DEMM Engineering & Manufacturing August 2011 by Adrenalin Publishing Ltd

NZ’S LARGEST ABC AUDITED CIRCULATION TO THE ENGINEERING & MANUFACTURING SECTORS August 2011 $6 INCL GST

Turning waste into ‘gold’ Rotorua’s innovative biosolid waste processing pilot plant.

❏ Water treatment & wastewater systems ❏ Hydraulics & pneumatics heads-up ❏ Maintenance Matters: includes lubrication and corrosion control

www.demm.co.nz 1

CONTENTS Editors

note

Ring of confidence Well, here we are, just one month out from the RWC2011 kick-off. If ever there was a time for confidence to be making its presence felt out there – it’s now. With all those international visitors about to descend upon us with open purses and wallets, it’s a good time to be feeling confident – after all, confidence wins rugby games, and the All Blacks have a huge mountain ahead of them. Confidence seems to be pervading our business community too. The latest Grant Thornton International Business Report, released in July, showed business confidence in New Zealand continues to lift from late last year and is now well ahead of Australia and sitting comfortably in the upper half of the 39 countries surveyed. New Zealand was one of only 15 countries where business optimism grew in the second quarter of 2011. Even our manufacturing sector shows an ongoing and steady level of expansion. The BusinessNZ Performance of Manufacturing Index showed that May and June were the strongest two months of manufacturing activity since early 2010. I can confirm that these are indeed confident times – may they continue long after the ABs have won the cup! Glenn HBaker editor@demm.co.nz

Product Watch

Water Treatment & Wastewater Systems

Turning waste into ‘gold’

Hydraulics & Pneumatics

Maintenance Matters

Industry Watch & Coming Events

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

Aheads up on new technologies impacting on the treatment of water and sewerage. Includes a look at pressurized wastewater collection systems – a far superior option to the traditional septic tank.

Rotorua District Council and CRI Scion recently opened a biosolid waste processing pilot plant in Rotorua. Jenny Baker reports on the potential commercial and environmental benefits of this technology.

The latest developments in the world of hydraulics and pneumatics, including the arrival of Hydro Leduc pumps and motors at Hyspecs.

This month there’s a special focus on corrosion control and lubrication – and Phil Hurford reminds us of the importance of TLC in maintenance – that’s Tightness, Lubrication and Cleaning in case you were wondering. Get those three basic components of maintenance right, he says, and you’ll easily halve equipment failures.

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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: Glenn Baker, Email:editor@demm.co.nz deSiGner: Hartman Reid, Email: production3@adrenalin.co.nz circulAtion MAnAGer: Kim McIntosh, Email: kim@adrenalin.co.nz SubScriptionS: Hilary Keen, Email: subs@adrenalin.co.nz proof reAdinG: Malcolm Bailey

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PRODUCT WATCH Edit o choi r's ce

Wheel delivers uniform satin finish on metal surfaces

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August 2011

DISCON Products hasn’t exactly reinvented the wheel – but it has certainly taken metal fabrication finishing up a notch or two with its new CVE Blenz Wheel. This patented abrasive flap wheel is designed for achieving a uniform satin finish on stainless steel and other metals. CVE stands for “Continuous Variable Edge” – these Blenz wheels have randomly arranged wave cut flaps that eliminate the problem of linear marks traditionally caused by having right angle flap corners. The cut of this new wheel tapers out to both edges, and overlapping passes result in a seamless grain finish. Adrian Bogalo, managing director of Discon Products, a specialist abrasive manufacturer, says the CVE Blenz Wheel has applications across all food grade sectors – as well as aesthetic applications. The latter includes

sinktops and other domestic and commercial stainless steel products. “I can especially see it being used successfully for refurbishing stainless steel benchtops – eliminating all those annoying scratches,” he says. “The Blenz wheel is particularly designed for flat surface finishing, where the width of the work material is much greater than the width of the wheel.” CVE Blenz wheels come in widths up to 100mm and are compatible with most brands of anglepolishers, sander-polishers and straight polishers. For best results use a lubricant (even a spray of water helps); use medium to light pressure and machine speeds of 4800rpm or less; and for an extra high-grade finish lightly hand sand with 3M 7447 Scotch-Brite pads. Go to www.demm.co.nz/ enquiry quote: D110802

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PRODUCT WATCH

Drives get higher power range, integrated motion IN THE first of several planned extensions, Rockwell Automation has expanded the power range of its Allen-Bradley PowerFlex 755 AC drives to 450kW while also including Integrated Motion. A key feature of the PowerFlex 755 drive is its roll-out capability, which allows easy access to the drive for fast installation and maintenance. The drive’s modular design helps simplify replacement of drive components, such as cooling fans, circuit boards and major sub-assemblies. This modularity also allows the drive’s converter and control pod to remain in the unit while the inverter is rolled out, so control wiring can remain connected. An added advantage is that the control pod can be mounted remotely for hassle-free access to lowvoltage control and diagnostics. The PowerFlex 755 drive comes equipped with an embedded Ethernet port and five option slots that allow users to tailor the drive to best suit their application. Options include I/O, feedback, safety, additional communications and auxiliary control power input. The PowerFlex 755 now also supports Integrated Motion, which means, for the first time, PowerFlex and Kinetix drives can be on the same EtherNet/IP network and configured, programmed and controlled using RSLogix 5000 via motion instruction sets. Users can enjoy all the benefits and simplicity of Rockwell Automation Integrated Motion on EtherNet/ IP, while getting complete machine support on a single, flexible EtherNet/IP network architecture. Integrated Motion on EtherNet/IP not only provides high performance closed- and openloop drive control on a single network, but (with motion profiles and instructions embedded in the controller) also helps ensure precise and synchronised device movement. Adding safety options creates an AC drive that can make a massive difference in machine performance. Integrating the PowerFlex 755 with ControlLogix controllers through Integrated Motion allows users to expand their system solutions to include drives with a higher power range, wider selection for feedback and motor support along with configuring, controlling Go to www.demm.co.nz/ and monitoring. enquiry quote: D110803

Power Flex AC drives deliver higher power range and integrated motion. PowerFlex 755 drives have a roll out capability allowing for easy maintenance access.

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PRODUCT WATCH

Jetpack stars at SouthMACH

IT IS just a few weeks until more than 80 suppliers from New Zealand and Australia come together at the CBS Canterbury Arena in Christchurch. SouthMACH11, held on 17 and 18 August, is New Zealand’s largest showcase of engineering, machinery and manufacturing technology. It includes a range of exciting attractions from exhibitors, including the mighty Martin Jetpack from Christchurch-based Martin Aircraft Company, who will be on stand 60. The Martin Jetpack is the world’s

first practical jetpack. It consists of a purpose-built gasoline engine driving twin ducted fans which produce sufficient thrust to lift the aircraft and pilot in vertical takeoff and landing, enabling sustained flight. The future of Jetpack travel is a step closer after the latest record‐ breaking test. The Martin Jetpack shot into the sky over the Canterbury Plains at a climb rate of 800ft per minute, reaching an altitude of 5,000 feet before safely deploying the first ballistic jetpack parachute. Named one of Time magazines’ top 50 inventions for 2010, the Martin Jetpack has the ability to fly for half an hour or more, climb more than 1000ft per minute and to cruise at 100 km/h. “In this test we limited the jetpack to an 800 ft/min climb so the chase helicopters could keep up,” says founding director and test pilot, Glenn Martin. Martin Aircraft Company will feature a static display of the Jetpack and the Martin Jetpack Flight Simulator, which continues to be upgraded to model actual jetpack

performance. SouthMACH11 is not just a trade show – it also features three streams of high quality seminars run by exhibitors and the NZ Manufacturers and Exporters Association (NZMEA). Visitors to the show are encouraged to pre-register for quick entry on the day at www.southmach.co.nz. Admission to the show and seminar programme is free for visitors. The professional seminars and exhibitor workshops cover a range of topics designed to keep visitors up-to-date with new and emerging technology and to assist in gaining valuable ideas and insights. Local firm, BVT Mechanical Engineering Consultants on stand 34, will present three seminars and cover ‘demystifying technical and legislative issues in plant, equipment and machinery’ and‘CE Marking – a guide to compliance in Europe’. Another Christchurch exhibitor, P.L. Berry & Associates on stand 15, will discuss ‘how to protect inventions and trademarks’ and‘the basics of intellectual property protection’. Uretek Ground Engineering on

stand 36 has also demonstrated its support for the show and will provide expertise on the ‘maintenance of factory floors and driveways, from slab repair to the re-levelling of shelving systems’. Longstanding exhibitor, Camplex on stand 52, will generate huge interest with its demonstration on ‘machining with robots and using CAM to produce Gcode that programmes these robots.’ NZMEAhas arranged a number of key speakers from Competenz, Improve Group and The Ideas Foundry to discuss topics ranging from ‘Why Manufacturing Matters’ and‘Competitive Manufacturing Programmes’ to ‘Lean Manufacturing – what is it?’ and the ‘Product Design Process’. SouthMACHis a trade-only show and associated onsite events are free to attend. Register now and go into the draw to win one of five Macpac Sundowner jackets. For further information, visitor registration, exhibiting enquiries, and a list of current exhibitors, go to www.southmach.co.nz

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17 – 18 August 2011 CBS Canterbury Arena Wednesday 10am – 5pm Thursday 10am – 4pm

the machines are back! the engineering, manufacturing and machine technology show is back! Over 95 companies will be showcasing, demonstrating and discussing the latest in engineering and machinery. Keep up with what’s important to your business at SouthMACH 11. This is the largest specialised engineering, manufacturing and machine technology trade show in 2011.

Register online to visit SouthMACH and go in the draw to win one of five Macpac Sundowner Jackets valued at over $350 each. Go to www.southmach.co.nz today to register for FREE. Draw closes 12th August at 5pm. In association with

August 2011

Official publication

Organised by

PRODUCT WATCH

Energy recovery for Christchurch laundry

AN industrial laundry in Canterbury recently required an efficient process for heating its main washing machine water feed and cooling its laundry effluent. Aurora Process Equipment was chosen to come up with a solution to this challenging project – made especially challenging by the common fouling issues typically associated with processing laundry waste. With quality process equipment and the technical knowledge and experience, Aurora made calculated recommendations

to provide not only an efficient production process, but also an environmentally considerate process line recovering laundrygenerated heat energy from the wastes and using it to heat the clean washing machine water. The heat exchanger Aurora specified was a DIMPLEFLO Monotube Modular Unit. It achieved the objective by pumping the hot laundry effluent through the inner heat exchanger tube, causing the heat to transfer into the main fresh water supply in the outer shell.

This meant that the fresh water was pre-heated – therefore the boiler did not use as much energy to get the fresh water up to the appropriate temperature to service the washing machines. Along with the pre-heating of the fresh water, the laundry effluent is cooled down to meet the Council standards for waste drainage – enabling faster disposal and preventing infringement fines. The heat exchanger system, designed to recover up to 775kW of energy per hour, achieved

Heat Exchange, Mix, Separate, Aurora make us part of your process www.aurora-nz.com

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DIMPLEFLO

AADEMM20110318

get with the ﬂow...

energy savings for the company of around $68,200 a year. This is based on the company working eight hours a day, 220 working days a year, and energy costs of $0.05 per kW per hour (775kW x 1760hr/year x $0.05 = $68,200). This saving gave the laundry a huge return on investment from a hassle-free, cost-efficient solution. Laundry process equipment is commonly subject to ‘fouling’ – a build-up of waste solids which cause inefficiencies and possible blockages. However, Aurora’s unique modular DIMPLEFLO heat exchanger works on the principle of creating maximum turbulence in both process streams. This encourages self-cleaning turbulent flow, eliminating any fouling or congealing tendencies. Therefore, not only did the DIMPLEFLO technology increase the efficiency, it also prevented any waste buildup or congealing, minimising maintenance requirements and down time. Feedback from the laundry manager says it all: “We’re very happy with the heat exchanger installed by Aurora, we haven’t needed to clean it in seven years!” Go to www.demm.co.nz/ enquiry quote: D110805

Tubular Heat Exchangers

MUELLER Plate Heat Exchangers

MIXQUIP Fluid Mixing Equipment

SPINCLEAR Particle Removal Hydrocyclones

sales@aurora-nz.com

PRODUCT WATCH

Fluke ups portable scopes line-up FLUKE’S new ScopeMeter 190 Series II two-channel handheld portable oscilloscopes combine the power of a two-channel oscilloscope with a 5000 count digital multimeter and paperless recording modes. This creates an advanced test and measurement tool that service and maintenance professionals can rely on for troubleshooting equipment performance problems in the field. The two-channel models join the recently-introduced four-channel 190 Series II models to create the first full line of high-performance portable oscilloscopes with two or four independently isolated input

channels, rugged sealed case and CAT III 1000V/CAT IV 600V safety rating. The Fluke ScopeMeter combines a sealed case that is dust and drip proof tested in accordance to IP51 with a design that is tested to withstand 3g vibration or 30g shock. Popular enhancements in the new 190 Series II include extended battery life, hot-swappable batteries and a higher safety rating. The ScopeMeter operates for up to four hours with a 2400 mAh Li-Ion pack (standard with two channel models) or up to seven hours with the high capacity 4800 mAh Li-Ion

pack (standard with four channel models optional for the two channel models). The battery door makes it possible to quickly swap in a fresh charged battery. The ScopeMeter 190 Series II is available in 200 MHz and 100 MHz, either two or four channel, plus an additional two channel 60 MHz model. With up to 2.5 GS/s sampling rate and deep memory of up to 10,000 sample points per input the new oscilloscopes will capture and display just about any waveform or waveform anomaly. With two electrically isolated USB ports, users can conveniently store data to a USB

memory device or easily connect to a PC and transfer waveforms or screen images for data analysis or archive. Go to www.demm.co.nz/ enquiry quote: D110806

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New controllers save time for machine builders MACHINE builders and end users who need a cost-effective control solution for their small applications will benefit from the new family of Allen-Bradley Micro800 componentclass micro programmable controllers and Connected Components Workbench software from Rockwell Automation. Together, the controllers and software are easy-to-configure, install and maintain. Designed to be used with other Allen-Bradley component class products, such as drives, motion control and operator interface products, the controllers are part of a solution bundle that offers machine builders easy selection, installation and commissioning of their low-cost, standalone machines.

“With this new line, Rockwell Automation is delivering the functionality and flexibility of a micro PLC for the price of a smart relay,” says David Black, product manager, Architecture & Software, SP Region, Rockwell Automation. “Yet, the greatest value of the new Micro800 family is the simplicity and convenience it offers users – namely, that it provides ‘just enough control,’ so they’re only paying for what they need.” Ideally suited for standalone machine applications with fewer than 48 I/O, the initial launch consists of two controllers – the Allen-Bradley Micro810 and Micro830 controllers – and Connected Components Workbench

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August 2011

Micro800 programmable controllers provide flexible communications.

software. Leveraging the controller’s embedded USB and serial ports, machine builders can quickly program the controllers and link them to HMI and other serial devices – ultimately helping minimise selection and installation time for themselves, and the total cost of ownership for end users. The Micro800 controllers offer a wide range of plug-in modules for analog/digital I/O, communications, and expanded memory. The plug-in modules enable machine builders to personalise the controllers to increase functionality without expanding the product footprint. The new controller family also offers removable terminal blocks (most models) and simplified

communication via point-to-point data exchange. The new Connected Components Workbench software follows established IEC-61131 standards. Asingle package that is easy to acquire, install and update, the software makes it convenient and cost-effective for machine builders and end users to leverage one platform for their programming and configuration needs. It allows machine builders to program Micro800 controllers and configure other devices in the system, including PowerFlex drives and PanelView Component HMI Go to www.demm. products. co.nz/enquiry quote: D110806a

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The Micro800 family of controllers for nano- and micro-level applications.

SEW-EURODRIVE—Driving the world

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Engineering Software

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MOVITOOLS® MotionStudio

CCU – Configurable

Application configurator

Control Unit Gear units

Servo Motors

Servo Inverter

Integrated

HMI DOP

Positioning IPOSplus®

Option Cards CMP 71/80/100

Accessories

Additional I/O

Braking Resistors

Fieldbuses

MOVIDRIVE®

Chokes

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ND/HD Filters

CMP 40/50/63

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CMP80S

13.4 Nm

CMP50L

3.3 Nm

CMP80M

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CMP63S

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CMP80L

27.5 Nm

CMP63M

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31 Nm

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PRODUCT WATCH

Motion Analyzer V5 very impressive THE recent release of Rockwell Automation Motion Analyzer software helps machine builders obtain the full benefits of a mechatronic design approach by making it faster and easier to analyse, optimise, simulate and select motion control systems. The latest version of the software offers a number of impressive enhancements. First on the list is support for new products, including MPAI and Kinetix 3. Mechatronics also see greater support thanks to an enhanced SolidWorks interface. More industry standard indexes have also been catered for, including 3rd Order Polynomial (Parabolic), 7th Order Polynomial, Adjusted Sine (Cycloidal) and Modified Trapezoidal. Finally, additional features and fixes include registration for the ‘Pro’ version and multiple language support. Using intuitive step-by-step data entry fields, users can rapidly build up their motion application including options such as load type and load data. This data can then be associated with a number of different variable vs time motion profiles. Mechanisms can also be added and adjusted, including belt drives, lead screws, chain and sprocket, rack and pinion and linear motors. Once the drive has been chosen, the user is then taken to a sizing and selection page before being presented with a number of solutions. The software also offers thermal modelling, system efficiency analysis, supply voltage tolerance analysis, system tolerance analysis, lifetime estimation and system tuning simulation. Once the primary requirements have been confirmed, users are then presented with a page to help complete an axis Bill of Materials, with items such as communication and power cables. Go to www.demm.co.nz/enquiry quote: D110808

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August 2011

PRODUCT WATCH

Fast acting doors built strong SICK of holding that button while waiting for your roller shutter door to slowly open? And the truck driver is getting impatient? Perhaps you have a doorway that is required to be closed as much as practically possible and that old roller door is just too slow? Or maybe you are losing all that warm air every time the door is opened, allowing the outside elements to come rushing in! Egmont Doors and Total Doors, specialists at providing fast acting door solutions for large openings, have the ultimate answer with their Ulti-Fold Fast Acting Door. Keep that warm air inside where it is needed and keep the cold, rain, dust and pests out with an Ulti-Fold Fast Acting Door. They suit almost any type of opening – such as small or large warehouses, distribution centres, manufacturing facilities, printing companies or logistics companies. The Ulti-Fold Fast Acting Door

can fit openings of up to 10 metres high and 12 metres wide and is especially suited to openings that are subjected to high winds. It has horizontal wind bars which help the door withstand winds of up to 150km/h. With its opening speed of up to 1.5 metres per second, the door opens quickly and only remains open for the minimum amount of time required before closing again – therefore maximising productivity, decreasing energy usage and minimising the chance of impact damage from speeding forklift drivers. The many options available with these fast acting doors include full width vision panels for the increased safety of staff who may be moving across the opening area. The Ulti-Fold Fast Acting Door can be activated by a number of different means, depending on requirements – such as a simple push button mounted on the wall, handheld/forklift remotes

operated via radio frequency, or the ever-popular radar sensors and floor induction loops which will pick up on any forklift traffic as it approaches the door (meaning the door will be open by the time the forklift arrives at the opening). There are other factors to consider when choosing a fast

acting door. Egmont Doors and Total Doors have years of experience in the industry and can help you choose the correct door for your facility. Arrange for a free onsite assessment and report on how an Ulti-Fold Fast Acting Door can benefit your facility. Go to www.demm.co.nz/ enquiry quote: D110809

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Ulti-Fold Fast Acting Doors can withstand winds of up to 150km/h.

ULTI-FOLD RAPID ACTING DOOR • Super large openings up to 10mH x 18mW • Withstands wind speeds of up to 150km/h • Safe, fast door opening speed up to1.5m/second • Multiple window options for enhanced vision safety • Fully Automatic controls • Safety sensor systems • Counterbalanced for safety Available from

totalDOORS & Egmont Doors

Call 0800 807 753 or visit www.ultiproducts.com 9

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PRODUCT WATCH

NZ gets good vibes from Oli

An OLI-powered grading machine. Photo courtesy of Tripax.

OLI, a world-leading supplier of quality industrial vibrators and flow aids, is now making its presence felt in New Zealand. OLI Vibrators Australia, in conjunction with Auckland-based materials handling specialist WAM, is making the connection to local business by offering tailored solutions to a broad range of manufacturing and engineering needs. With proven technology and reliability, OLI is fast becoming the preferred choice by many of New Zealand’s design engineers, maintenance fitters, manufacturers and consultants. Whether you need a vibrator for maintenance, flow control, screening, cleaning, sorting, grading, conveying or any other vibration applications, OLI has a precisely engineered solution for your application. As a group of professionals drawn from many areas of industry, the company knows exactly where problems arise

and the best ways to solve them. It is dedicated to sharing its expertise through its products. OLI Vibrators is an established global business with a solutionsbased methodology. It offers highquality, highly versatile vibration and fluidisation products for use in any industry. As part of OLI’s dedication to service, it also offers a two year warranty on all its electric vibrators. Go to www.demm.co.nz/ enquiry quote: D110810

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Versatile safety goggles BOC’s new UMATTA safety goggle offers wrap-around protection without compromising the panoramic vision of its user through the use of a blue nylon elastic strap and a soft, flexible PVC frame. The anatomical design of the goggle adjusts to the contours of the user’s face, ensuring maximum comfort and a secure fit. This new goggle includes the strap attaching locking system found in the very popular UMATTA Spoggle range. The patented C-Lock system provides an adjustable and removable

CMY

WAM (MHE) NZ Call: 09 6222803 Email: sales@wammhe.co.nz

April 2011 August 2011

(interchangeable) strap. In addition, an indirect ventilation system utilises an anti-fog polycarbonate lens to minimise fogging and provide splash resistance. UMATTA safety goggles are approved to Australian, New Zealand, CE and ANSI certified safety standards and can be worn over most prescription glasses. They’re available throughout the BOC Gas & Gear store network. Go to www.demm.co.nz/ enquiry quote: D110810a

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PRODUCT WATCH

Quick and smooth jaw replacement THE proper selection of workholding involves more than simply accepting the chuck that came with the machine as the solution. To incorporate the most efficient processes, workshop managers should invest the time to research the most appropriate solutions. Running high volume parts requires a stable process to ensure consistently produced high quality parts over longer periods of time. This frequently leads to more specialised workholding solutions rather than the flexibility desired in the job shop. Here, with the increasing use of multifunction machines, milling and turning in the same machine, chuck selection needs to focus on flexibility. The standard chuck that comes on the machine may work fine. However, if the lot sizes are very small, requiring frequent change-over, a quick jaw change chuck can be ideal. Dimac Tooling offers the Kitagawa QJR (Quick Jaw Release) series – a quick change power chuck. These chucks allow very rapid jaw change to minimise downtime and increase efficiency, delivering more speed, consistent gripping forces and bore size when compared to conventional chucks.

The QJR chuck can be easily mounted in place of a standard chuck to keep the installation cost low. The QJR is a directly interchangeable chuck with the popular BB200 series – they feature the same through bore, plunger stroke and drawtube connection positions. This allows a new QJR08 to effectively replace a BB208 chuck without the need for any special adaption parts. The QJR uses a quick change base jaw system that can accept standard metric serrated top jaws from existing B200 and BB200 chucks. The QJR series also has a greater gripping force compared to the BB200 series. The chucks are manufactured from high grade alloy steel. This large bore chuck fits Dimac standard metric top jaws, and an optional base jaw allows it to fit common cross tenon top jaws. Mounting dimensions are identical to matching B and BB series (B208, BB208, B210, BB210, B212, BB212) so no expensive new connectors or cylinder Go to www.demm. are required. co.nz/enquiry quote: D110812

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Sway control system boosts crane safety

PRECISE load control, optimized productivity, and safe, easy operation are all critical assets for crane operators and owners involved in materials handling, maintenance and fabrication tasks. The Konecranes DynaPilot sway control system is engineered to deliver all of these, allowing users

August 2011

to optimize the use of their crane’s speed and acceleration while still being able to position the load accurately. The DynaPilot system, integrated into the crane’s travelling inverter, is available as an option for the whole range of lifting solutions from Konecranes. By modelling the load swing,

the integrated electronic system is designed to prevent the load from swaying because of crane movements. “DynaPilot is a cost-effective and reliable way to provide extremely accurate control over loads of all sizes and all kinds of environments,” says Konecranes national sales and marketing manager Warren Ashton. “The product is designed to eliminate swing, to allow the operator to control and position loads with great precision and predictability. This precise control is very important in environments involving heavy and valuable loads, such as steel service centres, glass handling facilities, paper mills, the automotive industry, and the resources and energy sector.” The system allows faster crane speeds in the limit switch area, towards the end of the crane runway, and the end of the bridge girder, where the crane or trolley would normally have to operate at slower speeds. This speeds up loading and unloading, while maintaining safe load handling,

which saves both time and money, says Ashton. Because load movement is predictable, the environment around the crane is safer. “Traditionally operators have to switch their attention between crane movements and the actual load in order to anticipate potential sway – and therefore often run the crane at lower speeds to compensate for this. DynaPilot allows operators to concentrate both on the load and the environment around it. “The load can safely be moved at higher speeds, there is less stress on the operator, and the crane owner can optimise their use of available crane features,” says Ashton. Because motor torque usage is optimized, there is reduced wear and tear on the crane’s mechanical components. This translates into less maintenance and reduced unforeseen downtime. Go to www.demm.co.nz/ enquiry quote: D110812a

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PRODUCT WATCH

Automation increases brewery profitability IN ORDER to survive in a tightening market, Pyraser, a medium-sized brewery, decided among other things to scrutinise its packaging operations. What was needed was future-proofed technology that would optimise the company’s process sequences through short cycle times, gentle handling and high flexibility. Pyraser now employs two KUKAKR 150 robots equipped with pneumatic grippers, each of which does its work in the course of one shift, three days a week. Compared to the set of conventional machines with palletising systems that was used before, the floor space required has been reduced by approximately 150 square metres, a decisive factor in favour of the six-axis jointed-arm robots. Costs for the cell were comparable to those for the conventional equipment. While one of the KR 150s is taking four crates with empty bottles from the roller conveyor, lifting out all 80 bottles simultaneously and placing them on a conveyor belt, the second robot is taking the same number of full bottles from a belt, placing them in four empty crates, and then putting the crates back on the conveyor system. To complete one cycle, the robots require nine seconds for filling and 9.6

seconds for emptying. The difference is a result of the measurements that the robot makes of the position of the upper ends of the empty bottles. This way the system prevents the robot from colliding with the bottles. Apart from that, the robots do not need any other sensors, since the crates are centred for handling in a position defined in two dimensions, and at the most only their height can vary. The empty bottles did present one problem in the design of the gripper. Sometimes bottles are stuck into the crates upside-down, so that they cannot be gripped by the robot. To prevent system malfunctions and the associated time-consuming manual interventions, the KR 150 must be able to remove the crates from the pallet regardless. For this purpose, the robot, after two failed attempts to grip the bottles, moves at only ten percent of its usual velocity. At the same time, it increases the pressure of its sturdy wrist. This way the robot is able to engage its gripper hooks in the crates, and lift them off. KUKAS Robotics are represented in New Zealand by Aotea Machinery. Go to www.demm.co.nz/enquiry quote: D110813

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WATER TREATmENT & WASTEWATER SySTEmS

intelligent valves for water treatment VALVE technology has remained largely unchanged in recent years. As bus networks evolved and decentralised control systems came to the fore, control valves lagged behind – until now. Bürkert R&Dwent back to the drawing board, applying 60 years experience in valve engineering, plus insights from customer focus groups, to explore real-world experiences at every step of commissioning, processing and life cycle. Bürkert R&Dimagined improvements, investigated problems and solved every one of them. Element is a modular concept with actuators, controllers (direct and remote) for on/off and modulating control of angle seat, globe and diaphragm valves. Element valves integrate and advance control systems with feedbacks, positioners and process controllers (full PID). Developments were roughly categorised into three areas – improved service life, more flexible operation and human usability. To extend service life, all tubing has been internalised with integrated piloting and position feedbacks. This avoids any possibility of leakage, for simplified commissioning. Pneumatic air is filtered and recycled, which entirely eliminates the problem of actuator contamination – a main cause of valve failure. Patented double-seal O-rings which seal on both edges deliver true IP65-67 ingress protection. Coupled with high quality materials throughout (stainless steel 316L, PPS and EPDM high grade), the entire Element valve is designed to sit in virtually any environment and retain integrity for long service life. For improved human interface, Element valves have a simple top access point for LCDdisplay and push-button programming. This includes one-button positioner tuning and process controller tune. The modular controllers offer versions with super bright LEDs for position and fault indication. Element valves offer integrated intelligence for distributed closed-loop control systems, with simple user-friendly programming and operation. The valve controller communicates via fieldbus or PLC. Utilising modern technology, Element valves can integrate functionality that would have traditionally required a control panel and PLC – and with considerably less investment in planning, assembly and maintenance.

Central automation through control cabinets

Pneumatically operated valves are currently used widely within water treatment facilities, typically automated via conventional centralised

August 2011

control cabinet systems including valve terminal, I/Osystem and interfaces for communication via fieldbus. Each individual pneumatically operated device in the network must thereby be connected to the control cabinet through an air line plus a discrete feedback line. The costs for the planning and installation of such solutions are very high, especially in more complex processes. Long air lines increase air consumption and decrease switching times. Another disadvantage of such automation systems is that the respective pilot valves are a distance from the valve, making commissioning, maintenance and future proofing difficult. To side step this entire problem, modern facilities may integrate the required automation functions within the valves themselves. In this case, the control system monitors status and process, leaving actuation and automation at field level. At field level, pneumatically operated process valves are equipped with all required automation components including pilot valve with manual actuation, electrical feedback units and optical status indication, fieldbus interfaces and even positioners and process controllers. Plants based on such decentralised automation systems are true DCS’s with intelligent valve systems. By integrating an ASi fieldbus, for example, the advantages of this approach are maximised. Asimple two-wire line connecting a PLC supplies power, feedback and communication for up to 62

valves. Each process valve is connected directly to the main compressed air supply line in the field, in series. This reduces the number and length of hose and wire connections as well as the number of required control cabinets. IP65/67 Element valves are not affected by prolonged use in environments with high air humidity, low quality air supply or chemicals – making them suitable for challenging water treatment conditions. In comparison to conventional automation solutions, this design marks real progress in life cycle improvement and functionality. Even prior to commissioning, users benefit from the decentralised concept as it simplifies project planning and allows for more flexible solutions thanks to easier integration of the process and automation levels. This also applies to subsequent installation, commissioning and maintenance. To summarise, Element is a seamless valve package built for challenging outdoor or dirty conditions, fusing the features of Bürkert’s proven 2000 Series with integrated pilot valve and position feedbacks to deliver simple, precise on/off and modulating control. Article by Chris Hoey, MD of Bürkert Fluid Go to www.demm.co.nz/ Control Systems. enquiry quote: D110814

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WATER TREATmENT & WASTEWATER SySTEmS

Smarter, greener alternative to septic tanks

Karl Sentch (left) and Jon McGettigan. “Pressurised sewer systems will become the “new norm”.

NEW Zealand’s local councils are quickly catching on to a vastly superior alternative to old traditional septic tanks and, surprisingly, it’s a concept that has been around, and internationally proven, since the 1960s. The shortcomings of septic tank systems have been well documented over the years. These somewhat primitive sewerage treatment systems are renowned for their odour problems, concrete lining degradation, leaching and overflows – which often results in pollution of the local environment and health risks. And because they are often gravity fed, septic tanks can also be expensive to install. Most local councils are cracking down on effluent quality and in many regions and towns septic tanks have now been banned. The alternative is the EOne pressurised wastewater collection (PWC) system, based on quiet, reliable grinder pumps. It’s a technology invented around 40 years ago in the US, since proven and refined, and introduced to the New Zealand market four years ago by the sole local distributor Ecoflow Ltd – based on Auckland’s North Shore. Ecoflow project managers Karl Sentch and Jon McGettigan have many years combined experience in wastewater engineering, as well as a wealth of local success stories for the EOne sewer systems. They have already installed around 4000 units throughout the country, including substantial lakeside community projects at Rotorua, and housing projects at Huapai and Kumeu, north of Auckland. So how do these PWC sewer systems work? And what are their unique benefits? Their simplicity surprises most people. Buried

August 2011

unobtrusively just below the ground surface in a New Zealand-made, heavy duty polyethylene chamber, the units are based around a 0.75kW GP 2000i submersible, positive displacement grinder pump, with progressing cavity to deliver an almost constant flow to the council’s central treatment plant. “Standard centrifugal type pumps wouldn’t handle the fluctuations in pressure like these pumps,” explains Karl Sentch. “These pumps simply lift out and are extremely easy to maintain.” Pressure switches in the pump head for starting and stopping the pump are similar to

washing machine controls and eliminate the need for float switches which are known to fail. An integral check valve protects against system back pressure and an anti-siphon valve facilitates downhill pumping applications. The pump also features hardened stainless steel cutter bars and teeth. These create a shearing action and, coupled with the high torque pump, eliminate blockages. The EOne installation also comes complete with an IP65 weather-proof alarm panel which protects the pump from low voltage, running dry and over pressure situations. The alarms are backed up by Ecoflow’s 24-hour service line (Ecoflow’s turn-key service extends from

WATER TREATmENT & WASTEWATER SySTEmS initial design phase, through to installation, commissioning and full back-up support). Sentch and McGettigan say pressurised sewer systems are well suited to New Zealand’s terrain and they firmly believe that they will become the “new norm” in a world that is becoming increasingly conscious of the need to maintain clean environments. Running costs are not an issue either – the estimated annual power consumption is around $25, depending on the household’s water consumption – and there’s an estimated life expectancy on the pump’s wearing parts of around ten years. The EOne system comes with a standard two-year warranty, but extended warranties and different levels of service contract are available. As a replacement for ageing septic tanks, the EOne PWC system from Ecoflow appears to be out on its own. Advantages to home owners include a safer, cleaner environment and increased property values. Developers enjoy the freedom to sewer anywhere in any kind of terrain, as well as the low installation costs. Engineers and contractors love the fact that they can be easily retro-fitted, and every aspect of their installation keeps costs to a minimum. If you’re still struggling to cope with a tired old septic tank – hopefully an Ecoflow system will be Go to coming to your neck of the woods soon. www.demm.co.nz/enquiry quote: D110817

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WATER TREATmENT & WASTEWATER SySTEmS

Specialised blending system for WTP

Vaughan Chopper Pumps were preferred for their proven ability in handling difficult solids and to eliminate the risk of clogging.

PUMP Systems recently completed a challenging, yet interesting, project at the Palmerston North City Council's Totara Road Wastewater Treatment Plant. The Council has recently undergone work to install a state-of-the-art waste reception facility, which takes a combination of food wastes, raw septage (material from septic tanks) and piggery wastes before being processed and injected into the existing digesters at the plant. The introduction of fats, oils and greases (FOG) into anaerobic digesters can greatly enhance methane gas production. Vaughan Chopper Pumps were preferred for the site due to their proven ability in handling difficult solids and to eliminate the risk of clogging. Of the three Vaughan Chopper Pumps supplied by Pump Systems, duties included; septage receiving, for the unloading of

tanker trucks on arrival at the plant; sludge tank mixing, where the combined waste material is mixed and preconditioned to produce a homogeneous slurry; and digester feed, for transferring the blended sludge to the digesters. Pump Systems also designed and supplied the mixing systems for the two four metre diameter sludge tanks at the facility. Each mixing system consists of one wall-mounted double nozzle assembly in all-stainless-steel construction that is fixed in place at factory-determined angles. There are no moving parts within the process and no routine maintenance is required, making the systems very self-sufficient and easy to operate. The two tanks are dual powered by a single externally mounted horizontal Vaughan Chopper Pump. Go to www.demm.co.nz/ enquiry quote: D110818

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Peristaltic pumps save Council time and money HAMILTON City Council produces and delivers A-grade water to its 130,000 residents and surrounding districts – which the plant operators are justifiably proud of. The Council is also proud that it strives to optimise the process for the effective and efficient use of ratepayer money. Hamilton’s drinking water is sourced from the Waikato River and goes through a typical treatment process. After the water is initially screened to remove large debris it enters a coagulation process where raw water settles in tanks allowing unwanted materials to be removed. Polymer is added to the raw water to aid this process at flow rates of 150-200L/hr, 24 hours a day, 365 days of the year. The plant previously had four diaphragm pumps that were more than 40 years old for this service. While these pumps were almost antique items, there was also a string of drawbacks. Maintenance required a skilled fitter-tuner which was timely and costly, and because spare parts were difficult to source, the Council had resorted to having replacement diaphragms made in-house. The pumps were fitted with several ancillary items that also needed servicing, along with more complex integration of stroke and speed management into the PLC. Sven Ericksen the council’s team leader asset maintenance, was looking for a logical replacement pump that met the needs of product delivery in the most cost effective manner, while simplifying asset complexity and ensuring maximum reliability. The Watson-Marlow 620DuN/RE peristaltic pump was put to the test for a month, and met all

August 2011

of their expectations. “There are numerous advantages of the WatsonMarlow pump” states Sven. “Seeing the rotating pumphead enables the operator to acknowledge that the pump is delivering the polymer at about the right flow-rate; the pump was seamless to integrate into our system; and, best of all, you just need two index fingers and a thumb to change out the tube, saving us time and money.” On the subject of the tube, during the trial back in October the Watson-Marlow 620DuN/RE was fitted with a 12mm Marprene Loadsure tubing element with cam and groove fittings that lock into the pumphead. This same tube is still occluding in the pump, having given seven-plus months of maintenance-free service. The peristaltic motion is also key to ensuring that the polymer is not altered during the pumping process. Polyelectolyte is a viscous long-chain molecule that can be prone to crystallization and/or gelling. Due to its composition, shear can easily break the molecular chains. The WatsonMarlow pump has an open flow path with no intrusions from check valves or other items which makes the design inherently capable of moving shear-sensitive, viscous or particulate fluids with no damage. Also because the pump is selfpriming and can run dry, there is no concern for crystallization of the polymer. Hamilton City Council are currently in the process of replacing all of their polymer diaphragm pumps with Watson-Marlow pumps and are looking to optimise other areas of the Go to www. plant with peristaltic technology. demm.co.nz/enquiry quote: D110818a

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A polymer dosing control panel. The diaphragm pump wiring (left) verses the peristalticx pump (right).

The Watson-Marlow pump replacement with diaphragm pumps in the background.

Oil AND GAS

Turning waste into ‘gold’

The ribbon cutting ceremony. (L-R) Rotorua mayor Kevin Winters, Minister for the Environment Hon Dr Nick Smith, and Scion chairman Tony Nowell.

Turning sewage into bulky Rotorua District Council and Crown Research Institute Scion recently opened a biosolid waste processing pilot plant in Rotorua. The pilot plant uses thermal deconstruction to break sewage sludge from the council’s wastewater treatment plant down into water, heat, re-useable chemicals, and a range of other valuable byproducts. During thermal deconstruction the waste is combusted in water at a high temperature in a pressure vessel. The destination of most sewage sludge is a hole in the ground – landfill. Scion Group manager for sustainable design, Dr Trevor Stuthridge, says the thermal deconstruction process’s best potential outcome is that none of the biowaste ends up at the landfill but is fully recaptured and used elsewhere. The Scion process, named STOP (Scion Thermal Oxidation Process) can reduce the volume of a given stream of biowaste by more than 90 percent through deconstruction and byproduct recovery. The remaining solid material might be used as a phosphorus fertiliser if suitable. If not, it goes to landfill – but even so takes up a fraction of the space and has almost none of the negatives of the traditional landfill solution. “It has the potential to completely change the way we deal with waste,” Stuthridge says.

The history The basic technology for deconstructing sludge has been available for more than 50 years, but has only been taken up to a limited extent due to its capital and running costs. Scion scientist Dr Daniel Gapes says New Zealand’s landfill space is becoming increasingly limited. In addition, public opinion and the Waste Minimisation Act 2008 have focused stakeholders on finding other disposal solutions for the large percentage of municipal solid biowaste currently being landfilled. This approach is now a worldwide trend.

August 2011

“It’s getting expensive to send waste to landfill and, besides, people want to see more environmentally friendly methods of disposal. This means alternatives are on the table again,” Gapes says. The concepts used in the STOP technology arose from a Ministry of Science and Innovation funded program that focused on developing technologies to improve liquid and solid waste management for the pulp and paper and related industries. Scion recognised the enormous potential to direct some of these technologies towards the difficult issue of sewage biosolids. To work on this issue it created a partnership with its local authority, the Rotorua District Council, which was seeking innovative solution options for this problem. The partnership team carried out extensive laboratory trials of the STOP technology, and considered the trial results promising enough to take the work to the next level – a pilot plant. Rotorua-based consulting engineers Allan Estcourt Limited prepared the technical specifications for the pilot plant and Hamilton’s Longveld Engineering built it.

Wasting away The developed world has come a long way from simply dumping raw sewage in the nearest convenient spot and hoping Mother Nature will do her work. In cities, modern sanitation authorities spend huge amounts of money to convey sewage from the point of origin to treatment facilities. The objective of a treatment facility is to separate the raw sewage into clean water and solid materials, or sludge, and then return the clean water to the environment via a series of water purification processes. That leaves the problem of what to do with the solid materials. The raw sewage goes through several stages of sanitation. Aerobic and anaerobic bacteria play a

landfill matter and more

or less clean water is old

technology. But using more

than 90 percent of sewage’s mass to recapture as much as possible of its value?

That's tapping into the circle of life. Jenny Baker reports.

major role in breaking down the organic material in it. They also work in the treatment system to clean up the water. There are three types of sludge. The first is primary sludge – the incoming solid material that settles out in the treatment plant’s sedimentation tanks early in the treatment process. It consists of about three percent solids and 97 percent water. The second is secondary sludge – bacterial biomass recovered from the biological treatment process later in the treatment process. It consists of about one percent solids and 99 percent water. The two sludge streams go through several concentration and water removal processes to produce dry sludge cake. The standard way of dealing with dry sludge is either by landfilling, composting, or (rarely) burning it. Sludge cake contains concentrated nutrients and other contaminants that can enter the environment by, for example, leaching into the water table under a landfill. Burning it is a very energy intensive option and the market for compost has become very limited. Deconstructing sludge through oxidation processes may be a better option, but has proven very challenging technically and economically. Globally, the process has several variants, with the Zimpro method, developed in the 1950s, being

FEATURE the original technology. Newer supercritical water oxidation processes rely on extremely high temperatures and pressures to accelerate this breakdown. Scion scientists say the key to the STOP system’s success is to control the thermal deconstruction process to yield by-products for downstream uses, rather than just making the waste into ash, water, and carbon dioxide. The STOP technology’s other advantage is that it is amenable to treating very wet wastes that would not be suitable for incineration. It does this in a manner that recovers value while still destroying fractions that might carry disease, cause toxicity, or are not readily biodegradable. The oxidative conversion of complex organic material in the STOP system generates simple organic molecules, such as acetic acid, that can then be converted to a range of end products, such as biofuels, biodegradable plastics, and a carbon source for the enhancement of denitrification in the wastewater treatment system. The nitrogen and phosphorus in the solid waste are also converted into clean nutrientrich fractions that can be used for downstream fertiliser manufacture.

Inside the plant Certain preventative measures have been built into the pilot plant design to address potential issues of corrosion, scaling, and clogging. The STOP methodology will be tested, refined, and

Biosolids are a by-product of sewage treatment plants. Pictured is an aeration tank at the Rotorua Wastewater Treatment Plant.

adjusted where necessary during the pilot plant’s work to address these issues. Longveld Engineering business development manager Arthur Lelieveld says it has two interesting features to deal with the challenges associated with sludge deconstruction through oxidation. Firstly, the reactor vessels were built from austenitic-ferritic 2205 moderate duplex stainless steel rather than standard 304 or 316 stainless steel. This will allow the reactors to withstand

the high temperatures and pressure and corrosive media in the sludge mix. The duplex microstructure is known to improve the stress corrosion cracking and pitting resistance of stainless steel against chloride attack. Secondly, the plant uses a mixture of progressive cavity and gear pumps to ensure consistent performance and better maintenance demands. It took six months to build the pilot plant,

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FEATURE

STOP technology breaks original waste into added value products. Pictured is the sample at feed stage (left), and the final product after thermal deconstruction at 260 degrees Celsius (right). The two centre images show the result at 180 and 220 degrees Celsius. Equipment in the Scion laboratory used for measuring samples from the pilot plant’s output.

and the building process had its challenges. The Longveld team almost literally had to ‘bend over backwards’ to work and move about in the 8.5m long by 2.5m wide by 2.5m high structure. But Lelieveld says the team took it with good humour. “We had to fit a spaghetti of pipelines into a small area. It was very hard to get everything in the right places. It resulted in some very awkward welding positions. But with meticulous fitting and welding we brought everything to a satisfactory conclusion.” The adjacent treatment plant supplies the air and water the process requires. Anewly installed gas-fired oil heater supplies the heat. Intelectric from Hamilton did the electrical and instrumentation work.

Hard on results, soft on Mother Earth Scion says STOP has several other friendly features. It uses primary and secondary sludge as a feedstock, which means when used on a commercial scale it could potentially eliminate some of the most difficult challenges of the traditional sewage treatment process.

The process uses energy to start the reaction, but has the potential to be self sufficient and even generate excess heat or steam for other uses – depending on the levels and composition of biomass input and oxidative destruction. In addition, methane can be generated at several stages in the system for electricity production. STOP is very successful in solids destruction, removing more than 90 percent of the biosolids’ dry weight and sanitising all pathogens. The remaining solids are essentially a fine inorganic ash containing less than five percent of the original carbon content. This material is likely to be biologically stable and suitable for landfill if required. It won’t generate the large levels of greenhouse gas or nitrogenous leachates the original material could have produced under typical landfill conditions.

The way forward Stuthridge says the process’s eventual commercialisation could benefit the rate paying community and environment alike. “We see the potential of Waste 2 Gold to not only solve our waste disposal problems, but to provide a revenue source from the converted waste for the City Council involved.” Rotorua has approximately 8,500 tonnes of biosolid waste going to landfill every year at a

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INDUSTRIAL DRIVE TECHNOLOGY

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Geared motors Industrial gear units Drive electronics Drive automation August 2011

n o i at

v o nn

Developed D2of5-Aug11

cost of over $900,000. Acommercial STOP plant can change the situation drastically. In addition, commercial ethanol is currently used to improve the sewage treatment system’s ability to remove nitrogen. The acetic acid produced through STOP could replace this ethanol, with potential savings of $400,000 per year. The technology could be readily implemented in other urban centres, and for applications beyond sewage sludge. Other possible customers include industrial organic waste producers, such as the forestry, agriculture, dairy, and meat and fruit processing industries, as well as chemical companies that may want to generate and recover chemical intermediates from the waste stream as replacements for fossil fuel-derived equivalents. The current phase of the project will allow Scion and Rotorua District Council to design and cost a full-scale plant for the city’s biowaste disposal needs, as well as identify and test opportunities for other users in the municipal and industrial space. Meanwhile Stuthridge says Scion has received numerous enquiries from both New Zealand and offshore interested parties. Jenny Baker is an Auckland-based freelance Go to www.demm.co.nz/enquiry writer. quote: D110822

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HyDRAUliCS & PNEUmATiCS

Actuators enable compact lifts in confined spaces ONE of the frequent problems of heavy lifts in the construction, mining and energy sectors is the confined spaces in which crews must work and apply force. Where lifting cylinders are used beneath loads to overcome a lack of overhead access for cranes, work crews sometimes also have to contend with off-centre loads that can damage or destroy plungers in compact rigid cylinders. One solution is the range of Firestone Airstroke actuators offered byAir Springs Supply. Top of the range is the tripleconvoluted model 348-3s, which can lift more than 40,000kg using normal industrial compressed air at 7 bar to provide strokes of up to 350mm from a compact starting height of just 140mm. “One of the beauties of this type of actuator is that they don’t have any internal moving parts – such as a plunger or seals – to break or wear. This means they offer high reliability in industrial environments,” says Air Springs Supply general manager Simon Agar.

Because an air spring has a flexible, compliant bellows wall, instead of seals or guides, the bellows follows the path of least resistance. This means users attain greater tolerance for side loads caused by misalignment or uneven loads, typically without needing to use a clevis, says Agar. “Fine control of the lift can be obtained through valving and mechanical means, making the lift less of an engineering task than it might be otherwise.” Either compressed air or suitable liquids can be used as the lifting medium within the air springs. Single, double and triple-convoluted air springs offer the greatest stability for heavy lifts, while extended wall single-convoluted models offer between 25-60mm greater stroke than standard models, permitting them to be used in applications that might otherwise require more complex lifting and actuation alternatives. Rolling sleeve actuators are also available for extended stroke performance where stand-alone stability is less of an issue. Go to www.demm.co.nz/enquiry Suppliers of forward curve blower wheels & fan decks quote: D110823

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New AUSCO distributor AUSTRALIANBrake Controls has been appointed distributor for AUSCO Products, servicing the Australian and New Zealand markets. US-basedAUSCO is known for its innovative off-highway braking solutions and the invention of the spring-applied, hydraulically released multiple disc brake (MDB). “AUSCOare the market leaders in OEMbrakes for the construction, agricultural, mining, turf care and ATV/utility vehicle markets,” says ABC general manager Bill Watson. “AUSCO manufactures the widest variety of service and parking brakes in the industry, including spring-applied MDBs, hydraulic callipers, mechanical callipers and ball ramp brakes.” As a result of this appointment,

ABC is now able to source and supply both OE and after-market equivalent components. ABC is in the process of establishing local stock holdings of a range of core brake units across the AUSCOcatalogue range as well as essential service kits and lining and friction materials. “Current users of any of these types of off-highway brake products are encouraged to contact ABC to discuss the suitability of one of the many qualityAUSCOproducts for any of their current and future requirements that they may have,” says Watson.

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Suppliers of backward curve motorised impellors V Pro

ALASKON AIRA LTD T 64 9 835 2100 F 64 9 835 2201 E info@alaskon.co.nz W www.alaskon.co.nz

HyDRAUliCS AND PNEUmATiCS

Bent axis piston motors and pumps HYSPECS has been appointed New Zealand distributor for the Hydro Leduc range of bent axis piston motors and pumps. Hydro Leduc is a specialist in the design and manufacture of piston pumps, hydraulic motors, hydropneumatic accumulators, and customized hydraulic components. Founded in 1938 by Rene Leduc, the company’s main activity was aeronautics – building Leduc aircraft and designing and manufacturing various hydraulic components in airplanes. In 1958 the company converted from aeronautics to hydraulics and then to excavator hydraulics in 1968. It now also offers a range of hydraulics for the transport industry and launched its first bent axis motors in 2005. M Series motors Available in displacements from 12cc to 126cc, MSeries (ISO) fixed displacement bent axis motors are suitable for intensive long duty requirements. The motors are designed for both mobile and industrial installations. Typical applications include vehicle transmissions, high power crushers, forestry equipment and heavy duty winches.

Maximum pressure, continuous and peak is 400 bar and 450 bar respectively. The continuous maximum speed is 3400rpm to 8000rpm, depending on the displacement. These MSeries motors are built to suit all applications to ISOstandard 3019/2. Also available are the MA(SAE), MSI (semiintegrated) and MXP (DIN) series. WSeries fixed pumps W series bent axis piston pumps from Hydro Leduc feature leading-edge design and displacements from 12cc to 108cc. These W pumps were developed to satisfy the needs of both the industrial hydraulics market (hydraulic power packs, units for machine tools etc) and the mobile market (construction equipment, drilling machines, mobile cranes etc). Delta Series variable pumps Designed for open loophydraulic circuits, the Delta range of variable displacement pumps allow optimized performance for a given application. The

flow supplied by the pumpis automatically regulated according to the hydraulic load. This guarantees minimized energy consumption, minimized heating Go to www. of fluid and reduced noise levels. demm.co.nz/enquiry quote: D110824

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New aerators for wastewater applications THE latest range of Aquaplus Aerators features the Jet Aerator and Submersible Aerator which are ideal for aeration, pre-aeration and mixing in the wastewater, sewage treatment and agricultural industries. The new Aquaplus Aerators have undergone rigorous testing and are backed by a two year warranty. Their high performance impeller makes them an ideal solution for a wide range of wastewater requirements. The new Jet Aerators (ARJ Series) are specifically designed to mix water with low levels of oxygen transfer and are idea in sludge mixing applications. The Jet Aerators are constructed from high quality materials including a low noise, high efficiency submersible motor and a high performance impeller to reduce downtime and ensure maximum efficiency. The required shaft power

hardly changes with fluctuations in water depth. The Submersible Aerators (ARS Series) are specifically designed to blow in microscopic air bubbles with the water, producing a high oxygen transfer rate. The Submersible Aerators come standard with 12 radiated outlets and a unique inlet strainer that prevents the impeller from being blocked by foreign material. The double mechanical seal offers the highest level of protection. The launch of the Aquaplus Aerators follows the launch of the submersible dewatering pumps and the submersible sewerage pumps Go to www.demm.co.nz/enquiry in late 2010. quote: D110824a

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Balluff’s new pressure sensors BALLUFF has introduced BPS, a newly developed series of pressure sensors with IP67 protection for use in gaseous and liquid media. The rugged devices feature a high-quality, long-term stable ceramic load cell and an especially attractive price/performance ratio, simple installation, high operating comfort and high precision. Alarge, bright and easily visible display shows not only the current system pressure in bar, mbar, PSI and MPa, but also features fast and simple configuration of the sensors according to the VDMAstandard, using two keys and intuitive menu guidance.

August 2011

With 11 pressure range versions the BPS sensors cover all the important ranges from minus 1–0 bar up to 0–600 bar for monitoring process media in factory automation. Typical applications include hydraulics monitoring as well as pneumatics equipment. The new Balluff pressure sensors, available in the standard model with plastic housing and in the high-end version with stainless steel, offer either two switching points or one switching output plus analog channel (0...10Vor 4...20mA).

Thanks to their highly compact design the sensors can be easily located in the control cabinet without taking up valuable space. The display with operating panel and electrical connection can be rotated independently of each other by 320-degrees with respect to the flange. Go to www.demm.co.nz/enquiry quote: D11082b

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HyDRAUliCS AND PNEUmATiCS

larzep jacks get the nod PORTS of Auckland has selected the Larzeprange of Mammut air hydraulic jacks for servicing their straddle container hoists. Paul Stephenson, the workshopsupervisor for Ports of Auckland, was looking to replace the existing jacks as they were proving unreliable. Some were even failing after only six months of use. Stephenson had found it frustrating to find a reliable heavy duty unit that didn’t require constant ongoing repairs. “We liked the heavy duty construction of the LarzepMammut jack, and just as equally important was the support supplied by Hytorc NZ,” he says. Graeme Drummond of Hytorc NZpoints out that the LarzepMammut jacks are manufactured in Europe and have been designed for use in the tough mining industry worldwide. The jacks range in capacities from 60 tonne to 150 tonne, with two or three stage telescopic rams available. An added feature is that they can be connected to a remote operating consol for better operator safety. The jacks can also be operated by hand pumpif there is no available air supply in the field. “These jacks have, understandably, proved very popular with users, especially in the Australian Go to www.demm. market,” says Drummond. co.nz/enquiry quote: D1108025

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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

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HyDRAUliCS AND PNEUmATiCS

One man pipeline maintenance REFACINGof smaller diameter pipe flanges can be a real problem where the job is in awkward or hazardous locations. Sometimes such pipes can be located right at the top of a refinery, mineral processing, wastewater or processing installation – or out in the field far from the nearest power source. One solution is the Enerpac QuickFace portable hand-powered flange facing tool, which was demonstrated recently to staff of one of Australian industry’s most safety conscious employers when Rio Tinto Alcan (RTA) hosted a Manual Handling Ergonomics Expo at Queensland Alumina Limited (QAL) Gladstone. Enerpac demonstrated some of the world’s most compactly powerful nonimpact bolting and pipeline technology at the Expo, including the lightweight (6.8kg) QuickFace tool, which turns a two man operation (with heavy equipment, compressors and portable generators) into a one-man job. The tool is suitable for a wide range of processing and pipeline-intensive industries. “QuickFace operation couldn’t be

simpler,” says Enerpac national bolting manager Pat Molloy, after demonstrating the tool to interested QAL staff, who said they had never seen anything like it. Molloy showed how, after selecting the correct lead screw for the operation, the tool body is inserted in the pipe end and centres itself with adjustable locators to provide truly concentric operation. The tool arm is then rotated by hand using a worm-gear mechanism to provide a perfect spiral “gramophone” finish around the flange. The tool can be adjusted with a calibrated slide to define cut depth and the correct finish. QuickFace has a wide mounting range of 25.4mm – 157.5mm IDand is capable of facing 25.4mm – 304.8mm OD flanges using standard half-inch cutting tools. In addition the tool can be paired with different lead screws making it suitable for resurfacing damaged raisedface or lens-ring joint flanges to high Go to www.demm. safety standards. co.nz/enquiry quote: D110826

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NEW

The Driving Force In Pneumatics

S/S Collet & FKM Seals

SERIES KQB2

Metal One-touch Fittings

Electroless Nickel Plated Brass

• • • • • •

www.smc.co.nz SMC Pneumatics (N.Z.) Ltd

August 2011

Compact and light

(Dimensions: Approx. 30% down - Comparison with KQBL06-01S) More tube sizes added (ø3.2 (ø1.8”) and ø16 have been added) More configurations varied (17 models 9 models)

Metric size x G thread added Applicable tube size (4mm - 16mm) Connection thread: M5 - G1/8, G1/4, G3/8, G1/2

Auckland (Head Office) 5 Pacific Rise Mt Wellington Auckland 1060 T (09) 573 7007 F (09) 573 7001 E sales@smc.co.nz

MAINTENANCE MATTERS High gloss corrosion protection MODERN Maintenance Products has been in the industrial coatings market for 18 years, and for the past 14 years has imported Rust-oleum Industrial products into the country. During this time, a New Zealand performance history has been established and one of the most popular protective coating systems has proved to be the solvent based Rust-oleum 9100 DTM Epoxy Mastic. This coating can be applied to new and old structural steel, towers, concrete factory floors, industrial equipment such as truck chassis, storage tanks, non potable water containment and sewage treatment plants, to name just a few. Rust-oleum 9100 DTM Epoxy Mastic comes with four activator options, including one for a low temperature cure down to five degrees Celsius, and another for water immersion in fresh or salt water, that can handle a constant immersed temperature of 52 degrees Celsius – with a pH band from three to 13. This coating system is easy to mix with a 1:1 ratio (base:activator) and if partially used, tins can be sealed and the product has a good shelf life of several years. Steel surface preparation can be minimal, but will still require degreasing and the removal of any loose rust or existing unsound coatings. Rust-oleum 9100 DTM Epoxy Mastic is not recommended to be applied over acrylic or chlorinated rubber coatings, and these would need to be removed completely

before application. Abrasive blasting is not normally required and as a maintenance coating in severe coastal and industrial environments, the 9100 system has performed well. Many New Zealand industries continue to specify and apply it for that reason. Rust-oleum 9100 can be brushed, rolled or spray applied with a pressure pot or airless system, and to new steel, for example, a single coat application can be applied at 200 microns DFT, curing to a high gloss finish. When applying to steel, application costs and downtime can be greatly reduced by being able to spray apply a single coat instead of up to three, in some cases. The product also comes with a range of tint bases so nearly all architectural colours can be achieved. The dairy and meat processing industries have 9100 applied to chiller panels that have been damaged by hot chemical washing and carcass impact – giving them a high gloss easy clean surface that can handle constant cleaning and impact. It can also be applied to concrete floors with a non-slip additive that is broadcast between coats. Rust-oleum 9100 can be the primer coat for other high performance exterior topcoats that Rust-oleum produces – where maximum UV or protection from severe chemicals is required. Go to www.demm.co.nz/ enquiry quote: D110827

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INDUSTRIAL COATINGS

RUSTOLEUM 9100 EPOXY MASTIC SYSTEM • For superior corrosion protection that requires no priming • Excellent chemical, abrasion & impact resistance • Easy to mix - easy to apply • Single or multiple coats, cures to a high gloss finish • Greatly reduced application time and cost • Wide range of colours • 14 year NZ track record

EAT! HARD TO B CONTACT NZ DISTRIBUTOR: Modern Maintenance Products (NZ) Ltd Free Phone: 0800 180 677 Email: mmp.nz@xtra.co.nz Visit Website: www.mmpcoatings.co.nz

CORROSiON CONTROl

improving the life-span of assets

The Ruahihi penstock.

Manufacturer of high performance protective & marine coatings World Class technology Strong Global Network Applicator/Contractor Support

April 2011 August 2011

ALTEX Coatings is New Zealand’s largest manufacturer of protective coatings for both industrial and marine use. For more than 55 years Altex Coatings has been focused on protecting assets from corrosion and excessive maintenance costs. Altex has a diverse range of skills within its workforce – from sales staff in the field, through to the largest technical team within New Zealand to service the needs of its diverse client base. The two key points of focus for Altex are the initial coating system when the structure or equipment is built, and secondly, suitable maintenance regimes during the life of the asset. The company constantly aims to improve the lifespan of assets through designing coatings systems that protect valuable equipment in the most harsh industrial environments. As part of this service, Altex Coatings provides a Durability Assessment, based on the coating system and the environment where maintenance repaint work can be forecast up to 15 years ahead of time – enabling budgets and planning to be completed by the asset owner. This also means that

the owner can have a series of coating options, based on cost and durability, from which he can select what is appropriate for the organisation. The team of technical advisors at Altex have specialised qualifications in chemistry, engineering and coatings technology. And virtually all staff have coatings inspection qualifications from both NACE and the Australasian Coatings Association. To provide a recommendation regarding the maintenance repaint of a structure, a site visit and inspection is generally required by one of the company’s highly experienced sales staff. Considerations such as the environment, chemical exposure, health and safety, budgets and accessibility all need to be considered when drawing up recommendations. A formal specification is written, which becomes a key component of the tendering process. A prejob meeting with both the asset owner, the contractor and an Altex representative is another service that Altex facilitates to ensure the smooth running of a project. Once the project is underway, Altex further assists with on-site inspections and assisting the applicator with advice regarding application of the materials. Ruahihi penstock The Ruahihi penstock, located in the Bay of Plenty, required its exterior to be repainted. Back in 1984, Altex had supplied the coatings for the original fabrication of this penstock. The asset owner, Trustpower, requested an inspection of the pipework and a specification from Altex prior to putting the work out to tender. Trustpower contracted TBS Farnsworth to undertake this maintenance repaint project, which was completed to specification, on time and within budget. Interestingly, the industrial coatings manager for the TBS group, Cass Seeling, had sandblasted and painted this pipework prior to installation some 20 odd years prior! Go to www.demm.co.nz/ enquiry quote: D11828

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The right choice in lubricants

CORROSiON CONTROl

in-house plasma cutting made easy

GETTING started in in-house plasma cutting is now affordable. Advanced Robotic Technology (ART) in Brisbane has introduced the new SMART XR plasma profile cutting machine, designed with a small footprint to suit small to mid-sized shops. The SMART XR plasma cutter offers reliable plasma technology at a low investment

cost, yet featuring a high level of performance and features. Available in 1.6 and 1.9-metre wide process areas, the machine is designed to work with most commonly available sheet and plate sizes and thicknesses. The large user-friendly touch screen controller runs the latest version of ART’s ProfileShop software.

ProfileShop allows unparalleled usability over all machine functions through the company’s innovative touch-screen interface, giving the user control over each job while maintaining simplicity of use. On-screen displays give upto-date information on settings and plain-English messages warn of low gas pressure and other information. The controller features a comprehensive internal database which is optimised with settings for each material to make cutting a breeze. Moreover, the SMART XR plasma profile cutters are fully integrated with Hypertherm’s fourth generation PowerMax plasma torches. Operators now can easily cut metal that may have been hard to process in the past. Smart Sense technology automatically adjusts gas pressure to the cutting mode and consumable selection. Spring Start technology in the electrode increases reliability by eliminating moving parts in the torch body.

In addition to reducing production costs by improving productivity, PowerMax systems run on shop air. There's no need for bottled gases. And the technology improvements incorporated in new plasma systems can result in lower costs from longer consumable life. The new SMART XR plasma series features high-speed AC servo motors coupled to quality German planetary gear and rack and pinion drives. These work in conjunction with the advanced motion control algorithms to give the highest quality cut available with air plasma. Go to www.demm.co.nz/ enquiry quote: D11830

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ISO 9001 : 2008

PO BOX 164, WAIUKU PHONE 09 235 7679 MOBILE 021 475 407 FAX 375 8239

April 2011 August 2011

lUBRiCATiON

Advanced food grade grease RESEARCH and development spanning more than 25 years has resulted in Petro-Canada producing over 350 products which are utilised in around 60 countries worldwide. For customers here in New Zealand it means leading edge lubricants that exceed expectations for performance and quality. One such product is Purity FG Food Machinery Grease – an advanced food grade lubricant specially formulated to deliver superior performance and food grade purity under the highly demanding conditions found in food processing plants. Purity FG Food Machinery Grease resists breakdown in harsh operating environments. It maintains consistency and lubrication in the presence of food acids, juices and by-products. The grease won’t run from bearings under steam cleaning or near ovens – and it is highly resistant to water washout, water jet spray and most sterilizing chemicals used in cleaning. The grease is effective across a wide range of temperatures. It is pumpable at low temperatures and ideal for heavily loaded bearings operating under wide temperature fluctuations. There’s better protection of gears, bearings and processing equipment under shock loading too – the grease prevents seizure, scuffing and spalling in these conditions. Purity FG Food Machinery Grease provides long-term equipment protection from rust and corrosion. It is non-staining, and because the one grease can be used for a wide variety of applications, there is less inventory to carry and less chance of applying the wrong grease in a critical application. Purity FG Food Machinery Grease is fully approved for use in and around food processing areas and is NSF H1 registered. Go to www.demm.co.nz/enquiry quote: D110831

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HAVE YOU BEEN TO OUR WEBSITE LATELY?

Beyond today’s standards MAF C15/ NSF H1 food grade lubricants, ammonia refrigeration & industrial lubricants for gears, chains, compressors, hydraulics & greases call: THE CANADIAN OIL COMPANY LIMITED 09 837 11784 (fax 837 1708) patriciadavis@xtra.co.nz

www.demm.co.nz 31

lUBRiCATiON

Food grade lubricants exceed standards MOREYOil South Pacific is a privately owned family company based in Auckland, with a distribution branch in Brisbane, Australia and representation throughout the South Pacific as well as further afield. The company has access to the most advanced technologies in lubrication, and can supply and package to individual requirements. The Morey’s and Guardian brands offer a complete selection of USP and food grade lubricants that meet or exceed food industry requirements – such as NZFSA, Asure Quality,NSF H-1, FDA, NSF and Kosher. This, coupled with Morey’s ISO9001/2008 certification, ensures packaging and quality standards remain consistent each and every time an order is placed. “This gives you the peace of mind to focus on selling quality,” says company spokesperson Andy Slater. Morey’s and Guardian food grade lubricants are blended and

packaged in a dedicated‘White Oil’ facility, enclosed in a “dust free” clean room specifically designed to meet the cleanliness standards for NZFSA, Asure Quality, H-1 food grade lubricants. Technical and USP White Oils are finished products,

quality controlled and tested on site at a full service laboratory, measuring from basic viscometrics to laser particulate matter readings. This ensures maximum protection, product integrity and purity. Morey’s/Guardian food grade

lubricants are designed to be used in food processing and bottling plants. All are authorized for use in federally inspected meat and poultry plants as well. Go to www.demm.co.nz/ enquiry quote: D110832

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New distributor for Baroid drilling fluids BAROIDIndustrial Drilling Products has recently appointed AB Equipment to handle the distribution and marketing of the Baroid product range in New Zealand. AB Equipment stocks a full range of Baroid directional drilling products including: Bore-Gel (maximizes carrying capacity with high suspension sodium bentonite); EZ-Mud and Poly-Bore (both liquid clay/shale stabilizers, reduce swelling/sticking); Penetrol (a wetting agent to reduce clay balling/ sticking to reamer); Aqua-Clear PFD (a phosphate-free mud thinner to reduce frac-out potential); Quik-Trol LV(a fluid loss control polymer); No-Sag (a suspension enhancing biopolymer for gravel/cobble); N-Seal (a mineral fibre lost circulation material for sand/gravel/cobble); and Diamond Seal (swellable lost circulation polymer). Baroid Industrial Drilling Products is committed to the protection of the health and safety of all who may use or come in contact with the products, and to environmental stewardship. To adhere to this

August 2011

commitment the products are independently certified to NSF/ANSI Standard 60. The guidelines of this standard cover the health effects of drinking water treatment chemicals including drilling fluid products and additives. The standard addresses the health effects implications of these products and treatment chemicals and their related impurities. The two principle questions addressed are, first, is the chemical safe at the maximum concentration, and second, are impurities below maximum acceptable levels. The answer to both questions must be yes to be certified. “AB Equipment is committed to providing a superior level of service to the Vermeer HDDmarket,” says AB Equipment’s national sales and marketing manager – parts, John Familton. “Baroid and Vermeer’s Cutting Edge tooling programme combined with an increased coverage on proprietary parts and a focus on training will ensure that this new partnership will be an overwhelming success.” Go to www.demm. co.nz/enquiry quote: D110832a

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lUBRiCATiON

Ammonia refrigeration compressor fluid PETRO-Canada’s Reflo A is an ammonia refrigeration compressor fluid used in industrial refrigeration systems. It is formulated to outperform solvent refined paraffinic and naphthenic refrigerant oils by extending service life while significantly reducing operating costs. Reflo A’s superiority results from more than 25 years formulating experience. Using a patented HT purity process, Petro-Canada produces 99.9 percent pure base oils – one of the purest in the world. Free of impurities that can hinder fluid performance; these crystal clear base oils are fortified with specialty selected additives. The result is a refrigeration compressor fluid that offers reliable, long-term performance with significant operational cost savings. Reflo A’s lower oil volatility reduces fluid consumption and maintenance costs. Its lower solubility in ammonia

improves system efficiency and performance. Excellent resistance to oxidative and thermal breakdown guards against oil thickening, deposits and sludge formation. Additional performance benefits of Reflo A refrigeration compressor fluid include: • A high viscosity index ensures proper lubrication and protection from wear over a wide range of operating temperatures. • A high flash point ensures safe operation at elevated temperatures. • Reflo A provides some rust and corrosion resistance to help protect components from attack by moisture and chemical impurities. Reflo A is formulated to lubricate ammonia refrigeration compressors used in large commercial operations such as cold stores, food processing plants, marine systems and ice arenas. Reflo A is also used in manufacturing industries that

require low temperature control, such as pharmaceuticals and microelectronics. The product can be used in ammonia refrigeration systems where evaporator temperatures are greater than minus 42 degrees Celsius. Reflo A is approved or meets the requirements of most major

compressor OEMs. It is acceptable as a lubricant in and around food processing areas where there is no possibility of food contact and is NSF H2 registered. Go to www.demm.co.nz/ enquiry quote: D110833

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MAINTENANCE MATTERS

Good maintenance is all about TlC

WHEN I say‘good maintenance is all about TLC’ I’m not talking about the kind of TLC that your ‘significant other’ insists on from time to time. It’s much easier to define what is needed to satisfy the TLC requirements of plant and equipment. It comes down to Tightness, Lubrication and Cleaning – if we could get those three basic components of maintenance right we could easily halve equipment failures.

In one study it was found that 55 percent of all failures can be directly or indirectly attributed to incorrect tightness of fasteners. Imagine halving your equipment failure rate – it could be as simple as ensuring fasteners are correctly tightened and secured. I spent the first 16 years of my maintenance career in the aviation industry, which is arguably the most rigorous of industries when it comes to applying standards, and one in which correct security of fasteners

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August 2011

is paramount. Even so, I can still relate failures that were caused by the incorrect tightness of fasteners. Thankfully there weren’t many, but there were still somewhat frightening instances. Like when a pilot took a jet fighter for a flight test after a major service and as he pulled back the control stick on take-off the artificial horizon indicator gauge fell out onto his lap! In fairness, the guy popped it back in the hole and carried on, but it fell out because somebody (not me I hasten to add) hadn’t secured it. Tightness of fasteners is a crucial and fundamental part of maintenance. How easy is it for maintenance technicians on your site to get hold of an accurate torque wrench? When was the last time your torque wrenches were calibrated? We must ensure we are using the correct fastener; that it is correctly tightened and just as importantly that it is correctly secured. Abolt needs to be correctly tensioned to do the job for which it was designed. If it is over-tight it will become stretched and weakened. If it is under-tight it won’t do its job and could be put under shear forces it wasn’t designed to endure. If ‘T’ is for tightness then ‘L’ is for lubrication. This is a huge subject but let’s just look at how we store and care for lubricants. Every day, maintenance personnel unknowingly use lubricants that are mixed, chemically depleted, contain particulate, or are contaminated with chemicals or moisture. Lubricants should be considered working components in mechanical systems and great care should be taken in their shelf life, their storage and keeping them free from contamination. The three big enemies of lubricants are varying temperatures, temperature extremes and humidity. All of these can lead to condensation within containers, chemical degradation and moisture ingress. When it comes to lubrication, before we start looking into better and more high tech lubricants to solve our issues, we should look a little closer to home. Where are we storing our lubricants and under what sort of conditions? Do we have a procedure to regularly check for the shelf life of our lubricants? ‘C’ is for Cleaning. As engineers we love to play with gizmos like vibration analysers and thermographic

cameras – but give us a rag and ask us to clean a motor and we will probably find any reason not to do it. Amotor running as much as ten degrees over its intended operating temperature will last about half its intended life. Why is it running hot? Probably because it’s covered with sawdust/chemical residue/ milk powder, etc. Not only will cleaning ensure equipment runs at its intended temperature but it will also give us a proper opportunity to examine it. As one student on a recent maintenance course put it “Cleaning with meaning”. Don’t just clean equipment, take the chance to give it a really good examination. Many of the inspections carried out on aircraft engines are a simple clean and examine routine. We were always taught to use a torch to focus on the area in which you are looking, as this is a great way to ensure your attention doesn’t wander. Cleaning and examining must be more than a cursory wipe-over with a rag and then back to the smoko room for a cup of tea. Cleaning equipment is one of the worst jobs we have to do but is one of the most vital, as it gives us the opportunity to spot leaks and check for loose fasteners and early signs of failure such as cracking or fretting. Next time you are wondering how you are going to meet your reliability KPIs, before you look at more fancy equipment or introduce complicated new processes, make sure you are giving your equipment some TLC. Tightness, Lubrication and Cleaning will always be the cornerstones of good maintenance and reliability. Article by Phil Hurford, manager of the Skills4Work Maintenance Excellence programme. Email: p.hurford@ skills4work.org.nz Go to www.demm.co.nz/ enquiry quote: D110834

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MAINTENANCE MATTERS

A guide to air purifying respirators THE fundamental goal of any respiratory protection program is to control occupational diseases caused by breathing air contaminated with harmful dusts, fogs, fumes, mists, gases, smokes, sprays, and/or vapours. The defence against these contaminants is simple: keep them out of the air that workers breathe. Always implement engineering and/or administrative controls first. If contaminants still present a hazard, you must provide appropriate respiratory protection for every employee who might be exposed to them. MSAcan help you take a comprehensive approach to sound Respiratory Protection practices. It is extremely important to understand the need for respirators, how they work, and what their limitations are. AS/NZS 1715/1716, OSHAand NIOSH(the National Institute of Safety and Health) regulations define all the specific requirements which must be followed, including the capabilities of appropriate respiratory protection. Employers must follow the requirements of these governmental regulations, both the general regulations which

apply to all workplaces and the specific regulations for exposures in their particular industry, such as lead, silica dust, asbestos, and benzene. AWritten Respiratory Protection Programme is covered in seven steps: 1. Administration Establish written standard operating procedures governing the selection and use of respirators. Regular inspection and evaluation of the program will ensure its continued effectiveness. Awritten program will help employers, employees, and compliance officers gauge the adequacy of a given program. 2. Hazard Assessment Proper assessment of your specific hazard(s) is the first important step to protection. This requires a thorough knowledge of processes, equipment, raw materials, end products, and by-products that can create an exposure hazard. 3. Hazard Control Hazard control should start at the process, equipment, and plant design levels where contaminants can be controlled effectively at the outset. With operating processes, the problem becomes more difficult. In all cases, however, attention should be given to the use of effective engineering controls to eliminate and/or reduce exposures to respiratory hazards. 4. Respirator Selection Know what level of respiratory protection employees

need, as well as which size respirator is right for any face and facial contours. Respiratory protective devices vary in design, application, and protective capability. Thus, the user must assess the inhalation hazard and understand the specific use limitations of available equipment to assure proper selection. 5. Training Users must be properly instructed in the selection, use and maintenance of respiratory protection devices. Both supervisors and workers must be instructed by competent persons. 6. Respirator Care Proper inspection, maintenance, and repair of respiratory protective equipment are mandatory. The goal is to maintain the equipment in a condition that provides the same effectiveness as it had when it was first manufactured. 7. Medical Surveillance According to OSHA, “using a respirator may place a physiological burden on employees that varies with the type of respirator worn, the job and workplace conditions in which the respirator is used, and the medical status of the employee.” Employers must determine an employee’s ability to use a respirator. Workers should never be assigned to any operation requiring respiratory protection until a physician has determined that they are capable, physically and psychologically, to perform the work using the Go to www. respiratory protective equipment. demm.co.nz/enquiry quote: D110835

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MAINTENANCE MATTERS

Pipe stoppers aid maintenance COLLAPSIBLE pipe stoppers from Air Springs Supply can compactly fit around obstacles, corners and into previously inaccessible areas of surface, underground and underwater pipelines. The custom-fabricated and stock ranges of Pronal UniPlug stoppers – recommended for low-pressure applications – are water-tight and easy to install for maintenance, testing and emergency tasks. These include pipe repair, insulation of areas for welding, sealing of mine levels and isolation of risers in factories, power plants, water utilities and other infrastructure. Produced in stock diameters from 50mm to 1600mm – with larger custom-fabricated sizes available for particular applications – Uni-Plugs are a tough advanced technology product from the internationallyrespected Pronal organisation, which produced the enormously strong inflatable bags used to lift sections of the liner Titanic from

nearly four kilometres deep in the Atlantic. The reusable Uni-Plug range is made from reinforced fabric coated with synthetic elastomer, says James Maslin, sales manager for Air Springs Supply. “Space is often at a premium in pipelines serving complex industrial and infrastructure structures - such as desal and municipal water plants, power plants, mines and offshore rigs - and spaces available can be awkward for conventional stoppers to reach,” he says. “One of the beauties of the Uni-Plug system is that it can be collapsed into confined spaces then inflated at the place where it is needed. The quality of the product provides top levels of safety and reassurance, with Pronal products having been proven worldwide in both military and civil applications.” Go to www.demm.co.nz/ enquiry quote: D110836

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Uni-Plugs, left, and pipeline plugs from Pronal’s broader range

Planning & Scheduling for Planners 4 Day CourSe

Course Highlights

Leads to unit standard 26566 – Demonstrate Knowledge of Planning & Scheduling in BCM. Part of level 5 National Certificate in Mechanical Engineering. Training for existing planners and schedulers can increase tradesmen time on tools by 50% or more. Teach planners the tools they need to take planning to the next level.

Course content includes:

Freeing up of technician’s time with more effective planning and scheduling Improving the scoping of work orders

Developing plans to identify critical path, slack in the current system and resource identification Major maintenance event (annual shut) planning and management

Understand good work management process and subprocesses

Dates/Locations 14 – 17 June, Rotorua

23 – 26 August, Auckland

Investment $1,680 + gst

29 November – 2 December, Auckland

For more info: www.skills4work.org.nz or contact Phil Hurford p.hurford@skills4work.org.nz 027 488 6446

August 2011

Highly functional emergency stop switches XN4E series emergency stop switches from IDEC are the first and only to enable maintenance technicians to install up to 20 personal padlocks – preventing unauthorized resetting of the latched emergency stop switch and making service or maintenance safer to perform. The 30mm XN switches also incorporate the unique ‘Safe Break Action’. Only IDEC switches ensure NC contacts open when the contact block is separated from the operator. NC contacts of conventional E-Stops remain closed if the contact block gets separated from the operator. That means your E-Stop button may not be able to communicate to stop your machine, leaving workers at risk of accident, injury or worse. ‘Direct Opening Action’ ensures that even if the contacts are welded, the force applied on the button will directly open the contact. ASafety

Interlock Mechanism keeps contacts open when the operator is locked. The XN1E series of E-Stops also save you space behind your panel with depths of only 47.7mm for four contacts. The XN5E series only extends 21mm from the front of the panel, reducing the surface area for dirt or dust to collect. Go to www. demm.co.nz/enquiry quote:

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D110836a

MAINTENANCE MATTERS

Special edition power quality analyser

Committing to the future

Next Generation! With the professional Testo data loggers, a new age begins for you

Logger series testo 174

Logger series testo 175

Logger series testo 176

FLUKE’s new 434/PWR Power Quality Analyser helps electricians, field service engineers and maintenance technicians uncover energy waste in commercial and factory buildings as well as in equipment and machines. The 434/PWR can be used to conduct energy consumption studies and electrical load analysis, and perform power quality logging and analysis surveys. It can also help technicians demonstrate the benefits of efficiency improvements by testing energy consumption. The instrument measures harmonic distortion caused by electronic loads, and analyses reliability problems by capturing voltage dips and swells from load switching. A full-colour display uses industry-standard, user-selectable colour coding to correlate measurements with actual wiring. It logs incoming data with a unique AutoTrend function that highlights changes of data over time. The data can then be analysed with Fluke’s Power Log software, included with the 434/PWR. AutoTrend gives quick insight

into changes over time. With a push of a button, the system monitor gives an overview of power system performance. It also checks that incoming power complies with standard limits or custom specifications. Trend analysis is made easier by automatic scaling of the vertical axis, so waveforms can always be shown on a full display. The 434/PWR can perform extensive data analysis. Cursors and zoom can be used “live” while taking the measurements, or ‘offline’ on stored measurement data. The stored measurements can also be transferred to Power Log software. Designed to quickly view recorded data, the built-in Power Log displays all recorded parameters on interactive trends. Users can generate professional-looking, customised reports using the report generator, or copy and paste images into reports manually. Go to www.demm.co.nz/ enquiry quote: D110837

The new generation of Testo data loggerss Record the temperatures in refrigerated and deepfreeze rooms reliably, and if required additionally monitor the product temperature – e. g. with the testo 175 T1 – certied according to DIN EN 12830 Your benets from the new Testo data loggers: • High user-friendliness thanks to easy programming and readout via standard interfaces (Mini USB, SD card) • Security thanks to password protection and anti-theft lock • Large memory for up to 2 million measurement values (testo 176) • New software ComSoft Basic 5 as a free download

•

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

MAINTENANCE MATTERS

National Conference ‘Brings Back Buck’! By Craig Carlyle.

WE’RE bringing back Buck! Yes, you heard it right – the MESNZ is bringing iconic All Black captain, World Cup commentator and latter day men’s health advocate Wayne ‘Buck’ Shelford to Rotorua to fill the closing celebrity speaking role at the Hydac 2011 National Maintenance Engineering Conference. Buck’s journey after his All Black career controversially ended led him to become the poster boy for the Jenny Craig weight loss program and it is his life experiences from the world of rugby to men’s health that Buck will draw on to inform and entertain. But it’s not just the end of the conference that will deliver the bang; the entire two day event is peppered with experience, advice and inspiration. As promised last month, the conference schedule is rapidly firming up as we shuffle speakers into their slots and welcome attendees, exhibitors and sponsors into the mix. Conference papers will cover drive-train issues, counterfeit materials, chemical safety and HASNO, ultrasonics, machine tool alignment, lean manufacturing and plant justification, to mention just a few. The IPENZ paper on “Earthquake Engineering Performance” and Mike Mulholland’s “Fits, Fights and Fornification” Employment Law presentation in particular, will command

August 2011

riveting attention from the attendees. Featuring an eclectic mix of international, expert and peer speakers, this year’s program is well worth the wait, satisfying the ethos of reality-based maintenance management topics and the Society’s aim of raising the bar of maintenance engineering in New Zealand. The Conference will inspire all attendees and arm them with the knowledge to take positive change back to their own workplaces. For the latest updates on sessions and times, as well as program details and registration forms, click on www.mesnz.org.nz/nmec/. Last year’s sponsors saw so much value in what the event delivers and they are back with a vengeance in 2011. Supporting Hydac’s premium sponsor role, SKF has taken up the Exhibition Hall and Marquee sponsorship, while SGS instantly won a lot of new friends with their sponsorship of both the social night and the social night drinks. It is easy to take events like the National Maintenance Engineering Conference for granted, forgetting that it is run by a nonprofit Society and it is only with the support of companies like Hydac, SKF and SGS that the Society is able to stage the event. Rotorua is primed and ready to showcase its local maintenance engineering expertise to a national audience just as keen to explore the best the region has to offer. Registrations are open and bookings are ahead of schedule – a good indicator that maintenance engineers are keen to network and explore ways of lifting the engineering game in their own place of work. If you have not yet booked, Rotorua will be the place to be if you want to learn from your peers and experts about how to manage

maintenance in the modern world or get up to speed with the latest regulations and requirements of people management. So, for the cave dwellers, yes, you need to be there and, no, it’s not too late….if you hurry. The Hydac 2011 National Maintenance Engineering Conference is being held at The Distinction Hotel in Rotorua on November 9 and 10. The event presents a popular format of thought provoking papers, while providing ample breakout opportunities for engineers and suppliers to explore solutions to their particular issues. The attendance fee of $680+GST per person makes it the cheapest two day conference in the country. If that’s not good enough, the second and subsequent attendees from your site may attend for a miserly $400+GST per person! A better bang for your buck will not be found anywhere else for such an inspiring and informative event. Registration forms and background details can be found on the Society website at www. mesnz.org.nz/nmec/ or you can contact the event manager Leanne Powley direct on (09) 296 1333 info@adminoncall.co.nz or www.mesnz.org.nz Craig Carlyle is secretary of the Maintenance Engineering Society.

Photo courtesy of Destination Rotorua Marketing.new burner.

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EVENTS

MHl 11 keeps business moving ON September 21 to 22 New Zealand’s materials handling, warehousing and logistics industry will showcase the latest supply chain solutions at MHL 11, the sector’s premier trade show. With over 50 exhibits and a live, interactive theatre and seminar programme, MHL 11 is your one-stop destination for materials handling, warehousing and distribution solutions. Register online today for complimentary admission to the MHL Show, seminars and live demonstration theatre. MHL 11 is two days of comprehensive problem solving and networking to provide attendees with solutions to the complex supply chain challenges facing industry. Registration is free and can be easily completed by visiting www.mhlshow.co.nz. Registration also permits access to The National Safety Show 11, which is held in conjunction with MHL. MHL 11 offers much more than your standard, static trade event. Scott Kerr and Les Wootton from Kerrect Interlogic (on stand 260) have teamed up once again to create the Advanced Automation Theatre, featuring live demonstrations of the latest in automated warehousing systems. PowerSave Light Company on stand 248 will showcase its range of commercial and industrial

lights – proven to have halved the running costs of typical business lighting systems. PowerSave will also provide the lighting for the Advanced Automation Theatre which will feature live demonstrations three times during each show day. Oak Tree Devanning on stand 234 specialises in container devanning and prides itself on operating fast, accurately and with fixed costs. With branches in Auckland and Christchurch, Oak Tree Devanning annually awards the Mike Cooper Cup to the top devanners of the year. At MHL 11, the top devanners from Auckland face off against the top devanners from Christchurch for The Pride Cup – the MHL version of the Ranfurly Shield. Witness the fastest display of unwrapping, re-stacking, shrink wrapping and racing ever attempted in New Zealand. One repeat exhibitor, Dematic on stand 257, a global leader in intelligent logistics and materials handling solutions, will amaze crowds with its voice-directed computing technology and new supply chain software, allowing SMEs to integrate voice-directed computing into their warehouses on their current system. Secure ALoad on stand 237, a leading supplier of cargo handling and load restraint systems, will prove the advantages of investing a little to reduce

theft and make the transport and handling of materials safer. Two shows, two days, one venue The National Safety Show, now in its third season and already established as New Zealand’s largest workplace safety event, features three streams of professional seminars run by exhibitors and health and safety experts. Visitors can look forward to the most current equipment, up-to-date services, developing technology, product launches and industry knowledge at New Zealand’s one-of-a-kind trade show. MHL 11 and The National Safety Show 11 will be held in pavilions one and two at the ASB Showgrounds on 21 and 22 September. For further information, visitor registration, exhibiting enquiries, and a list of current exhibitors, go to www.mhlshow.co.nz or www.safetyshow.co.nz

•

Two Shows... Two Days... Days...One Venue... Wednesday 21st & Thursday 22nd September 2011 ASB Showgrounds, Auckland

the materials handling warehousing and logistics trade show (held in conjunction with the national safety show)

r k e e p y o uo v i n g m business r e g is te r

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August 2011

iNDUSTRy WATCH

Vineyard grows its own bioenergy A MARLBOROUGH wine producer has slashed nearly $170,000 off its annual heating bill by swapping LPG for one of its own waste products: vine prunings. Yealands Estate has replaced its LPG-fired boiler with two wood-burning boilers to produce the heat it needs for winemaking. But instead of wood, the vineyard is burning off-cuts from its own grapevines. The result, based on its 2011 harvest, is a drop in LPG consumption of more than 466,000kWh and a saving of $168,000 – in just one year. Because burning the vine prunings is carbon neutral, the company also looks set to cut CO2 emissions by 161 tonnes a year, further enhancing its green credentials in export markets. The project was supported with funding from the Energy Efficiency and Conservation Authority (EECA). “It’s not brand new technology,”

says winery owner Peter Yealands. “Humans have been heating water by burning things since the dawn of history – this was just a new application for old knowledge. “The deal maker was, when we did our sums, the payback was extremely good. So we’re happy from an environmental view, and our accountants are happy too!” Yealands uses less than ten percent of its vine prunings to fire the boilers, with the rest mulched into the ground as before. With more than 18,000ha in Marlborough planted in vines, the region’s vineyards could potentially provide as much as 0.5 PJ in heat energy – equivalent to the amount of electricity used every year by 14,000 homes. The two 250kW Central Boiler Pallet Burners cost $187,600 to install. At current production levels, they will pay for themselves in less than 18 months. EECA promotes innovative energy-saving and renewable

Peter Yealands with baled prunings and the new burner.

energy projects with funding, advice and support. For more case studies on companies saving energy, reducing costs and

converting to renewable energy, see www.eecabusiness.govt.nz/ case-studies

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Shell celebrates centenary at Oil & Gas Expo SWAN Exhibitions and Energy Publications are proud to announce that Shell New Zealand will have a display at the New Zealand Oil & Gas Expo in August to celebrate its 100 year anniversary in New Zealand. Added to this milestone is the news that New Zealand is one of the top five countries in the world for oil and gas exploration. Its offshore resources have been compared to that of the North Sea in terms of petroleum production by the Institute of Geological and Nuclear Science. Along with Shell, the following exhibitors are the most recent additions to the growing list of companies that have joined the New Plymouth exhibition: HV Power Measurements and Protection, Instrumatics,

Teltherm Instruments, CPS Limited, Entire Fire, Kernohan Engineering, Roxar Pty Ltd, Sensear, Forman Building Systems and the Directorate General of Oil and Gas for the Republic of Indonesia. A full list of exhibitors can be viewed at www.nzoilandgasexpo.com.au Swan Exhibitions welcomes all new exhibitors and past supporters, for what promises to be an exciting event at the TSB Stadium in New Plymouth on August 10 and 11. The New Zealand Oil and Gas Expo and Conference will again feature the industry’s A-listers as ‘the land of the long white cloud’ proudly showcases its resource achievements and potential to an international audience.

•

iNDUSTRy WATCH

Tell your forklift story, win prizes MITSUBISHI forklift owners and operators can now be in to win with Centra Forklifts. This year Centra Forklifts celebrates 30 years of an exclusive partnership with Mitsubishi in New Zealand and the company wants everyone involved with Centra and Mitsubishi forklifts to share in the celebrations. The Centra Mitsubishi Forklift ‘Tell us your story’ competition invites Mitsubishi forklift owners and operators to submit their stories about how their Mitsubishi forklift truck has helped in everyday work or added value to business operations. In October Centra Forklifts will

select and announce regional finalists and each will receive a limited edition Mitsubishi forklift truck model plus a Speight’s Alehouse voucher. Regional finalists will go into a draw for the grand prize of a 12-month forklift service contract to the value of $1000. People can also vote for their favourite entry online in the People’s Choice Award. Entry forms are available online at www.centrafork. co.nz or from Centra Mitsubishi dealers. The competition closes on 30 September 2011.

•

AB Equipment’s new premises at the Mount ACCORDING to AB Equipment’s Niall Farrell a bigger workshop and better access are just two of the main benefits of the new Mount Maunganui location at 5 Triton Avenue. “The repositioning is an important step for the company and will give us the opportunity to provide some additional enhancements that will further strengthen our long standing relationships with the local business community,” says Farrell. “Being able to display new equipment on a road frontage is something we didn’t have before with the old premises. This alone

will create greater opportunities to promote and market our equipment.” AB Equipment has a long history with the Bay of Plenty. The building signals the start of an exciting new era for the company and confirms its commitment to providing materials handling and forestry related products to one of the country’s fastest growing export regions. The new building will accommodate a range of after-market support services, with expanded areas for workshop maintenance, parts and operator training featuring strongly.

•

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April 2011

iNDUSTRy WATCH

Spray dryer facility a first THE Minister of Agriculture, Hon David Carter, has turned the first sod at the Waikato Innovation Park in preparation for constructing New Zealand’s first and only independent product development spray dryer. The $11 million spray dryer facility will open in May 2012 and is the third building on the 17-hectare campus of the Waikato Innovation Park in Hamilton. “With New Zealand's future growth firmly based on primary production, it is imperative we continually seek innovative food and beverage sector opportunities,” says the Minister. “The New Zealand Food Innovation Network and this development for the Waikato Innovation Park are important steps in making this happen." Waikato Innovation Park Chairman, Michael Spaans, indicates the dryer is one solution that can help the dairy industry move further up the

product value chain. “Our spray dryer will give dairy companies an opportunity to research and develop high-value products, which is very difficult to do in large, commercial factories,” explains Spaans. The spray dryer is the Waikato component of the Ministry of Economic Development-sponsored New Zealand Food Innovation Network. Waikato Innovation Park’s parent company, Innovation Waikato Ltd, has formed a subsidiary – New Zealand Food Innovation Waikato Ltd – to own and operate the dryer. CEOof the subsidiary, Derek Fairweather, says the spray dryer “will initially be set up to allow companies to research, develop and manufacture new milk powders. However, the medium-term strategy is to expand the plant’s capability to manufacture infant formula.”

•

Michael Spaans and Hon David Carter turning the first sod.

Oriental Motor partners with John Brooks ORIENTAL Motor Company (OMC) recently confirmed John Brooks Ltd as its automation partner in New Zealand. OMC’s motto is ‘to contribute to the automation needs of every industry, for everyone, everywhere, with small precision motor products’. Oriental Motor Co. manufactures AC standard motors, speed control motors, brushless DC motors, stepping motors, controllers, linear and rotary actuators as well as fan motor products. The Kseries AC motor and modular gearbox combination is available off the shelf in New Zealand. The full motor range is from one, six, 15, 25, 40, 60 to 90 watt 230Vac

single and three phase, with variable speed options. Inline and right angle gearheads mount to the motor with mounting bolts provided – offering a compact and cost efficient combination. The FPW Series are geared motors which conform to the IEC standard IP67 (recognized by UL) – ideal for applications where there is water. These watertight induction motors are available in 25W, 40W, 60W and 90W models. The AC 5-Phase RKStepping motor and control Series incorporates new functions and state-of-the-art technologies to achieve the ultimate

use of a control motor. The Series offers various types including the standard type, electromagnetic brake type, IP65 rated motor type, and four geared types. Three frame sizes of 42mm, 60mm and 85(90)mm are available. Vibration commonly found in most stepper motors is drastically reduced, thanks to the RKSeries vibration control circuitry. The EZS ll Series Linear Slide can perform positioning at high speeds, supporting large transportable mass. The structure of this motorized linear slide has been optimized to achieve greater convenience and performance

in positioning applications. The compact design facilitates installation and wiring to your system. Also from OMC, and now available from John Brooks Ltd is the NX series AC Servo motors and control range – sizes from 50 watt to 750 watt and with four control modes: Speed, Torque Position andTension. Smooth operation can be achieved for high inertia applications that are up to 50 times of the rotor inertia. No vibration occurs for belt and pulley applications. The control can be tuned by potentiometers and rotary switches when desired, saving the hassle of doing the setting on a computer.

•

Dear reader! Is your business associated with any of the following industries? SeptemBer

● Oil & Gas Industry ● Industrial Cleaning ● pumps & Valves ● Welding

OCtOBer ISSue:

● energy efficiency ● motors, Drives & transmissions ● maintenance ● recycling & Waste management

Key suppliers to these industries will be profiling their products and providing productive solutions in the upcoming issues of DEMM Engineering & Manufacturing magazine, please enjoy the magazine and stay informed. All we ask is that you tell the supplier where you saw them, here in DEMM magazine. Best regards The DEMM Engineering & Manufacturing magazine team. PS: If you are a supplier to the engineering and manufacturing industries and would like to know more about highlighting your business, your industry or product news in this magazine please contact Frank Atkinson on frank@adrenalin.co.nz or 09 477 0362, mob 021 464 156

iNDUSTRy WATCH

Coming in association with Events TelstraClear Pacific 2011 NZ Oil & Gas Exhibition & Conference

10-11 August, 2011 TSB Stadium, New Plymouth Staged by Swan Exhibitions. Contact Mike Twiss, mike@energy-pubs.com.au or visit www.nzoilandgasexpo.com.au

From the mailbox

Foodpro

10-13 July, 2011 Sydney Convention & Exhibition Centre Showcasing the very latest in food processing machinery, technology and packaging innovation. For more go to www.foodproexh.com

SouthMACH 2011

17-18 August, 2011 CBS Canterbury Arena, Christchurch The South Island’s only dedicated engineering, machinery and technology trade show. For further information visit www.southmach.co.nz

MHL 11

21-22 September, 2011 ASB Showgrounds, Greenlane, Auckland New Zealand’s materials handling, warehousing and logistics trade show. For further information, exhibiting enquiries, visitor registration and a list of current exhibitors, go to www.mhlshow.co.nz

National Safety Show 2011

21-22 September, 2011 ASB Showgrounds, Greenlane, Auckland New Zealand’s largest dedicated workplace health and safety event. For information, exhibiting enquiries, visitor registration and a list of current exhibitors, go to www.safetyshow.co.nz

NZ Clean Energy Expo

14-16 October, 2011 NZ Clean Energy Centre, State Highway One, Taupo Ashowcase of clean energy innovation – including geothermal and bio-energy initiatives.For more information call Rob McEwen, CEO, NZ Clean Energy Centre on 021 728 875 or visit www.nzcleanenergycentre.co.nz

Water New Zealand Annual Conference & Expo

9-11 November, 2011 Rotorua Energy Events Centre ‘Advancing Water Reform’. For more information visit www.waternz.org.nz

www.pacific.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 City 0754, Auckland, 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 ______________________________________________________________________ _______________________________________________________________________

August 2011

ITWAS interesting to read the recent article on machinery safety (DEMM, July 2011 issue) about inadequate guarding leading to hefty fines – and I guess rightly so. But I never see any reports of employees being fined for using dangerous tools. The picture you show (and I appreciate it is only indicative for the article) is a serious health and safety failing on an employer’s part but does the employee stand up and declare ‘I’m not using that, it’s dangerous’? No. He has a job to do and the pressure is on, perhaps from the employer or maybe as peer pressure – the rest of the team is forging ahead and poor old Joe Blow is struggling. Just suppose for an instance that there was some form of penalty for not reporting a defective machine or using one even, [the employee’s] sent home for a day without pay to enable him to consider the potential consequences of his actions. What would the outcomes be? The first thing that comes to mind would be industrial action in support of their hard done-by mate – but if he had not operated the saw without the guard he wouldn’t be in this situation. The position is similar in some respects to that of reporting near misses. The employers have to encourage such reports by rewarding those who do submit reports – but it is a requirement. The days of ‘we don’t need that reported in the books’ are long gone – it’s called “taking responsibility”. Another consideration is what happens when another operator uses the machine and loses a finger or two? The employee responsible for the machine’s safety should be held accountable. Lock them out, tag the switch or disconnect the thing. I reviewed a factory some time back (no names mentioned) and admired a new bit of tooling – all shiny and smart, gizmos and safety paraphernalia a-plenty. But there in the corner was the original machine, stripped to the bare bones and a health and safety nightmare. “We use that as a back upwhen we’re busy,” they said. The responsible person should have made it safe – removed the plug lead in this case. So who is in the wrong – the employer for not disposing of it or the employee for not taking his share of the responsibility? My own personal view on this is; I don’t want it to happen to me or my buddy, colleague or workmate – and I certainly would not want to be knocking on the door of his family home to deliver the news that he won’t be coming home tonight because I failed to stophim using defective equipment. Take responsibility, look after your mates, or there could be consequences. Steve Setterfield

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2011

ENGINEERS, MAINTENANCE MANAGERS, TRADESMEN, LINE MANAGERS, ASSET MANAGERS

Twenty eleven Lifting the Game of Maintenance Engineers in New Zealand Presentations from peers and experts on Lifting YOUR Game in Maintenance Management; Preventative Maintenance, Staff Management, Health and Safety Management, Training, Apprentices, as well as Technical innovations, practical applications and case studies. Trade Expo representing: engineering suppliers, careers and employment, hydraulics, pneumatics, electrical, bearings, software, preventative maintenance, condition monitoring, electric motors.

November 9/10

@ The Distinction Hotel, Rotorua PRICE: $680 + gst pp (accommodation not included) Bring extra colleagues for ONLY $400+gst pp

FREE PUBLIC ENTRY TO TRADE EXPO: Tuesday 8 November EXHIBITORS: participation from only from $550+GST (small business table top)

Contact Leanne Powley - Admin on Call P: 09 296 1333 | M: 021 134 6315 E: info@adminoncall.co.nz Proudly Supporting MESNZ

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5_DEMM_010511

• • • • •