DEMM Engineering & Manufacturing Magazine January 2013

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Next generation Time for the old guard to step aside

Water treatment Keep it clean

Pumps & valves How to keep the pressure up

Maintenance matters Avoid time-loss failures

Electrical Institute Get ready for the conference

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Ed Says

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I hear some buyers from a New Zealand manufacturing company went on a trip to China to buy some machinery parts.

The sales guy at the Chinese fabrication firm showed his Kiwi visitors exactly what they asked for and the price was much cheaper than an original part from a New Zealand authorised dealer. But our Kiwi troupers wanted a bargain akin to a deal they might see at The Warehouse.

Despite the parts apparently matching their spec exactly, our Kiwi heroes were under the gun from their firm’s bean counters to save even more money.

The parts offered were about 70 percent the cost of the authorised dealers’ ones – you know, the ones that come with a warranty and that are specifically made for the machine in question.

Despite the apparent bargain, our Kiwi heroes played hardball and got the price down even further.

Contents 3

News

really couldn’t make the parts to the spec required at

5

Product watch

the price their new Kiwi client was prepared to pay –

12 CEOs on notice – Steve Hart

something had to give so that the bean counters in Beijing

14 Water treatment

were kept happy.

17 Pumps & valves

Well, the Chinese firm was happy to get the order but

Ten minutes after fitting the new part from China,

20 Materials handling

the Kiwi firm’s managers were scratching their heads,

22 Maintenance matters

wondering why it had failed. It was pulled out and given a

24 Feature – Rust barrier saves money – Steve Hart

close inspection.

Apart from the damage it now had, it was perfect except for one thing. The metal it was made from was cheap and nowhere near the standard needed. It was destined to fail from before the ink was dry on the Chinese contract.

27 Comment – Craig Carlyle, MESNZ 28 Feature – Apprenticeship training pays off – Steve Hart 29 Electrical technology 32 Comment – Allan Hill, NZEI

Steve Hart

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Editor

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

Editor: Steve Hart, Email: editor@demm.co.nz Advertising Frank Atkinson, Email: frank@adrenalin.co.nz Publisher: Cathy Parker, Email: cathy@adrenalin.co.nz Designer: Email: Rob@adrenalin.co.nz Subscriptions: subs@adrenalin.co.nz Proof reading: George Ward

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1

NEWS

Celebrating training success Every year several thousand skilled kiwis graduate from industry training – gaining a Level 4 or higher certificate is the equivalent of a university degree – with both taking four years to complete.

As a celebration of this hard work, industry training organisation Competenz has published a Roll of Honour handbook that acknowledges more than 500 graduates who received their certificates in Level 4 or higher qualifications in 2012 within the engineering, manufacturing, baking, maritime and food and beverage manufacturing sectors that Competenz works with.

“But it’s not just the graduates who

are owed recognition,” says John Blakey, CEO at Competenz. “Employers should be equally celebrated, as without their support for on-job training and their investment in lifting transferable skill levels throughout New Zealand, we would not have any graduates to celebrate.

“With current and looming skill shortages, there has never been a more crucial time to be skilled in New Zealand, and their career prospects should look bright.

“Hopefully we will see them enrolling in even higher level training in the near future – their skills are an asset for New Zealand’s economy.”

Joy Inyuang from Eagle Burgmann graduated in 2012 with the National Certificate in Mechanical Engineering, Fitting & Machining, Level 4.

Industry’s chance to shape qualifications Late last year Competenz staff traversed the country to meet with more than 70 employers and industry associations to inform stakeholders of the Targeted Review of Qualifications (TROQ) for the mechanical engineering industry, which is due to kick off in April.

The TROQ was initiated by the New Zealand Qualifications Authority to reduce the duplication of qualifications at Levels 1-6 on the New Zealand Qualifications Framework – making the system easier for employers and learners to understand.

“We’ve been spreading the word about the changes to qualifications that are coming up and we’re trying to get industry to start thinking about the review and start talking among their industry associations and networks,” says Bill Sole, Competenz industry leadership project manager.

The main messages received from stakeholders at the pre-review workshops were that there is a clear commitment from industry to apprenticeships, and companies that have committed to their apprentices generally have positive feedback about the system. But there is still room for improvement.

The first step when the TROQ process starts in April is to appoint a governance group to oversee the review.

“For this we will also be looking for technical experts to lead each specialist strand within mechanical engineering, such as welding and

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January 2013

fabrication,” says Sole.

“These people will have a direct influence in the review. The meetings have been successful in getting people to go away and start the ball rolling to find someone to represent their local area, but we are still interested to hear from anybody who wants to have a say in shaping the future of the mechanical engineering qualifications.”

Competenz staff plan to travel the country again during 2013 to gather the

feedback of as many stakeholders as possible.

“We’re casting a much broader net than ever before. We really want to consult with a far wider network of people,” says Sole.

“It’s really up to industry now as to how much involvement they want to have in remodelling training pathways into New Zealand qualifications, where learners are armed with transferable skills that meet the needs of industry.”

Moving times for Regal Beloit Last year saw a great transition for Regal Beloit in New Zealand, particularly with the combining of four Auckland companies under one roof at the Jomac Place site in Avondale.

“Relocating a business that has successfully operated in a location for 30 years to the other side of town certainly has its challenges,” says the firm’s general manager David Priestley.

“The driving motivator for moving was a reduction in overheads with

a potential to pass savings on to our clients – a familiar theme that all good businesses discuss with their clients and suppliers these days.”

CMG Electric Motors and the CMG Service division relocated from Avondale to the new purpose-built facility from without disruption to daily business.

OBA Insulating Materials and South Pacific Rewinders also moved to the Avondale site under the Regal NZ umbrella.

NEWS

New Zealand to shine in Oil and Gas Future Next year’s New Zealand Oil and Gas Exhibition and Conference (NZOG2013) held in March will again be hosted in the oil and gas capital of New Plymouth, bringing together the energy industry for two days of trade and education in one of the Oceania region’s most established oil and gas development areas, Taranaki.

New Zealand has considerable know-how and experience, being the region’s first producer of oil, to make the most of the upcoming oil and gas driven Asian Century.

For the past 30 years, the NZOG event has given the oil and gas industry a place to showcase their skills, services and products. The 2013 event will be no exception, with a new management team and a new strong focus doing business

with Australia, South East Asia and Papua New Guinea as well as a dedicated career’s pavilion and special presentation speakers.

Get the latest news and announcements on NZOG2013 and register your interest by visiting: www.nzoilandgasexpo. co.nz Last year’s New Zealand Oil and Gas Exhibition and Conference.

Compressed air

by Boge German-engineered Boge air compressors are represented in New Zealand by Air Gas Compressor Specialists.

This Boge distributor has service facilities in Auckland, New Plymouth and Christchurch.

The compressors have been installed in places such as an Auckland plastics firm and a timber firm in New Plymouth.

Other installations include a winery and hospitals.

Boge in New Zealand offer a product for almost every application and back this with trained technicians to support the brand.

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NEWS

Stop fuming about bad air In today’s workplace where health and safety of employees is paramount, the use of welding fume extraction equipment has become essential for manufacturing processes.

“Welding without adequate ventilation is dangerous,” says Cameron Prestidge from Egmont Air. “Symptoms of a sore throat, nausea, sweating, chills and pneumonia are all signs that a correctly designed fume extraction system is urgently overdue.”

Prestidge claims increased productivity, employee well-being, reduction in absenteeism and staff

turnover are direct benefits he has seen from installing an Egmont Air extraction system.

“Care of employees is seen as a major contribution to retaining staff and creating loyalty between workshop employees and management,” he says.

The firm’s fume extraction systems are designed to suit welding bays, general engineering or maintenance workshop scenarios.

Options are available for special processes such as robot welders, plasma fumes, grinding, and dust applications.

Energy savings win award Energy efficiency initiatives have helped Trevelyan’s Pack and Cool take out the Emerging Large Business award at the 2012 Sustainable Business Network awards.

EECA Business general manager Ian Niven says the firm’s sustainability efforts achieved energy savings across the kiwifruit and avocado cool storage business.

“Electricity is the company’s third biggest cost. By keeping an eye on energy use, through the use of price monitoring, and actively managing electricity demand, Trevelyan’s Pack and Cool was able to cut its costs by $23,000 a year,” says Niven.

“They also managed a 45

percent reduction in carbon emissions by improving the fuel efficiency of their transport fleet, and encouraging measures such as carpooling among staff.

“Key to its success in winning the award was senior management taking a leadership role in applying sustainability principles to the business.

“Their achievement is an example to all businesses of how management commitment to energy efficiency can deliver on many levels.”

The EECA Businesssponsored Emerging Large and Corporate Business award is for companies with more than 100 employees.

Chemical brothers Chemical engineers from Australia and New Zealand celebrated success at the Institution of Chemical Engineers 2012 international awards in Manchester, UK. New Zealand’s multi-disciplinary engineering services organisation, Aurecon, walked away with the Food & Drink award.

More than 500 chemical engineers and invited guests from around the world attended the event which was hosted by journalist and TV presenter Colin Murray.

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January 2013

An Egmont Air Fume system in use by a welder at DH Steel. Photo supplied.

13 million drills and counting Patience & Nicholson NZ has celebrated 50 years of manufacturing in New Zealand. The factory is located in Kaiapoi, Canterbury, and first opened in November 1962 as a small jobber drill manufacturing plant.

Back then the first production was for 55,000 drill bits a month, nowdays the company produce more than 55,000 drill bits a day.

That’s 13 million a year with and estimated volume of 326 million drill bits ever made in total.

Healthy and safety taskforce More than 400 submissions have been made to the Independent Taskforce on Workplace Health and Safety.

The taskforce released a consultation document in September last year (2012) and has been on the road to get as broad a cross-section of views as possible.

Chairman of the taskforce is Rob Jager. He is also chairman of Shell Todd Oil Services in New Zealand.

Jager says the taskforce has already begun assessing information provided through the consultation process and will test its thinking with reference groups over the coming months before beginning to write its final report to government.

“What is clear is that many organisations and individuals share the same concerns as we do about the state of our current workplace health and safety system,” says Jager. “I also believe there is a groundswell of support for the types of changes we will almost certainly be recommending in our final report.”

The taskforce’s final report is due to government on 30 April.

PRODUCT WATCH

See who’s on the network Fluke Networks has a new version of its OptiView XG v9 network analysis tablet. It provides network professionals with a graphical view of network infrastructure to help speed up root cause identification and resolve issues.

The network navigator capability reduces the time it takes to understand network issues by displaying network topology and problems.

The new version includes

Which is Easier?

in-line testing that eliminates the need for an external tap or span port when observing conversations between client and application servers.

This delivers fast and exact insights into real time traffic flows, and visibility into client/ server conversations without the need for packet capture and port spanning.

If detailed packet analysis is required, the in-line function captures all full line-rate speed, assuring complete

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With the Fluke Networks OptiView XG v.9 tablet’s new Network Navigator capability, network engineers no longer have to mentally visualize connections. The new visualization feature makes it easy to see and troubleshoot networks in an instant.

For more info: www.flukenetworks.com/optiviewxgv9

analysis. In addition, the product’s existing network virtualisation feature has been enhanced, increasing visibility into new virtualised

architecture, which improves workflow in data centre environments.

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Aurora process equipment Aurora Process Equipment is rapidly increasing in their industry experience, technical knowledge, product ranges, system solutions and backup service capabilities.

With its four divisions – bulk materials handling, industrial packaging, fluid process and quality assurance in full swing Aurora continue to provide clients with market-leading process solutions.

Its bulk materials handling and industrial packaging divisions offer a large selection of bag filling, closing and handling equipment; bulk bag filling and unloading; aero-mechanical, screw, flat belt, ‘V’, trough and roller conveying; silos, screw feeders and hoppers, and blenders.

In its fluid process division, the firm specialises in plate, tubular and scraped

surface heat transfer systems, mixers and agitators, hydrocyclone separators and product recovery projectiles (Pigs).

The quality assurance division is dedicated to protecting client’s product, equipment and brand with high performance magnetic separators, metal detectors, X-ray inspection and check weighing systems.

The firm was involved in a multitude of different industries during 2012, including the dairy, food, beverage, brewery, wine, grain and seed, fertiliser, growers, HVAC, stock and animal Feed, wastewater, laundry, quarry and mining, oil and gas, pulp and paper, industrial and more.

It continues to establish strong strategic global partnerships to increase its range of process solutions, along with an intense R

& D and system development.

“With our fantastic and enthusiastic team we are looking forward to partnering with you in developing your process throughout 2013 year and beyond,” says the firm.

• Go to www.demm.co.nz/enquiry quote: D130105a

ACHIEVING

EXCELLENCE

IN PROCESS SOLUTIONS

B&AUA0052

Aurora designs, manufactures and supplies quality equipment for efcient process solutions in many industries. Meeting excellence every day with our products, systems and service.

Callll us and C d experience i our quality lit service i ttoday d

0800 55 77 33 | www.aurora-nz.com

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PRODUCT WATCH

Dome manufacturer expands capability A South Taranaki inventorcome-manufacturer continues to expand the applications and capabilities of his engineering service, specialising in the double curve forming stainless steel Sheetmetal plate.

Lincoln Raikes is known for making mirror polished stainless steel balls for sculptures that are seen around the world, but says he has developed further

methods for double curve forming.

“We have found other applications for these balls such as diesel tanks, pop corn kettles, cake mixing bowls, cheese curd making vats and pharmaceutical pressure vessels,” he says.

His firm recently manufactured two large 6mm thick stainless steel hemispherical domes (half

balls) for a company in a Hamilton – they were used for the bottoms of vessels.

“Our obsession with trying to master the art of double curve forming stainless sheet has boosted our reputation as a capable dome manufacturer which is probably the backbone of the business,” says Raikes.

His firm has also upgraded the capacity of its knuckling

machine so it can offer 150mm radius knuckles on domes up to three metres in diameter and up to 12mm thick.

“We found that customers need these larger knuckles for their certified pressure vessels, so we went out and bought the 150mm roller and found a lot of work for it,” says Raikes.

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Lubricate where it’s needed

• Radius 150mm knuckle and dishing.

• Radius knuckles from 20mm to 150mm.

• Diameter up to three meters.

• Thickness up to 12mm.

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January 2013

UltraLube products have four times the natural lubricity of petroleum-based oils. They instantly penetrate into areas where lubrication is needed most, creating a long-lasting bond to metal and plastic surfaces. UltraLube is eco-safe and non-toxic, making it safer for use in work environments.

UltraLube greases and oils are ideal for environmentally sensitive areas, since they are VOC-free and nonf lammable with extremely high f lash points.

Certified by the USDA’s BioPreferred programme, UltraLube supplies superior lubrication for hundreds of industrial purposes including ball and socket joints, bearings, cables, conveyors, cutting tools, drive chains, electric power tools, gears, glides, hinges,

hydraulic components, linkages, precision tools, pumps, rollers, valves and many other applications.

UltraLube products are also effective rust inhibitors.

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PRODUCT WATCH

High performance waterproofing Polymer Group has launched Ultraure 80, a two component polyurethane composite system that it says provides extended wear and high impact traffic durability.

The firm says waterproofing membranes need to be tailored for specific applications and that simply specifying “a polyurethane membrane” will not ensure people get the best product for their needs.

Polyurethane chemistry is a complex science and the formulation of high performance polyurethane waterproofing membranes,

(while at the same time maintaining cost effectiveness), requires careful selection of the type and the final physical properties that are required.

Is the application static, pedestrian traffic or vehicular traffic? If it is the latter, is the traffic comparatively stationary, i.e. a car park where vehicles arrive, stay all day, and then depart or, as in the case of a shopping mall, the traffic is continuously coming and going and therefore the wear (on any roof deck waterproofing system) will be extreme.

Polyurethane waterproofing

BUILD IT Exactingly right – Every time –

systems can be water based, solvent based, solvent-free, one component or two component.

When designing a system, all of these options form part of

the development chemist’s formulating criteria.

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Light vision safety glasses 3M’s Light Vision II safety glasses have lights mounted on each arm to provide hands-free task lighting. The LED system provides ultrabright beams that swivel and adjust for directional convenience.

The polycarbonate lenses protect against UV and impact at extreme temperatures. They feature an anti-fog coating on a clear lens with a grey frame. The wide coverage wrap-around design protects against flying particulates,

says 3M. The frame has rubber temples and rubber nose pads and the glasses have an AS/ NZS1337 medium impact rating. The LED lights have a battery life of up to 50 hours.

The glasses come with a microfibre bag and lanyard.

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

Quality European Manufacturing • Motors • Gear Components • Control Technology

Final test.

High voltage motor test.

Painted to customer application requirement.

Individual components selected to specification for the gear unit.

Finished products ready for delivery.

Fast, customised assembly at purpose designed workstations.

New Zealand Assembled

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

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

24/7 Service backup

E&M212

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

INDUSTRIAL DRIVE TECHNOLOGY

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PRODUCT WATCH

Hand-held hot air tool

Mind your head

Leister Technologies AG, Switzerland has released the ‘Triac AT’ hand-held hot air tool.

The Triac AT is ‘intelligent’ and robust, designed to meet the needs of the most demanding professional, whether plastic fabrication, roofing, civil engineering, industrial fabrics, f looring, forming, shrinking, drying – in fact any application requiring precise, consistent heat.

The closed-loop, electronic temperature control gives 1°C precision from ambient

The warning and protective bumper guards from Knuffi act as a personal crumple zone for people, machines and fixtures, absorb hard impacts and help preventing injury or damage.

This can mean that staff absences or downtimes due to repairs or injury are a thing of the past.

The highly effective warning capability of the black and yellow markings highlights sources of danger at edges, gaps and obstacles

temperatures to 700°C. The electronics give variable airf low from 120-240l/minute, with all settings visible on the large, easy to operate ‘E-Drive’ display.

The electronics also display incoming voltage, service requirements, error messages, and automatic cool-down and shut-off.

making them easy to recognise and so help reduce accidents.

Knuffi is resistant to temperatures from -40˚C to 100˚C and are also resistant to damp, making them versatile for use both indoors and outdoors, e.g. on transport routes within a company’s premises, on machinery, on walls and thoroughfares, shelves, gates and much more.

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Lanyard with RFID MSA’s Workman, a selfretracting lanyard, is fitted with an RFID chip for easier product tracking and inspection.

The lanyard has a 136kgs working capacity and is available with a 9m/30ft galvanised or stainless steel cable.

The firm has also made it easier to connect visors to its range of V-Gard helmets using an alignment guide and three touch-point loading.

This makes changing visors simpler, quicker and foolproof.

The firm has added features such as a replaceable debris control ‘system’ to prevent and reduce the effect of debris between gaps in the visor frame and visor.

The frame has a sloped design and a V shaped channel to allow debris to be removed from the frame.

There is also a retractable chin protector option to allow more movement and less interference.

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January 2013

Submersible pressure transmitter The LH-20 submersible pressure transmitter from WIKA fulfils the highest requirements within level measurement technology. The slender, highperformance instrument, with a diameter of only 22mm, impresses with an accuracy of up to 0.1 percent, even in harsh operating conditions.

As a result of numerous options and functions, the level probe is suited to just about all applications in level measurement with full media contact.

The LH-20 exhibits a low temperature error and is available with a parallel temperature output signal, Hart communication and a scaleable measuring range.

For the highest resistance to media, the highperformance probe is available in a stainless steel or titanium version, with PUR, PE or FEP cable.

The variety of application possibilities is enhanced by the design of the submersible pressure transmitter.

In the specific design variant for drinking water applications, the LH-20 meets the KTW and ACS regulations for drinking water conformity.

Furthermore, the probe is available in an explosion-proof version.

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D130108c

PRODUCT WATCH

Automatic label inspection The IML Watcher Inspection machine from IntraVis Vision Systems is a quality control system for in-mould labelling of injection moulded and blow moulded products, particularly for decorated parts such as bottles, cups, lids and pails.

The system can be integrated into the automation robot of most injection moulding machines, supporting fast cycle times and to detect typical errors relating to the IML process such as label offset, angular rotation, print errors, label identification, back injection mouldings and holes.

The IML Watcher is equipped with cameras and lighting units that inspect multiple cavity products with good accuracy and repeatability. Scrap rates are

Octane polarised safety glasses minimised by the accurate ejection of defective parts from the line and alarm trending software.

The machine can check other types of labels such as wrapped, glued or base labels, even when they come in a ‘no-label look’ style.

The machine can inspect up to 10 objects per second with a simultaneous shot evaluation.

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BOC Gas & Gear’s latest addition to its range of safety glasses is the Umatta octane medium impact, gray polarised safety specs.

Senior product manager, safety at BOC, Joe Martinez says the glasses, which were approved to Australian and New Zealand standards 1337.1:2010, offer “great eye protection for work or the weekend.

“Featuring a smoke polarised, polycarbonate lens,

with category three lenses provide a high level of sun glare protection,” he says.

“They reduce unwanted sun glare while providing better visibility with minimal colour distortion.”

Constructed of durable and lightweight materials the glasses feature UV 400 protection on all lenses that are also anti-scratch and anti-fog.

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For the Most Demanding Industrial Markets

HGA Series Motors

CW Series Motors

Sales: 0800 676 722

MT Series Motors

HPD Series Motors

PPA Series Motors

www.cmggroup.co.nz

AUCKLAND • CHRISTCHURCH • ROTORUA

DEMM_2013_01.indd 1

7/12/2012 2:55:29 PM

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PRODUCT WATCH

See beyond the temperature

Hose for CO2

The VT02 Visual IR thermometer from Fluke bridges the gap between low cost IR thermometers and higher priced thermal imagers and allows you to see beyond temperature.

Using hyper-thin pyroelectric technology, the company discovered a way to push the limits of this technology, pioneering an array dense enough to create an infrared heat map.

The VT02 Visual IR thermometer is the missing link – the ultimate inbetween tool for those times when a single spot temperature reading isn’t enough and a high-resolution thermal image is more than you need.

Now, instead of the tedious tasks of taking and recording multiple, individual temperature readings, you

ReCoila’s Gen III FD series hose reel is specifically designed for use in wineries to dispense CO² and nitrogen when blanketing vats and tanks during storage, transfer, fermentation and other processes.

The FD series features a ratchet tensioning system resulting in a spring rewind reel. Available with 20 metres of 6, 8 or 10mm ID hose, the design enables easy wall, ceiling or under bench mounting, keeping hoses up out of the way,

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get the complete picture with a blended visual and thermal image of your target area.

High performance inverters

Go to www.demm.co.nz/ enquiry quote: D130110

Beijer Electronic’s P2 performance inverters can control standard induction motors and permanent magnet motors.

The inverters offer open loop vector control of standard induction motors providing up to 200 percent torque from zero speed as well as closed loop encoder feedback capability.

The choice of control method and motor type provides premium control and optimum energy efficiency for the actual application.

Extensive I/O and communications interface capabilities ensure the drive can be integrated quickly and efficiently into a wide variety of control systems and the simple parameter structure, with carefully selected factory settings, provide fast and easy commissioning.

The P2s are available in frame sizes from 0.75 to 160kW with a range of options such as single or three phase input, main switch, ethernet and fieldbuses, etc.

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Airborne particle counter The TSI 8530 DustTrak airborne particle counter is a laser photometer based instrument that measures and logs total particle concentrations in the air.

This portable aerosol monitor detects potential problems with airborne contaminants such as dust, smoke, fumes and mists, and can now measure higher concentrations, up to 400mg/m³.

Features include real-time spot measurements, logging with user selectable start-stop times and recording intervals for continuous unattended monitoring. Logging intervals can be set from between one second and one hour, up to 60,000 data points can be saved

neatly coiled inside the reel when not in use.

and software is supplied for downloading the results.

It is suitable for clean office settings as well as harsh industrial workplaces, construction and environmental sites, and other outdoor applications when used with an environmental enclosure.

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January 2013

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D130110c

Summer’s here – best get some boots Combining rugged comfort and support, the Chore boot from Muck Boot is made to withstand physical punishment with a new XpressCool lining material engineered to keep your feet cool in warmer weather.

Featuring a flexible, lightweight rubber outsole for maximum comfort and support, the stretch-fit nylon materials is 100 percent waterproof. The Chore boot is for complete protection in all work conditions and available in high and mid-boot heights.

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PRODUCT WATCH

Be kept in the dark

Going up The 2210 Spider Lift is a selfpropelled elevated platform that combines height access with the advantage of being track mounted for versatility and portability.

It has maximum working height 21.7 metres, the two man platform can rotate 90 degrees both ways.

Self-levelling stabilisers make it suitable for steep terrain and difficult to access building applications. The stabilising legs have narrow and wide settings allowing the unit to be used in tight places, such as between building and factory situations.

Variable track width

provides additional stability when it is in motion.

The Spider Lift reduces down, once the tracks are retracted, to a compact size, and has non-marking tracks to allow it to operate without damaging flooring.

Powered by diesel and electric, it can be used for interior and exterior applications.

Remote controls allow the operator to control all functions from within the basket as well as from the ground.

The P550 from Optrel is an auto-darkening welding helmet with a choice of optional side covers to suit the standard Black & White Bulldog helmet.

The high impact helmet shell guarantees a long life and good standard for welders.

The headband and high impact certification also ensures that the P550 offers the comfort and protection.

Other features include solar cell driven batteries that reduces the need to constantly switch on and off, a potentiometer knob to provide variable shade adjustment from shades 4/9-13 or 4/11, and a two-year warranty. It is also certified to AS/NZS 1337.

• Go to www.demm.co.nz/enquiry quote:

D130111a

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Go to www.demm.co.nz/ enquiry quote: D130111

Respirator for organic vapours 3M’s 9542A particulate respirator with P2 rated filter offers protection against dusts, mists and fumes.

Designed to fit a range of facial sizes, its low profile design allows better visibility as well as compatibility with eyewear. Each respirator is individually wrapped, protecting it from contamination prior to use, as well as making it practical for storage and dispensing in the workplace.

Moreover, the nose foam is soft on the skin while the dual latex-free straps help to provide a secure fit during wear. The nose clip is easy to mould around the nose for custom-fit.

Suitable for use in foundry operations, mining, metal processing, printing, light duty welding, agricultural operations, laboratory, waste disposal etc, the 9542A meets performance requirements of AS/NZS 1716:2012.

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Go to www.demm.co.nz/ enquiry quote: D130111b

11

FEATURE

CEOs are put on notice A senior lecturer in engineering tells Steve Hart that business owners need to ensure their young people are freed up to keep abreast of industry trends.

Senior managers of engineering firms need to do more for their younger staff by having them attend industry training seminars and conferences.

Larry Wiechern, a senior lecturer of engineering at the Manukau Institute of Technology, says he is disappointed by the level of support he sees from the industry for upskilling “the next generation of specialists”.

He points to three conferences he attended last year where few young engineers were present to hear international guest speakers and highly skilled NZ and Australian practitioners highlight the requirements for the manufacturing industry to operate more efficiently.

Wiechern, who is also manager of the institute’s maintenance and reliability centre, says: “Each conference was well supported by engineering product sales companies demonstrating their support to the industry. But many of the paid engineering attendees were older and ready to be put out to pasture… they should be handing the reins to the younger employees by now.

“Where are the young people who should be attending events such as this?

They are just not there.

“Organisers of events such as these go to an awful lot of trouble to bring in international speakers and local experts to help make New Zealand manufacturing sharper and better focused, but I see no evidence that these older engineering and account managers are implementing the ideas they pay to hear about.”

Wiechern says he sees “very little sign” of firm’s investing in upskilling their operators, young tradesmen and young graduates and says more needs to be done on moving into the field of the reliability department.

“Young engineers need to know about things such as vibration, balancing, ultrasonics, thermography, oil analysis etc, the reasons for a lubrication audit, and issues such as the correct techniques for fitting bearings – there are bearing failures from one end of New Zealand to the other – all caused by a lack of ongoing training.

“I think if you send the right people for training then they will be the driving force behind discovering those first signs of trouble at a plant.”

Wiechern says training courses run in partnership with SKF attracted just five people in November last year, with an

Coming up in the February 2013 issue S Energy Efficiency SMotors, Drives & Transmissions

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12

January 2013

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Larry Wiechern, a senior lecturer of engineering at the Manukau Institute of Technology.

earlier one having just two people register.

Counterfeit products One of his concerns is that engineers are not educating themselves about the high volume of counterfeit products entering the market.

“They have no idea about the dangers and high failure cost when implementing a suspect product into their industry,” says Wiechern. “From counterfeit oils that are starting to surface, to counterfeit refrigerants, bearings, transmission products and gearboxes.

“There are also issues with low quality heat treated steel being imported. Poorly manufactured threads, under tolerance, drunken threaded nuts, the list goes on and on.

“The only way people can pick this up is by attending conferences and seminars and appreciating the high cost of failure should those lessons be ignored.”

To help companies free up staff for industry training seminars Wiechern has reformatted the seminar programme for 2013 with several half-day events.

“It means people need only come along for three and a half hours and then they can get back to work,” says Wiechern.

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WATER TREATMENT

Christchurch rebuild gets a boost The demand for state-of-the-art, superresilient infrastructure to underpin the rebuild of Christchurch received a boost with the commissioning of a multimillion dollar plastic pipe manufacturing plant by Christchurch company FrankPKS New Zealand.

Christchurch mayor Bob Parker officially commissioned the production plant at a ceremony held at FrankPKS in Francella Street, Bromley.

The $3 million-plus production line enables the company to more than double production of its specialised high-density polyethylene (HDPE) pipes, as well as produce a significantly expanded array of pipe sizes – up to four metres in diameter.

Frank PKS New Zealand general manager, Bryan Wilson, says the project is a major vote of faith in the future of Christchurch, and particularly the city’s East.

He says that will position it to supply critical materials for the Christchurch rebuild, as well as service growing demand from local government and heavy industry around New Zealand.

The manufacturing technology used by FrankPKS at its Bromley plant is unique in the southern hemisphere, and the company has invested heavily in importing expertise and supporting standards specifications, to help the wider industry understand, scrutinise and test the suitability of the processes and products, Wilson says.

The 25 October 2011 event was attended

by David Browne, a representative of the New Zealand investor group which owns the majority of shares in the company and Thomas Frank, general manager of Frank GmbH of Germany – a shareholder and partner in the company’s technology and sales & marketing operations.

Franks PKS was established in 2005, it currently employs about 20 people and is a leader in large-diameter high-density polyethylene pipes for water, wastewater and sewerage systems.

An associate of Frank GmbH of Germany, which is also a shareholder and partner in the Christchurch company’s technology and sales & marketing operations.

Frank PKS NZ uses a German-developed system of pipe manufacture known as tangential extrusion. Its production line creates polyethylene compounds from raw plastic pellets and extrudes this in molten form via dies on to a heated, rotating mandrel to create the pipe.

The firm says that among the process’s

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January 2013

advantages, are that it allows short, one-off lengths of pipe to be made with minimum waste; and offers precise control over the properties of the final product, to suit the specific demands of its end use.

The pipes are extraordinarily strong but flexible, says the company, and can be designed to almost any environment, carrying almost any substance.

The pipes can also withstand the forces of a liquefaction episode during large earthquakes, claims the firm.

Specialist welding techniques ensure they remain leakproof and can be prefabricated to go around bends, without the need for extra manholes.

They can be laid quickly and without some of the complex systems required with heavier materials. Besides use in applications from irrigation systems to carrying mining waste, the products can be put to numerous more novel uses.

• Go to www.demm.co.nz/enquiry quote:

D130114

Mayor Bob Parker (left) and Thomas Frank, general manager of Frank GmbH of Germany, turn on a tangential extrusion production line at the commissioning of a multimillion dollar plastic pipe manufacturing plant by Christchurch company FrankPKS New Zealand.

Projects that have used Frank PKS pipes include: • Woodham Road trunk sewer. earthquake rebuild.

• Tahuna wastewater treatment plant – stage II upgrade.

• Christchurch oxidisation ponds.

• South Canterbury irrigation pontoon.

• Gore sewer renewal.

• Timaru main trunk Sewer renewal.

• Kaiapoi stormwater.

• Invercargill stormwater.

• Tauranga sewer.

• Masterton wastewater treatment plant.

Award recognises innovation in drinking water technology A water treatment process that has cut Wellington Regional Council’s chemical bill by a quarter has won recognition at the New Zealand Engineering Excellence awards.

Judges described the Com::pass process, winner of this year’s Chemical Bio and Food award, as an innovative solution to a problem experienced worldwide – namely, responding quickly to variations in impurities entering water treatment plants with precisely adjusted amounts of chemicals.

Com::pass combines advanced instrumentation technology and software to calculate the exact amount of chemicals necessary to remove impurities.

The process was developed by Martinborough-based consultancy h2ope and the New Zealand arm of DCM Process Control in conjunction with the council.

Regional council water supply group manager Chris Laidlow said the savings in chemicals and improvements in water quality had sparked worldwide interest.

He said the savings now amounted to about 1,000 tonnes of chemicals, or $250,000, a year.

“Our original intention was to improve water quality and treatment plant reliability, though it has had the added benefit of lower running costs,” he says.

“Com::pass has mainly attracted international interest and sales from Australia and Britain, but also from places as far afield as China, South Korea, the United States, Canada, Brazil and Europe.”

The process is also in use at plants in Dunedin, New Plymouth, Tauranga, Palmerston North, Matamata and Hamilton.

Laidlow says the regional council began operating a prototype at its Wainuiomata plant in 2007 and introduced the process at its main Te Marua plant in 2009.

“This has proven to be a great example of collaboration between the public and private sectors, with h2ope and DCM Process Control each providing their particular expertise and our technical staff also making a contribution to the development.”

• Go to www.demm.co.nz/enquiry quote: D130114

WATER TREATMENT

Treating fatty wastewater Dissolved air flotation (DAF) is often the most appropriate technology when treating wastewater streams that are high in fats, oils and grease.

Over the past few years Apex Environmental has been perfecting its dissolved air flotation plant design. What makes Apex’s design different, says the firm, is the ability to increase throughput by up to 25 percent, by eliminating the need for recycle flow – unlike in traditional DAF designs.

The robust type of white-water pump used can handle solids and fibre, therefore eliminating the need to use treated water in the air saturation loop.

This type of treatment is particularly effective in industries such as dairy

Great Kiwi summer water survey Organisers of Project Blue are asking everyone to let them know about the water quality they experience this summer by uploading data to its Facebook page.

The project’s lead scientist, Susan Harris, says the survey will run until 9 February 2013 and will process photos, videos and observations of water quality uploaded by smartphone users.

“We hope to crowdsource a data-rich sample of recreational demands, trends, preferences, and water quality experiences of New Zealanders and others on holiday this summer,” says Harris. “Smartphone users will pay for their uploads to Facebook, but the progress of the survey and summary of results will be free to view online as the summer proceeds.

“The third report of the Land and Water Forum noted there is a gap in our knowledge of water-based recreation needs, and that an inventory of water bodies suitable for recreation is needed.”

Harris says if one in eight smartphone owners take part then there will be 100,000 uploads.

“It will be fascinating to review the live evidence on-line of summer water experiences, and how they match the ‘100% Pure’ slogan used for the New Zealand holiday experience.”

On the web http://alturl.com/wcdmy

• Go to www.demm.co.nz/enquiry quote: D130115c

factories, textile processing, meat works and food and beverage procession.

Apex has designed and installed DAF plants ranging from 25m³/hr up to 130m³/ hr, with one recently installed at a Fonterra milk powder factory.

Apex also specialise in the design, build, optimisation and upgrade of wastewater treatment solutions for industry.

• Go to www.demm.co.nz/enquiry quote: D130115

KSB performance impresses council Otago Regional Council has had two KSB PNT 500 pumps providing drainage to an area of the Clutha River Delta for 22 years and they are still in service and going strong.

With this track record Chris Smy from the KSB New Zealand South Island office and the KSB New Zealand team have continued to impress the council with a high standard of technical sales ability and professional tendering quotations plus providing service support for the existing PNT pumps.

This effort, says KSB, has established a relationship based around honesty and trust that lead onto the tendering for the supply of a new pump for the council’s Barnego Pump Station in February 2012.

KSB won the order to supply an Amacan PA4 600-350 pump. However, the service did not stop there. When the pump was delivered Smy assisted in the installation and commissioning that “went without a hitch”.

The proof of a satisfied customer

came from the council’s manager of engineering, Ramon Strong, when KSB New Zealand received the following note: “We appreciate KSB’s help with all of this – by all accounts the whole job has gone very smoothly. Most impressed with the performance of KSB on all counts.”

This contract is already having an impact with the council who now see KSB as a major player in the market of submersible pumps in discharge tubes.

KSB has recently won another supply contract with the Otago Regional Council to supply two Amacan PA4 1000-700 pumps that are to be installed in their refurbished Waipori Flood Pump Station in April 2013.

Smy says the council sees KSB as a manufacturer that can offer a total service package from the pre-tender stage right through to commissioning and after sales service.

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Go to www.demm.co.nz/enquiry quote: D130115a

Sonatax sc with sc200 Profibus The Hach Sonatax SC with sc200 controller allows you to use sludge extraction, manage recirculation, be warned of potential solids washouts or process upset by continuously measuring the sludge blanket level with Sonatax.

Its digitised probe eliminates interferences and features a quick LED system check. For graphical display of sludge profile the probe must be connected to an sc1000 controller.

Among the benefits of the system include high accuracy with automatic frequency adjustment, an

automatic sensor wiper, temperature compensation for seasonal changes and visual performance indicator to enhance troubleshooting.

• Go to www.demm.co.nz/enquiry quote: D130115b

15

SAVE MONEY YOU DIDN’T EVEN KNOW YOU WERE LOSING

EXPERT ADVICE LED TO A $115,000 SAVING Energy wastage from compressed air systems can go unnoticed because system inefficiencies aren’t always obvious. An audit by a compressed air specialist can identify opportunities to save energy throughout your site – from air generation to distribution and end use.

Andrew Lawes Environmental Administrator for Red Stag says: “Expert help from compressed air systems specialists was key to identifying the best solutions for our business”.

Red Stag Timber’s audit revealed opportunities to reduce leakage and improve compressor controls.

By making changes the business is achieving a 48% reduction in compressor electricity use, saving around $115,000 a year. It also improved productivity, and increased their competitiveness in export markets.

Many industries can benefit from improvements to compressed air systems. Talk to an EECA Business programme partner for expert advice and to unlock any funding that may be available.

www.eecabusiness.govt.nz

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January 2013

PUMPS AND VALVES

SEE HOW MUCH YOUR BUSINESS CAN SAVE, CONTACT ONE OF OUR PROGRAMME PARTNERS Atlas Copco (NZ) Ltd Location: Wellington Contact: Andrew Drummond, 04 568 6049 www.atlascopco.co.nz Demand Response Ltd Location: Wellington Contact: Steve Broome, 04 472 6061 www.demandresponse.co.nz Enercon Ltd Location: Christchurch Contact: Kees Brinkman, 03 384 7905 www.enercon.co.nz Emsol Location: Nelson Contact: Erin Roughton, 03 538 0686 www.emsol.co.nz Energy NZ Ltd Location: Auckland Contact: Andy Logue, 09 488 0942 www.energynz.com

Danfoss’ new pump for RO applications Danfoss RO Solutions continues to build its range of dedicated high-pressure pumps for small and medium-sized reverse osmosis plants.

The latest addition, APP 38, has a capacity of 38m3/h and is the Danfoss APP pump with the largest capacity to date – despite sharing the same small footprint as the APP 21 - 30 pumps.

Danfoss is adding the new APP 38 after the introduction of the APP 16 – 22 pumps, which the company revealed at IDA in Australia in September 2011.

According to sales director Jesper Bentzen, the APP 38 represents an important milestone for the RO division.

“Pound for pound, and cubic inch for cubic inch, the APP 38 gives more high-pressure capacity than any other pump on the market,” he says.

“We know from our market research that this one pump can replace many double-pump configurations. And we also expect to break into new segments as customers discover the advantages of such high capacity with a small footprint and low energy bills.”

Like all other APP pumps from Danfoss, the APP 38 is energy efficient, operating at up to 97 percent volumetric efficiency. The axial piston design results in constant f low regardless of pressure variations, as well as fewer moving parts for improved reliability and reduced maintenance costs.

Belt drivers and pulsation dampers are both things of the past with the APP series, and no oil lubrication is needed, as the pumped medium itself lubricates moving parts.

“Energy efficiency and reliability are key parameters for our RO customers,” says Bentzen. “Our proven performance in these areas is always a door opener. But what often ends up closing the deal is our compact design and small footprint. Our APP pumps can be installed either vertically or horizontally.”

Many APP pump sizes are fully compatible with the Danfoss iSave, an integrated isobaric energy recovery device that further increases energy savings by up to 60 percent – and eliminates the need for separate high-pressure f low meters, exchangers and booster pumps.

• Go to www.demm.co.nz/enquiry quote:

D130117

Ivan A Fraser Location: Auckland Contact: Ivan Fraser, 09 410 5008 PSL Wholesale Ltd Location: Christchurch Contact: Robert Norriss, 03 348 3348 www.pslwholesale.co.nz

EEC2656B

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PUMPS AND VALVES

Hydraulic soft start relief valves Pressure shocks in hydraulic systems can cause instability in cylinder or motor actuations and also shorten the life of both hydraulic and mechanical components. However, Hydraulic Cartridge Valves has two solutions to eliminate this common issue.

The first solution is the RP*T, which is interchangeable with all other SUN relief cartridge valves or can be supplied in a standard manifold. The RP*T is a pilot operated soft start balanced poppet relief valve. It ramps pressure up from a threshold pressure to the maximum set pressure over a fixed period of time, which is slow enough to eliminate all pressure spikes.

The second solution is the HCV 211 adjustable soft start valve. This version comes in a standalone manifold, or could be designed into a custom manifold to suit your application. The softness or hydraulic

pressure ramping can be set from a few milliseconds up to several seconds depending on the severity.

Both valve solutions will eliminate pressure overrides and reduce mechanical stress. These adjustable soft start valves can be set to give extremely smooth actuation to systems that are using on/ off/on solenoids.

They are also useful on systems where cylinder bounce occurs on a counterbalanced lowering load. The pressure rate will gradually build up giving the counterbalance valve a chance to open slowly in a controlled manner, eliminating the shudder and flexing.

• Go to www.demm.co.nz/enquiry quote: D130118

Integrated measuring for tube bending machines Those who want to accurately bend steel or stainless steel tubes and tube systems must accept long processing times for the generally unavoidable measuring and adjusting process.

This is because the rebound behaviour of materials can differ widely – even if the tubes come from a single batch.

The Springmatic optical measuring system provides a remedy. The development from Schwarze-Robitec, which is integrated into the bending tool, measures the tubes while tensioned on the bending machine and immediately starts the required further bending process if desired or saves the required correction value for subsequent bends.

Instead of removing the tube after the bending process, checking it on an external measuring system then retensioning it for subsequent bending, Springmatic allows operators to measure and adjust in a single stage.

Immediately after the

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Oval flowmeters

bending of a tube, the measuring system that Schwarze-Robitec is integrating into its bending tools records the rebound value, from which the CNC control of the tube bending machine calculates the required subsequent bending angle.

Subsequent bending is carried out immediately afterwards – either fully automatically if desired or after clearance by the machine operator.

When developing the

January 2013

measuring system, the tube bending specialists from Cologne placed particular emphasis on a broad range of applications: Springmatic reliably checks both thick and thin-walled tubes in the broadest range of materials and diameters.

The system can be integrated into almost any bending tool and combined with almost all tube bending machines from Schwarze-Robitec.

Trimec Flow Products has released a new range of oval gear flowmeters under the Dimak Flow brand.

The new flowmeters come in size from 4mm to 100mm in aluminium, stainless steel and ductile iron for flow ranges from 0.04 l/h to 1500 l/m.

They can be used for fuel oils, additives, chemicals, food bases, paints, viscous emulsions, insecticides, alcohol and solvents, either pumped or gravity fed.

Among the many flowmeter design principles available today, the oval gear meter still holds a top place both in simplicity and field proven performance.

Go to www.demm.co.nz/ enquiry quote: D130118a

Go to www.demm.co.nz/ enquiry quote: D130118b

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PUMPS AND VALVES

Elementary valve solution The Element range of valves from Burkert has been extended into larger-format valves and drives with sizes up to DN50 and actuator to 130mm. This will enable their use at higher process pressures and larger flow rates.

Element is a modular valve concept that delivers single-unit controlled valves, with a choice in valve style, and feedbacks, positioner or process controller needs. Valves have a stainless steel housing with a flexible system architecture. The range extends to flow, level, and analysis chemistry sensors.

Burkert’s expanded line of larger size valves and drives encompasses on/off Types 2100 angle-seat and 2101 globe valves, the corresponding proportional control Types 2300 angle-seat and 2301 globe valves, and the on/off and proportional control 2103 diaphragm valve family. All valves are available with 50mm to 130mm actuators, with orifice sizes DN8 to DN50.

The company anticipates that these more powerful and larger format valves will have a wide application scope. The valves reliably control fluids, steam, caustic solutions and chemicals, as well as abrasive or high-purity substances in many applications and process environments.

A robust IP65/67 construction suits hygienic process caustic washdown areas (FDA and EHEDG certification), to high-dust mineral processing areas. Their on/off and proportional control heads offer network interfaces, push-button commissioning, LED status indicators, and numerous feedbacks and options.

The drive design facilitates integration of automation units at all levels of the modular valve system, fitting to the broader Burkert control philosophy.

Valve positioners and process controllers link seamlessly with sensors for a monitoring and control system, for complete decentral automation of complex systems with minimal expense for cables and Go to www.demm.co.nz/enquiry quote: D130119 hoses.

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I’m a Total Fan

Honeywell has launched a new range of SmartLine industrial pressure transmitters that it says will enhance communication abilities, improve operational efficiency and reduce lifecycle costs for process manufacturers.

In industrial process plants, field devices that measure pressure, flow and level are used throughout the manufacturing process to support safe and efficient production. Large industrial complexes can have thousands of these devices to support their manufacturing processes.

Honeywell SmartLine pressure transmitters make it easier to support field devices and promote plant reliability with their unique efficiency-enhancing features, such as a graphic display capable of showing process data in graphical formats and communicating messages from the control room.

SmartLine transmitters also feature modular components to simplify field repairs and reduce inventory required to make those repairs.

It communicates to all automation systems through open communication protocol modules and is integrated with Experion PKS and legacy DCS customers.

• Go to www.demm.co.nz/enquiry quote:

s us the “Total Lubricants’ reliability give ge of confidence of having the best ran products to work with. vice, Great value for money, great ser great people, great product.”

Engineering - Total Robert Neal, Seafarer Marine customer since 2001

ATTN12TOT92

Smart transmitter improves efficiency

For technical information, latest specials or to find your nearest distributor call 0800 TOTAL OIL or visit www.totaloilsolutions.co.nz

D130119a

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MATERIALS – HAnDLING

Do more with automation CNC routers have revolutionised cutting and drilling processes as well as improving accuracy and efficiency. Investing in automated sheet loading systems can bring a greater return on investment, writes David White Profile cutter automation earns returns in various ways. But the pinnacle of automation is the chance to keep producing while the machine is unattended. Even if this is not the immediate goal, there can be wide ranging benefits for extending your CNC cutting machine with an automated sheet loading system.

Although this might make the CNC router seem more expensive, it can quickly bring returns on investment through improved productivity in a number of areas.

Speed Manual loading might not be an option because the machine sets the pace and operators may struggle to keep up.

OH&S. Automated material handling means no heavy lifting and no back injuries.

Consistency Automation turns the load/unload time into a fixed and repeatable value.

A business that uses at least some automation can add machines without necessarily adding people, making it easier to respond to increasing demand.

In general, and in particular for parts with short cycle times, the principle reason to automate is productivity. If the sheet is relatively lightweight, an automated system is likely to load and unload the blanks and sheets faster than a person can, and this loading time advantage will accumulate over time.

An automatic sheet loader allows automation of the production process straight from the pallet, which means there is no operator intervention when lifting from the material stack to the machine. No intervention means lean manufacturing and higher profits.

Most materials and thickness can be handled by an automatic loader. The Advanced Robotic Technology (ART) sheet loading system includes an automated scissor lift that automatically elevates a whole pallet of material to table height.

This is integrated with the CNC router gantry that includes a powerful lifting arm fitted with automated vacuum cups.

While the machine is doing its work,

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January 2013

the ART sheet lifter positions the next sheet on the loading station behind the machine’s table.

In conjunction with the CNC controller, the arm automatically picks up the material from a designated area and transports it safely onto the machine table. The unit positions the sheet against the side and back stops

and then automatically starts the CNC cutting process.

With the sheets lifted off the pack, there is no damage to sheets or the machine, which can happen with manual handling.

David White is the director of Advanced Robotic Technology in Brisbane.

• Go to www.demm.co.nz/enquiry quote: D130120

Stainless steel castors – clean & smooth Rex Industrial Equipment now stock a range of medium/heavy industrial, stainless steel castors.

Available in both a swivel and fixed plate option, the heavy-duty fabricated construction allows these castors to withstand high shock and impact loads. The 100mm or 150mm wheels are nylon centred with tough urethane tyres and stainless steel precision bearings as standard.

Swivel plate castor bodies consist of a double headset raceway for a smooth swivelling action and include a grease nipple to the headset bearings.

The addition of dust sealing rings

increases the life of the bearings. Swivel plate models are available in a braked option, with the robust brake assembly having an adjustable brake pad.

This EHI stainless steel castor series has been developed for applications such-as medical, institutional, food processing & preparation, and industrial laundry equipment etc.

They’re ideal for use in environments where they may be exposed to cleaning agents, moisture, steam and caustic or other corrosive chemicals.

• Go to www.demm.co.nz/enquiry quote: D130120a

MATERIALS – HAnDLING

No more guessing with Trueconnect Konecranes’ Trueconnect remote services give hoist and overhead crane users access to the usage and safety related data of their lifting devices via a web-based connection.

With the information provided, users can plan maintenance with increased confidence and pick up on any safety issues.

On the cards are plans to expand the system for remote services ranging from periodic data reporting to real time diagnostics, technical support and production monitoring.

Remote monitoring and reporting is the core of the full Trueconnect product. With this service the usage data is collected from the equipment through a remote connection and compiled into reports that are available through a secure online customer portal to a web page.

Easy-to-interpret reports include information about safety, operating statistics and service life of the equipment.

Safety alerts such as hoist overloads can be sent to the customer by email or text

message shortly after each occurrence.

“In the reports we emphasise safety issues such as overloads or emergency stops that have occurred, and how the maintenance can be optimised,” says James Dowe, head of service, Asia Pacific and Americas.

“As all data is based on real usage, it is possible to tailor the maintenance for individual cranes.

“It helps our customers not just to improve the safe use of their equipment, but also to help to plan the right maintenance at the right time and to assess the life cycle of certain equipment components.

“Remote monitoring lays the foundation for real-time services. In the future it will enable live diagnostics as well as technical support and advanced predictive maintenance planning.”

• Go to www.demm.co.nz/enquiry quote: D130121

Trueconnect data can be read online or emailed to users.

Expand your capabilities

Watertight transmitter

Expanding on the scalability of the Logix family of controllers, the CompactLogix 5370 series of controllers from Rockwell Automation offers a variety of options for specific applications.

With up to 3MB user memory, and supporting up to 16 axes of motion, these controllers are ideal for small, standalone equipment to general purpose machine control in applications such as indexing tables, process skids, case packers, erectors and packaging.

The Kinetix 350 is a single-axis EtherNet/IP servo drive designed for coordinated motion applications. When used together, they

Noshok’s 613 series cage-protected submersible level transmitter is on the market. The firm says it is ideal for a wide variety of industrial and municipal liquid level measurement applications requiring watertight protection, including severe high solids environments such as sewage, lift stations, storm canals, wet wells and slurry tanks where sludge, slurry or turbulence may be present.

The 613 is welded at both the cap and the base to provide a rugged, tamperproof, leak-proof seal. It also provides highly accurate, shock resistant and extremely stable performance over long periods of time.

Other features and benefits include standard half-inch NPT conduit for attaching lifting rings or mounting brackets, advanced diffused semiconductor or sputtered thin film sensor for maximum stability, and off-the-shelf ranges from 0 inH2O to 50 inH2O through 0psi to 300psi.

Other options include cable clamp, desiccant cartridge, filter element, cable junction box (NEMA 4X), lightning protection and lifting ring..

significantly lower the cost to deploy integrated motion in a variety of machine applications.

The Stratix 5700 switch provides high performance switching capability to help simplify integration into your infrastructure and the ArmorBlock dual port EtherNet/IP QuickConnect provides the added functionality of EtherNet/ IP, which allows for quick connection between the controller and ArmorBlock module (within 500ms).

• Go to www.demm.co.nz/enquiry quote: D130121a

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Go to www.demm.co.nz/enquiry quote: D130121b

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MAINTENANCE MATTERS

Microbes turn diesel to sludge

Budget welding units

Diesel specialist Gordon Legge says a reason for backup power generators not working after long periods of sitting idle could be that their fuel has been infected with microbes.

“Now that we have a lower sulphur content in our diesel it is much more susceptible to microbial contamination,” says the Aucklander.

“Although sulphur was a nasty pollutant once mixed with diesel fuel, creating carcinogenic pollutants, it helped prevent the growth of microbial contamination and kept the fuel in a good state for long periods,” he says.

“But in New Zealand, just like in Europe, environmental laws have required the sulphur content to be lowered.

“This means that organisations that need to keep diesel in storage for long periods are having to revise their fuel management plans.

“When the fuel is lying idle – sometimes for months at a time – sulphur would help prevent the growth of microbes, acting as a natural biocide.

“It is microbial growth that transforms diesel into a jelly-type substance in the bottom of fuel tanks – eventually blocking fuel lines and filters.”

Two new multiprocess welding machines have been an instant market hit for BOC, according to the gases and engineering firm.

Its Smootharc multiprocess 175 and Smootharc TIG 185 ACDC machines are well suited for farmers, professional trades people, hobbyists and the DIY market.

BOC’s senior product manager for welding products in Australia and New Zealand, Richard Fowles, says the 175 single-phase machine is regarded as a great investment for the all-round welder, coming with torches ready-toweld for all processes.

Simple to set up, the synergic machine is easy to operate and ideal for light industrial, maintenance and DIY applications.

The TIG 185 ACDC is an inverter-based machine with added MMA welding capability.

Delivering smooth arc characteristics for high-quality welds, the unit is ideal for all materials.

A variable balance control allows the operator to select the amount of cleaning or penetration required for aluminium welds and the pulse capability means they can control heat input when working on thin materials.

It has a simplistic control panel making it easy to use and is, says BOC, the perfect tool for sheet metals, stainless steel and aluminium fabrications.

William Hughes shows how good quality diesel fuel should look (left) and how it looks when microbes thrive in the fuel, because there is no sulphur to inhibit their growth.

Legge says this can be potentially dangerous if the fuel is suddenly needed to quickly restore power to a businesses such as during a power cut.

“The major fuel companies recommend that diesel should not be kept for more than 12 months without being subjected to a regime of testing to ensure it is in a usable condition “Once the microbes start growing they can affect fuel quality within just a few weeks.”

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Make a resolution to protect motor efficiency Developing a motor replacement policy, and making a commitment to use only quality certified motor rewinders, are two actions that will pay off in energy savings, reduced maintenance costs and safeguarding production, says the Energy Efficiency and Conservation Authority.

When motors fail or are at risk of failure, the choice whether to repair or replace is often made under pressure and frequently isn’t the most economic one, says EECA industrial programme manager Rod Treder.

“Companies with a proper motor replacement policy will be doing the right thing when failure happens, and the business will save money as a result,” he says.

EECA’s motor replacement policy guide helps companies develop sound policies, taking into account motor size, configuration, loading, operating hours, and electricity prices.

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January 2013

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Picture courtesy of Energy NZ

EECA also promotes the use of motor rewind workshops, which are quality certified to ISO, 9001:2008 or the Telarc Motor Rewind Workshop Quality Code 2009.

“A poor quality motor rewind can prove expensive, leading to increased electricity use, poor reliability and higher maintenance costs. Qualitycertified workshops have the right systems to achieve high quality rewinding, protecting your investment,” says Treder.

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MAINTENANCE MATTERS

Flexible coating for steel Nanomyte TC 3001 from NEI Corporation is a new flexible coating specifically designed to protect oxidising steel and aluminium exposed to corrosive chemicals or harsh environmental conditions.

Unlike conventional paint, which will chip or crack when exposed to stress from vibration, expansion, or f lexing, TC‐3001 will move, bend and conform to the substrate that it covers. The coating can last 10 to 15 years, or more, in the field with little or no maintenance. Nanomyte works by replacing traditional solvents and binders with a high‐solids carrier.

The material is heated until liquefied, then applied by hot airless spray. The result is a smooth, uniformly thick coating.

Cracks and crevices in pre-existing paint, and even spalled concrete, can be filled

as the metal surface is covered.

TC‐3001 is able to protect the metal substrate by adapting to changing environmental conditions. The coating maintains its resiliency and structural integrity over time, better than conventional anticorrosion paints and coatings.

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Airless chain lubrication SKF New Zealand has launched ChainLube, an airless system for accurate and automatic chain lubrication in the food & beverage industry.

It provides accurate lubrication of chains, with no need to connect to a compressed air supply. This reduces the risk of potential food contamination from oil mist, and oil evaporation in high temperature applications. The system can withstand nozzle-area temperatures of minus 40 degrees Celsius (depending on oil viscosity) up to 220 degrees Celsius.

The system is best suited for lubrication of parallel chains with speed below three pitches/sec in applications such as baking ovens, dryers, proofers, freezers or conveyors in wet areas.

ChainLube features a volumetric piston pump and a control unit that enable delivery of accurately metered lubricant volumes at preferred intervals, pitch-by-pitch. Projection nozzles, which have no mechanical contact with the chains, prevent dirt accumulation and applicator wear.

Chains are available with pitches ranging from 12.7 to 1,000 mm. Tensile strengths range from Ultimate (UTS) to 900 kN. With modification, higher tensile strengths are possible. The Long Pitch (LP) roller chains are in accordance with DIN 8187, ISO 1977 and BS 4116 (Part IV), covering series M, MC, FV and Z series, in metric and inch sizes.

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Corrosion proof pressure sensors Bestech Australia has been providing Keller titanium versions of its pressure transmitters for use in heavily corrosive media for years.

Due to its neutral chemical and biological properties, and a protective surface layer of oxide, titanium has a number of advantages for use in wastewater that may be contaminated with unknown corrosive substances.

Pressure transmitters with titanium housing and an implantable sensor made of titanium make it possible to carry out hydrostatic level measurements effectively in brackish water, or even in iron chloride.

Normal pressure sensors

using a steel diaphragm can only be exposed to temperatures of up to 60°C. Otherwise, the heat-induced expansion of the oil causes so much deformation of the steel diaphragm that it will not return to its original position.

However, the titanium diaphragm shows no deformation up to 120°C, which leads to better stability than steel diaphragms in pressure transmitters.

Titanium is increasingly used to manufacture high-quality pressure transmitters that meet the most demanding stability requirements in harsh environment.

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HOSE REELS

for every e y application! app ca o !

MANY MODELS

AVAILABLE IN NZ

ReCoila hose reels are tough, reliable and built to last from steel, stainless steel, aluminium or polypropylene.

Many popular polypropylene models are available locally from NZ stores; contact us for your nearest reseller, or get in touch if you are interested in a custom made hose reel.

+64 9 441 0177

www.recoila.co.nz

D130123b

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MAINTENANCE MATTERS

Rust barrier saves money A spray coating to protect equipment from the elements is helping firms mothball gear and ensure maintenance programmes are kept on track, reports Steve Hart.

A technique for protecting metal fittings on North Sea oil rigs from the corrosive effects of salt water is being offered by a New Zealand firm.

Integrated Maintenance Group (IMG), which has three sites dotted across the North Island, uses the Enviropeel thermo plastic system to spray a coating of hot plastic over almost any equipment to protect it from the weather and prevent rust.

IMG’s Gordon Bayliss says the thermo plastic coating features corrosion inhibitors and is designed to combat hot spot corrosion as well as mothballing and standby equipment storage.

“We are an engineering company, but see a need for Enviropeel as companies decide to take machinery out of use and place it outside to the mercy of the elements,” he says. “Spraying equipment with Enviropeel means this gear can stay outside.

“We first started using it when we were asked by NZ Steel to protect their equipment in long-term storage.”

While the coating is often used to protect parts such as nuts, valves, bearings and shafts etc, it can also be used to make routine maintenance tasks easier.

“It can protect vulnerable parts so that cracking open or closing a valve once a year will be a lot easier as it won’t have rusted up,” says Bayliss.

He says the coating is 170 degrees C when it is applied, but quickly cools to a soft plastic that can be peeled away when engineers need to remove it.

“An oil residue leaches from of the coating to protect the item it covers,” says Bayliss.

He says the product’s built-in rust inhibitors are constantly released providing complete protection for the life of the component. The system has been proven overseas to provide protection for more than 20 years in the harshest of conditions.

The base colour of the coating is grey but different colours can be used to identify a particular component. Plus all coated items are tagged with the date and the person who applied the coating.

Bangs and knocks that may cause the coating to snag can be repaired with a

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January 2013

The plastic coating is applied to a gear part.

small hand-held applicator.

“This can be useful if an inspection of the component is required without fully exposing the area,” says Bayliss.

The coating can also be melted down and sprayed again, so long as it is clean when removed – otherwise it could clog up the application machinery.

Bayliss says IMG can apply the coating

to equipment delivered to any one of its sites, or its staff can visit clients to spray equipment at their premises.

“The good thing about Enviropeel is that the coating doesn’t break down under the sun,” says Bayliss.

He says the firm has talked with the military about using the coating to protect gear when it is sent abroad.

The soft plastic Enviropeel coating is easily and cleanly removed.

MAINTENANCE MATTERS

Better storage Traditionally, machinery lubrication has been seen as a function of low importance, being messy work, requiring limited skills, and lacking organisation and structure.

The risks of misapplication are high with many oils being supplied in the same basic drums with only complex codes indicating the different oil characteristics. The consequences of the incorrect oil being used can be catastrophic to machinery.

Lubrication Engineers NZ best practice lubrication storage solutions contribute to 5S, LEAN and TPM improvement initiatives

and also assist with addressing OSHA right-toknow and other workplace safety and environmental compliance issues.

Lubrication Reliability programmes are now readily acknowledged as being a critical factor in the successful operation of a modern industrial plant.

Worldclass lubrication provides demonstrable benefits with increased component reliability, reduced maintenance costs and improvements in overall equipment performance.

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Extend the life of your equipment

Safety rail system Easily installed along an entire unprotected work area, the Soll MultiRail horizontal rail system offers the advantage of fixing distances of up to six metres and can be used by six people simultaneously, thereby offering greater safety and flexibility to all workers when compared with regular anchorage points.

It can be installed at different levels: foot, wall or overhead, and is available with three different types of gliders to suit each of these applications, closed, open-able or overhead.

In addition, pre-constructed

corner sections allow the system to be easily customised to suit any structure.

The Millar floating rail design from Honeywell allows for thermal expansion and reduces the impact transmission to the structure in the event of a fall.

Honeywell Safety Products also provides a range of personal protective equipment for a variety of uses and offers the best-in-class safety, quality and performance for you and your workers every day.

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Gough Analytical has provided expert advice and analysis to customers across New Zealand since 1973.

With its cutting-edge technology and committed team, the firm is dedicated to making your business a success. Whether you require oil, fuel, coolant, grease or filter analysis, and regardless of the make or model of equipment, Goughs can provide a detailed evaluation.

“Our service is trusted and proven in a variety of different industries including construction, road transport and power generation and defence just to name a few,” says the firm.

“We know that maximising your investment in your equipment is top priority.

We also know that one of the easiest ways to avoid costly repairs and breakdowns is to routinely sample and analyse the fluid and components that are the ‘life-blood’ of your equipment.

“As the leading equipment

fluid analysis service provider in NZ, we can help identify potential problems or abnormal wear patterns, enabling you to be proactive before more serious damage occurs.”

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25

MAINTENANCE MATTERS

Fluke 810 vibration tester Vibration testing is an important tool not only for your preventative maintenance programme, but also trouble shooting, commissioning new equipment and ensuring proper installation. The Fluke 810 is a simple, easy to use instrument and guides you through entering basic machine information such as RPM and horsepower.

It uses an optical tachometer and tri-axial accelerometer to measure speed and vibration.

The data is analysed and you are presented with a qualitative measure of the condition of the equipment.

This will identify

any problem’s root cause, location and severity and can also provide some repair recommendations.

Once the tests are completed, store vibration results to your PC and use these first tests as a baseline reading. Compare these against future tests as part of periodic preventative maintenance schedules.

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Longer warranty for thermal imaging cameras Flir, a maker of thermal imaging cameras, has increased the warranty period for many of its fixed mounted security and surveillance products to three years.

Its uncooled microbolometer detector, for fixed mounted security and surveillance thermal imaging cameras, now comes with a 10 year warranty.

If a problem should occur within the warranty period the company will replace the uncooled microbolometer detector free of charge or, depending on the case, replace the entire thermal imaging camera.

The company says Af and Apt-Series thermal imaging cameras are not included in this new policy and the PT-602CZ is not included in the extended warranty policy since it does not contain an uncooled microbolometer detector.

Owners of Flir products need to register ownership of the Flir products with the firm via its website www.flir.com/ cs/warranty.

The new policy is only valid for thermal imaging cameras that are purchased since 24 September 2012.

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Asset management

Skilled mechanical engineers securing your firm’s future

Congratulations to our Graduates of 2012 Industry training for the engineering sector

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January 2013

PAS 55 is the British Standards Institution’s specification for the optimised management of physical assets. It provides clear definitions and 28-point requirements specification for establishing and verifying a joined-up, whole-life management system for all types of physical assets.

In New Zealand, the Asset Partnership is among the leading maintenance and operations management consulting organisations and has been endorsed by the Institute of Asset Management to provide assessment and certification services against PAS 55 requirements.

This, says the firm, provides its clients with assurance of the quality of its assessment processes and the experience of the company’s assessors.

The Asset Partnership’s staff can identify areas that require improvement, design and implement asset management systems, review and develop your asset management policies, strategies, objectives and plans to ensure organisational alignment.

A working asset management strategic framework can reduce life cycle costs by up to 20 percent, says the firm.

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MAINTENANCE MATTERS

Date set for this year’s conference The Maintenance Engineering Society (MESNZ) wrapped up a busy and fruitful 2012 with a bang, presenting the most successful national conference seen by maintenance engineers yet.

All the critical numbers were up against a framework of tight economic times and the mix of presenters, exhibitors and activities was “bang on” according to the masses.

More importantly, the team of volunteer society members proved that they too could build on their previous experiences and “lift their game”.

The biggest measure of success though, is what will be happening in companies throughout New Zealand as we speak, immersion of the shared learning back into industry. This organised osmosis is the true reason behind the biggest manufacturing and maintenance engineering event of the year; providing a forum to meet, learn and share.

Among too many standout papers and moments to mention, the presentation of Bill Buckley left the attendees gobsmacked. To see this humble and quiet kiwi engineer explain what he has achieved on the global stage and see what Buckley systems continues to lead the world in was truly special.

Bill is made from the same mould as Bert Munroe and Edmund Hillary and inspired the conference with his Kiwi can-do approach.

By Craig Carlyle, secretary MESNZ.

Craig Carlyle

Reliability and Maintenance

training courses

The national conference doubles as the venue for the MESNZ AGM. The relatively benign affair saw the appointment of new Chairman Karl Hayward (Orica).

Karl superseded Barry Robinson (SAFE Engineering), who stands down under the constitutional rules after four years of dedicated input.

The other executive and committee roles remain largely unchanged and the committee yet again sports of full bench of wide ranging skills and representation.

Budding engineer Craig Piggott nervously accepted his 2013 MESNZ Engineering Scholarship at the 2012 SKF National Maintenance Engineering Conference.

Bookending Bill Buckley, this young man was enthusiastically endorsed by the committee with his self-driven attitude, achievements and demonstrable passion for engineering. The irony was not lost on attendees, treated to two similar men at

opposite ends of their careers.

With the 2012 conference held in a year that saw major developments in the MESNZ’s representative, training and networking activities, the committee could be excused for kicking back on the run into Christmas.

No luck there, they have been busier than ever, laying the foundations for this year’s event. Put a ring around 12 and 13 November, when the 2013 SKF National Maintenance Engineering Conference will be back again at the Novotel Lakeside in Rotorua.

Yes, SKF has not hesitated, stepping up immediately to support maintenance engineers yet again. The next event is budgeted to welcome 150 attendees and 50 exhibitors and will sport a full mix of international, expert and peer papers.

Awesome!

On the web ask u www.mesnz.org.nz s

The knowledge path for staff in their work environment

Training Needs Analysis: skills improvement for your staff today

The knowledge path for staff in their work environment

ab our U PSKI out L L-V Mem IP ber Prog ship ram!

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

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

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

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

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

www.skf.co.nz

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

The Power of Knowledge Engineering

27

www.skf.com.au/training

FEATURE

Investing in training pays off One engineering firm that’s playing its part in training our youth is Page Macrae Engineering. The firm’s Mike Lehan talks to Steve Hart.

A commitment to training apprentices is paying off for a Tauranga-based heavy engineering firm.

Page Macrae Engineering in Mount Maunganui has been employing apprentices since the firm started in 1954. It currently has 15 apprentices enrolled with plans to increase this to 17 this year.

The firm’s general manager Mike Lehan has been with the firm since 1999 and while he couldn’t give an accurate figure, he says the firm would have trained hundreds of apprentices since the business started.

Altogether the firm has 175 full-time staff, and contractors take its payroll to more than 300 people.

“Our aim is to have 10 percent of our staff in apprenticeship training which covers general engineering, welding, machining and fabrication,” says Lehan.

The company offers work experience to Year 13 students, which helps introduce them to a career in engineering.

“It filters out those who really want to learn the trade from those who don’t,” says Lehan. “You can usually tell who will be a good fit for the trade

by how they get on during their work experience placement.

“From work experience they can go into a pre-trade course with the local Polytechnic, which is where we select most of our apprentices.”

People wanting an apprenticeship with the firm have to go through a tough interview process which involves sitting before a panel of six of the company’s managers.

The company also runs tutorial evenings with a tutor from the local Polytechnic. These take place every second Wednesday and are open to apprentices in the area.

“What we are interested in is putting back into the trade what we take out of it,” says Lehan. “It isn’t necessary that the apprentices who obtain trade qualifications stay with us – we encourage them to go and gain wider experience outside the company.

“We retain about half of all the apprentices we train, and find most of the others end up in Australia or further afield. Generally those who return home come back as more rounded tradesmen.”

Lehan says plenty of former apprentices knock on the company’s

An apprentice at Page Macrae Engineering is helped by a senior member of staff.

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door, keen to work on the wide variety of projects it is involved in.

“If you don’t invest in training you will eventually find a shortfall of the trained and skilled people you need,” says Lehan.

“If companies don’t put something back into those trades then the manufacturing sector will eventually disappear because the skilled people needed to carry it on won’t be here.”

However, Lehan concedes that not every firm is large enough to carry an apprentice, as they may not really contribute to its bottom line in their first year of training.

“However, the upside is you get to train a person to fit with your business and your industry – so that has got to be good,” he says.

“The government should share more of the burden for funding apprenticeship training – particularly with smaller firms who don’t have the financial resources. The government really needs to get behind these companies as that might help them get more involved.

“Back in the 1980s training was fully subsidised by the government – what’s changed?”

Smaller plugs with a twist With the M17 compact series of round plug connectors, Phoenix Contact has reduced the size of its standard connectors. The diameter of the cable connector was reduced by 2.6mm to 18.7mm; the total length was also reduced by about 15 percent.

In addition to cable and coupler connectors, there is also a panel feedthrough with integrated mounting flange.

By simply interchanging the moulded seal, users can use the panel feed-through for rear and front panel mounting.

In addition, eight and nine-pin insulators, which are factory equipped with 1mm crimp contacts, are being launched. Another new feature is the

incorrect connections being made.

With the Speedcon rapid interlock system, plug connectors are quickly and reliably interlocked with just half a turn.

The position can be identified by the “open/locked” marking.

The IP67-compliant housings and are shielded against electromagnetic interference. All of the previous isolators of the standard M17 series from Phoenix Contact can be combined with the round M17 compact plug connectors and provide an optimum solution for supplying power to compact devices and drive units. optional colour marking using plastic rings on the housing, which help prevent

Anybus CompactCom expanded Anybus CompactComTM from HMS Industrial Networks is a range of embedded communication solutions that provide devices with connectivity to any industrial network.

HMS’s new offering – the 40-series – gives users the possibility to choose their level of integration to the host device and the desired performance level.

The new Anybus CompactCom consists of ready-made communication interfaces for all major fieldbus and industrial ethernet networks in several form factors: Chip: A full network connectivity solution on a single chip for integration into the user’s PCB design.

Brick: Ideal for users who have limited space or want to add their own choice of network connectors.

Module: A complete and

interchangeable communication module gives the fastest time to market.

The Anybus CompactCom 40-series supports all major industrial networks but is especially suitable for high-end industrial ethernet and fieldbus applications.

Since the CompactCom 40-series practically offers zero delay between the device and the network, it is ideal for high-performance applications with fast network cycles and synchronisation demands such as servo drive systems.

The company says the 40-series gives users access to “all types of industrial networks” – traditional fieldbuses as well as industrial ethernet – through one single development project.

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Stand-alone NI CompactDAQ system The NI CompactDAQ stand-alone system offers a high-performance embedded measurement and logging platform with a built-in dual-core Intel processor for running data acquisition, online analysis, and logging software.

With this platform, you can customise a complete measurement system using NI LabView system design software or take advantage of more than 600 companies in the NI Alliance Partner Network for a custom turnkey data-logging solution.

Stand-Alone NI CompactDAQ system features 32 GB non-volatile storage, and 2 GB RAM, more than 50 hot-swappable I/O modules with integrated signal conditioning, run up to seven hardwaretimed analogue I/O, digital I/O, or counter/timer operations simultaneously and simultaneously stream continuous measurements with sample rates up to 1 MS/s/ch.

In addition, you can connect C Series chassis to expand the number of module slots for large applications; it is compatible with LabView 2012 and features USB, ethernet and serial ports.

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CABLE MANAGEMENT

Couple and clamp Integrating strong, secure strain relief into energy chain mounting brackets is vital for good cable performance in moving applications.

Limited space, high pull forces, vibration, temperature extremes, oil and coolant lubricants, are all challenges that need to be met by any strain relief system.

Conventional strain-relief products do not always cope well with such conditions. For this reason, Cologne-based company Igus has developed Chainfix saddle clamps for fixing cables properly within energy chains.

Ribbed plastic saddles ensure a positive connection with the cables. The cables remain clamped even under very large pull so that they cannot slip out.

Abrasion-free and easy

on cables, they work very well with a wide range of sheathing materials (PVC, PUR, TPE etc). The clamps are available in black varnished steel or in stainless steel, and as a single, double or triplelayer version.

A wide range of strain-relief possibilities can be achieved with the new Chainfix multi-clamps. Four different double-saddle geometries are now available allowing the user to install different cable diameters quickly and compactly, inside one single space-saving modular clamp.

These multi-row multiclamps can also fix cables with small outer diameters securely. The double-saddles can be ordered individually to combine existing systems or as ready-to-install multi assemblies ex stock or can be

freely configured according to customer wishes.

Chainfix saddle clamps currently represent standard strain relief for energy chains of all kinds with plastic mounting brackets.

Chainfix Nuggets can be used for fixing cables and hoses up to a diameter of 20mm. This space-saving

strain relief element slides into the C-profile rail with no tools needed. Strain-relief separators combine energy chain interior division components with strain relief and are particularly suitable for energy tubes.

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3D cable carriers

Lift cables high

No matter what your application you can count on KabelSchlepp to have a cable and hose carrier solution to meet your requirements. From light-weight micro-sized mono cable carriers up to large super-duty steel chain designs, KabelSchlepp has the perfect solution for any application.

Its range also includes carriers with 3D movement for multiaxis robotic applications and tube types for superior protection from chips and debris.

Made in Germany for more than 50 years and with proven technology used worldwide, the KabelSchlepp Online Engineer configuration tool helps you quickly select and configure the optimal cable carrier system for your application.

Design assistance includes application photo and video galleries along with 2D and 3D CAD drawings to save time.

The Liftband is suitable for long vertical travel paths where only a low basic height of the energy chain system is permissible.

Like a paper streamer, the strip can be pulled a long way up from an almost completely flat initial position – where space is limited the strip can also be arranged in several following layers.

It is made up of only a few parts that allow a wide range of configurations. Its basic shape can be round, rectangular or square, meaning that adaptation to customer requirements and space conditions can be done tailor-made in almost all cases.

The modular system comprises of three basic elements: straight and curved strip pieces as well as clip-on cable clamps.

The connected strip segments determine the basic shape, the cable clamps connect the segments and route the cables at the same time.

The frame options include: easy (for the simple clipping in of the cables), snap open (frame with hinge), and a height-adjustable lockable frame.

Since the chain links do not rub against one another, the system has an extremely low level of wear and is very quiet. Taken together, the properties of the Liftband make it an alternative for a whole series of applications.

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D130129a

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D130130b

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January 2013

Rugged module for tough application Kontron has premiered its second new module in the ULP-COM (ultra low power) standard, extending the its computer-onmodule concept to countless ultra low power and SFF smart devices.

The scalable Kontron ULP-COM-sAMX6i with single, dual or quad core ARM Cortex A9 technology covers a wide performance range.

Based on Freescale’s i. MX6 series processors, they enable an efficient development of scalable smart devices that need an extremely compact, fanless design with balanced processor and graphics performance.

OEMs benefit from these new modules by a standardized basis for the industrial environment with enhanced design

security for the rapid and efficient development of mobile, energy-efficient embedded appliances with open standards software.

It exceeds the traditional scale of longevity with their availability of at least 10 years. Furthermore, they support the extended temperature range from -40°C to +85°C by-design. The ULP-COM module family is ideal for market sectors demanding highest ruggedness and longterm availability.

The built-in watchdog timer enables its use in mission-critical applications with the most demanding levels of reliability in the medical, security and military markets.

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Ethernet switches for gigabit networks Westermo has enhanced its Viper range of compact, managed Ethernet switches with the introduction of four new 12-port devices designed to manage gigabit networks. The Ethernet and power-overEthernet (PoE) devices help meet the growing demand for communication networks with higher data rates on-board railway rolling stock to support video, LCDs and wireless LAN access points.

The new devices are part of Westermo’s IP train concept that delivers a complete Ethernet switch and routing solution to provide a robust network infrastructure for the creation of intelligent trains.

The four new models provide a range of standard Ethernet, Gigabit Ethernet, and PoE port options as well as additional routing functionality. The Viper-112-T3G has three Gigabit Ethernet ports and nine standard Ethernet ports.

The Viper 212-T3G provides the same port configuration, but with additional routing capability to enable the connection of subnets and improved overall network performance.

The Viper-112-T3-P8 offers three gigabit ports, a single standard Ethernet port and eight power-over-Ethernet ports that support the IEEE 802.3at ‘plug-andplay’ PoE communications standard.

PoE enables both power and data to be transmitted on a single multi-core cable, especially useful for camera applications, reducing overall wiring and enabling faster installation.

The Viper 212-T3G-P8 provides the

same port configuration, but extends the functionality by offering routing capability. The Viper PoE switches deliver up to 66W of power across their eight PoE ports and are able to isolate the input DC voltage from the connected devices, to protect them from power surges.

Power distribution is managed, with ports ‘tuned’ to maximise distribution efficiency.

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Intelligent surge protection The Plugtrab PT-IQ product family from Phoenix Contact is the first generation to provide proactive functional monitoring for signal interface surge protection devices.

A yellow status signal indicates that the performance limit has been reached as a result of frequent surge voltages, while a small reserve capacity ensures that protection remains effective.

The user is informed and can replace the protective connector before the protective function fails due to component overload. Thanks to the remote signalling feature, users can inspect the system from any location and at any time.

0800 474 643 www.singergroup.co.nz

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31

Annual conference planning underway Allan Hill, national secretary/manager NZEI The Auckland branch of the NZ Electrical Institute is hosting the 2013 annual conference/AGM in Auckland on 8 and 9 March 2013.

The conference programme will follow a new, exciting format, focussing on electrical/electronic trade displays with suppliers promoting new and innovative products and services. There will also be workshops with guest speakers from EWRB, Energy Safety, DOL and Standards New Zealand.

The Auckland branch has set up a special conference committee and would welcome your ideas to make this a truly learning and memorable experience, please email me at ics.ltd@xtra.co.nz NZEI Inc members and the general public are welcome to the technical session on Friday 8 March, could those who intend to come please contact the national secretary/manager at the national office as soon as possible so we can ensure seating and catering is adequate.

Standards AS 4024:2006 - Safety Standard - Safety of Machinery, Design of Safety Related Parts of Control Systems, General Principles for Design.

The first special functions (SF) 041 meeting for five years was held on the 12 and 13 November 2012. The meeting was productive and those present got through the full suite of standards that comprise AS 4024.1.

They also discussed the part 2000 standards, such as light curtains (IEC/TS 62046), ISO 14122 (access to machines), ISO 14159 hygiene requirements for design, and the part 3000 machine specific standards which we urgently need to adopt.

The regulators from New South Wales and Victoria agreed to find out which classes of machinery are most highly represented in the incident statistics so the SF 041 committee can prepare direct text adoption proposals for the relevant ISO standards to cover these.

The SF 041 committee expect the following groups to be high on the list: wood chippers, injection moulders, workshop machines, dough mixers, woodworking machinery, meat processing machinery.

With regard to part 1, SF 041 had some

32

January 2013

changes to the original proposal I put to Standards Australia, its system is so inflexible that it has had to put new project proposals together to reflect these changes.

AS/NZS 3000 Amendment No. 2 AS/NZS 3000 amendment No. 2 has received the necessary approvals to allow publication to be made, it is expected that copies of the “paste in� amendment slips format will be available by the time you read this in January 2013.

A consolidated copy of AS/NZS 3000, containing all amendments, AS/NZS 3000 plus amendments 1 and 2, is in the course of preparation and is expected to be available in the near future.

This consolidated version will be in a new format of a ring binder, and it is also proposed that in future all amendments will be covered by the issue of replacement pages only.

The formal recognition of AS/NZS 3000 amendment No. 2 will not occur until the Electricity (Safety) Regulations 2010 amendment 3 to Schedule 2 has been issued in 2013.

The use of AS/NZS 3000 amendment No. 2 provisions may be used in advance of the formal recognition for new work

as the amendment has a formal approval for publication in New Zealand.

EL-001 meeting A meeting of the EL-001 committee is currently scheduled for February 2013, and it is proposed to discuss the need for an amendment No. 3 to AS/NZS 3000 and the content of the amendment.

Also set down for discussion is the ongoing format of AS/NZS 3000 plus amendments. If any NZEI member has any constructive comments on the current format of AS/NZS 3000 would they communicate those comments to the national secretary/manager.

It is also expected that detailed drafting work on the revision of AS/ NZS 3010 will commence shortly, in particular, the connection of generating sets to electrical installations to switchboards other than the main switchboard of the electrical installation.

It is also intended to address the safety issues that some configurations of portable generators sets bring, when being fixed wired or connected by a f lexible supply lead connected to permanent electrical installations.

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

Email: nzei@xtra.co.nz

Welcome interruption

Universal signal conditioner

ABB has developed the world’s first circuit breaker for high voltage direct current (HVDC).

It combines mechanics with electronics, and will be capable of ‘interrupting’ power flows equivalent to the output of a large power station within five milliseconds – 30 times faster than the blink of an eye.

The breakthrough removes a 100-year-old barrier to the development of DC transmission grids, which will enable the efficient integration and exchange of renewable energy.

The firm says it will also improve grid reliability and enhance the capability of existing AC (alternating current) networks.

“ABB has written a new chapter in the history of electrical engineering,” says Joe Hogan, CEO of ABB. “This historical breakthrough will make it possible to build the grid of the future. Overlay DC grids will be able to interconnect countries and continents, balance loads and reinforce the existing AC transmission networks.”

The Hybrid HVDC breaker development has been a

The universal signal conditioner combines measurement and control functions in a single instrument and provides user selectable solutions for most signal conditioning applications including PID control.

The USC has two analogue inputs that can be programmed to measure AC/DC current or voltage, resistance, potentiometer, strain gauge and temperature.

It has two pulse (digital) inputs that can be programmed to measure frequency or phase and used as control inputs to perform hold, reset and enable.

There is one isolated proportional output that can be

flagship research project for ABB, which invests more than US$1 billion annually in its R&D activities.

Hogan says the breadth of ABB’s portfolio and “unique” combination of in-house manufacturing capability for power semiconductors, converters and high voltage cables (key components of HVDC systems) were distinct advantages in the development.

“HVDC technology is needed to facilitate the long distance transfer of power from hydropower plants, the integration of offshore wind power, the development of visionary solar projects, and the interconnection of different power networks.

“ABB is already working on the construction of multi-terminal systems and the latest DC breaker innovation is a major step in the evolution of HVDC grids.

In parallel to the new hybrid breaker development, ABB has an established HVDC grid simulation centre developing solutions for future DC overlay grid operations.”

configured as an analogue output or a pulse output; two independent relay outputs; excitation output (voltage or current); digital (bus) outputs; calibration and set point variables; arithmetic function variables and four 101 point tables.

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First certified smart grid vehicle charger Australian technology company DiUS Computing unveiled its ChargeIQ electric vehicle charger at the 10th Annual Australia and New Zealand Smart Utilities conference.

The conference, at the Melbourne Convention and Exhibition centre, is the largest platform across the region with a focus on the latest water and electricity industry developments.

The technology behind Charge IQ allows it to communicate with smart meters and adjust the electric vehicle’s charging load based on requests received over the smart meter network from utilities.

ChargeIQ will provide significant benefits to the electricity industry by enabling demand side participation through the introduction of flexible pricing tariffs, which encourage demand to be shifted from high cost peak to lower cost off peak prices.

The charger recently became the first electric vehicle home charging unit certified to the Zigbee communications standard used

by Victoria’s smart meters.

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D130133b

33

Stand back and measure Fluke’s CNX wireless system connects multiple measurement modules and sends simultaneous readings to a master device up to 20 metres away. The rugged, customisable tool set lets users choose various measurement modules based on their troubleshooting scenario.

At the core of the system is a CAT III 1000 V / CAT IV 600 V multimeter with a screen that displays its readings along with live readings from up to three other measurement modules. For more complex troubleshooting, users can view see measurements from up to 10 modules simultaneously on a computer equipped with the CNX PC Adapter.

The modules, which include AC voltage, AC current clamp, iFlex AC current clamp and K-type temperature units, can

take live measurements or log up to 65,000 sets of data. Logged data can be saved to a computer in the CSV format.

The system lets users place modules in hazardous or awkward places and then watch the readings from a safe distance. For example, technicians can de-energise a panel, connect voltage or current modules to all three phases and close and re-energise the panel. The measurements can then be read outside the arc flash zone.

By leveraging the most common electrical test tool, the multimeter, the CNX system allows technicians meet market demand for more complex three-phase work without retraining on more complex test tools.

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Processor board for variable temperatures Advantech’s 2.5-inch MI/O-ultra single board computer (PicoITX) is the firm’s first Intel ultra low power Atom N2600/N2800 dual core processor board that supports temperature operations between -40°C and 85°C. Measuring 100mm x 72mm, the MIO-2261 is equipped with flexible multiple I/O interfaces and the company’s MIOe connector that can extend to additional functions.

The MIO-2261 is designed with wide temperature components including management IC that prevents poor power conversion efficiency from rising temperatures.

Capacitors with a high melting point (350°C) help ensure constant stability, which is much higher than electrolytic capacitors (120°C). MIO-2261 uses a high heat resistant TG-150 PCB type board for stable production and quality.

The unit features a 12V DC

power input design with a +/- 10 per cent tolerance. A DC power hot-plug design protects from current fluctuations damaging the board when DC power is plugged in/out.

The MIO-2261 is designed with a high level industrial grade ESD COM port driver IC (15KV air protection/8KV contact protection for RS-232), and transient voltage suppressor design on the power input side to protect it from events such as lightning and other transient voltage events.

The heat-generating parts and active components are on the top side of the board for a more efficient thermal spread. In addition, MIO-2261 has an optional heat spreader to conduct heat to the chassis cover for more compact and low-profile designs.

•

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Automatic light switch

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

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

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

34

January 2013

The Quattro HD is a high definition sensor from Steinel Sensors with four digital pyro heads behind the lens to control lighting in offices.

The sensor radiates 4800 switching zones to an area, so it will pick up the smallest of movements. With a presence detection of 8m x 8m and an overall detection area of 20m x 20m it is suited for larger office spaces.

The Quattro delivers a square detection zone that means all areas of a room are covered, even into the corners.

The detection range of the sensor can be mechanically scaled back to suit the size of the room. In IQ mode the sensor will continuously scan and learn the usage of a room, dynamically adjusting

the run-on time to suit the user’s requirements.

This ensures that the lights are only on when required and when the room is vacant, the sensor will read this and reduce the run-on time to suit and turn off the lighting, saving power and money.

With the built-in lux detection from 10-1000lux the sensor can also manage ambient light levels for light harvesting.

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