaires provide high quality, uniform light, which is essential for general office environments. The panels have a slim profile, so don’t add bulk to the ceiling. “These are one of the first Philips SmartPanel LED solutions to be installed in New Zealand – they really are the latest and greatest, and genuinely live up to their name,” says Ken McDonald.

With Philips LEDs able to provide different shades of white, Pudney & Lee were able to tailor the warmth of the light to different settings. For task and work areas, a cooler white was used, while in hallways and communal areas (like the bathrooms and tea room) a warmer, more yellow light was used. As well as breaking up the spaces, the warmer light helps to create more relaxed spaces for staff. In the bathrooms and main entry, Philips Greenspace LED downlights were used. With a simple and elegant design, the downlights provide high-quality energy-efficient lighting. The diffused cover enhances the light’s uniformity and reduces glare.

Compared to CFL downlights, Philips’ Greenspace LEDs can provide energy savings of up to 60 percent, which provide a significant cost savings over their 30,000-hour lifetime.

The energy-efficiency of the lighting can also be improved with smart controls, which can achieve additional savings of up to 30 percent.

“Rather than hounding people to remember to turn off the lights, we installed Philips OccuSwitch sensor technology. These turn the lights off once there has been no movement in the room for a certain amount of time – maximising the life of our lighting and keeping our running costs down,” says Graham Pudney.

The energy efficiency of the lighting and technology was enhanced with good lighting design. “We really wanted energy-efficient solutions that were also cost effective, so we ensured that the lighting design and layout made best use of the large amount of natural light in the building,” says Philips’ Ken McDonald. As well as providing natural light, these windows act as the building’s first port of call for staff looking to cool down. Rather than constantly running the office’s air conditioning, staff are encouraged to first open a window.

The result “We knew a bit about LED, so had high expectations, but it turned out even better than expected – we were blown away by the quality of light LED provides – people really notice the difference,” says Graham Pudney. The extent of the energy savings was also surprising – even to the electrician installing the lighting.

“Our electrician put a clamp around a circuit with the SmartPanel LEDs, and he found that they were drawing much less power than traditional lighting.”

Pudney & Lee were so convinced by the LED lighting that they’ve used it exclusively throughout the building, from the lights over the sinks in the bathrooms to the exterior security lighting. Staff are also looking forward to avoiding the regular fluorescent tube replacements that CFL lighting brings. “We’ve been really pleased that Philips has been able to bring Pudney & Lee a lighting solution that is not only environmentally friendly and leading edge technology, but is also a sound commercial solution,” says Ken McDonald.

Article submitted by Philips Lighting New Zealand 1 www.rightlight.govt.nz/business/save-money/ better-business Go to www.demm.co.nz/ enquiry quote: D120548

•

Engineer your future with Open Polytechnic

Open Polytechnic’s Bachelor of Engineering Technology degree (BEngTech) is ideal for people who want an engineering career in New Zealand or Australia.

The degree is taught by distance in partnership with the University of Southern Queensland (USQ) and has been designed to let you continue studying while working so you

can fit study around your life.

The qualification is recognised by the professional engineering organisations of Australia and New Zealand.

You can choose from three majors in mechanical, civil and electrical engineering which will prepare you for employment in consultancies and businesses who work on projects such as constructing and maintaining roads and testing the environmental effects of buildings and machinery.

You will attend practice units at the USQ in Australia (this is not included in your course fees). The units will benefit your study by giving you communication skills, teamwork and knowledge of the environment.

If you have the New Zealand Certificate in Engineering (NZCE) or Level 6 National Diploma you can also apply to cross-credit your study and fast-track your progress through the degree.

You’ll be fully supported during study by experienced tutors, library and learning support staff who are available by free phone and email.

You can also access the USQ website to get

help from tutors in Australia.

Open Polytechnic also offers a range of construction diplomas, trade certificates and mathematics bridging courses.

If you want to engineer your future please contact Open Polytechnic on 0508 650 200 or visit openpolytechnic.ac.nz/bengtech.

EnginEEr

your futurE Give your engineering career a kick start with a Bachelor of Engineering Technology from Open Polytechnic.

This joint Open Polytechnic / University of Southern Queensland degree is designed for those wanting a career in engineering or for those already employed in engineering who want to upgrade their qualifications.

The degree has three majors, allowing you to specialise in: • Mechanical Engineering • Civil Engineering • Electrical Engineering Delivered by distance the Bachelor of Engineering Technology has been designed so you can fit your study around your life, letting you choose when and where you study.

Right now we’re helping around 41,000 students fit study into their lives. If you’d like to join them we’re here to help.

Open Polytechnic also offers related qualifications including construction diplomas and trade certificates, as well as mathematics bridging courses.

To find out more visit openpolytechnic.ac.nz/bengtech or call us on freephone 0508 650 200

49

Compact plug connectors for weight-sensitive applications The compact design of Heavycon Compact plug connectors from Phoenix Contact supports the trend toward ever-smaller devices in automation technology. Cost-effective plastic housing is light and particularly well-suited for weight-sensitive applications. The plug connectors are available in straight and angled line inputs for diameters of 9 to 15mm. Housing designs include plug, mounting, socket and coupling housing. Along with 8-pin (500V, 16A) and 17-pin (200V, 10A) crimp contacts, a mixed contact model with four power contacts (400/690V / 40A) and two control contacts (250V, 10A) is available.

Mixed contact plug connectors connect different power circuits in one plug connector. The power supply is connected via the power contacts, and sensor signals are connected via the control contacts. This enables the supply voltage to be fed in over the pin insert, which is protected against accidental contact. Go to www.demm.co.nz/enquiry quote: D120550

•

High efficiency DC/ DC converters for tight energy budgets

New cellular VPN router series

Soanar is pleased to introduce the new R1S/E, RO/E and RB/E series of high efficiency 1W DC/ DC converters from Recom. They have been designed for use in low power applications including battery operated products, green energy products and general isolation and DC conversion applications. Limited energy budgets require highly efficient converters also at low loads. The new converters achieve excellent efficiency up to 84 percent and more importantly, they can reach 70 percent efficiency even with a 20 percent load. Low losses allow these converters to provide an extended ambient temperature range of -40° to 100°C without derating. They are ideal for use where high efficiency, wide temperature range and good isolation are required. The new converters come in three case styles. The R1S/E is an unpotted SMD version available in tape and reel. They are also offered in SIP4 (RO/E series) and in SIP7 (RB/E series) packages. The converters have a 5V 200mA output and input voltages of 3.3, 5, 12 or 24VDC and feature standard isolation of 1kVDC/1sec with optional 2kVDC/1sec and have UL-60950-1 certification. Go to www.demm.co.nz/enquiry quote: D120550a

ORing’s Transporter series cellular VPN router is designed for industrial and rolling stock wireless applications, such as vehicle, and railway applications. TAR-3120-M12 is a reliable Dual-RF IEEE802.11a/b/g and IEEE 802.11b/g cellular VPN router with two ports LAN which is fully compliant with EN50155 certification. It supports 802.1X and MAC filter for security control. It can be configured to operate in three modes of routing function: Dynamic/Static IP route, PPPoE authentication, and Cellular Modem dial-up.

Users can set up WLAN environment to fulfill demands of various applications rapidly by dialing up cellular modem.

TAR-3120-M12 EN50155 cellular VPN router use M-series connectors to ensure tight, robust connections, and guarantee reliable operation against environmental disturbances, such as vibration and shock. TAR-3120-M12 provides dual RF wireless interfaces, which can provide IEEE 802.11 a/b/ g and IEEE 802.11 b/g dual band wireless communication and can be applied to fulfill any demands of wireless applications.

TAR-3120-M12 provides dual Ethernet ports in switch mode, so that you can use Daisy Chain to reduce the usage of Ethernet switch ports. Go to www.demm.co.nz/enquiry quote: D120550b

•

•

Coming up in the June issue SPlastic Industry

SThermal Imaging SCondition Monitoring SMaterials Handling SSCADA Deadl i ne edi tori al 4th M ay | D e adline adv e r t is ing 11 M ay 50

May 2012

Highest efficiency through application-specific drive configuration Despite the introduction of energy efficiency classes IE2, IE3 etc. and the subsequent information that is now available, finding the most resource-efficient drive solution is far from easy with the devil very much in the detail. A simple catalog-based choice will often miss out on potential savings, and therefore motors should be carefully selected according to the actual load profile of the application.

To avoid inefficient drive specifications, Nord Drivesystems concentrates on power reserves which are derived from various sources. Firstly, the power a motor can generate in compliance with its temperature class is higher than the rated output as given in the catalogue and on the motor type plate.

Secondly, performance classes rise gradually; for a 3.7kW output, for instance, it takes a 4kW motor. Many customers will even select the next motor in size. This kind of “bigger is better” approach is anything but efficient.

Yet more reserves are added during the drive configuration stage. Many mechanical engineers anticipate the worst case while disregarding that only normal motor operation (around 100 percent) will ensure high efficiency and optimum savings. Comprehensive motor specifications will include overload tolerances, i.e. which high and peak performance motors can run permanently or temporarily. Machine manufacturers know the typical load profiles but in addition, a consultation with the end

For energy-saving motors Nord employs innovative material concepts and technologies – however, optimum efficiency also necessitates careful configuration.

user might be advisable; after all, they are the ones primarily profiting from lower operating costs and they can often help determine the requirements. Additional potential power reserves result from different operation modes.

While catalogue specifications of nominal loads refer to continuous operation under constant load (operating mode S1), many actual applications require only periodic duty. During short-time and intermittent operation, longer overload periods are possible, provided that motors can cool down sufficiently in interim periods. Nord drive experts offer application-

specific support considering these and related aspects for tailored drive configurations. For a quick overview and in addition to face-toface consultation, Nord provides helpful and instructive information about efficient drive solutions at www.nord.com; the material includes a decision tree for motors in line with energy efficiency requirements, an interactive energy-saving calculator, and a motor catalogue listing the various different international regulations on efficient drive solutions. Go to www.demm.co.nz/enquiry quote: D120551

•

NZ’S LARGEST ABC

HYDRAULIC GUILLOTINES

• 5.5kW / 7.5hp 415V • Hydraulic operated motor machine • Motorised back gauge with DRO counter • Blades made from 9CrSi material suitable for cutting stainless steel

• 5.5kW / 7.5hp 415V motor • Rack and pinion back gauge design • Equipped with shadow line lighting-alignment • Photo electric device rear guarding with 3 beams • Plate support tables with transfer balls

SUBSCRIBE NOW! • Ground segmented • 45T punch fingers • 5HP, 415V motor • Four stations • Punch capacity ø22 x 15mm • Flat bar shearing 350 x 8mm • Angle shearing 80 x 80 x 8mm

• Set of 3 - 30", either side • Lifting handles on • Powder coated system 36" & 48" • Tamper proof locking x 310mm • 30" box 775 x 430 x 570mm • 36" box 915 x 440 x 700mm 630 • 48" box 1220 x

364kg

364kg

2500mm x 2mm

9,500

$

RELE

• 2hp 240V motor • 275mm blade • 75mm round capacity system • Dual material clamp pump • Built in blade coolant construction • Rugged cast iron

cap.

1,500

• 3 rolls rolls & shafts • Hardened & ground frame • Steel fabricated • 60 x 20mm flat bar capacity • 50 x 10mm flat bar on edge capacity • 30 x 30mm solid square bar • 40 x 40 x 5mm angle capacity

cap.

110 x 70mm Rect.415V) (240V, $ (S827, S828)

2,750

PK-30F SECTION & MACHINE ROLLING are powered

$

11,950 (S748A)

GRINDER SG-820 SURFACE P4 ball bearings

• Precision Japanese nozzle & flow control valve with • Coolant system 400 x 200mm • Magnetic chuck 220mm • Table feed 460 x 415V motor • 1100W / 1.5HP, • Cross grad. 0.02mm • Vertical grad. 0.01mm • Lubrication pump • Halogen work light

$

PB-1030 (S585)

3050 x 3.2mm

SAVE 2,000

SAVE 2,000

$

HG-2504 (S934)

2500 x 4mm

16,800

17,500

$

23,500

NZ’S LARGEST ABC

AUDITED CIRCULATIO

N TO THE ENGINEERIN

135T x 4000mm

$

28,000

42,950

$

SAVE 2,000

PB-160A (S910G)

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176T x 4000mm

62,900

$

NZ’S

$

MILLING$ MACHINES (L626D)

17,000

750 (Q810)

s efficiency initiative ❏ Our smartest energy update ❏ Air compressor ❏ Maintenance Matters: l coatings analysis and industria includes vibration

www.machineryho

CUTTING EB-320DS MITRE METAL BAND SAW

HG-440B HYDRAULIC GUILLOTINE

9,500

9,500 11,450 (S924)

fully enclosed fan-cooled

SAVE 1,000

$

5,050 (B067) BM-40V $

$ $

BAND SAWS

• 305 x 178mm Dr, rectangle capacity Highbrook 0.75kW D/38 / 1hp 240V motor Unit•• Adjustable 2717 234 4-speed (09) T: pulley drive system enabling 26-50-73-95mpm East Tamaki cutting speeds • 750W/240V

• 3 axis digital readout • 5hp 415V motor • 1500 x 300mm worktable • NT40 spindle • Variable 60-3600rpm • Includes: halogen light, coolant system,

clamp kit, swarf tray • Travels: (X) 925mm (Y) 420mm (Z) 480mm

www.d emm.c o.nz

SAVE $ 950

(M607D)

change without are subject to GST. Prices & specifications30-06-11. All prices Exclude valid until notification & are

10,950

$

BM-65VE (M629D)

SAVE

o.nz $18,000

neryhouse.c www.machi • 406 x 125mm rectangle

$ BM-70VE (M630D) 1,450

SWIVEL HEAD METAL

capacity • 1.1kW / 1.5hp 240V • Adjustable 4-speed motor pulley drive system cutting speeds enabling 25-40-52-72mpm • 750W/240V fully enclosed fan-cooled motor

motor

• 3 axis digital readout • 5hp 415V motor • 1500 x 305mm work table • NT40 spindle taper with 105mm chrome & ground quill • Z-Axis powered elevating motor • X & Y-Axis inverter power-feed • Includes: light, pneumatic draw bar system & coolant system • Travels: (X) 1050mm (Y) 420mm (Z) 500mm

19,500

$

CUTTING BAND SAWS

• 310 x 205mm rectangle capacity • 2hp 415V • Swivel head double mitre cut to 45º • 2-speed motor right & left, 60º right enabling blade speeds of 35 & 70mpm

• 315 x 230mm rectangular capacity • 2hp 415V motor • Swivel head double mitre cut to 45º • Coolant system right & left, 60º right • Quick action lock / release lever • Adjustable

SAVE $ 160

BS-912

hydraulic cylinder • Electronic variable blade speed 20 - 75mpm

SAVE $ 300

(B014)

1,920

$

BS-916A

3,160

$

SAVE $ 200

(B015)

EB-320DS

5,050

$

Specifications

use.co.nz

SAVE $ 200

(B067)

EB-320DSV (B067D)

6,050

$

Unit D/38 Highbro ok Dr, East Tamaki Ph: (09) 2717 234

& Prices are subject to change without notification. All prices exclude GST and valid until 30-12-11

11_DEM_011111

LARG

EST AB

Se pte

LanzaTec

√ Secure online ordering √ Fast nation wide delivery √ Stock level indication √ Monthly specials √ Most up to date pricing & information √ Over 3500 products online √ Quality customer service

• 2 axis digital readout • 3hp, 240V motor (M603D) • 3 axis digital readout • 3hp, 415V motor (M604D) x 205mm • •3hp 310415V • 1270 x 254mm motor work table / 2HP 415V • 1370 • 1.5kW x 4mm cutting capacity • NT30 spindle • 1300mm x 254mm worktable mitre cut to 45º right head double • •NT30 415V motor Swivel • X axis power • 5.5kW / 7.5hp P4 ball bearings spindle SAVE machine valve feed • Precision Japanese nozzle & flow• control 60º right • Variable & left,70-3500rpm operated $ Includes: halogen with • Hydraulic counter 450 light, • Coolant system motor 2-speed back gauge with DRO suitable for • X•axis power feed 150mm vice, coolant 400 x 200mm • Motorised • Magnetic chuck blade system, • Includes: enabling made from 9CrSi material clamp kit, swarf• Blades 220mm halogen 70mpm tray • Table feed 450 x of 35 &light, speeds 150mm 415V motor • Travels: (X) 760mm vice, coolant system, cutting stainless steel • 1100W / 1.5HP, clamp kit, swarf (Y) 360mm tray • Cross grad. 0.02mm • Travels: (X) 860mm (Z) 430mm • Vertical grad. 0.01mm (Y) 360mm • Lubrication pump (Z) 430mm • Halogen work light

9,600 (G220)

SECTORS

$

HG-3206 (S940)

3200 x 6mm

$

BRAKE

8,550 (P192A)

product • Flatness system page precision • product • 2-Axis digital readout • Manufactured pdfto brochures ‘O’ • 560 x 2000mm DIN standards grade • larger images spindle bore • 80mm • new freight • Test certificate supplied calculator • 7.5kW / 10hp 415V(25-1600rpm) • include • Does not new wish list • 12 spindle speeds chucks, face plate, • new subscribe NATA certification jaw • Includes: 3 & 4for news work light & special offers steadies, coolant, • and much more…

SG-820H HYDRAULIC SURFACE GRINDER

G & MANUFACTURING

November 2011 $6 INCL GST

SAVE 1,950

$

HG-3204 (S935)

3200 x 4mm

$

HYDRAULIC NC PRESS

• Ezy-Set NC-89 Go-To • Hydraulic / Mechanical controller X & Y-Axis ram, synchronised • Solid one piece positive stop design four way multi vee • Quick action top ("v") die block tool holder with wedge type adjustment • Segmented 86° offset top punch • Fitted with safety light curtains

PB-135B (S908G)

SAVE 2,000

19,950

$

MACHINE

$ (S840) 5,350 • easy SURFACE PLATE register GRANITE 100mm & login size x HEAVY DUTY• improved search H) • 600 x 600 & navigation x 680mm (L x W x PIPE • newCL-75 • Stand 460 x 410 LATHE compare within 3.253/µm CENTRE

5,150 (S744A)

$

6,400 (G218)

SAVE 1,150

$

HG-860B (S932)

2500mm x 6mm

$

BRAKE

• 35T punch pressure • 5HP, 415V motor • Punch capacity ø18 x 14mm • Throat depth 310mm • Table size 700 x 500mm

BM-30A BM-30 240V (M603D) 415V (M604D)

$

18,000

3,500 products Mis sion pos sibl e online remarkable story. h’s

$

Don’t miss a single issue of New Zealand’s leading engineering and manufacturing magazine

SAVE 1,500

$

HG-1040B (S929)

3100mm x 4mm

$

HYDRAULIC PRESS

• Ezy-Set NC-89 Go-To controller “X” & “Y” Axis • Segmented 86° offset • Hydraulic / Mechanicaltop punch ram, synchronised • Solid one piece positive stop design four way multi vee • Quick action top ("v") die block tool holder with wedge type adjustment • Fitted with Omron safety light curtains

SAVE 1,450

17,500

12,500 (P173)

PM-35T PUNCHING

• 2.2kW / 3hp, 415V, capacity • 110 x 110mm cutting • Self centring vice • 500mm length stop& 90º • Swivel head at 45º switch • Deadman trigger • Includes: stand, blade, coolant system, length stop & material support

• 2 rolls rolls & shafts • Hardened & ground frame • Steel fabricated • 80 x 15mm flat bar capacity • 50 x 10mm flat bar on edge capacity • 30 x 30mm solid square bar • 35 x 35 x 5mm angle capacity

$

SECTORS

HYDRAULIC NC GUILLOTINES

• Ezy-Set NC-89 Go-To back gauge • Rapid blade gap with fine adjustment adjustment • Individual • Swing away back gauge for long sheets hydraulic hold downs • 4 edge 9Crsi • Shadow line lighting blade for stainless steel • Stroke counter & short stroke adjustment • 250mm throat shearing longer material • Three photo electric rear guarding

steel

$

2500 x 4mm

$

$

7,950 (P170)

MC-370F INDUSTRIAL COLD SAW 22/44rpm

• 2hp 240V or • 315mm blade • 100mm round capacity system • Dual material clamp construction • Rugged cast iron pump • Built in blade coolant • Lock at any angle between -45° or +45° coolant • Includes: stand, pump & HSS blade

$250 (S820)

PIPE PK-40 SECTION & MACHINE capable ROLLING are powered & pre-bend

14,500

websiteLaunch

700 (T739)

SAWS CS-315 COLD 415V

OPTIONAL STAND

90 x 50mm Rect. $ (S816)

SAVE 1,000

$

HG-840B (S927)

2500mm x 4mm

$

fabricated

clamping notcher

PB-830A (S584A)

SAVE 1,450

$

New $

$

330 (S010)

CS-275 COLD SAW

• Heavy duty steel

• Five stations, including • Punch capacity ø28 x 15mm • Flat bar shearing 350 x 15mm • Angle shearing 100 x 100 x 13mm

PB-820Y (S583A)

NEWASE

364kg

RELE

$

lever

5_DEMM_010511

• Dimensions (LxWxH) 1955 x 610 x 1830 shelf • 364kg capacity per • Silver corrosive resistant powder coated finish

NEWASE

bending with manual material clamp • Heavy duty

steel fabricated construction • Easy to use single • Single angle programmable construction & SHEAR angle controller incorporating programmable IW-60H PUNCH controller incorporating digital readout 0-130º & SHEAR • Rapid radius adjustmentdigital readout 0-130º • 60T punch pressure • SafetyPUNCH IW-45MQ top beam support Hydraulic stop • 7.5HP 415V •motor pressure

SET TOOL BOX 36", 48"

INDUSTRIAL STEEL SHELVING

& MANUFACTURING

GST

guarding with 3 beams • Plate support tables with transfer balls • Equipped with shadow line lighting-alignment • Blades made device from 9CrSi material suitable for cutting stainless

√ Cold Saws √ Folders HG-440B (S924) √ Threading Machines √ Grinders 1300mm x 4mm √ Measuring SAVE √ Engine Stands HG-840B (S926) $ Tooling √ Vices $ 500 2500mm x 4mm√ Linishers SAVE √ Rolls 11,450 √√ Accessories √ Motorcycle Lifter $ √ Band Saws $ 1,000 Cabinets √ Presses 13,500 √ Tool Boxes √ Sand Blast HYDRAULIC Panbrakes √ Wood Working √ NC PANBRAKES 5.5hp 415V motor √ Workshop •Equipment √ Parts Washers • Hydraulic

√ Swage & Jennys √ Pressbrakes √ Mills √ Pipe Notchers √ Lockseamers √ Drills √ Bar Benders √ Punch & Shears √ Lathes √ Welders Rolls √ Guillotines √ Ring

TO THE ENGINEERING

AUDITED CIRCULATION

• Motorised back INCL gauge 2011 $6 design with DRO May • Photo electric counter rear

AND POP ULA R BY DEM

C AU

mb er

20 11

DITED

$6 INC

CIRCU

LATION

L GST

TO TH

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Co

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ntac t Ener ❏ Food and Proces sing gy unde

rgro

technology ’s ne w 20 un 0M

ak

update

d ga W pe s❏ stoCAD/CA aker rage M/CNC facili plant ❏ Heat Treatment case ty.

❏ Maintenance Matters

Monitoring grease

www. demm .co.nz

study

including: condition

Oil & Ga Weldi s Indust ry up ng & date Fum Spec e Ex ia Maint list Pumps traction enan ce M & Valves atters www & Indu .d em strial

Title: _______________________________________________________

Company: _____________________________________________________________________________________________________________________ m .c o.

nz

Clea

ning

Address: ______________________________________________________________________________________________________________________ Phone: (

)____________________________ No. of employees:____________

Email: _______________________________________________________

Post your subscription to: DEMM engineering & manufacturing magazine, Freepost 4359, PO Box 65-092, Mairangi Bay, Auckland 0754.

I enclose my cheque/credit card details for $59.00 (incl. GST).

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51

• EVENTS

Coming events CIVENEX 2012

16-17 May 2012 Western Sydney Dragway at Eastern Creek, Australia This exhibition for civil works, construction, infrastructure and open space management features innovations in engineering, construction, excavation, paving, pipes, landscaping, arbor, environmental, water, sewer, trucks, sweepers, waste, roads and traffic, power equipment, signs and much more. www.civenex.com

EEA Conference 2012

20-22 June 2012 SkyCity Convention Centre in Auckland The Electricity Engineers’ Association Conference and Trade Exhibition is the premier power engineering event for the New Zealand electricity supply industry.

The aim of the conference is to provide a national forum for engineering practitioners and technical experts to examine and discuss industry issues, developments and technologies in the field of power engineering. www.confer.co.nz/eea/index.htm

Best Practice in Industrial Compressed Air Systems

06 July 2012 University of Waikato, School of Engineering, Hamilton Attendees will be able to leave with a basic capability to identify system efficiency opportunities and work confidently with skilled service providers to realise the energy efficiency opportunities available.

Contact: jamesn@waikato.ac.nz, www.energyefficiencynz.com

New Zealand Oil & Gas Exhibition 2012

08-09 August 2012 TSB Stadium, New Plymouth The event will see the oil and gas industry’s best come together for two days of information, networking and education on New Zealand’s unique and quickly expanding oil and gas industry. www.nzoilandgasexpo.co.nz

Foodtech Packtech

25 to 27 September 2012 ASB Showgrounds in Auckland This biennial event gives you the opportunity to come face-to-face with the experts behind the key innovations entering the New Zealand market. Foodtech Packtech will showcase the freshest ideas, latest technologies and the newest developments entering the food technology and packaging technology market. www.foodtechpacktech.co.nz/

Safety 2012 World Conference

01-04 October 2012 Wellington Safety 2012 is the 11th World Conference on Injury Prevention and Safety Promotion. The conference is held biennially under the auspices of the World Health Organisation. It brings together the world’s leading injury prevention and safety researchers, practitioners and advocates, to build our knowledge and strengthen the fields of injury prevention and safety promotion worldwide. www.conference.co.nz/worldsafety2012

54th ECANZ National Conference

11-14 October 2012 Quality Hotel Plymouth International, New Plymouth The Electrical Contractors Association of New Zealand (ECANZ) Conference 2012 will provide a focus on what is required to energize and support the needs of business. The conference is a yearly meeting where ECANZ members and their partners learn from each other and invited speakers. It is an opportunity for all delegates to network and socialise with colleagues.

Contact: dave@eventuate.co.nz, www.cvent.com

2012 IEEE International Conference on Power System Technology (POWERCON 2012) 30 October-02 November 2012 Auckland The theme of this conference is “Towards Smarter Resilient and Economic Power Systems”. This is topical in the context of emerging trends of Smart Grids; resilience of electricity infrastructure to recent earthquakes, floods, nuclear-meltdown in the Asia-Pacific region; and, trends towards Emission Trading Scheme and increased participation of private capital markets into electricity generation. www.PowerCon2012.com

National Maintenance Engineering Conference 2012

07-08 November 2012 Novotel Rotorua Lakeside The National Maintenance Engineering Conference is preceded by a Trade Expo representing: engineering supplies, careers and employment, hydraulics, pneumatics, bearings, software, preventative maintenance, condition monitoring, electric motors. www.mesnz.org.nz/nmec

Read an article in this magazine and want to know more?

It's simple, fill out the form and fax it in to 09 478 4779 or mail it to: DEMM Engineering & Manufacturing reader enquiry, Freepost 4359, PO Box 65 092 Mairangi Bay, Auckland 0754, or for quicker results go to

www.demm.co.nz/enquiry or email frank@adrenalin.co.nz Reader reply form Reader enquiry number:________________________________________________________ Name:_____________________________________________________________________ Your business name:__________________________________________________________ Position:___________________________________________________________________ Phone numbers:______________________________________________________________ Email:_____________________________________________________________________ Postal ______________________________________________________________________ _______________________________________________________________________

52

May 2012

LOOKING FOR NEW BUSINESS AND SALES ENQUIRIES? Contact Frank Atkinson Email / frank@adrenalin.co.nz DDI / (09) 477 0362

ROTORUA 7-8 NOVEMBER g The forum-based open networkin ineers. conference for maintenance eng

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ENGINEERING SOLUTIONS TM-2680G CENTRE LATHE MADE IN TAIWAN

• 660 x 2000mm capacity • 2 Axis digital readout system • 115mm spindle bore with D1-11 camlock • 4-position knock out feed system • Rapid traverse buttons on saddle • 400mm wide induction hardened bed • 11.25kW / 15hp 415V main motor • Includes: 3 & 4 jaw chucks, faceplate & steadies

SPECIAL PRICE

$

E V A S 50 $ 1,4

(L639D)

34,500

HG-3204 HYDRAULIC NC GUILLOTINE

PB-63A HYDRAULIC PRESSBRAKE

• 3200 x 4mm capacity • Ezy-Set NC-89 Go-To back gauge • 250mm throat • Rapid blade gap adjustment • Individual hydraulic hold downs • Shadow line lighting • 4 edge 9Crsi blade for stainless steel • Stroke counter & short stroke adjustment • Three photo electric rear guarding • 5.5kW / 7.5hp 415V main motor

• 63 tonne x 3200mm capacity • ESTUN-E-10 2 Axis digital controller • 35˚ segmented top tool punch • Segmented four way multi vee die block with rail • Quick action intermediate top tool clamp • Powered operated leadscrew backgauge • Wedge type adjustable top tool crowning • Includes light curtains

23,950

33,000

$

$ (S935)

(S972G)

E V A S 950 $ 6, PACKAGE DEAL $ (S935 + S972G)

50,000

√ Mills √ Drills √ Lathes √ Guillotines √ Pressbrakes

√ Lockseamers √ Punch & Shears √ Ring Rolls √ Swage & Jennys √ Pipe Notchers

√ Bar Benders √ Welders √ Vices √ Band Saws √ Wood Working

√ Parts Washers √ Engine Stands √ Motorcycle Lifter √ Sand Blast Cabinets √ Workshop Equipment √ Threading Machines

√ Tooling √ Accessories √ Panbrakes √ Folders √ Measuring √ Rolls

√ Presses √ Cold Saws √ Grinders √ Linishers √ Tool Boxes

See us at stand 4017

(09) 2717 234

Unit D/38 Highbrook Dr, East Tamaki 54

May 2012

www.machineryhouse.co.nz

5_DEMM_010512

Specifications & Prices are subject to change without notification. All prices exlude G.S.T. Valid until 31-05-12