Demm February 2012

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

Temperature and vibration send maintenance signals ❏ Quarrying & Mining update ❏ Motors, VFDs & Transmissions ❏ Handling Air Efficiently ❏ Power Factor Correction

> Now including

www.demm.co.nz

1

Take a vibration expert along

SLIGHT

MODERATE

SERIOUS

EXTREME

Fluke 810 Vibration Tester

The simple way to identify machine problems Finally, an easy way to check the health of your machines and get instant answers. With the Fluke 810 Vibration Tester you can assess the level of mechanical wear in motors, water pumps, compressors and the like without the need for historical data. The Fluke 810 simply displays the severity of the condition so you can decide if action is needed.

The Fluke 810 is the most advanced troubleshooting tool for mechanical maintenance teams.

See it for yourself at: www.fluke.com.au Contact Fluke and quote ref#: 810FLK for your FREE demonstration today: 2

P: +61 2 8850 3333 e: sales@fluke.com.au

February 2012

Fluke. Keeping your world up and running.速

> CONTENTS

Editor's

14

20

22

26

note

Warming up to energy efficiency New Zealand houses are strange, leaky and bitterly cold. I read this tongue-in-cheek comment by Nigel Isaacs, Principal Scientist at BRANZ, in some old press release. Well‌I have to agree. My last home in Germany pampered me with features such as solid brick walls, cutting-edge insulation, double glazing, and under-floor heating. Every room was cosy and warm, with cold feet, runny nose and sore throat being the rare exception rather than the rule. In New Zealand, poor insulation, inadequate heating systems and damp homes not only cause many Kiwis (and immigrants) to freeze, but also account for respiratory illness, especially amongst children, and entail avoidable costs for sick days off and healthcare.

But this is not a health magazine, so let’s focus on another characteristic of NZ homes and commercial buildings: they are not very energy efficient.

The KEMA NZ Electric Energy Efficiency Potential Study (2007) found that annual electricity consumption in commercial buildings is 8,135 GWh (worth around $1.25 billion) and that annual economic electricity savings potential by 2016 is 1,849 GWh (around $280 million).

Almost 90 percent of the savings potential is supposed to be in lighting, HVAC and refrigeration. The case study on page 28 provides an impressive example of how this huge savings potential might be tapped. By swapping the existing centrifugal belt driven fan of the air handling unit for an EC plug fan, it was possible to increase the supply air flow and the cooling capacity in an Adelaide-based office building by 10 and 20 percent respectively while cutting the amount of fan energy used in half. After all, saving money and having warm feet must not necessarily be a contradiction.

Stefan Richter

Product Watch

A roundup of technologies and services designed to increase the productivity, efficiency and safety of the engineering and manufacturing sector.

Quarrying & Mining

Read about the benefits of peristaltic pump technology and its application in the mining industry.

Motors, VFDs & Transmissions

A quick roundup of new technologies, including a new range of variable speed drives for HVAC applications.

Calibration

Discover how you can make sure your thermal imaging camera operates reliably and accurately.

Air Handling

It is possible to handle air more efficiently. Read this feature to learn more about the savings potential in HVAC applications and ways to tap it.

Maintenance Matters

This feature includes the benefits of renting test and measurement equipment and how to diagnose your machine by monitoring temperature and vibration.

Electrical Technology

Kevin Kevany takes a closer look at power factor correction and what you get with (and without) it.

Coming Events

Stefan@adrenalin.co.nz SubScriptionS: An 11-issue annual subscription in New Zealand is $59.00 (incl GST). Please call us for overseas rates. 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: Hartman Reid, Email: hartman@adrenalin.co.nz circulAtion MAnAGer: Kim McIntosh, Email: kim@adrenalin.co.nz

SubScriptionS: Hilary Keen, Email: subs@adrenalin.co.nz proof reAdinG: George Ward

AdrenAlin publiSHinG ltd.

14c Vega Place, Mairangi Bay. P.O. Box 65 092 Mairangi Bay, Auckland, 0754. pHone: 64-9-478 4771 fAcSiMile: 64-9-478 4779 printinG: GEON ISSN 1172-4536 circulAtion: 10,287

Supported by:

1

> PRODUCT WATCH

Liquid cooling package for industrial applications Edit o choi r's ce Due to increasing packing density, heat loss in enclosures is rising significantly, and higher cooling outputs are required.

One example that illustrates this is the significant growth recorded in cooling systems of 5kW or more in the period from 2006 to 2010. Since water has noticeably better thermal conductivity than air and allows more efficient cooling in a smaller space, air/ water heat exchangers have also been successful in mechanical and plant engineering. The Rittal LCP (Liquid Cooling Package) technology, which has been tried and tested for years, is now also available for use in mechanical

and plant engineering for the first time. Due to a complete separation of the water circuit and electronic components in the enclosure, the air/water heat exchanger gives maximum protection against water.

The Rittal TS 8 enclosure serves as the basis for the LCP Industry.

Thus subsequent integration into existing system environments is also possible at any time. In contrast to the IT variant, in which the 482.6 mm (19") level is cooled laterally at a constant 22 degrees Celsius, air routing in the industrial LCP is adapted to the requirements of enclosure climate control. Since the cold air has to be routed to the bottom of the enclosure, right in front of the mounting plate, the warm air is taken in from the top and blown out cold at the bottom.

In the enclosure, a typical control temperature of 35 degrees Celsius must be maintained. Two high-power blowers provide for

very good air circulation. Both air intake as well as cold air exit is possible on both sides. The bayable air/water heat exchanger can be flexibly mounted in the middle between two enclosures or at the outer end of an enclosure suite. The option of mounting the water connection above or below and the variable air routing provide room for individual adaptations. The fact

that the essential components are easily accessible facilitates replacement when service is needed. The TS 8 TopTherm Chiller combined with the product solutions for door, base and roof heat exchangers offers customers an integrated complete solution based on water-cooled systems.

Go to www.demm.co.nz/ enquiry quote: D120202

•

New extraction methods

Egmont extraction bench, smoke injected from left side

2

February 2012

Egmont Air have released a series of new ‘extraction benches’ which provide a unique method of extracting and collecting dusts and/ or smokes while protecting the operator. The Egmont extraction bench provides a sturdy work surface perfect for grinding, mixing, polishing and welding processes that generate a combination of dust, smoke or fumes. Effectively the bench provides four separate functions: sturdy work-top surface, down-draft suction to extract harmful pollutants, protection

of employees and filtration and fan system to purify and discharge clean air. The bench has a steel louvered top (which can be quickly removed) to allow an airflow down through the bench, capturing toxic pollutants before they reach the operator's breathing zone or spread throughout the workspace. The dust components drop out in a removable tray and the lighter dust and smoke particles pass through the high-efficiency cartridge filtration. The fan is mounted on the clean side of the filters

> PRODUCT WATCH

(free from abrasive wear) and clean air is discharged back into the workshop area. The discharge can also be ducted to the atmosphere which provides an added ‘ventilation’ air-exchange factor for the general grinding area. The room requires a free-air supply path for this to occur.

Cartridge filtration is the leading filtering technology and has a much higher filtration efficiency compared to traditional bag, sleeve or pocket-filter systems. This guarantees complete capture of micron particles associated with any smoke, fume, grit and other abrasive dusts and provides discharge of purified air back into the workplace (or atmosphere) to comply with stringent clean-air discharge regulations.

Egmont Air, specialists in dust and fume extraction, offer a free on-site evaluation to assess your particular workshop and provide a solution for any dust or fume issue in manufacturing applications. Health and safety is critical where industrial processes expose employees’ to dust, powders, smoke or fumes and it is important that the correct airflows and capture designs are specified. In this way the toxic or nuisance pollutants are removed before entering the employees breathing zone and spreading throughout the working environment. Egmont Air also specialise in wood dust and shaving extraction systems for sawmills, joinery shops, kitchen-makers, boatbuilders and associated woodworking trades. Many bag-house filters and fans are available ex-stock and can be specified for large or small applications. With a range of dust and fume extraction and filtration equipment, Egmont Air have solutions for all applications covering the mechanical, chemical, plastic and printing industries.

Go to www.demm.co.nz/ enquiry quote: D120203

Extraction turned off

•

3

> PRODUCT WATCH

Boost for heavy-duty battery charger line-up With the addition of six new models, Projecta now offers one of New Zealand’s most comprehensive range of robust heavy-duty battery chargers to suit workshops from the small suburban garage to the heaviest industrial equipment service workshop. The range includes four bench-top models and four trolley models. All eight chargers are constructed with high quality pressed metal outer casings for superior strength and durability and all utilise ultra-reliable heavy-duty transformer technology to facilitate high current engine start. The entry level chargers start with

two basic models for general workshop use, offering simple, low-high adjustable output for 12-volt and 12-and-24-volt manual charging respectively.

Using the engine start facility in the chargers, vehicles can be started after a controlled five-minute charge.

The next two bench models include two-stage automatic and manual multi-voltage 6/12/24V chargers with 12A and 21A options. These are designed for demanding environments and are ideally suited to mechanical and auto electrical workshops, with the 21A version delivering an abundance of power for heavyThe Workshop 7000 is one member of the enlarged range of Projecta heavy-duty battery chargers.

The Hygienic Belt Drive for Food Conveyors Fisher Food Grade Motorised Drums are the hygienic alternative to gear motor drives for the food industry • IP66 PROTECTION • ALL DRIVE COMPONENTS ENCLOSED • IDEAL FOR FOOD GRADE INSTALLATIONS

STRONG • RELIABLE • COMPACT • EFFICIENT EASY TO CLEAN Standard sizes (mm): 110, 135, 160, 216, 270 diameter DRIVE YOUR DOLLAR FURTHER WITH THE SUPERIOR INTEGRATED CONVEYOR DRIVE.

RR Fisher & Co Ltd PO Box 23293 Auckland

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

4

February 2012

duty transport and agricultural vehicle applications. These chargers are fully featured with 0-14 hour timer, engine start function and LED displays with volt and amp readings for accurate charge status.

The Projecta trolley models represent a further step up in serious charging with a 12/24V 3-stage intelligent 30A automatic and manual charger with digital controls and adjustable output. This model also features a precise dial for accurate charge status from 1-to-30A for small-tolarge starting and deep cycle batteries. A powerful 12/24V 70A manual charger, the HDBC90, is also available in a similar trolley housing.

This unit produces the most amount of charging power available from a single phase power point. Both the 30A and 70A models are equipped

with engine start.

For large vehicles such as earth moving machinery, heavy trucks, coaches, large tractors, bulldozers, mining dump trucks and forestry equipment, two powerful 3-phase manual chargers are now available in 12V 160A/24V 185A and 12V 270A/24V 440A options.

The latter being the ultimate charger for any site servicing the heaviest of industrial equipment, as it is the most powerful charger in the Projecta range at 1,000A in engine start. Both these heavyduty chargers include easily navigable controls; multiple charge settings; engine start with remote leads, yet they are easily manoeuvrable within the tight constraints of a busy workshop environment.

Go to www.demm.co.nz/ enquiry quote: D120204

•

> PRODUCT WATCH

Designed to withstand demading operations Aurora Process Equipment specialises in bulk materials handling and conveyor products. The range of equipment includes conveyors, silos, material mixers/blenders, bagging scales, bag presenters, sewing and sealing systems, conditioning conveyors, accumulation systems and bag palletisers. The company offer manual, semi-automated, and fully automated handling and bagging lines to suit varied production facilities. Each component has been designed to withstand years of demanding, repetitive operations, reliably and cost effectively, from one of the leading suppliers of handling, filling and closing equipment. Aurora Process Equipment has for many years provided superior machinery for the bagging industry which they are able to combine with modular type equipment for bagging plants large and small.

Systems can be added to over

time as production requirements increase or change and custom applications are competently addressed.

The Galaxy range of conveyors includes powered rollers, belts, troughs, vacuum, or plain level and gravity frames, just to name a few available features. The Floveyors, Galaxy elevators and screw conveyors or TR troughed belts are ideal for loading the Smart Silo range of bagging hoppers, coupled with intake and discharge options. The Flexflo coreless augers allow for simple product transfer, Fischbein bag closing equipment for bag sealing or stitching, and the Magnattack range of magnetic separators help keep contaminants out of the customer’s quality products. Fischbein palletisers and wrappers add to the range to complete a packaging line.

Simple yet durable design incorporating rugged con-

struction to withstand years of industrial use, and basic mechanicals for ease of maintenance has seen our equipment favoured in almost every application, says the company.

Full stainless steel systems are suited to food grade wash down situations, meeting IP

requirements and hygienic standards, if necessary.

Go to www.demm.co.nz/ enquiry quote: D120205

•

AADEMM20110211

we dig the way you do things...

Lift, Transfer, Bag, Aurora make us part of your process www.aurora-nz.com

0800 55 77 33

GALAXY Bucket Elevators, Troughed Belt Conveyors

FLOVEYOR Aero Mechanical Conveyors

TAYLOR Bagging Systems

SMART SILOS Storage & Bulk Product Handling

sales@aurora-nz.com

5

> PRODUCT WATCH

Combined oil moisture and temperature sensor Water is generally not wanted in hydraulic liquids and lubricants. High concentrations can seriously damage machines, disturb the production process or cause standstills. This would result in significant costs.

The combined oil moisture and temperature sensor from ifm electronic ensures reliable protection against such damage and interference. This new sensor measures the relative humidity in oil in the range of 0-100 percent by means of a capacitive measuring element.

Besides the relative humid-

ity the unit also provides the medium temperature in the range of -20 to 100°C. For this, two analogue outputs 4-20mA are available. Another feature is the large input voltage range of 9-33VDC. For flexible and direct installation the sensor is equipped with a G ¾ process connection. Safety and machine efficiency become more and more important and are the goals of condition monitoring systems (CMS) and real time maintenance. This offers the possibility to optimise production and reduce high costs.

Thanks to its continuous and precise condition monitoring, the combined oil moisture and temperature sensor effectively helps to prevent damage and

additionally increases machine efficiency. Go to www.demm. co.nz/enquiry quote: D120206

•

Christchurch company develops unique earthquake pipe-coupling solution As major repair work continues to underground piping networks damaged by Canterbury’s earthquakes, Christchurchbased company FrankPKS has developed a “New Zealand first” producing an earthquake expansion coupling for large, high density polyethylene (HDPE) pipes. The company produces large-bore HDPE pipes from its manufacturing facility in Bromley and has been extensively involved in supplying HDPE pipe solutions to major contractors for the repair of the city’s earthquake damaged wastewater and sewer system. “The value of flexible HDPE pipes has been repeatedly proven throughout this year’s devastating events in both Canterbury and Japan, with

6

no significant damage occurring to the piping itself,” said general manager Bryan Wilson.

“However, the ongoing series of aftershocks in Canterbury, particularly during repair work, has highlighted potential weaknesses at the point where PE pipes are connected to static objects such as building foundations, sump walls and existing concrete sewer systems,” he said. The company has developed a new earthquake expansion coupling with welded “break points” which will withstand small to medium-sized earthquakes but which are designed to shear apart under larger earthquake pressure. This allows the pipe inside to move freely, sliding backwards and forwards through the coupling

February 2012

FrankPKS New Zealand general manager Bryan Wilson demonstrates an HDPE Earthquake Expansion Coupling

instead of damaging the static structure that the pipe and collar are attached to. “The Canterbury earthquake has thrown up some unique challenges due to the multi-directional movement and the huge variation in the amount of lateral spread occurring in surrounding soils,” said Mr Wilson.

“Once Geotech engineers have

determined the expected spread we can individually custom-build each expansion coupling to compensate for that movement.

This will give much greater flexibility and confidence in the long term viability of any repair work undertaken.”

Go to www.demm.co.nz/ enquiry quote: D120206a

•

> PRODUCT WATCH

New range of IR windows for infrared inspections Flir has lifted the cover on its new range of Flir IR windows which it says is a safer and more efficient way of carrying out electrical infrared inspections.

According to the company, 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 the user can put the added safety of new Flir IR windows between themselves and energised equipment and eliminate the need for opening enclosures. The IR windows are compatible with all thermal cameras and enables the user to work faster with greater

confidence, perform inspections more efficiently, reduce the threat of arc flash injury and stay within compliance regulations. All Flir IR windows feature a secure, permanently-hinged cover that opens easily with one hand, which means there’s nothing to remove, drop or lose. The 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. The IR windows install quickly and securely using the same design as common conduit connections.

Go to www.demm.co.nz/ enquiry quote: D120207

•

BUILD IT Exactingly right – Every time –

• 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

7

> PRODUCT WATCH

Unified motion and automation for next-generation machines The NJ machine automation controller from Omron seamlessly integrates motion control, automation, vision inspection and communications. The company says that its unique architecture offers performance and reliability advantages over current controllers. Based on Intel Multicore Processing Unit technology and QNX OS, it achieves highperformance and industrial reliability. Performance surpasses PLC-based motion-automation, matching Industrial PC (IPC) levels. The minimum motionautomation cycle is 500µs.

Using QNX, NJ’s reliability betters Omron’s trusted CJ PLC benchmark, greatly surpassing

8

reliability of IPCs which mostly run variants of Microsoft Windows OS (company information).

NJ also boots in eight seconds, versus Windows times. Advanced motion and synchnonisation of servos is possible, via the EtherCAT machine network and distributed clocks. EtherCAT refresh is 100µs with less than 1µs jitter. Topologies are flexible, suiting remote I/O like Omron’s GRT1 I/O slices. Motion functions include linear and circular interpolation, electronic gearing and CAMS, and virtual axes.

Automation is equally impressive, supporting maximum 2560 rack I/O (40 CJ1W series I/O units).

USB, EtherCAT and Ethernet/

February 2012

IP ports are built-in, plus CJ1W communications unit support. NJ creates opportunities for machine builders. Its programming software, Sysmac Studio, cuts development costs. The solution features IEC61131-3 compliance, PLCopen motion function

blocks, automation and 3D motion simulation, CAM editor, user-defined function blocks, and more. Advanced solutions are made quicker and easier.

Go to www.demm.co.nz/enquiry quote: D120208

•

> PRODUCT WATCH

Weather-resistant panel PCs for extreme temperatures Phoenix Contact has expanded its range of VMT 3000 panel PCs to include a device with a 10.4" high-resolution display with IP65 protection. This display was specifically developed for use under harsh industrial conditions and has a resolution of 1024 x 768 pixels. These panel PCs are distinguished by an attractive enclosure manufactured out of solid die cast aluminium. As a result of the dust-protected and waterproof enclosure with IP65 protection, these panels are weather-resistant and are insensitive to humidity and moisture. Further, these devices can be used in extreme temperatures ranging from -20°C up to +55°C, which allows them

to be employed outdoors and in refrigeration systems. They can be optionally equipped with a sunlight readable display which allows them to be used even in direct sunlight.

The panels are especially energy-efficient thanks to their Intel-Atom platform, a combination of a highly integrated chipset and a power-saving processor. The Atom processor can either be clocked at 1.1GHz or 1.6GHz, and has a thermal design power (TDP) of 2.5W. The lower power consumption is also noticeable in the lower amount of heat generated. The device does not require a fan.

This means that users get a fully-fledged industrial PC

equipped with an industrialgrade touch screen and all of the relevant interfaces. It can be used for years as an energy-efficient operating console for machinerelated use or outdoors.

•

Go to www.demm.co.nz/ enquiry quote: D120209

Rapid Acting Doors High Performance Doors from Italy!

What makes Ditec doors so attractive…

NZ assembled – short lead times, minimal freight costs Low maintenance, cost effective design Competitively priced with models to suit all applications High quality European engineering Doors for: Process Rooms, Airlocks, Freezers, Loading Docks and Truck Bays

For nationwide service:

unli Two ye m a war ited cy r ran cle ty

Call free: 0800 267 888 9

> PRODUCT WATCH

Mobile cassette filter offers cost effective solution New Zealand Duct & Flex have just launched a new mobile cassette filter unit aptly named the ‘Fume Cube’ which is an ideal solution for smaller work shops or schools where continuous filtration is not required.

Many smaller workshops do not need (and would struggle to finance) a complete filtration system operating continuously, leaving workers needlessly exposed to welding fumes, grinding or polishing dusts.

As the most effective way to deal with dry impurities is to remove them as they are generated, the mobile cassette filter unit includes a 160mm self-supporting fume arm, filter and fan producing 1000m³ per hour at the hood. Fume arms from New Zealand Duct & Flex use

external joints for smoother air flow, minimal build up and lower static pressure. The European manufactured units are simply plugged into a 3 phase outlet with the fitted 16Amp plug, are easy to manoeuvre with large caster wheels (2 lockable).

The two filters, an aluminium mesh pre-filter and main cassette filter, both pull out for easy access and inspection. These products are a cost effective solution to improve the workshop environment and safeguard employee’s health.

Go to www.demm.co.nz/enquiry quote: D120210

•

Meet all your needs with one cost-effective controller.

When you need a flexible, scaleable, integrated control and motion solution Logix is the answer. From simple to complex machinery CompactLogix™ is Integrated Architecture in its simplest form helping reduce the volume of hardware Experience your future today, visit www.RockwellAutomation.com/ think/yourfuture

10

February 2012

you need, making it quicker for you to meet your customers’ requirements. www.RockwellAutomation.co.nz

> PRODUCT WATCH

Contributor to the boiler industry Due to the disruption caused by New Zealand’s temporary gas shortage, companies are now looking at their contingency plan for future situations. Advance Boiler Services (NZ) Ltd are major contributors to the boiler industry and suppliers of Oilon burners from Finland – recognised as one of the market leaders in design and manufacture.

ABS supplies single fuel burners and dual fuel burners providing a backup fuel source option. This allows a company to maintain productivity and a competitive edge over others when services are disrupted. The company installs boilers and carries out boiler conversions, as well as supplying boiler spares for companies throughout New Zealand, Australia and Fiji. They offer annual boiler surveys, quarterlies and maintenance. ABS pride themselves on being one of very few companies in New Zealand who are ISO 9001 certified and also do inspections of unattended and limited-attended boilers.

The company are also agents for Mechmar boilers and can supply up to 15MW-sized boilers ranging in fuel types from oil, gas, coal and wood waste. With a growing concern for energy efficiency in New Zealand, ABS have developed products with others to improve cost efficiency with updated control panels on boilers with electronic air fuel ratio control systems. They also manufacture fintube and fintube heat exchangers which are used for improving efficiency of boilers. These exchangers can also be used for heating/cooling purposes. Go to www.demm. co.nz/enquiry quote: D120211

•

Advance Boiler Services (NZ) Ltd Advance Boiler Services (NZ) Ltd are suppliers of Oilon Burners manufactured in Finland to the highest standards. These burners are reliable and of high quality for total peace of mind in critical industries.

To prevent outages in your industry the use of Oilon dual fuel burners could be the difference between your plant shutting down and maintaining profits.

For further efficiency we can also install a New Zealand designed electronic air/fuel control system for increased accuracy and savings in fuel cost.

Reliability from experience of several decades Oilon burners can burn all usual mineral oils and usual types of gas. Capacity range 45 kW – 22.500 kW. For solutions to your future contingency plans regarding quality energy supply call us for advice today.

Advance Boiler Services (NZ) Ltd Phone: 07 847 1821 Fax: 07 847 5222

Advance Boiler Services (NZ) Ltd 101 Duke Street, Hamilton

Burner Sales: kmalpas@absboiler.co.nz Mobile: 027 229 8647

PO Box 15393 Dinsdale, Hamilton

11

> QUARRyINg & MININg

Complex control conversion at zinc smelting operation

Cell house at Hobart site

Nyrstar Hobart, a leading global multi-metals company, has awarded a $2.5 million+ order to Rockwell Automation and its Global Solutions team to replace a distributed control system (DCS) at the company’s zinc smelting operation in Hobart, Tasmania, Australia, with the PlantPAx process automation system.

Nyrstar is an integrated mining and metals business, with market leading positions in zinc and lead, and growing positions in other base and precious metals; essential resources that are fuelling the rapid urbanisation and industrialisation of our changing world. Nyrstar has mining and smelting operations located in Europe, Australia, China, Canada, the United States, Central and Latin America and employs over 6,600 people. Nyrstar is incorporated in Belgium and has its corporate office in Switzerland.

“Our current distributed control system would be cost-prohibitive to upgrade. Hardware was failing and repairs were becoming expensive and requiring longer lead times. The Rockwell Automation solution provides us with better integration between different process areas, improved diagnostics, increasing plant uptime and more accurate plant performance reporting,” said Jeremy Kouw, General Manager, Nyrstar Hobart.

12

According to research performed by the ARC Advisory Group, the global process industry loses approximately $20 billion annually, or about five percent of annual production, due to unscheduled downtime from ageing DCS systems.

Rockwell Automation won the order by developing a three-year phased integration with a backup option that uses custom input/ output cabling to ensure process continuity, coupled with technical support for the existing installation. NHP Electrical, a Rockwell Automation authorised distributor, provided long-term committed support to the project, which also weighed in the favor of Rockwell Automation. “This win represents a milestone for us given the size and complexity of the DCS conversion,” said Terry Gebert, Vice President and General Manager, Rockwell Automation Global Solutions. “We won the order over two major process automation companies, based on the excellent support we provide for the existing operation and a clear vision of control conversion to a long-term sustainable operation. The order includes project management, application engineering, system cutover engineering, hardware and software. Our experience, domain expertise and global resources will help Nyrstar Hobart in this critical conversion from a legacy DCS

February 2012

system.”

Nyrstar Hobart’s Australian facility is one of the world’s largest zinc smelters with a capacity of 280,000 tonnes. It produces zinc and zinc alloys that are exported primarily to Asia. The existing DCS operates process control for roast-leach purification electrolysis, acid plant and water treatment. The order for Rockwell Automation PlantPAx process automation system incorporates 7,000+ distributed input/ output connections in complex DCS conversion.

Rockwell Automation has recently extended the reach of its PlantPAx process automation system to integrate critical rotating assets, such as compressors, pumps, turbines and fans, giving users the ability to manage plant-wide operations with a single platform.

The PlantPAx system combines the company’s core process automation capabilities and technologies with those of partners and acquisitions to deliver an integrated control and information solution for customers.

Users now can tie intelligent motor devices into this unified-control architecture, making an immediate and measurable impact on asset availability, operational efficiency and energy management. The tight integration between process automation and motor control is especially beneficial in heavy industrial applications with considerable

mechanical investments, such as metals, mining, cement, power, oil and gas, water/wastewater, and pulp and paper applications.

PlantPAx system users will have access to diagnostic information on any device in the system from any location – including motor control centers, drives, compressors, pumps, fans and instrumentation.

Leveraging the EtherNet/IP network, engineers can monitor process conditions such as electric motor current, vibration signatures of key rotating assets and torque signatures of variable speed drives.

This allows plant engineers to predict potential problems and help avoid equipment downtime – resulting in improved productivity and reduced maintenance costs.

“To improve plant performance, our customers prevent unplanned shutdowns while protecting expensive machinery,” said Andrew Sia, Process Solutions Manager, Rockwell Automation. “Leveraging a single-network architecture to bring operational information from motor control devices into the control system helps engineers extend the life of their mechanical assets and improve their overall configuration, operation and maintenance experience.”

Unlike other distributed control systems that require users to manually map data from motor control devices to the control system, the PlantPAx system mirrors

> QUARRyINg & MININg the device memory, making data automatically available within the control system. Users can also setup applications in the PlantPAx system to collect and archive performance data from motor control devices into databases for analysis.

This convenient data acquisition provides cost savings throughout the lifecycle of the equipment.

For example, bringing intelligent motor control devices into the PlantPAx system is useful in managing the performance of energy-intensive assets.

Furthermore, since EtherNet/IP is the delivery mechanism for the PlantPAx system, users can avoid electrical hazards by accessing information remotely, helping personnel safely monitor, troubleshoot and diagnose motor control centers and other equipment. This saves time associated with suiting up with personal protective equipment and helps protect personnel from exposure to hazardous conditions.

According to the ARC Advi-

sory Group, “The PlantPAx system helps lead the trend in the convergence of power and process automation systems, which will result in improved productivity and energy efficiency for end users in metals, mining, cement, power, oil and gas, and pulp and paper industries.”

In addition to integrating motor control devices into the control system, other key features with the PlantPAx system include: • EtherNet/IP network support for redundant systems and Device Level Ring network topology that provides a highly available EtherNet/IP network without any additional infrastructure costs.

• Improved device integration and asset management as drives, for example, are now exposed via icons and faceplates in the visualisation layer, and managed in the asset management layer to provide disaster recovery, automatic backup and restore of drive configuration,

The PlantPAx process automation system optimises user uptime and improves profitability by integrating motor control devices into a plant-wide control system.

and change auditing.

• Accelerated design engineering with initial sizing and architecture design, the creation of reusable engineering and template objects, and engineering and deployment tools for

objects and diagnostics in the PlantPAx library.

Go to www.demm.co.nz/ enquiry quote: D120213

•

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

13

> QUARRyINg & MININg

Peristaltic pumping technology in the mining industry the thickener determines the maximum allowable dry solid content – therefore the pump technology is the limiting factor.

Moving ores, concentrates and residues in slurry form are essential parts of industrial mining processes. In an effort to reduce water, energy and chemical consumption, and improve slurry transportation reliability, more and more mining operators are discovering the simplicity and benefits of peristaltic hose pumps.

In a recent paper prepared for the ICMM, the Center for Water in the Minerals Industry (CWiMi) suggested that water access, quality, use and environmental impact directly affect the ability of the industry to operate worldwide. Yet despite these challenges, mine operators face ever-increasing obligations to reduce water consumption and operate within a framework that cuts overall environmental and water footprints. The importance of water cannot be underestimated, and consequently all mines must carefully assess the impact of mining on local and regional water quantity and quality in order to retain a social licence to operate. With this in mind, best practice water management is the new trend that defines credibility for the

14

mining industry while negating the potential impact of additional costs.

Broadly speaking, the extraction of precious metals can be based upon two techniques; leaching or filtration-based methods, although hybrids of both techniques are also used.

The focus on water consumption within filtration-based mining is very strong because high volumes of water are used inherently in the process.

Here, the first stage involves the crushing and grinding of the ore, after which the fine ore is mixed with water at the froth floatation cells in order to extract the mineral. The resulting tail froth will be thickened in a sedimentation tank, where the overflow is water and the underflow contains the concentrated ore or tail. This paste-like substance is called the thickener underflow.

Following the thickener there is usually a filtering stage to dry the sludge for further processing. It is desirable to have a thickener underflow with a high dry solid content: the less water involved, the higher the efficiency of the filter. The pump installed underneath

February 2012

Less water equals fewer costs Among the key drivers for water reduction and greater water re-use in the mining sector are: • Increasing price of water.

• The limited availability of water at mines located in desert areas or at altitude.

The Antofagasta region in Chile is the driest place on earth, and here several mines are located at high altitudes.

• Intake water needs to be conditioned i.e. alum dosing, pH control, etc.

• Effluent water of operation needs to be treated.

• Environmental responsibility. For instance, the Pascau Lama project on the Chilean-Argentinean border was delayed by a decade because of possible environmental impact.

In order to increase production and, at the same time, minimise rising costs, companies need to adopt new approaches, which means optimising their mining procedures. Decreasing the amount of time a mine requires to pump, add or remove water in the course of processes usually translates into reduced operating costs. However, the taut relationship between maintaining a reliable supply of water to support mineral processing, and using as little water as possible in order to have the smallest volume on hand at any time, means that mine water inventories must be managed carefully.

Here pumps have a vital role to play, and peristaltic pumps

specifically can be considered water-saving devices, not simply because they can accommodate very high solids-content materials found commonly in mining operations, but because they do not require seal gland water, thus eliminating the requirements to either treat process wastewater or provide pump service water. Pumps such as these can play a key role in new management trends like water balance modelling.

Benefits of peristaltic pump technology All peristaltic pumps supplied

by Watson-Marlow Pumps Group can be considered as inherent metering pumps offering repeatability of 99.5 percent. Furthermore, many models include integral digital drives with Profibus or SCADA control. Easy system integration with new or existing controls is coupled with operator-friendly use. Often, there is no need for separate VFDs or complex control devices, while a wash-down IP66 corrosion-resistant enclosure suits arduous mining environments. The pursuit of ever more cost-efficient pump technology is of ongoing interest to mine operators. Pumps such as Watson-Marlow’s Bredel SPX series, for instance, accommodate continuous flow rates up to 80m³/h and are extremely durable (pressures up to 16 bar).

There are no internal universal joints, valves, dead corners or glands to impede flow, and they are reversible for back-flushing.

Handling thicker slurry flows Although one main goal of mine operators is to use less

> QUARRyINg & MININg

Limitations of centrifugal and membrane pumps While centrifugal and membrane pumps have traditionally dominated the mining sector, particularly for operations such as thickener underflow applications, they are not without their shortcomings. For instance, the amount of dry solids which can be handled by centrifugals is limited. In several applications,

rotors or impellers on slurry pumps last only weeks and membrane pumps clog, leak or fail due to factors such as strong acidity in a matter of months.

Attempting to overcome these problems, some mine operators previously purchased special pumps constructed from acid-resistant materials rather than put up with frequent, costly pump maintenance or replacement. But this is an extremely expensive alternative. For these reasons, the latest peristaltic (hose) pumps are today taking ever greater slices of market share. Among the many benefits of peristaltic pumps are: • No mechanical seals.

• No requirement for seal gland water.

• No seal water flush systems.

• No moving parts in the product zone.

• Low and easy maintenance – just one wearing part; the hose.

• Almost all materials can be pumped, including slurries.

• Backflow and siphoning are prevented without the need for valves.

• Wear-free performance.

For the mining sector this last point is arguably the most advantageous. Obviously, the longer a pump can operate without maintenance or failure, the better. The wearfree performance of peristaltic pumps is an attribute that results from a unique operating principle. Unlike other pumps, the abrasive nature of the product has no bearing on pump life and the need for routine maintenance and spare parts is reduced greatly.

Go to www.demm.co.nz to read the whole article.

Article by Rick Balek, Sales Manager Industrial & Environmental Divisions, WatsonMarlow Pumps Group.

Go to www.demm.co.nz/enquiry quote: D120215

•

TOTAL SERVICE It’s not just our top quality products but our exceptional service, distribution network, turnaround times and local technical support that makes us stand apart from the other suppliers.

We understand your industry and have an experienced team to advise and assist with your lubricants requirements.

Have a chat to your local distributor about how our products are right for your business.

For details, technical information or to find your local authorised distributor call 0800 868 256 or visit www.totalsolutions.co.nz

ATTN11TOT69

water in the transportation process, doing so creates thicker, more paste-like slurries, which in turn creates other issues.

More product can be transferred at lower velocities, but pump and hoses must be designed to handle thicker flows. Bredel SPX high-pressure hose pumps can handle undiluted tailings and thickener underflow up to 80 percent solids. No seal water flush systems, strainers, dampeners, in-line check valves, run-dry protection devices or other ancillary equipment is needed. The entire family of pumps are self-priming to 9m, can run dry safely and can meter accurately to ±1 percent.

This innovative technology fits with wider current research into more efficient modes of high concentration slurry transport. The ultimate aim is to reduce water use, energy consumption and capital costs, as well as improve slurry transport reliability by establishing a more fundamental understanding of slurry flow behaviour and design.

According to Dr Jie Wu of Australian research organisation, CSIRO, there are errors of up to 600 percent associated with conventional designs of high concentration flows, which can result in pipeline transport failures or the inability to pump the desired quantity of solids.

It is clear that being able to make more accurate predictions will help the industry optimise design and achieve a far better outcome.

15

> QUARRyINg & MININg

Vehicle fire suppression systems

Quarry and mining sites see a vast number of heavy vehicles, plant and equipment being operated every day, loading and unloading goods and transporting materials. These heavy vehicles have significant ignition/heat sources such as energised wiring and turbochargers and with the potential for onboard goods to add to the fuel load, it’s clear that the risk of a fire while in operation can be high. It is therefore essential that vehicles are fitted with a suitable fire suppression solution.

Furthermore, heavy vehicle operators must understand the risks involved in their role and how to ensure their safety should a fire break out in or on the vehicle they are operating.

Fire protection specialist Wormald offers a range of vehicle fire suppression (VFS) systems which are designed to provide vital

risk management for heavy vehicles. The various systems are developed to suppress fires occurring in key risk areas such as the engine and transmission compartments, brakes and hydraulic areas of all kinds of heavy vehicles, plant and equipment. The systems are designed to provide early detection and warning allowing extra time for the driver to safely evacuate, whilst also quickly suppressing the fire to help minimise damage to the vehicle.

Wormald follows a formalised fire risk assessment process, in accordance with Australian Standard, AS 5062-2006: Fire Protection for Mobile & Transportable Equipment, which assists in identifying and determining the level of fire risk in order to offer the most appropriate system for a particular vehicle in its operating environment. Both the Wormald Foam Water Spray Vehicle Fire Suppression (VFS) System and the Ansul A-101 Vehicle Powder System are ActivFire listed to be compliant to AS 5062.

The Foam VFS System features high pressure and small droplet nozzles which target risk areas such as the turbo charger and starter motor in the engine compartment.

The system utilises the fire suppressing and containment features of Aqueous Film Forming Foam (AFFF). In the event of a fire,

a continuous stream of foam water spray is discharged to rapidly suppress flames and dramatically cool hot surfaces. At the same time, the generated foam acts to smother fuel and oil-spill fires, helping to prevent re-ignition.

The Ansul A-101 Vehicle Powder System, which discharges a dry powder known as Foray into the risk area to suppress the fire, is well suited to three dimensional liquid fuel fires. Both the Wormald Foam VFS and the Ansul A-101 systems can be installed with automatic detection and actuation systems, as well as cabin and ground level actuators.

These allow the operator to manually activate the fire suppression system from either the cabin or at ground level if required.

Vehicle operators must also be fully trained on how to manually activate the vehicle fire suppression systems and on how to use any fire protection equipment located in their vehicles, such as portable fire extinguishers.

Wormald offers a range of fire safety training through practical theory, and hands-on learning experience. The company also offers a range of fire safety training programs suitable for the quarrying and mining industries including fire extinguisher training and fire warden training. Go to www.demm.co.nz/ enquiry quote: D120216

•

Belt scale for mobile equipment Accurate weighing and measurement is essential for improving quarry productivity – but quality measurement has not always been readily available for mobile conveyors, according to Soeren Schramm, Product Manager for Loadrite. “Traditionally, belt scales have only been used on fixed, not portable plant equipment, because the shorter length of conveyor belts on portable plants has not been sufficient for accurate results. But being able to accurately weigh materials crossing the conveyors on a mobile crusher, screen or stacker is really important if operators want to get the best results from their business,” Soeren said.

Loadrite’s C-Weigh for mobile equipment is more than a traditional belt scale used in a portable application – it has been developed specifically for the portable equipment environment, with rugged components, flexible frames, easy modular installation and a repeatable accuracy rare in the industry. With a C-Weigh

16

February 2012

belt scale on their mobile equipment, customers can access reliable data on their tonnage crushed per hour, day, week or month, and an overview of the efficiency of their crushing and screening processes.

“The scale frame is very well suited for retrofitting and doesn’t require major structural modifications, and it is tolerant to shock, vibration and extreme temperatures. The design ensures C-Weigh is very cost effective and unobtrusive so retrofitting is very achievable,” Soeren said. A range of reporting options is available to suit the needs and experience of the user. “It starts with the simple digital display that shows tonnes per hours and total tonnes,” Soeren explained. “It is also possible to print out the report using a hardy printer specially designed for the system, or reports can be emailed directly to the user’s inbox. Connection to Loadrite’s MMS allows for basic inventory and stockpile reports or the system can be integrated with third party

software.”

For advanced reporting requirements, the CWeigh can be coupled with Loadrite’s Insight software, a new web-based system that offers the reporting power of very expensive PLC/ SCADA systems at a fraction of the cost. CWeigh uses the same robust, easy-to-learn user interface as Loadrite’s wheel loader scales, works with a range of wireless data communications options including Wi-Fi, radio modems or cellular modems and is able to fit most crushers, screens and stackers.

Loadrite is manufactured in New Zealand, the mobile scale has been installed all around the world, from Australian mines to quarries in Qatar, France, the USA and Canada and offers unparalleled support with more than thirty years of experience backed by Loadrite’s global distributor network. Go to www.demm.co.nz/ enquiry quote: D120216a

•

17

There’s a lot riding on your truck. So we built the new Shogun HD Euro to do the job better than ever. There’s more power and improved economy, coupled with lower emissions and maintenance costs. And with the improved driver environment, you can bet your business it’ll deliver the best productivity available. Call 0800 PAYLOAD or visit www.fuso.co.nz for more.

> MOTORS, VfDs & TRANSMISSIONS

CMg offer a solution to harmonics CMG have the ability to simulate true harmonic conditions and provide accurate distortion figures based upon specific transformer setups and even harmonic levels generated from the use of a generator. Harmonics are multiples of a fundamental frequency. For example, a fundamental frequency of 50Hz yields a 2nd harmonic of 100Hz, 3rd harmonic of 150Hz and so on. All waveforms are composed of harmonics and can be of particular importance in electrical systems where a nonlinear load is generated. Harmonics can be particularly disruptive because they cause disturbances in the electrical supply. A variable speed drive is an example of non-linear load. Other non-linear loads include PC power supplies and compensation capacitors. For 3-phase rectifier loads (such as a standard 6-pulse VSD), there

is current present in 6 x n±1 harmonics ie. 5th, 7th, 11th, 13th, 17th, 19th etc. For 2 x 3 phase rectifier loads (such as a 12-pulse VSD), current is present in the 12 x n±1 harmonics ie. 11th, 13th, 23rd, 25th etc.

These harmonics do not carry any power but do carry current.

This current itself does not affect other equipment but it can create harmonic voltage which can cause: • A risk of overloading conductors • A suffering total power factor • A suffering of correction capacitors • Deterioration of other equipment on the supply • Disturbances in power line communication equipment.

Harmonic currents decrease with the increase in frequency, so in order to eliminate the problems, the focus needs to be

www.cmggroup.co.nz SOLUTIONS, not just products

415V and 690V, IP00 and IP23.

Active filters actively cancel out distortion frequencies and can be specifically tuned for problematic harmonics. Active filters are placed in parallel with the drives, hence it can be used to treat many drives at once without taking the risk of the drive power relying on the filter being operational. Total harmonic current distortion can be reduced to less than 5 percent.

Vacon’s unique Active Front End (AFE) solution minimises harmonics down to 4 percent by tuning o ut specific harmonics.

Coupled with a regenerative filter, the cleanest power can be fed back to the supply in braking situations.

This range includes front end units, inverter units and brake chopper equipment. Power factor correction is also possible here.

Go to www.demm.co.nz/enquiry quote: D120218

•

Call Us on: 0800 676 722

AUCKLAND • ROTORUA • CHRISTCHURCH

CMGNZ_DEMM_1112_02_OUTLINED.indd 1

18

on the lower end of the frequency range. The best way to improve harmonic distortion is by using a choke. Chokes are effective at reducing harmonics to a large degree however cannot eliminate all harmonics. All Vacon drives come equipped with an AC choke for this reason. All standard Vacon NXL, NXS and NXP drives come equipped with a 6-pulse rectifier and “normal” choke.

12-pulse and 18-pulse units are available upon request.

When harmonics reduction provided by an AC choke is not enough, a passive filter can be applied. Passive filters are an important solution because they solve the problem of harmonics on six pulse rectifiers from no load to full load. Total harmonic current distortion can be reduced to 5 percent or 8 percent with a passive filter. These filters are available in

February 2012

18/01/2012 9:13:08 AM

> MOTORS, VfDS & TRANSMISSIONS

Energy efficient variable speed drives for HVAC applications Schneider Electric has just launched the new Altivar 212 range of variable speed drives for HVAC applications in buildings. Altivar 212 builds on the success of its predecessor, the Altivar 21, while remaining 100 percent backwards compatible, effectively increasing the lifecycle of the user’s investment. The VCDs have dedicated functions for HVAC (Heating, Ventilation, Air Conditioning) applications including a PID controller, sleep and wake-up functions, configurable forced fire mode, damper control, skip frequencies, under and overload detection, etc. It also features specific motor control

algorithms to optimise the energy consumption. Typical applications for Altivar 212 include centrifugal pumps and fans in air cooling units, air handling units, rooftop ventilation machines, condensation units, ventilation and air distribution and chilled/hot water pumping units.

With four BMS (Building Management System) protocols built in as standard, Altivar 212 can easily integrate into the building’s BMS, enabling superior control and monitoring. Energy consumption can be optimised with accurate control of the process, while instant fault detection and preventative

maintenance diagnostics can prove invaluable for long-term operation of the system. Builtin protocols include Modbus, BACnet, METASYS N2 and APOGEE FLN P1, while an optional card provides an interface for LonWorks.

While typical drives use AC or DC chokes to reduce harmonic current draw, the Altivar 212 incorporates award-winning reduced harmonics technology to limit THDi to around 30 percent.

No additional chokes are needed to comply with product standards, effectively reducing RMS current draw, installation costs and improving overall efficiency.

The benefits of reduced harmonics technology: • Less THDi than limits requested by IEC/EN610003-12 (<48 percent).

• No additional AC or DC chokes required.

• Reduced footprint size and faster installation.

• Reduced RMS line current, smaller electrical distribution components.

• Less losses the electrical system, improved efficiency.

All Altivar drives sold in New Zealand have an EMC/ RFI filter as standard. With the buildings market generally being classed as 1st environ-

The way to roll

RR Fisher pride themselves on being Australasia’s only manufacturer of motorised drum rollers with over 40 years of experience. Their drums are extensively used in the food and packaging industry where hygiene, reliability and safety are paramount.

The high degree of sealing provides a unit that can be washed down. There are no rotating parts outside the conveyor frame, which makes

the drive more operator-safe.

A range of diameters from 110mm through to 270mm is available with power range from 0.18kW through to 22kW. With all helical and straight cut all steel gears the drive displays superior lifespan when compared to low efficiency worm boxes and imported drums with plastic gears. The entire range of the company’s drums is designed with longevity in mind and the units can be pulled apart for servicing if required.

Stainless steel shafts, zinc plated shells and aluminium end flanges are standard features on all models with all stainless steel units also available. Go to www.demm. co.nz/enquiry quote: D120219

•

HAZARDOUS WASTE Disposal Specialists

CALL US - Nationwide Branch Network

0800 835 645 ADVICE

COLLECTION

DISPOSAL

457899 CMYK Proof version a

19

> MOTORS, VfDS & TRANSMISSIONS

The new Altivar 212 range of variable speed drives is dedicated to HVAC applications in buildings.

ment (residential) according to AS/NZS 61800-3, Altivar 212 includes a class C2/C3 EMC filter as standard. For long motor cable runs, or where even lower levels of EMI are required, an optional class C1 filter is available, either as a footprint mounted device for the IP21 version or included inside the IP55 version. In order to reduce the audible noise emitted from fan motors, Altivar 212 can operate at a switching frequency of up to 12kHz without de-rating.

Altivar 212 can adapt to the installation environment as both IP21 and IP55 versions are available. The sensitive electronic components within the drive are conformal coated to enhance resistance to harsh environments, while the use of high-quality plastic film capacitors leads to extended product life and protects your investment. Operating in ambient temperatures of up to 50°C without de-rating is possible.

While the Altivar 212 includes a built in keypad

20

February 2012

and 4-digit 7-segment LED display, an optional English text graphical keypad makes start up and commissioning a breeze. The user can configure the drive from their PC using PCSoft software, which is freely available to download, while the Multi-Loader tool can be handy to download parameters to multiple drives quickly and efficiently. It is also possible to program the Altivar 212 from a mobile phone using the optional Bluetooth adaptor.

Whatever the fluid (air, water), Altivar 212 makes buildings more comfortable, easier to manage and, at the same time, saves energy.

Compared to traditional flow control devices with fixed speed motors, Altivar 212 could save up to 70 percent of the energy used in pumps and fans. ECO 2 software has been developed to help the user calculate potential energy savings and return on investment, which is usually within 24 months. Go to www.demm. co.nz/enquiry quote: D120220

â&#x20AC;˘

> MOTORS, VfDS & TRANSMISSIONS

gearbox range allowing for easy assembly STM gearboxes, stocked

by Hastings-based power transmission specialists EQM Industrial, are interchangeable with other brands and feature a unique input coupling system that eliminates fretting in the keyway, as well as allowing it to be easily assembled or dismantled. These high-quality gearboxes are designed and manufactured in Italy. They are ideal for any manufacturing engineers with production lines who need something to power them. EQM Industrial provides opportunities for effective operation through products that deliver both reliability and quality. These STM products offer a smarter mechanical advantage.

STM, an Italian company, manufactures the widest range of gearboxes and geared motors. STM provides forefront technical solutions in every field of light and heavy mechanics according to specific user requirements.

Its policy is “high technology for successful products” and EQM Industrial are New Zealand importers of the full range of STM gearboxes. This family-owned business has been servicing New Zealand’s power transmission and conveying needs for over 20 years.

The central location in the city of Hastings enables access to nationwide networking and ensures prompt delivery.

EQM Industrial prides itself on making customer service its number one priority and ensuring the client gets the right product to best suit

their needs. They provide a complete service – from importing, distributing and assembling to manufacturing.

EQM Industrial offers a wide and innovative product line of easy-to-use equipment, new technologies and turnkey easy-to-install packages and systems. All products are guaranteed and the company also provide a technical helpline and parts and service backup. They stock both components and preassembled products. EQM Industrial describe their mission as providing a comprehensive range of new and used equipment and components to a wide range of industry, with a specific focus on the processing, packing, manufacturing and bulk supply sectors. They say they strive to be the leading supplier of power transmission products and electric drive systems to manufacturers and production facilities that make and use effective automated equipment. While their market focus has traditionally been on manufacturing engineers, pack houses and factory facilities, they have branched out to the mining and quarry industries in the last year and a half. Go to www.demm. co.nz/enquiry quote: D120221

•

21

> CALIBRATION

Building trust with your camera

Stefan Richter visited CPS, the first IANZ-accredited laboratory in New Zealand for the calibration of those cameras.

What’s the temperature in this area up there? 50ish? An accuracy like that might work in a kitchen environment, but when it comes to making important and sometimes expensive decisions about investments, maintenance schedules or

shutdowns, you definitely want some more precision than that flowing into your decision making process. Kirsty Russell, CPS Laboratory Manager, recalls what happened when they talked to the attendees of a training course on thermal imaging about the necessity of having their cameras calibrated. “We took one of our IR black body calibrators out to the premises where the course took place so that people could test their cameras and see how much the readout varied from the reference temperature.” The temperature of the black body was set to 50ºC and about eight of the course attendees gave their thermal cameras a shot.

“Everybody was expecting their

Calibration Specialists Electronic Test Equipment Electrical Safety Testers Multi-Meters & Clamp Meters AC Power Meters Function Generators Data Loggers Optical Tachometers Stroboscopes Lux Meters

Pitot Tubes – Type S Medical Air Samplers Medical Test Equipment Thermometers (Digital) Humidity RH Meters Manometers & Barometers Water Flow Meters Anemometers

Email your calibration enquiry to calibration@techrentals.co.nz or Call our Experienced Calibration Experts Mauray or Tony on

0800 832 473 www.techrentals.co.nz 22

February 2012

cameras to read 50ºC, but how big was the surprise when some of the cameras actually measured 50.5 or 51ºC. One of the cameras even displayed more than 51ºC.” CPS is an Onehunga-based supplier of calibration equipment.

In 2011 it celebrated 25 years in business. The laboratory for the calibration of thermal imaging cameras was set up last year. “We got talking to one of the importers for the cameras and they said how they had to go to Australia for a check, and that check wasn’t even traceable,” says Chris Woudenberg, the Managing Director of CPS. “Therefore we decided to do it ourselves.” CPS worked closely together with the Measurement Standards Laboratory of New Zealand (MSL) for a couple of months to iron out and set up a state-of-the-art calibration laboratory and finally gained registration over a year ago. “And to this day we are the only ones in New Zealand and Australia who can offer this kind of service,” emphasises Chris Woudenberg.

CPS bought two precision IR black body calibrators from Fluke Calibration to create a standard every thermal imaging camera has to measure up to. Kirsty Russell takes the cap off one of the black bodies, sets the temperature to 40ºC, and, while waiting for the temperature to ramp up and stabilise, explains: “We use two of these black body calibrators in our laboratory. The first reaches temperatures from -15 to 120ºC, the other one offers a temperature range from 35 to 500ºC. Both emit a radiometrically calibrated IR radiation that serves as the reference for our measurements.” One of these calibrators was also taken out to the already mentioned training course.

Next Kirsty Russell takes a camera out of a drawer, securely mounts it on a platform and adjusts it to the right height so that it points directly at the centre of the black body’s face.

“We test every camera at certain temperature points between -15 and 500ºC and at various distances

up to three metres. When this test run is completed CPS uses all the readings obtained to calculate the measurement uncertainty of each set point rather than determining an overall uncertainty for the camera. “That way people can take the uncertainty at a specific distance and insert it into their calculation, which thereby becomes more accurate,” explains Chris Woudenberg. Meanwhile the black body temperature has stabilised at 40ºC, and a push on the camera trigger reveals a reading that is only slightly different to what it should be.

The calibration laboratory tests thermal imaging cameras to manufacturer’s specifications, but, in order to improve the accuracy for the user, also tries to emulate the operating conditions of each camera as closely as possible.

“We ask every customer to fill in a checklist, detailing make and model of the camera, the types of objects usually measured, the measuring distance from the object and the emissivity value setting used,” says Kirsty Russell. “There is no point in testing a camera mainly at a distance of 0.5 metres when the user usually works at a distance of two metres or more.”

At the end of the whole calibration procedure the customer is finally presented with an IANZ-endorsed certificate.

“We often find that people who use thermal imaging technology are unaware of the fact that they should have calibrated their cameras regularly. We recommend having it done every year,” says Chris Woudenberg. At the end of the day, you should not only be able to use a camera correctly, but also to count on what it is telling you. Out of the eight cameras at the earlier mentioned training course, only one had previously undergone calibration. “My experience tells me that there are still a lot of thermal imaging cameras out there that are not calibrated yet.”

Go to www.demm.co.nz/ enquiry quote: D120222

•

> CALIBRATION CPS’ state-of-the-art thermal imaging camera calibration laboratory in Auckland

Strategic marketing: Industry analysis A quick, easy way to make sure your product, messaging and distribution plans match the current local market environment is through an industry analysis.

Often referred to as an industry situation analysis, this simple review of major aspects effecting the people and businesses within your proposed market, can significantly reduce costly mistakes and improve your chances of success.

There are many ways to complete an industry analysis, from an in-depth research report through to a round-table discussion and everything in between.

Either way, an hour invested at this point can save a year or more at the delivery end.

One of the quickest and easiest methods I’ve found is the PEST Analysis (‘Google’ it!). Basically you write the key headings on a whiteboard – Political, Economic/Environmental, Social, Technological – and brainstorm any major trends, aspects or developments that may effect your marketing plans.

This very simple process will allow you to better understand any market or product life-cycles, key influencers, potential threats and opportunities. A review of this information will also lead to you making better decisions for your strategic marketing plan, including: • correct positioning of your product (accurate messaging); • appropriate distribution strategy (agent, channel partner, licensee, direct or combination); • best product mix (product package, components, services, etc); and • strategic alliances (who do you need to be friends with).

Case Study: Coriolis mass flow meter – right place at the right time Compac NGV is the leading designer, manufacturer and distributor of CNG dispensers and dispenser technology worldwide.

In particular, the Compac meters are the most accurate CNG mass flow meters in the world.

How, when and where Compac introduces the Coriolis mass flow meter as an individual product depends directly on the situation of the local industry environment.

For example, when a developing country is just starting on the path to implementing natural gas as a primary fuel resource, Compac NGV is able to enter the market with its complete dispenser units, incorporating the mass flow meters.

As the country’s natural gas industry reaches maturity there is no need for local businesses to import complete dispenser units as they will now be manufacturing these in-house.

However, high-tech calibration and metering equipment such as flow meters require extremely high levels of R&D, testing and production expertise.

This then becomes a strong supply position for Compac NGV which then establishes and maintains partnerships with local manufacturing companies worldwide. Many of these relationships have been nurtured through the early stages of the industry development and growth phases where Compac is able to establish a position of respect and quality. So it becomes a natural transition to continue working with Compac as the market matures.

Article by Chantelle Laurent, Marketing Strategist, Formula One Results.

We measure it.

NEW SEE MORE : THE NEW THERMAL IMAGERS FROM TESTO

With a rotatable display, you can see into any corner: The new testo 876.

With 320 x 240 pixels, you can discover every detail: The new testo 882.

With the new thermal imagers from Testo, you are on the safe side when measuring: Thanks to sharp focus images and the 32° lens, you no longer ever miss a detail. In addition to the intuitive menu structure, you can also rely on a fast and comprehensive analysis of your image data – thus saving money in the long term. The new thermal imagers testo 876 and testo 882: See more and have more security and flexibility when thermographing!

AUCKLAND : Tel : (09) 579 1990 WELLINGTON : Tel : (04) 499 3591 CHRISTCHURCH : Tel : (03) 366 0017 Email : sales@eurotec.co.nz WEBSITE : www.eurotec.co.nz

23

> AIR HANDLINg

Handling air more efficiently With energy costs continually rising, energy efficiency is paid more and more attention in the HVAC sector. Stefan Richter talked to Andrew Cooke, Cooke Industries’ General Manager, about the trend towards more energy-efficient air handling systems.

In a recently-issued press release, Ewan Gebbie of the Energy Management Association of New Zealand (EMANZ) highlighted the importance of a mandatory building energy rating system for this country. The association executive officer estimated the potential savings for New Zealand at about $500 million, based on auditor’s reports which regularly identify available savings of between 30 and 50 percent for commercial buildings. In this context improving the efficiency of heating, ventilation and air conditioning systems constitutes a significant possibility to save energy and money: According to the Energy Efficiency and Conservation Authority (EECA), HVAC equipment generally accounts for about one third of the energy used by commercial buildings.

“Without a mandatory building energy rating system, people intending to buy or rent property have little chance to gauge how one building performs against another in terms of operating costs,” says Andrew Cooke, the General Manager of Cooke Industries Ltd. “When it comes to enforcing energy efficiency, the legislation in our country tends to lag behind that in Australia and

24

Europe.” For example, the National Australian Built Environment Rating System (NABERS) rates a building based on its measured operational impact on the environment, and public buildings in the UK are pressure tested for air leakage and issued with a Display Energy Certificate. Energy-efficient technology, such as HVAC systems, and proper insulation can significantly reduce the impact the building has – and with it the total cost or life cycle cost necessary to operate all its systems. It has been estimated that the energy costs of running equipment is several times higher than the original purchase price and can add up to over 80 percent of the total cost. “A big part of the commercial office development market in New Zealand is driven by the interests of property developers rather than those of potential tenants or end users,” explains Andrew. “A traditional property developer does not care much about the life cycle cost of a building, which includes energy and service costs. They appear to be concerned about the cost of putting the building up.

A mandatory rating system would certainly help to change the thinking in this industry.”

From plumbing to air handling Cooke Industries Limited, part of the Cooke Group founded in 1926 by William L Cooke, is the business unit manufacturing air conditioning, refrigeration, heating, and acoustic products for the commercial, institutional, and industrial markets. From

February 2012

(L-R) Andrew Cooke, General Manager of Cooke Industries Ltd, and Dave Noyer, Sales Manager, showcase one of their Airpak air handling units.

the original Cooke business specialising in plumbing and heating installations, the business has expanded to include sheet metal working, ventilating and air conditioning. “We have been dealing with air handling products for over 40 years now,” recalls Andrew Cooke, “Back in the 1970s, we had problems sourcing suitable locally-manufactured products, and there were too many restrictions in place for imported items. It was then that we started manufacturing our own Airpak range of air handling products. Over this period we have grown to become a dominant player in the market, and we pride ourselves on being the leading supplier of air handling units for the commercial and industrial sectors in New Zealand.”

The company’s products are installed in hospitals, universities, prisons, production facilities, pharmaceutical companies and commercial buildings throughout the country.

Cooke Industries’ air handling product range includes air handling units, fan coil units, centrifugal fans, air heaters, heat recovery

products and ductwork. “Our air handling units come in 25 standard sizes, with four different options of construction for each size, and we have a standard solution for every air treatment requirement such as filtration, humidification, dehumidification, heating, cooling, and energy recovery,” explains Andrew, “But many of the air handling units we build are uniquely customised to suit the customer’s special application requirements.”

How to increase the efficiency of a HVAC system HVAC systems provide filtered air, heating, cooling and humidity control in a building. Increasing the energy efficiency of such a system can be quite easy.

Cool or heat only as much and as long as necessary, avoid heating and cooling the same room at the same time, close windows and doors to the outside. But there are of course also more sophisticated technical solutions available.

One way is to recover heat by extracting it from the exhaust air stream before it is vented outside, redirecting it back into the process. Cooke

> AIR HANDLINg

Industries’ air handling units come with the options for air to air plate heat exchangers, rotary thermal wheels, run around coils and heat pipes.

“We observe a growing interest to include heat recovery solutions in HVAC systems,” says Andrew. “We work together with a number of industry leading suppliers to ensure our heat recovery solutions are as energy efficient as possible.”

Another important way to increase the energy efficiency of HVAC systems is minimising the pressure drop within the system. The pressure drop characterises the resistance to air circulation of a piece of equipment. The higher the total pressure drop through all components of a HVAC system, the higher the energy consumption of the fan which drives the circulation. “There is increasing emphasis on reducing the specific fan power (Watts per litre per second). One way to reduce the pressure drop is to design the HVAC system with slightly larger component sizes; increased cross-sectional areas of filters, air treatment coils and ducting means less resistance, decreased fan power, more efficient heat transfer, and lower noise as well,” explains Andrew.

“For example, increasing the casing/enclosure area by 50 percent will enable the service life of filter components to increase by 100 percent, and allow optimisation of air treatment coil and fan efficiencies.”

HVAC filters play a key role when it comes to improving the indoor air quality for the user or the process. They remove contaminants and dust from the air stream and also keep downstream components clean, thus maintaining the system components in their as-new state. Clean cooling

and heating coils, fans and ductwork result in lower pressure drops and reduced energy and maintenance costs.

“Over the last ten years there has been a trend towards increasing filtration efficiency in air handling systems. We recommend a F7-class filter as minimum when specifying, and have standardised on this minimum filtration efficiency class some ten years ago. 99.9 percent of the particles in atmospheric air have a size of 1µm or less; the majority of which go straight through the lower filter classes,” says Andrew. “Keeping downstream components clean from dust and salt can slow down microbial growth and also inhibits corrosion of the components.” Andrew recalls a number of cases in which the company was asked by customers to replace totally corroded components of an air handling unit. “If they had called us earlier they would have saved some money.

People tend to cut their maintenance activities back to the absolutely necessary minimum to save on operational costs, but in the end they might pay far more to have components replaced.

You wouldn’t wait for a scratch on the bonnet of your car to totally bubble up with rust before treating it.”

UVGI limits microbial growth When you combine higher performance filters and ultraviolet germicidal irradiation (UVGI) you create a powerful duo to increase indoor air quality and energy efficiency alike. “A UVC emitter, used to complement the filter unit, reduces the amount of surface mould, bacteria and associated toxins and odours in the HVAC system. Heating and cooling coils, drain pans and ductwork stay clean, the pressure drop is minimised,

Absolutely anything you need for Dust and Fume Extraction New Zealand

DUCT & FLEX Flex

In-stock for overnight delivery

Modular Duct

Widest Range Baghouse Filters

Dust Storm Filters

Fans

European Quality Fume Arms

Freephone 0508 NZ DUCT (0508 69 38 28) 13F Saleyards Road, Otahuhu, Auckland Ph: 09 276 8020 Fax: 09 276 8070 Email: info@nzduct.co.nz

www.nzduct.co.nz 25

> AIR HANDLINg

and less effort and money has to be spent on maintenance activities and cleaning chemicals,” reports Andrew. It is understandable that hospitals, especially, are interested in this technology, but also end users such as pharmaceutical, food manufacturing, airports, and universities are keen on the concept. “We are aware of a number of our air handling units at Auckland Airport having been retrofitted, and we are currently in discussion with a number of other end users regarding the retro-fitting of UVC emitters within existing and proposed new units.”

Increased fan efficiencies The fan unit that drives the fresh air and the exhaust air

stream is the centrepiece of an HVAC system and are typically one of the biggest users of energy. Fans have to be reliable, energy-efficient and quiet. “In applications utilising smaller fan coil units (<1m³/s), fans with brushless EC motors are pushing aside those with standard AC motors,” says Andrew.

“EC drives are, due to their construction principle, more energy-efficient and reliable; they are built smaller, reduce the noise levels in the HVAC system, and also allow for an efficient application control.”

Applications utilising larger air handling units (>1m³/s) rely more and more on direct-drive plenum fans. “We were the first suppliers to mass introduce plenum fans

into this country in the mid1990s,” remembers Andrew, “The housed, belt-driven fans that were used at that time were causing air quality problems in various applications in the health care sector and the pharmaceutical and food production industries.” Direct drive applications, with the fan impellor mounted on the shaft of the motor, avoids 5-7 percent transmission losses associated with belt drives.

This setup reduces maintenance and also eliminates the hazards caused by belt dust entering the air downstream.

“When we first introduced direct-drive plenum fans, they were slightly less efficient than a housed fan; nowadays, when you compare the overall efficiency of the modern

generation plenum fans, they are at least as efficient as a housed fan, and more often than not, more efficient.”

Apart from the motor, the geometry of the fan blades affects the overall fan efficiency.

“When I started in this industry 20 years ago, engineers were typically specifying forward curved fans. The past few years, we haven’t supplied a single forward curved fan. They still have their place in very low static pressure applications, but 99 percent of the applications in our business require the more efficient backward curved or aerofoil bladed impellors.

We don’t even stock forward curved fans anymore.”

Go to www.demm.co.nz/ enquiry quote: D120226

•

Stainless steel air handlers

Air handling unit incorporating Hepa filters, dehumidifying and reheating stages.

Air handling units play an important role in many HVAC applications in the industry. An air handling unit is essentially a device to modify the condition of the air passing through. The air may need to be cooled, heated, filtered or the moisture content adjusted to suit the requirements of a particular process or to provide a comfortable working environment for the staff.

To achieve the desired temperature changes in the air stream, heat exchangers of one form or another are incorporated within an air handling unit. In most cases these

26

are finned tube heat exchangers, with a fluid flowing in the tubes and the air passing over the fins.

Drying processes require air with a low moisture content to ensure the drying is effective. An air handling unit known as a dehumidifier can reduce the moisture content (humidity) of the air by cooling to a point where the water content of the air can no longer exist as vapour. The water vapour in this cold air condenses as a mist and is separated from the airstream and drained away. When this air is reheated, it is now drier having

February 2012

much lower water vapour content.

Compressed air is often required in processing plants. The process of raising the pressure of the air also raises the temperature. Where this is undesirable an air handling unit known as an aftercooler can be used to reduce the temperature of the compressed air.

Steelfort Engineering has been manufacturing air handling units for many years with a particular emphasis on units for the food processing industry. The Palmerston North-based company manufactures a range of finned tube heat exchangers for lowering the air temperature, utilising refrigerants or chilled water, and heating the air utilising steam, hot oil or hot water. Finned electric heating elements are another heating option that can be built into an air handling unit.

As specialists in stainless steel fabrication, Steelfort constructs the stainless steel air handlers with a particular emphasis on fabrication

techniques that eliminate crevices, promote the ease of inspection, cleaning and serviceability. Filters and inspection ports or manways are usually part of the air handling unit.

The finned tube heat exchangers can be rated for steam up to 40barg pressures, and for a range of refrigerants, water and other fluids.

The tubes can be stainless steel, carbon steel, and the copper family of alloys. The fins are usually aluminium, but copper or stainless steel fins are also common.

Air handling units with fans, capable of processing up to 47 tonnes of air/hour and with steam coils up to 1000kW have been built for milk powder drying.

Article supplied by Ron Sanders, Research & Development Manager, Steelfort Engineering Company Limited.

Go to www.demm.co.nz/ enquiry quote: D120226a

•

Air-Handling Units

Produced complete with stainless steel housing and transitions fabricated to meet industry standards Designed to achieve a specified duty and to condition the air to meet individual specifications Can incorporate filters, heaters, chillers and demisters Can be supplied with fan and stand Suitable for corrosive atmosphere Designed to suit site limitations Enquiries to Craig Beissel - Sales Engineer 06 350 1350 027 505 0731 c.beissel@steelfort.co.nz

Established 1946

500 Rangitikei Street Palmerston North â&#x20AC;˘ P 06 350 1350 enquiry@steelfort.co.nz â&#x20AC;˘ www.steelfort.co.nz 27

> AIR HANDLINg

No more blowing money on fan energy comprised a coil face bypass arrangement, with air distributed via a belt driven backward curved centrifugal fan arrangement. In October 2011, the existing fan was replaced by an ebm-papst EC Plug fan. Minor works to the damper were also performed.

The installed product, ebm-papst EC Plug fan K3G560

The Wakefield House Building in Adelaide, Australia, recently realised an amazing 50 percent reduction in fan energy. The new EC plug fan, which replaced the existing centrifugal belt driven fan, has not only shrunk the energy bill, but also increased airflow and cooling capacity of the air handling unit.

For commercial office buildings, up to 70 percent of the total energy use is attributed to the heating, ventilation, and air conditioning (HVAC) systems. Fan energy is typically the most significant consumer of energy within a commercial building. Approximately 50 percent of energy can be saved by replacing the existing AC belt driven backward-curved fans throughout a building to EC plug fans.

The original fan and air handling unit arrangement for level 14 of the governmentowned Wakefield Building in Adelaide, which is typical throughout all floors of the building, System

Starting current

Old system vs. new system The main issues with the above arrangement and system relate to performance and the ability to adequately distribute the air to the floor. Due to the system type and the fanâ&#x20AC;&#x2122;s proximity to the cooling coil, the cooling capacity of the air handling unit is reduced as only part of the coil face is utilised. Air from the fan is only incident on part of the cooling coil, which then is reflected by insufficient capacity being delivered to the floor.

The new ebm-papst EC Plug fan was installed away from the cooling coil, and the damper was rearranged above the cooling coil in the bypass ductwork. The new damper was installed to provide an equivalent pressure drop to the cooling coil, which provides more stable distribution and controllability of supply air. The EC Plug fan, pressurises the plenum chamber and rather than delivering an uneven air profile as per a centrifugal fan, it provides uniform air pressure and therefore volume across the whole cooling coil, achieving greater capacity from the coil.

The belt-driven backward curved centrifugal fanâ&#x20AC;&#x2122;s starting currents on each day exceeded 80 amps, whereas the average current across the phases throughout daily fan operation is 8.55 amps. With the new EC Plug fan Operating current

Annual kWh

The Wakefield House on 30 Wakefield Street, Adelaide, Australia

starting currents now approach 6 amps and the average current across the phases throughout daily operation of the EC plug fan is 4.7 amps.

Contributing to the insufficient capacity of the old arrangement was the reduction in supply air to deliver cooling to the floor.

Locating the fan so close to the cooling coil creates turbulence and increases the system static, which in turn reduces the supply air quantity by approximately 10-15 percent from design. When combined with the reduced performance of the cooling coil, the net reduction in capacity to the floor is approximately 45 percent from design.

As part of the EC plug fan upgrade works, airflow was increased by 10 percent returning the supply air quantity to the design figure and combined with the resultant increased coil efficiency, cooling delivered to the floor was increased by approximately 15-20 percent.

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

â&#x20AC;˘

D120228

CO2 Emissions

Annual Operating Cost

Old Belt Driven Centrifugal Fan

>80 A

8.55 A

18,637.3

12.7 tonnes

$ 3,541.09

New EC Plug Fan

<6 A

4.7 A

9,166.6

6.2 tonnes

$1,741.66

9,470.7

6.5 tonnes

$1,799.43

Savings Supply air flow

+10 percent

Cooling capacity

+20 percent

Fan energy used

-50 percent

NGA 2011 scope 2 emission factor for consumption of purchased electricity of 0.68 kg CO2 -e/kWh was used. The comparison assumes an average daily operation of 10.5 hours, with energy costing $0.19 / kWh. Fan running time is also assumed to be five days per week, 51 weeks per year. A power factor of 0.85 has been used for the existing belt fan, while a power factor of 0.95 was used for the EC plug fan.

28

February 2012

> MAINTENANCE MATTERS

Temperature and vibration send maintenance signals If a tree falls in the forest it makes a noise, whether anybody’s there to hear it or not. Just like that fabled tree, machines in trouble provide telltale evidence you can read to diagnose their problems – if you just know how to look and listen.

Two of the most useful indicators are temperature and vibration.

Most mechanical components emit a certain amount of heat and vibration in the normal course of operation. But excessive heat, cold or vibration can tip you off to underlying problems, so you can fix them before they lead to breakdown and bring production to a halt. New test tools – the Fluke Ti32 thermal imager and Fluke 810 vibration tester – are available to help measure heat and vibration and even interpret the data. They tell you what the underlying problem may be and guide you in making repairs.

An abnormally hot or cold spot or an unusual thermal pattern on process equipment often indicates an emerging problem. That makes handheld thermal imagers, which capture two-dimensional images of the apparent surface temperatures of objects, useful tools for regular predictive maintenance of pumps and other equipment.

With thermal imaging users can discover and diagnose various issues, including high-resistance electrical connections, that impede airflow and bearing issues on motors, tank levels, and many mechanical problems. In a major Florida brewery, scanning with a Fluke thermal imager revealed that the gearbox of a bottle labeling machine was running hotter than normal – nearly boiling hot. A physical inspection showed that the box was filled with water, not lubricant. A damaged seal had

allowed the water in. A breakdown could have shut down the bottling line.

One way to prioritise infrared scanning is to begin with critical assets whose failure would threaten people, property or product. Then determine what conditions add stress, and monitor those assets more frequently. For example, the sludge and particulates found in many processes put extra stress on motors – affecting bearings, windings and insulation. That stress can show up as heat detectable by a thermal imager. Such motors should be scanned more frequently than others.

Use your handheld thermal imager to look for hot spots, cool spots and other anomalies. Be especially aware of similar kinds of equipment operating under similar conditions but at different apparent temperatures. Such deviations might signal problems. A good approach is to create inspection routes that include all critical assets.

Each time you inspect a piece of equipment, save a thermal image of it and the associated data on the computer and track its condition over time. That way, you will have a baseline for comparisons that will help you determine whether a hot spot (or cool spot) is unusual.

You will also be able to verify when repairs are successful.

Whenever you use a thermal imager and find a problem, use the associated software to document your findings in a report that includes a digital photograph as well as a thermal image of the equipment. That is the best way to communicate the problems you find and to suggest repairs.

Vibration can be normal in machine operation – or it can be both a sign and a source of trouble. Most industrial devices are engineered to operate smoothly

and avoid vibration, not produce it. In electric motors, rotary pumps and compressors, fans, and blowers, zero vibration is the ideal.

In these machines, vibration can indicate problems or deterioration in the equipment. If the underlying causes are not corrected, the unwanted vibration itself can cause additional damage.

But how can the plant maintenance professional tell acceptable, normal vibration from the kind of vibration that requires immediate attention, to service or replace troubled equipment?

Common causes of machine vibration Imbalance – A “heavy spot”

in a rotating component will cause vibration when the unbalanced weight rotates around the machine’s axis, creating a centrifugal force. The cause could be a manufacturing defect or a maintenance issue. Imbalance can severely reduce bearing life and cause undue machine vibration and heat.

Misalignment/shaft runout – Angular misalignment occurs when the axes of a motor and pump are not parallel. When the axes are parallel but not exactly aligned, that is parallel misalignment. Misalignment may be caused during assembly or develop over time, due to thermal expansion, components shifting, or improper reassembly

Congratulations to our Graduates of 2011 733 skilled engineers now ready to build New Zealand’s economy

www.competenz.org.nz

29

> MAINTENANCE MATTERS

Rising heat becomes visible with a Fluke Ti32 thermal imager, which captures two-dimensional images of the apparent surface temperatures of pumps and other equipment.

after maintenance. The resulting vibration may be radial or axial (in line with the axis of the machine) or both. Misalignment can cause coupling wear and failure.

Wear – As components such as bearings, drive belts or gears wear, they may cause vibration. When a roller bearing race becomes pitted, for instance, the bearing rollers will cause a vibration each time they travel over the damaged area.

Looseness – Vibration that might otherwise go unnoticed may become obvious and destructive if the component that is vibrating has loose bearings or is loosely attached to its mounts. Looseness can allow any vibration present to cause wear and fatigue in bearings, equipment mounts, and other components.

Effects of vibration The effects of vibration can be severe. Unchecked machine vibration can accelerate rates of wear (i.e. reduce bearing life), damage equipment, create noise, cause safety problems, and degrade plant working conditions. In the worst cases, vibration can knock equipment out of service and halt plant production.

Measured and analysed correctly, vibration can be used in a preventive maintenance program

30

as an indicator of machine condition, and you can target remedial action before disaster strikes. The handheld Fluke 810 vibration tester is designed and programmed to diagnose the most common mechanical problems of imbalance, looseness, misalignment, and bearing failures in a wide variety of mechanical equipment, including motors, pumps, fans, blowers, and more.

The Fluke 810 quickly detects vibration along three planes of movement, and then provides a plain-text diagnosis with a recommended solution. Its diagnostic technology analyses machine operation and identifies faults by comparing vibration data to an extensive set of rules developed over years of field experience. It is all done with the intelligence built into the tester, without the long-term monitoring, recording, and analysis required for typical long-term vibration monitoring programs.

Case study from oil industry It was the ideal solution for the area logistics manager for a major oil company. For the past year he has been using the Fluke 810 vibration tester to diagnose issues in pumps, blowers and motors up to 3,500 horsepower that pump

February 2012

8,000 barrels an hour.

“This is something I’ve been waiting on,” he said. “The neat thing about it is the Fluke will give you its idea of what it thinks is wrong. But it also gives you that signature you can give to the engineers. We went down to our transport station and were able to find some bearing problems on one of our units,” he said.

The Fluke 810 “called out for a bearing problem. Once we got the pump into the shop we found out the shaft was out of round, which took the bearing out.” Ease of use is another advantage. “You can give this thing to just about anybody, and they can learn how to use it in a matter of a few minutes. You can log all your equipment, you can pair it up with Fluke’s infrared camera and it will give you a full picture.”

Used together with a Fluke thermal imager, the Fluke 810 delivers results fundamental to the company maintenance program. “With the big motors, we do the vibration analysis, we look everything over on an annual basis with the Fluke imager so we can see if there’s any heat rise, and we use it on all the switch gear,” he said. “I call it shoot – fix – move on.”

Characteristics of vibration To understand how vibration shows up, consider a simple rotating machine like an electric motor.

The motor and shaft rotate around the axis of the shaft, which is supported by a bearing at each end.

One key consideration in analysing vibration is the direction of the vibrating force. An imbalance would most likely cause a radial vibration as the “heavy spot” in the motor rotates. A shaft misalignment could cause vibration in an axial direction (back and forth along the shaft axis), due to misalignment in a shaft coupling device.

Another key factor in vibration is amplitude, or how much force or magnitude the vibration has.

The farther out of balance a motor is, the greater its amplitude of vibration. Other factors such as speed of rotation can also affect amplitude. As rotation speeds up, the imbalance force increases.

Frequency patterns in the data can be related to machine fault templates. By looking at the patterns, the user can identify the source of the vibration and therefore the machine fault.

Examples of this include: motor shaft, components in the roller bearing, fan blades, gear teeth, and pump vanes.

It refers to the oscillation rate of vibration, or how rapidly the machine tends to move back and forth under the force of the condition or conditions causing the vibration. Frequency is commonly expressed in cycles per minute or Hertz (CPM or Hz). One Hz equals one cycle per second or 60 cycles per minute. Even a simple motor could be vibrating in multiple directions (radially and axially), with several rates of amplitude and different frequency patterns. Imbalance vibration, axial vibration, and vibration from deteriorating roller bearings could combine to create a complex vibration spectrum.

Article by Michael Stuart and Demi Namli, Fluke. Go to www. demm.co.nz/enquiry quote: D120230

•

> MAINTENANCE MATTERS PROfILE

Why buy test and measurement equipment when you can rent it?

Equipment demands are many and varied, often you only need it for a short time, a specific project, a specific problem on-site or at a customer’s premises. And capital is scarce.

Stefan Richter paid a visit to TechRentals to discover why it makes good sense to rent test and measurement instruments.

“Our typical customer has technical staff who know exactly what they want to achieve, but not necessarily the precise instrument needed to get the job done. Or they just don’t have access to the right equipment or technology,” says John Thurston, Director at TechRentals. “Our trained and experienced application engineers are available to assist in exactly those circumstances. When a customer describes their application and the goals they want to achieve, our engineers, who know all

the features, advantages and capabilities of each unit in our rental fleet, can recommend which instrument best suits their needs.”

Another common scenario where renting makes sense involves contractors. They undertake projects for customers, provide maintenance or repair services, troubleshoot, or want to extend the range of services offered to their clients. “Contractors have access to our fleet of calibrated test and measurement equipment: they rent whatever they need, whenever they need it. And apart from the rent, which they can pass on to their customers, it doesn’t cost them anything because they don’t own it.

They can also provide their customers with the calibration certificate of the equipment, an increasingly demanded requirement these days.”

Most equipment is rented on a short-term

basis, 30 days or less. “But long-term rental up to 36 months is increasingly becoming a viable option, for example with clients involved in larger projects,” explains John. “Companies rent cars, buildings, office equipment because they understand the benefits, be it cash-flow, immediate tax deduction, preserving capital, no disposal risk, no maintenance or calibration costs. Companies are starting to consider these benefits for their test and measurement equipment requirements.”

TechRentals originally started in Australia, and the company has been offering rental solutions in New Zealand since 1980. Originally owned by the Australian company TechRentals NZ was sold in October 2009 and is now under local ownership. “When ownership changed an exclusive distribution agreement for New Zealand with TechRentals Australia

31

> MAINTENANCE MATTERS PROfILE

“It’s ensuring the equipment meets the customers objectives, this is what our application engineers are available for.” – John Thurston, Director TechRentals

was negotiated, which means their vast range of rental equipment remains available to our customers here in New Zealand,” says John.

A broad range of available equipment Customer requirements vary significantly. Hence TechRentals carry a wide range of equipment and are continually adding to the fleet as requirements change or

new technology becomes available.

“We try to encourage customers to always call us when they have a need, as most new equipment is added based on customer requirements. We may have just added the instrument or will add it for them if there is sufficient demand.

Or through the wide experience of our application engineers we can often suggest alternatives.

In one recent case a customer

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

32

February 2012

was finishing a project, and the equipment they were using failed.

We purchased and imported a new item within four days. They were extremely impressed and met their deadlines!”

With over 140 different models covering such a broad spectrum of applications there are simply too many to describe.

One area where TechRentals has an extensive offering is electrical power analysis equipment. “An application area within in this is energy auditing. Companies can make considerable savings from an audit, and over the last 18 months we invested significantly in equipment for this purpose.

This includes the Hioki 3169 power quality analyser, specifically designed for energy audits, and several thermal imaging cameras” says John. “This is an ideal rental application as these assessments are carried out infrequently, and over a limited period. It makes no sense to tie up valuable capital in such circumstances.”

TechRentals is also increasing the range of personal health and safety equipment available. Traditional areas where equipment was offered included noise, radiation, gas detection, lux measurement and environmental (temperature, humidity, air quality). Recently a full body vibration analysis instrument was taken by a customer.

Also heat stress equipment has been added, both a personal dose monitor and a portable monitor that assesses an areas heat stress potential. All equipment can be viewed on the TechRentals website, although customers are always encouraged to call to discuss their particular application.

Ensuring the equipment meets the customers objectives is one of the key services TechRentals offers.

The advantages of renting instruments Renting is easy - you don’t need to do an awful lot of research, you just talk to the TechRentals experts, pick up the instrument

(or have it couriered nationwide for next day delivery) and hand it back when you are finished.

And you only pay for the days you have the instrument. “What we find with a lot of companies is that they buy an instrument and it sits on the shelf a lot of the time. That’s not exactly the best use of business capital. And rental payments are fully tax deductible,” says John. “You also haven’t got any worries or costs for calibration and maintenance.

We triage the instrument after every rental, calibrate our rental fleet regularly and perform routine maintenance, in accordance with the recommendations given by the manufacturers.”

What’s more, if a client provides the details of his application, for certain instruments, they can have the instrument set up in advance

by TechRentals. So when it arrives on-site its ready to go, minimising downtime. The company provides initial training on how to use the test device correctly when it is collected. Should there be any problems while in use, getting their expert’s help is only a phone call away. And last but not least, if desired, TechRentals offers to download the recorded data and provide it in electronic form.

TechRentals also calibrate customers’ electronic test equipment and offer both IANZ endorsed and traceable calibrations. “We’ve been offering this service for over 15 years and it’s become an increasing part of our business. We calibrate most of our own rental equipment, and the calibration business grew out of that,” explains John, and adds, “We also send reminders to our customers when the next calibration of their instrument is due. We also run a booking system reducing the time the Customer is without the instrument, and offer a 25 percent discount on our standard rental rates should they need to rent an instrument while theirs is away.”

Go to www.demm.co.nz/enquiry quote: D120232

•

> MAINTENANCE MATTERS

Plan for productivity In an average maintenance organisation the effective working or wrench time of our technicians is only around 35 percent of their workday. Effective and efficient work management can be a force multiplier and has the potential to increase that figure to 55 percent and beyond.

The purpose of our work management system is to provide the standardisation and rules to follow in order to lessen and, in time, eliminate the disruptions to the function of maintenance.

If our staff are not performing their roles and complying with that system then our process is crippled.

If good work management has the potential to double the effective working time of our staff then why don’t we invest in training for our planners? As an industry we often put energy and resources into training our staff in root cause analysis, for instance, even though the root cause often turns out to be poor work management.

Surely it makes sense to get the work management right first.

Good work management defines how work is identified and

authorised, planned, scheduled, regular review and update, and executed and closed out when most importantly it will require completed. It describes how ongoing training to ensure that work is managed in a standard all staff acquire the knowledge manner across an organisation. needed to implement and follow It supports income generation the work management process. through delivering reliable and The concepts of an effective consistently performing plant planning and scheduling system and equipment to operations. have been around for years. In a This further provides a systematic world where only the strong surprocess through which stakehold- vive, it’s imperative that we focus ers perform work management on the costs that are within our activities in a consistent manner. control. By expanding what we As a result, it also gives joint traditionally see as planning and consideration and prioritisation scheduling into a fully functioning to work asset specialists, both work management process we can operators and maintainers, in an help ensure that our organisations effort to sustain the most suitable will continue to survive. generation of throughput, today In New Zealand we rank 22nd and into the future. out of 30 countries in the OECD To maximise the effectiveness for productivity. If the All Blacks of our assets and specialists we were as good at rugby as we are as must move away from our current a nation at productivity we would culture of allowing tradesmen to be sitting between Uruguay and just drift into the role of “planner”. Spain in the international rugby We must recognise the roles rankings rather than sitting at of our work management staff the top of the table after recently and give them the full support winning the world cup. they need to carry out their tasks If we are able to punch way effectively. above our weight in rugby and This process is a living one, other sports then it should be subject to continuous improvepossible to do the same with ment. The system will require productivity.path I firmly believe The knowledge for that

one of the quickest, easiest and cheapest ways we can improve productivity within maintenance is to invest in our planners, as they carry out what is arguably the most important role within the maintenance department.

You must ask yourself this question: “Have my planners been trained or did they just drift into the role?” If you answered the latter then do your organisation a big favour and invest in your work management staff. For most organisations it is the simplest, cheapest and quickest way to boost productivity within your maintenance department.

Reliability and Maintenance

training courses

Phil Hurford is the manager of the Skills4Work Maintenance Training Centre. You can contact him on 027 488 6446 or p.hurford@ skills4work.org.nz to find out more ask about training in work management our U us about and other maintenance functions. PSKIL LMem bersh V staff in their work environment ip Prog ram!

Training Needs Analysis: skills improvement for your staff today

The knowledge path for staff in their work environment

Needs Analysis (TNA) starts with a good initial understanding of Training Needs Analysis: skills improvement for yourTraining staff today

where your staff is today by assessing their training needs through a progressive

structured approach to competency skillby assessment and where they need to Training Needs Analysis (TNA) starts with a good initialand understanding of where your staff isand today be tostructured attain optimum planttoperformance. assessing their training needs through a progressive and approach competency and skill assessment and where they need to be to attain optimum plant performance.

The TNA enables this crucial understanding by combining SKF Reliability Systems experiThe TNA enables this crucial understanding by combining SKF Reliability Systems ence and in training and our knowledge of maintenance and reliability. experience in training and our knowledge of maintenance reliability.

• Classroom and onsite courses with hands-on applications directly • Classroom andtraining onsite training courses with hands-on applications directly transferable to the transferable toworkplace the workplace • Selflearning paced learning and computer courses • Self paced throughthrough online online and computer basedbased courses • Customised your industry and application • Customised coursescourses specificspecific to yourtoindustry and application • Comprehensive courses that cover all aspects of machine reliability from asset • Comprehensive courses that cover all aspects of machine reliability from asset management to basic maintenance skills management to basic maintenance skills • Nationally and internationally accredited courses • Nationally and internationally accredited courses • 20 expert instructors who have 25+ years teaching experience • 20 expert instructors who have 25+ years teaching • Quality process developed through proven leanexperience 6 Sigma and ISA 9001 techniques • Quality process developed through proven lean 6 Sigma and ISA 9001 techniques For further information on Public Course or to organise an Onsite Course:

www.skf.co.nz

For further information to organise course Phone 03 9269or0763 or Emaila rs.marketing@skf.com Phone 0800 753 872 or email marketing.skfnz@skf.com

The Power of Knowledge Engineering

33 www.skf.com.au/training

> MAINTENANCE MATTERS

Lifting the game of your maintenance function For most companies, the installation of a computerised maintenance management system (CMMS) is seen as a holy grail to cure the ills of an underperforming maintenance operation. However, rather than seeing the task as fixing an underperforming function, the operation may miss the point that the professional maintenance management can have an enormous positive effect on the bottom line. While it is simplistic to blame underperformance on staff ability (or lack of), the opportunity exists to improve and leverage the maintenance management to professional outcomes, without a change in staff.

All CMMS systems are essentially the same, regardless of hype or price. Let us ignore the technicalities and functionality and presume you have selected and installed your system, uploaded your data and got some runs on the board. Project finished? Sorry, this is where the

fun begins.

Once your maintenance management system is off the ground, it is immediately possible to start leveraging your system to benefit the operation.

With a well-structured CMMS spares register and an ability to link spares to assets, you are now in a position to make engineering decisions about your stocking levels. Let's assume the current stock level is shown as 4. Without the engineering data, it would be difficult to justify the stocking levels or make reasoned judgments.

By linking all known occurrences of this bearing across the site, now (assuming that the plant is critical and not all the packers will suffer catastrophic failure overnight) we can state that the minimum stock level is four bearings. We can also individually argue and record stocking decisions based on criticality or lead time.

A North Island meat company with a stores

inventory evolved over 30 years of operation went through the exercise described above.

After linking in their spares register to the assets and consulting with their local bearing suppliers and tradesman, they were able to identify and remove $262,000 of unnecessary bearings, without any risk or consequence to their “firefighting” capability.

Once material requirements for PM tasks have been established with links to the spares register, it makes little sense to purchase the materials until they are required for the PM task. This is the essence of JIT (just in time) practice. Using the combination of spares-asset linking and forecast purchasing, it is possible to radically challenge stock levels, the resulting physical levels being dictated by reasoned emergency spare levels and actual usage.

Most New Zealand operations have evolved predictable parameters for shutdown

Think of us as The World healTh organisaTion!

Filtercorp designs, builds and services air purifying and dust extraction systems for NZ and around the globe. So if your work atmosphere needs to get its clean air act together, talk with us.

We’re NZ owned – making a world of difference to the environment.

Contact us on 0800 481 9999.

Or visit www.filtercorp.biz

Filtercorp International Limited Filtration at its finest…world-wide

34

February 2012

FCDemm03

> MAINTENANCE MATTERS

windows, based on traditional seasonal, market or maintenance requirements. Unfortunately, the site culture often expands out to fulfill these windows, making them self-fulfilling prophesies.

It is often a challenge to re-educate the company culture that once the technical and planning ability of the maintenance function reaches a competent level, traditional windows can be challenged altogether. While a high degree of confidence is required to pitch the removal of maintenance shutdowns, it is proven that tight planning can either remove the culture of annual replacement or achieve significant preventative maintenance tasks and overhauls within production shoulder periods.

A primary processing plant had scheduled annual three month shutdowns over its 30 year history. PM tasks, resource requirements and spending had expanded to fill the three month period. After developing a new maintenance management process and refining its PM routines, technical capability and confidence level, the site was able to challenge its “annual overhaul” mentality and successfully complete an annual shutdown in one and a half weeks.

At an annual turnover of $300m, the extra 10 ½ weeks plant availability was worth $60m to the business on top of the reduction in PM cost.

For some sites, it is quite difficult, or sometimes impossible in practical terms to remove the need for an annual shutdown (for instance, where the production season dictates that the plant is closed regardless) but the point is that the astute maintenance manager can remove “maintenance” as the main driver for the shutdown and reduce shutdown costs and stresses by challenging his PM routines and leveling them across the year.

The reality of arguably every real maintenance operation is that a significant proportion of its resources are spent on non-maintenance activities. It is abundantly incorrect to lump improvement tasks and costs onto a maintenance process and then chastise the department for the resulting resource costs, both labour and materials.

There are two categories of non-maintenance spending that the maintenance manager should consider; capital and improvement (or non-maintenance). Taxation rules dictate the categorisation of this spending on the balance sheet, but it has been traditionally beneficial to the manufacturing budgets benefit to bury improvement spending in the maintenance budget. For our purposes, we will now call such spending “improvement tasks”. The following acid test is useful for removing doubt about maintenance versus improvement.

• If the light bulb exists and you need a replacement, I can replace it for you under my maintenance budget. (maintenance) • If there is no light bulb and you want one above your head I do not have the financial authority to put one in. (non-maintenance) • If you want it moved, that is not maintenance and I do not have the authority to sanction that task. (non-maintenance) There is nothing wrong with capital, non-maintenance and improvement tasks per se. In fact denying improvement tasks halts innovation. What the maintenance manager must understand is that he needs to ensure his processes stream flagged improvement tasks so that they can be distinctly managed.

Demands from production, health and safety and compliance for non-maintenance tasks cannot be answered with a simple “no”. For the maintenance manager, a process is required to control these tasks.

With the previous sections in mind, it will soon become apparent to the astute maintenance manager that he is in a position to take control of his maintenance budget and defend it with hard data. Instead of the budget being an arbitrary number based on a combination of external factors and controls (read – accountants), budgets can now be built from first principles based on: • Zero based planned preventative maintenance forecasts.

• Segregation of maintenance versus capital spending.

• Agreed amounts for unplanned maintenance, major maintenance, fixed costs, planned labour, contract labour and discretionary improvement tasks.

No matter what politics and drivers are involved in your particular operation, it is a lot harder to argue against hard PM facts than the traditional emotive defense of “budget cuts”.

The final hoary old chestnut is the “cost of PM”. The simple answer to this oft-tossed management hand grenade is simple; a well-managed “PM” system will reduce spending for two reasons. It will ensure that maintenance only does what it is planned to do rather than a scattergun approach. If developed professionally, it provides the opportunity to achieve the appropriate amount of productivity and asset protection for the minimum cost. It will also reduce and identify non-maintenance spending dumped onto the maintenance budget.

The most basic objective measure of a good maintenance system is its level of

proactive versus reactive maintenance.

A simplistic approach is to measure the ratio of planned preventative tasks versus unplanned reactive tasks. Far more importantly though, the astute maintenance manager will consider the subjective measures of proactive maintenance: • Adding value to the total operation.

• Promoting a perception of professionalism.

This is where you really need to stop being an engineer and become a marketing manager.

In order to promote the professionalism of your system, you need to not only keep your customers in the information loop with reporting, but also be on the front foot of reminding them of your effectiveness. Ensure your customers are kept constantly and fully-briefed on the status and forecast of scheduled work.

Your information system can not only be used to report historic or technical facts, but also to generate a wealth of current and forecast information that can be of actual or perceived benefit to other departments.

Nothing described in the above paragraphs requires any IQ beyond common logic. It does not necessarily require complicated academic theory, extensive engineering experience or maintenance heroes. Yes, your staff should be able to grasp these simple examples and develop their own. If your site is not performing to this level, all that is required is the opportunity to excel. If you are unsure where to start, talk to other engineers about their experiences. Better still, contact the Maintenance Engineering Society (MESNZ), who will put you in touch with appropriate peers or experts.

Article by MESNZ Committee member, Craig Carlyle, of Maintenance Transformations Ltd.

IS 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

35

Cost-saving potential using the correct printing system

The optimum printing systems and configuring software ensure flexible and cost-effective marking in all industries.

As cost pressures rise, fast commissioning, a high degree of functionality, and the permanent availability of machines and plants is becoming more and more important.

However, increased functionality means the scope and complexity of the electrical wiring also increases. Thermal transfer printers ensure efficient and cost-effective marking.

Itâ&#x20AC;&#x2122;s important that downtimes remain short when service or repairs have to be carried out. For this reason, clear and permanent marking is critical. Suitable marking products, tailored to the particular application, are required to label terminals, conductors, cables, and equipment. Marking materials can be printed using compact printing systems, which can be used in production facilities or for wiring in the field.

Today, generally CAE systems are used to plan and engineer electrical plants and systems. All of the marking-relevant data, such as identification information or the cross sections of conductors and cables, are saved there. Software programs, such as Clip Project from Phoenix Contact, are used to prepare the data for direct processing in the printing systems. As part of the value-added chain, the program retrieves the information from all conventional CAE systems at the click of a mouse: information on terminal points, cables and conductors, as well as

36

February 2012

identification data from the circuit diagram.

The complete ordering, parts, design, and assembly lists are generated in addition to a two-dimensional image of the terminal strip.

Clip Project also allows labelling data to be directly entered in cases where the cabinet builder does not receive the CAE data from his customer electronically but in paper form.

The diagrams and technical data of the marking materials that Phoenix Contact offers have all been integrated in the software, a feature that certainly simplifies selection.

Product data is regularly updated through the Internet.

Selecting marking materials The actual application and processing required define the requirements placed on the marking materials. For instance, fast and simple handling for the cabinet builder is important in order to minimise assembly time. Simple replacement when commissioning or carrying out repairs on electrical plants and systems should also be taken into account.

When marking electrical components, a distinction is made between marking terminals, conductors/cables, and equipment. A clear print image ensures good readability of the information even where space is restricted.

To ensure a uniform standard of quality when marking various pieces of equipment and terminals, the range of marking materi-

als should be tailored to components from various manufacturers.

Selecting a suitable printing technique State-of-the-art marking offers many advantages: good permanent readability, an optically attractive image, as well as a high degree of resistance to mechanical and chemical effects. Various printing techniques fulfil these demands. For instance, a laser printer ensures that the marking has a high level of durability. However, this is infrequently used in cabinet building because of the high safety requirements and high investment costs.

Ink-based systems such as labelling plotters are more frequently used. In this case, a solvent-based ink is used, which hardens when the solvent vaporises. The principle is simple, but has the disadvantage that the labelling pens simply dry out when the solvent escapes. Ink-based systems contain solvents that ensure that the printing ink has the required viscosity. As a result of vaporisation, with or without applying heat, solvents such as alcohol, oils, or water are dissipated to the environment and the ink dye itself remains as a solid on the substrate. This procedure can barely be controlled, as vaporisation depends on additional factors.

Ambient temperature, air humidity, and the time between the printing operations play a decisive role. Continually regulating the

> CABLE MANAgEMENT

Whether terminal, conductor, cable, or equipment marking – thermal transfer printing generates good marking images even for small font sizes.

printing process costs a lot of time and also results in high costs in operation. Not only this, the dried-out pens and print cartridges are damaging to the environment.

The “Bluemark” printer also uses ink jet technology. The system developed by Phoenix Contact does not use solvent-based ink, but rather a solvent-free labelling fluid.

UV light, utilising LED technology, is used to cure the fluid. As a consequence, the labelling is resistant to solvents, smearing, and scratches. Thus this printing system is designed for high labelling volumes.

The thermal transfer printer is an alternative to solvent-based marking systems; this is a printing technique where there is direct contact with the marking material. The

Thermal transfer printing with “fixed” ink colour: the printer is immediately available again even after it has been idle for a longer period of time.

heating elements are very quickly heated up and cooled down again. The ink is applied to the print medium where the heating element comes into contact with the ink ribbon: smear-proof, insensitive to alkalines and acids, as well as resistant to temperatures up to 150°C. The advantages of this system, which operates with a fixed ink colour, are quite clear: low purchase costs, compact and mobile, always available without any waiting times.

Professional marking systems for industrial environments operate with quite different

materials, which fulfil different requirements depending on the application. Software programs form the basis for simple and direct input or for user-friendly transfer of labelling data from a CAE system. In each case, software, printing system, and marking materials form a closed system, in which all of the parameters are harmonised and coordinated with one another. Users not only save time and money, they also profit over the long term from high-quality marking.

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

•

D120237

CONTROL IT Drive Electronics, Drive Automation, Geared Motors – The Movitrac B range of contollers provide solutions for most speed control applications.

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

Quality European Manufacturing • Motors • Gear Components • Control Technology

The powerful Movidrive range of controllers for when sophisticated positioning and control is required.

Geared motors in a huge range of gear configurations, mountings, sizes and power. Fast customised assembly for every customer application requirement.

New Zealand Assembled • Fast, customised assembly for every drive requirement

Every finished assembled product is given a unique ID code to be backed by complete SEW-Eurodrive 24/7 service.

Application software is created for each customer requirement at our Auckland & Christchurch plants.

A control project complete and ready for delivery – this application required cabinet mounting.

When you deal with SEW-Eurodrive, you are dealing with the `manufacturer’. Our huge range of quality European manufactured componentry is held in 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&M312

Customised assembly to each customer application specification.

INDUSTRIAL DRIVE TECHNOLOGY

37

> POWER fACTOR CORRECTION

Having real

POWER Kevin Kevany gives three perspectives on power factor correction: a lesson, a beer and a promise.

When it comes to the subject of power factor correction, all fingers point to Mark Empson, author (of, amongst others, of the “No BS Guide to minimising EMC with VFDs”), blogger, creator and administrator of what seems to be half-a-dozen highly-technical websites. In addition, Empson is an electrical/electronics engineer, a director of Advanced Motor Control Ltd, in Christchurch, the owner of L M Photonics Ltd, a radio ham and a genealogist too.

He reckons his specific skill is as a “motor control solutions provider and problem solver in industrial installations involving motion control”.

“I have a strong belief in empowering people to work with the technologies and solutions, so I frequently run training seminars at Advanced Motor Control, where I’ve been for just over a decade, on a wide range of topics, including causes, effects and solutions. As a company, we believe the end result is most important. We have a good technical team and work with clients to establish what their real needs are and help to find a working solution.

“We have expertise in the fields of motor control using VFDs, also known as VSD or variable speed drives in New Zealand, soft starters and automation; plus a high skill level in the technologies that both cause EMC and harmonic issues and the technologies which can be used to provide working

38

solutions,” he adds.

Why bother about power factor correction (PFC), you might ask, since it seems to be something easily shrugged off, albeit with a somewhat anxious look over the shoulder of the “shrugger”?

Perhaps that should read: “What do you get without PFC?” How about: •Increased energy costs (increased kVA charges).

• Higher transmission and distribution losses.

• Variable voltage regulation.

• Constrained supply capacity.

Power factor – the basic principles Having got your attention – I trust – it’s time to lay in a bit of ground work with the ‘No BS expert’.

“Let’s start with power factor. It is the ratio of the Kilowatt (kW) – the real power in the load in thousands of watts – to the kVA, or apparent power in the load, and is a measure of how efficiently the current is being used. If the power factor is less than 1.0, the current is not being used to maximum efficiency. There are two types or sources of reduced power factor: displacement power factor and distortion power factor.

“Displacement power factor is caused by a reactive component in the load. If there is an inductive component in the load, then there will be an inductive current flowing in addition to the resistive current. The inductive current

February 2012

Lessons from a stein of beer: The more froth (reactive power kVAr) and the less beer (real power kW) you have, the less your thirst is quenched (the less efficiently energy is drawn from an AC source).

follows the voltage waveform by 90 degrees.

“Likewise a capacitive component causes a capacitive current which leads the voltage waveform by 90 degrees. The vector sum of the reactive (capacitive and/ or inductive) current(s) and the resistive current results in a single current with a phase angle before (leading) or after (lagging) the voltage waveform.

“The displacement power factor value is the cosine of the angle between the voltage waveform and the resultant current waveform.

From a practical point of view, the displacement power factor is typically decreased (made worse) by inductive loads such as induction motors, transformers and lighting ballasts,” says Empson.

Which brings us to distortion power factor, probably something a little easier to grasp based on our everyday exposure to lift music.

Empson again: “To give you the technical background first; distortion power factor is caused by non sinusoidal load currents which are made up of harmonic currents. These harmonic currents are caused by solid-state rectifiers and controllers.

“Poor distortion power factor is commonly caused by VFDs (Variable Frequency Drives), DC Drives, switch mode power supplies, computers and most electronic products. This causes reduced non-productive load on the system and reduced supply

current.”

According to Empson, power factor comes in two ‘flavours’, displacement and distortion.

“Displacement power factor is caused by inductive loads, such as induction motors and can be corrected by adding power factor correction capacitors. On the other hand, distortion power factor is caused by non-linear loads, such as switchmode power supplies and VFDs, which cause harmonic currents. Distortion power factor can only be corrected by the use of either active or passive filters. Since there are no domestic penalties in New Zealand for having a poor power factor, there is no advantage in adding power factor correction in the average domestic installation,” Empson says.

But it remains a constant problem for IT organisations, according to Emerson’s Arunangshu Chattopadhyay, Head CTS – Power Product Manager, Emerson Network Power Asia.

“IT organisations continue to be faced with slimmer budgets and electrical consumption issues.

As infrastructures change and demands grow, energy-efficiency has become a popular point of focus among IT infrastructure components.

“This trend explains why power factor has emerged in the industry as an important key to enabling the most efficient use of electrical power. Power factor is often a dimensionless number between 0

> POWER fACTOR CORRECTION

and 1 when assessing the ratio of the real power flowing to the load over the apparent power in the circuit,” says Chattopadhyay.

“Power factor is an important measure of power quality and shows how energy is efficiently drawn from an AC source. A higher power factor means reduced power (kVA) consumption which results in reduced electrical cabling, switchgear cost, and it is often associated with reduced harmonic level which improves the efficiency of an electrical system by reducing transmission system losses too.

“Various analogies have been used to describe power factor. I particularly like the one used in an article in the Australian quarterly, Industrial Electrix Magazine, which further simplifies the concept of power factor, likening it to a glass of beer!”

Beer tankard visual “Let’s say a large, cold beer is ordered to quench the thirst of a thirsty individual. The beer has some froth on top which does nothing to quench the individual’s thirst. This represents the kVAr (reactive power). The beer does quench the thirst – this represents the kW (real power). The total contents of the mug (the beer and the froth) represent the kVA, or apparent power. The glass needs to be full of beer – with no froth – so the thirsty person drinking it, gains maximum benefit from the full glass of beer. That means it is the same for maximum efficiency with power, as the system should not be drawing any kVAr (or froth) in the analogy,” Chattopadhyay says.

According to him, Emerson Network, “as the world’s leading enabler of BCC (business-critical continuity), delivers innovative solutions which run efficiently, while maintaining the necessary level of availability and reliability”.

This includes the introduction of power supplies with high PFC to keep pace with today’s demanding electrical requirements.

“High power factor means companies can handle the increased load without the risk of overload-

ing, while meeting efficiency goals.

PFC prevents noise, harmonics and distortion from being passed on to connected loads or from being fed back to the utility.

Currently, to coin a phrase, almost every new server and networking device requires a power factor as high as 0.98. Which brings us to the Liebert GXT3.”

Providing the same capabilities of a physically larger system, the Liebert GXT3, with 0.9 power factor, has been developed using “True Online Double Conversion” technology to help customers improve power infrastructure, while reducing overall operational costs.

Emerson Network claims it is “one of the most-advanced-technology UPS systems in its class” and “leads the industry in combining small size, high capacity and high reliability features”: • Zero transfer time from external to internal power; • Output power factor of 0.9 better matches up with switchmode power supplies used in today’s IT equipment; • 4-8 minutes of battery backup time at full load; • TVSS circuitry for additional protection from spikes, surges and other power anomalies; • 2U rack/ tower and minitower models; • User-replaceable, hotswappable batteries; • Two-year, no-hassle replacement warranty; and is • Suited to large enterprise requirements as well as SMB and SOHO users.

Back in 1985, Ron Davey, the current MD, founded Mahanga Holdings Limited, initially as an agency/distribution company trading in heavy electrical products.

Since then, the company has expanded to incorporate associated companies, which collectively employ ten permanent staff in New Zealand and Australia, with a manufacturing facility in Auckland. Most of the group’s detailed engineering activity is undertaken at this combined office/warehouse/factory facility of 13000-sq ft., with a branch in Sydney.

Liebert GTX3 (0.7 to 3kVA) tower/rack-mount model

The group has grown over the years to include Mahanga Holdings Limited Auckland, the marketing arm of the group; Power Consultants Limited Auckland; Electrical Distribution Equipment Auckland and Power Consultants Pty Ltd Sydney, Australia. The principle functions of the group continue to be representation and distribution of heavy electrical equipment for power generation, transmission, distribution, supply networks, heavy-industry and large commercial developments and enterprises.

It manufactures medium and high voltage electrical distribution and automation equipment for integrated networks.

Engineering design and investigative services; budgetary and quotation services; project management, contract supervision and installation, plus training make up the balance. Power Consultants is one of New Zealand’s leading specialist suppliers of PFC services and products, having installed more than 40-million VAr of power factor correction throughout Australasia.

“Because we also manufacture power factor correction gear, we are very aware of what to look for when carrying out a site survey. We won’t just send you the results of your survey with a ‘kVAr required’ column. We will comment on anything we may have seen at your site that may affect the performance or design of a suitable unit. Combining our knowledge of the industry with our years of experience ensures that this survey will produce what you want – a comprehensive study of what it will take to correct the power factor on your site,” a spokesperson says.

Power Consultants can model parts of a customer’s power system to determine the resonance conditions and harmonic paths, therefore solving harmonic interference problems before they begin – with equipment only, components only or consulting for capacitors, filters and blocks for an electrical system.

39

> MEASUREMENT MATTERS

Disunity in our units

When the Metre Convention was signed in 1875 by 17 countries, including the USA, one could have been excused for presuming that the worldwide harmonisation of measurement units was not far away, and that the era of awkward conversions would soon be gone forever with the adoption of the International System (SI) of units (the decimal system of weights and measures based on the metre and the kilogram). Despite this, most of us have observed that different systems of units still persist today, stemming largely from the continued use of Imperial units by many industries in the USA. These different systems ought to be able to coexist in harmony, but errors still slip through occasionally. These errors can result in consequences ranging from the grave to the absurd, and three examples below epitomise this range, from risk to life, through risk to a billion-dollar project, to risk of unintended amusement.

The “Gimli Glider” is the

40

nickname that was given to a 1983 Air Canada flight from Ottawa to Edmonton, on which the pilots found themselves running out of fuel less than halfway to their destination.

It was only the special gliding expertise of one of the pilots, and his extraordinary manoeuvres (used for the first time on a laden commercial airliner), that averted disaster and saved the lives of all on board, allowing the plane to crash-land at the remote, disused airfield at Gimli. While the heroic efforts of the pilots were awarded the highest honours in airmanship, quite rightly, the sequence of errors that led to their mid-air predicament began with a much more ordinary mistake. At the time of the incident, Canada was converting to the metric (SI) system, and the new Boeing 767s being acquired were the first to be calibrated in the new system, using litres and kilograms instead of the Imperial units of gallons and pounds.

All their other aircraft were still

February 2012

operating with Imperial units.

The Gimli Glider had been refuelled in pounds rather than kilograms, a shortfall of about half the fuel required, and as the normal fuel gauges were not functional, this went undetected.

The second tale of woe relates to NASA’s Mars Climate Orbiter spacecraft, inadvertently sent to its doom on Mars. Instead of moving into safe orbit around Mars, it skimmed a little too close to the surface and burned up in the thin atmosphere, never to start its mission as a weather satellite and communications relay to other probes on the surface of Mars. Once again, checks and safeguards should have picked up the problems at an earlier stage. However, the root of the cause was the use of incorrect units of force in a mathematical model of the forces experienced by the craft.

When directing the firing of jets to make minor corrections to its trajectory, the Imperial unit “pound force” was used instead of the assumed SI unit, the

“newton”, leading to a disparity of a factor of 4.45. Hence even rocket scientists can be plagued by unit error.

The final story moves us from North America to the small seaside town of Kingston, South Australia. A seafood restaurant with big plans and a big name (The Big Lobster) ordered a model befitting their name, of their favourite speciality, the rock lobster, to sit on the veranda of the restaurant. The model was duly designed from steel and fibreglass, based on a real, stuffed lobster, and delivered to the restaurant, causing much surprise. Though the owners had intended the dimensions to be measured in feet, the lobster was built in units of metres instead, and they are now the proud owners of a 17 m tall, 4 tonne lobster, which towers over the restaurant and has brought more publicity than the restaurant could have imagined!

No doubt the combination of differing systems of units and human error will continue to provide us with anecdotes, large and small.

Article by Lucy Forde, Measurement Standards Laboratory of New Zealand Lucy can be contacted at l.forde@irl.cri.nz.

WHAT'S HOT

government energy efficiency agency saves from energy monitoring The Energy Efficiency and Conservation Authority (EECA) has recently installed an energy management system in their Wellington offices to demonstrate the value of monitoring energy use. The system features an energy monitoring display using PowerLogic ION Enterprise software from Schneider Electric, which gathers, analyses, stores and displays all energy data in a user-friendly format.

The display provides an easy, cost-effective way of tracking energy use in the offices and saves on administrative costs as no manual meter reading is involved. It has also been tailored to allow EECA to compare energy use between its two different office floors.

Mike Underhill, Chief

Executive, says the system allows EECA to identify opportunities to refine existing energy saving measures and demonstrate the potential for improving energy use in an office environment. “The energy monitoring display has enabled EECA to identify a series of small improvements that combined add up to a noticeable saving year on year.

The project also provides a valuable demonstration model that can be viewed by commercial building owners or tenants.”

Anyone interested in viewing the system should contact Senior Relationship Manager Mike Bourke at EECA, email mike.bourke@ eeca.govt.nz or phone (04) 470 2227. PowerLogic ION

Enterprise software is a complete power management solution for energy providers and industrial or commercial operations. Quasar’s solutions using the PowerLogic

products are giving energy suppliers and consumers a unique level of insight into every energy-related cost, risk and opportunity. Go to www. demm.co.nz/enquiry quote: D120241

•

Newly released panelboard increases efficiency The well-established range of concept panelboards from NHP have featured in projects across Australia and New Zealand for the last decade and have recently been bolstered by a new release. To remain at the forefront of panelboard technology, the latest edition of the Concept Plus now offers a safer, more efficient panelboard with great new features including a new NC chassis, improved neutral bar mounting and a new flush door handle.

Complete with a mechani-

cally insulated busbar chassis that differentiates this new panelboard from the previous version, the NC chassis also has the full complement of connection kits, providing IP2X (touch) protection. The new design also ensures the subcircuits and main bars are not relying on the busbar coating as a method of insulation, which further improves the life of the installation as well as the cost of maintenance. The Concept Plus chassis is retrofittable with the old CD chassis (DIN

MCBs) and is much simpler to install, which improves the overall assembly time.

•

Go to www.demm.co.nz/enquiry quote: D120241a

41

> WHAT’S HOT

IO-Modules with integrated display and manipulation protection

For more than four years, Balluff I/O modules with their up to 32 inputs and outputs have been indispensable in the machine building and automation world. Characteristic features include the rugged, full-jacket zinc die-cast housing, the flat profile with rounded edges, the clear, large area displays as well as ease of mounting

can now be visualised, making diagnostics and system availability significantly simpler.

Mechanical attachments such as damage-prone rotary switches can be completely eliminated. This makes the new IP67 generation even more rugged and reliable than the previous series.

Menu guidance on the bright, high-resolution display is easy to use and self-explanatory.

Two keys are used for entering and displaying the individual menu points. A special feature is the integrated manipulation protection. This means the display can be locked out by the PLC, preventing unauthorised access. The new module generation from Balluff is also equipped with an integrated search and rescue function. Two LEDs controlled by the PLC allow the operator to visualise

with just two attachment points. The new generation of I/O fieldbus modules features an illuminated LCD display which opens up new possibilities for operators in setting, maintenance and repair. The baud rate, node address and information about the hard- and software of the module along with much more

predefined events which are not module or port-specific directly where the event takes place. Also interesting is the integrated web server, a specific feature of the Ethernet/IP and Profinet module versions. Using a standard web browser the user has access to comprehensive diagnostics functions such as the display of all LED indicators located on the module. Under “Device Properties” one can parameterise for example the devices connected on the IO-Link port. Other features are available under the “Configurations” function, such as assigning the IP addresses.

Go to www.demm.co.nz/ enquiry quote: D120242

•

SUBSCRIBE NOW! Don’t miss a single issue of New Zealand’s leading engineering and manufacturing magazine A one year (11 issue) subscription costs $59.00 (incl. GST).

Name: _________________________________________________________

Title: ______________________________________________________

Company: ____________________________________________________________________________________________________________________ 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).

For overseas rates please contact us.

Card type: Bankcard

Amex

Mastercard

Visa

Diners

Name on card: ________________________________________________

Card No.: ______________________________________________________

Expiry date: _________________________________________________

Signature: _____________________________________________________

“FREE” PCB DISPOSAL! A FREE service to collect and safely dispose of Polychlorinated Biphenyls (PCBs) by Transpacific Technical Services (NZ) Ltd (TTS) has been extended.

The nationwide promotion will now run until 31 December 2012* Call 0800 PCB WASTE to register PCBs for collection (see detail below).

The promotion is focused particularly on the disposal of small PCB containing capacitors, typically found in older style fluorescent lighting ballasts. These ballasts may still be operating in some older buildings.

Transformers and other items of electrical equipment containing PCBs are also eligible.

Where there is a requirement to replace light fittings that contain PCBs, the replacement cost can be offset against the savings from modern energy efficient lighting. In addition, by registering for this promotion with TTS, PCB disposal costs are FREE, therefore removing a cost barrier when dealing with PCBs. This is an attractive offer that can encourage building owners to get their fluorescent fittings checked and upgraded.

There are significant quantities of PCBs still remaining in New Zealand, despite legislation in place since 2004 prohibiting their use or storage. Increased awareness of this legislation and the mandatory elimination of PCBs is one goal of the promotion.

This promotion is made possible by a grant from the Waste Minimisation Fund, managed by the Ministry for the Environment.

TTS also acknowledges Tredi NZ Ltd as its PCB offshore disposal agent and promotion partner. *Conditions of this promotion are: • This PCB elimination and disposal promotion expires 31 December 2012.

• This promotion is limited to the collection and disposal of 8 tonnes (maximum packaged weight) of PCB waste.

• All applicants under this promotion must register with TTS by phoning Carolyn Armstrong on 0800 PCB WASTE. Acceptance approvals will be issued by TTS prior to pick-up.

• Any applicant currently on ERMA’s PCB register must disclose this status.

• Free collection and disposal will be applied on a first come first served basis.

• TTS will assist applicants with information on identifying PCBs and on any requirements concerning PCB storage, handling, registration, transport and disposal.

• TTS retains sole discretion as to whether or not to accept PCB waste and is not obligated to accept waste it considers outside the promotion’s objectives.

• PCBs must be removed from lighting systems or fittings and rendered safe, prior to TTS accepting possession.

TTS is able to provide more information about the project to building owners and other organisations who think they may still have PCB components. This includes information to help identify whether or not suspect capacitors and ballasts contain PCBs. Further information on PCBs is available on the websites below.

1. Safe Management of PCBs Code of Practice publication is on the MOH website: http://www.moh.govt.nz 2. Phasing out Small PCB Holdings is on ERMA website: http://www.ermanz.govt.nz

43

> EVENTS

Coming events Introduction to Oil & Gas Production for Technical Managers

05-06 March 2012, Quality Hotel, New Plymouth This intensive two-day training course provides a technical overview of oil and gas production process. The course will use process engineering fundamentals to explain the operation of each process unit. All attendees will be provided with a workbook and a certificate of completion. For more information: www.conferenz.co.nz/training/introduction-oil-gas-productiontechnical-managers

Rockwell Automation on the Move

Melbourne Olympic Park (06 March 2012), Sydney (02-03 May 2012), Brisbane (22-23 May 2012) and Perth (06-07 June 2012) See and hear about best industry practices, new technologies, products and services and talk to industry experts in the areas of automation, process control and safety solutions. Showcasing a combination of hands-on lab sessions and presentations from industry specialists, the event will also feature a comprehensive Safety Forum, highlighting leading industry automation safety and process control applications. www.rockwellautomation.com/events/raotm

New Zealand Downstream conference 2012

06-07 March 2012, Pullman Hotel, Auckland The New Zealand Downstream conference is set to become the premier annual event of the energy sector. Each year it will set the scene for the main strategic issues pertaining to the electricity, downstream gas and downstream petroleum sectors. The conference programme covers the main strategic, commercial, regulatory, policy and environmental issues affecting the sector today. www.nzdownstream.co.nz/

RFID World Australia 2012

20 March 2012, Sydney Convention & Exhibition Centre, Sydney, Australia RFID World Australia 2012 is a one-day executive level conference that will focus on RFID applications and wireless technologies increasingly associated with the control, management, identification, real time track and trace of

products and solutions. Senior executives from government, manufacturing, SCM, automotive, aviation, retail, hospitality, healthcare and pharmaceutical will be attending. www.terrapinn.com/conference/rfid-world-australia/

Planning4Reliability

21-22 March 2012, Melbourne, Australia The forum will provide two days of presentations, encompassing things such as Shutdowns and Turnarounds, CMMS utilisation, Cost Reduction and Reliability Improvement through Defect Elimination. www.sirfrt.com.au

Engineering Machinery & Electronics Exhibition New Zealand 01-03 May 2012, ASB Showgrounds, Greenlane, Auckland EMEX is the most comprehensive engineering, machinery, electronics and manufacturing industry event in the country and is seen by many as the prime professional and business tool for anyone working in industrial engineering and maintenance, control and instrumentation, machine technology, plant automation and monitoring, welding, forming and cutting, and software and computerisation. http://emex.co.nz/

National Manufacturing Week 2012

08-11 May 2012, Sydney Showground, Sydney Olympic Park, Australia NMW 2012 will house a record 12 product zones, including two new zones: The Sustainable Manufacturing zone will focus on opportunities for reducing industry’s environmental footprint; while Metals & Composites presents new developments in industry’s quest to develop reliable, lightweight, easily moulded manufacturing materials. www.nationalmanufacturingweek.com.au/

68th Annual Plastics Industry Conference

10-12 May 2012, Queenstown This year’s theme is “Plastics – The Economic Enabler”, linking to Government policies and plans for the development of the New Zealand Economy. www.plastics.org.nz

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 ______________________________________________________________________ _______________________________________________________________________

44

February 2012

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

Novotel Rotorua Lakeside

Official media sponsor Official event sponsor 45

A CUT ABOVE THE REST HYDRAULIC GUILLOTINES STANDARD SPECIFICATIONS: Blades made from 9CrSi material suitable for cutting stainless steel

HG-440B • 1300 x 4mm capacity

Support tables with transfer balls for quick & easy material alignment & manoeuvrability

11,450

*

$

Motorised back gauge design with DRO & cut counter

(S924)

Squaring arm incorporating flip over stops Photo electric rear guarding with 3 beams

HG-840B / HG-860B / HG-1040B

Roving foot pedal

• 2500 x 4mm capacity (S927) • 2500 x 6mm capacity (S932) • 3100 x 4mm capacity (S929)

14,500

*

$

17,950

$

(S927)

18,000

*

$ (S932)

(S929)

HG-2504 / HG-3204 / HG-2506 / HG-3206 • 2500 x 4mm capacity (S934) • 3200 x 4mm capacity (S935) • 2500 x 6mm capacity (S937) • 3200 x 6mm capacity (S940)

17,500

$

*

25,500

√ 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

29,950

(S937)

$

$

√ Mills √ Drills √ Lathes √ Guillotines

26,500

$ (S934)

(S935)

√ Threading Machines √ Tooling √ Accessories √ Panbrakes

√ Folders √ Measuring √ Rolls √ Presses

(S940)

√ Cold Saws √ Grinders √ Linishers √ Tool Boxes

(09) 2717 234

Unit D/38 Highbrook Dr, East Tamaki 46

February 2012

www.machineryhouse.co.nz

2_DEMM_010212

Specifications & Prices are subject to change without notification. *Special price on current stock only. All prices exlude G.S.T. Valid until 29-02-12