Demm Engineering & Manufacturing July 2012 by Adrenalin Publishing Ltd

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

• Food Processing Industry • Packaging & Labelling update • Taking action for machinery safety • What’s in the reliability toolbox? • Terminal blocks for price sensitive markets Now including

www.demm.co.nz

• CONTENTS

Editor's

note

Of sickles and safeguards The other day I entered my favourite warehouse store to buy a shovel (for planting) and a sickle (for trimming my lawn at the edges). I swiftly located the aisle containing the warehouse’s assortment of shovels, chose a suitable model and asked to be directed to the location of the sickles. The response I got quite amazed me: “We are not allowed to store or sell sickles, because they can be used as a weapon.” Looking at all the weapons-grade tools around me – axes, spades, saws and the like – I denied myself an answer along the lines of,“Ok, then please show me where you have displayed the chainsaws. I desperately need something to get even with my neighbour,” and left the shop, scratching my head and threatening imaginary passers-by with my new digger. Even with New Zealand’s streets being void of sicklewielding sickos, our country seems to be a dangerous place. Especially when you are employed in one of the following sectors: manufacturing, construction, agriculture (do they still use sickles on farms?), forestry and fishing. In March 2011 the Minister of Labour, Hon Kate Wilkinson, launched the National Action Agenda 2010-2013 to reduce the work toll in these five sectors, supported by five Sector Action Plans. One part of the Manufacturing Sector Action Plan, the Safe Use Of Machinery Project, is supposed to lift the standard of machine guarding and thus reduce the work toll paid by the manufacturing sector (26 fatalities between 2005 and 2010, over 330,00 new ACC-approved claims in the 2009-2010 year). I talked to safety specialist Pilz about ways to reduce these horrendous numbers. The corresponding article starts on page 22.

Subscriptions: An 11-issue annual subscription in New Zealand is $59.00 (incl GST). Please call us for overseas rates. COPYRIGHT:

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

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

Food Processing Industry The latest developments in the world of Food Processing. Includes

a closer look at how cleaning in place works and where it should be used.

Packaging & Labelling A range of stories relevant to this sector, including a new solution to protect anything and everything, anywhere.

22 Machinery Safety Editor Stefan Richter asked safety specialist Pilz where the

alarming work toll in the manufacturing sector comes from – and what to do about it.

25 Fastenings The EDL Kanban System helps users of fastener and consumable products reduce labour costs and inventory levels.

Maintenance Matters This feature includes a description of the most important tools

every maintenance engineer should have in their reliability toolbox.

Electrical Technology We take a closer look at cabling and wiring and the changes

that have occurred with the Machinery Directive and standards influencing AS 4024:2006.

Coming Events

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

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• PRODUCT WATCH

Accessible and attractive thermal imaging With the launch of the Flir T400-Series, Flir Systems says it wants to make thermal imaging even more accessible and attractive for both the advanced user and the beginner. Experienced users of thermal imaging cameras such as utility service providers, mechanical, electrical, and professional building inspectors are demanding more from thermal imaging cameras. They want ergonomic systems that they can use several hours per day without tiring, cameras that offer high image quality and that are equipped with all the necessary features that help them to save time when doing their everyday jobs. The new user-friendly T400-Series is designed for the user looking to combine excellent ergonomics and high performance with

high image quality of 320 x 240 pixels – all at an affordable price. Especially for the building inspection sector, a compass has been integrated in the T440bx model. This way the inspector can see which direction he is looking and to which direction a wall is oriented. This can be important information when doing building inspections. The T400 and T400bx-Series come with a tiltable optical unit which makes it possible to measure and take images of objects in all angles, still in a comfortable working position. Top-of-the-line T440 and T440bx models are equipped with the innovative ‘multi spectral dynamic imaging’ (MSX) feature, which produces an extremely detail rich image. Due to this new feature more anomalies can be detected,

more detailed analyses and conclusions can be drawn in a split second. The T440 measures temperatures between -20°C and +1200°C (T440bx -20°C and +650°C). Objects of interest, both on the thermal image and the visual image, can be highlighted by sketching directly on the camera touch screen. An ‘instant report’ of the inspection (with sketches or other text comments included) can be created directly in the T440. A programmable button provides easy access to favourite functions. Built-in Wi-Fi allows connecting smart phones or tablet PCs for the wireless transfer of images or

Edit o choi r's ce

remote control of the camera. The Bluetooth based Meterlink function transfers readings from external measurement instruments to the thermal image. Go to www.demm.co.nz/enquiry quote:

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D120702

Online spectrum colour measuring system

Bestech Australia is introducing the very first online colour measuring system, colorControl ACS 7000 from Micro-Epsilon Eltrotec. The measuring principle is based on the most accurate method of colour measurement – spectral imaging, where the spectrum of reflecting light is compared to the white light reference that is illuminated on the measuring target. The new system supports three operating modes and

July 2012

the colour value resolution exceeds E 0.01 for a spectral resolution of 5nm. The also supports online and offline measuring and is operated via a web browser that also displays relevant measuring parameters, including a black/white balance feature. Process interfaces such as Ethernet/EtherCAT, RS422, USB and Digital I/O are included. Go to www.demm. co.nz/enquiry quote: D120702a

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• PRODUCT WATCH

Nesting Software offers new features Advanced Robotic Technology has released version 2.0 of its toolpathing and nesting software ToolShop. The CAM package has undergone a major re-engineering and now offers a whole suite of new features. “The primary focus of version 2.0 was on the integration with factory processes,” says ART Director David White. “ToolShop 2.0 can now talk to MRP software (manufacturing scheduling software) and enables manufacturers to schedule parts in the office and have them automatically cut in the factory.” ART ToolShop is a Windows-based software package that allows users to draw and import components using standard CAD tools. Using the many automated features found in ART ToolShop, users can quickly apply machining toolpaths and nest into material for minimal waste, ready for output to their CNC router or plasma cutter. ToolShop 2.0 can be fully integrated in existing processes and manages all necessary data such as CAD drawings, parts libraries or customer data. The software now features a full remote material library on the company network that allows the entry of sheet and plate stock levels, which are automatically subtracted when a nest is created on that sheet. “Although our customers have consistently been able to reduce production times with the current version of ToolShop, we realised that there was still room for improvement, particularly in inventory and off-cut management,” Mr White explains. “If a remnant is left over for instance, it is then added back to the material library as a unique one-off

sheet. Priority is given to using remnants up first. Moreover, the software gives information about tool life and costs, so users have more control over their processes.” The extended material database can be hosted on a central server, so multiple ToolShop users can

simultaneously get up-todate information of current stock levels. The intelligent post processor is suitable for different machines, brands and processes including plasma cutters, lasers, routers or water-jets. Improved features include fully automatic toolpathing, auto nesting

function, automatic cut order, auto lead in sizing and position, nest reports, cut time projections, remnant cut-off and full material management, excel and CSV file importing, improved true shape nesting algorithms and many more. Go to www.demm.co.nz/enquiry quote: D120703

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MetalFix

Waterbased Primer For Heavy Rust

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

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

MetalFix 1000®

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

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

• PRODUCT WATCH

Improved worker performance and communication

In high-noise environments, noise-induced hearing loss can be a real problem for workers. While workers need protection, they also need to be able to hear and communicate clearly, which is why Honeywell Safety Products have developed Quietpro QP100Ex. This intelligent hearing protection and communication system provides smart personal hearing

protection, verifiable personal noise exposure measurement and clear communication throughout a full range of work environments. It is connected to two-way com radios, which allows users to hear without compromising listening quality, even under high-noise situations. It also enables a user to speak at a normal level and be heard by the person

on the other radio without picking up environmental noises or compromising speech intelligibility. The system utilises patented in-ear dosimetry to measure every sound that reaches the user’s eardrum. The continuous monitoring of personal noise exposure enables safety managers and workers to address the potential of noiseinduced hearing loss in real time. Audible and visual signals alert workers when they are approaching or have met their daily noise dose, information that can prevent further hearing loss as well as allow managers to schedule shift hours that match permissible exposures. The headset’s microphone captures voices inside the ear tip via air conduction, eliminating sounds commonly picked up by external microphones, while the exterior microphones constantly analyse surrounding sounds, adapting continuously to facilitate natural hearing.

Upon ear tip insertion and system startup, Quietpro QP100Ex performs a quick calibration check to detect proper fit, validating adequate hearing protection and clear communication in each ear. It also alerts the user if they do not achieve a minimum level of protection and are required to refit. The Quietpro QP100Ex’s bionic hearing expands your workers’ personal situational awareness, understanding, and communication by adapting to changing noise levels. This allows workers to remain aware of their surroundings, assess rapidly changing environments and potential threats, and reduce further exposures to hazardous noise. The control unit includes volume control buttons, which permits the user to reduce or increase the level of Go to the surrounding sound. www.demm.co.nz/enquiry quote:

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D120704

Tough hand-held solution Hose reels for

Food Processing

Applications

ReCoila’s SE Series spring rewind stainless steel reels are strong, compact and perfect for hygienic food processing and manufacturing environments. The SE Series is available in a wide range of sizes to suit various hose sizes and pressures. Need a reel for a different application? We’ve got thousands to choose from - or we can design and manufacture a reel for your specic requirements. Call us for more info or visit us online at www.recoila.co.nz

P 9 441 0177

E sales@recoila.co.nz

www.recoila.co.nz 4

July 2012

Dematic is pleased to announce the release of the Psion Omnii XT15. This new hand-held computer is designed for rugged industrial operation; its extreme duty display is tougher and can withstand a 1.25 Joule impact breakage. The XT15 is fully modular which means components can be changed whenever advances are made. New data capture options include a range of high-performance, sensitive scanners with good/bad scan indicators, Imager Control Services (ICS) and cameras. An expanded wireless offering introduces 3.8G HSPA+ and 2G EDGE (WWAN-Broadband), and 802.11n (WLAN-WiFi). The tri-sensor features an accelerometer, GPS and a digital compass to enable screen rotation; data geo-tagging; compass calibration detection and motion sense+. Go to www.demm.co.nz/enquiry quote: D120704a

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• PRODUCT WATCH

Checking overall health of rotating equipment Fluke Corporation introduces the Fluke 805 vibration meter, a portable multifunction vibration screening tool that provides quantifiable information on the bearing and overall health of motors and other rotating equipment. The Fluke 805 is suitable for frontline mechanical troubleshooting teams that need reliable and repeatable measurements of rotating equipment to make imperative go/no-go maintenance decisions.

The device measures overall vibration from 10 to 1000Hz and provides a four-level severity assessment for overall vibration and bearing condition. It detects peaks in the vibration signal readings of roller bearings from 4000Hz to 20,000Hz, and uses a proprietary algorithm to interpret severity to determine if the bearing is going bad. An infrared sensor automatically measures contact temperature and displays it along with the vibration reading for a broader understanding of machine health. The hand-held vibration meter has a unique sensor tip design that minimises measurement variations caused by device angle or contact pressure. This reduces

Comfortable and protective Oliver Footwear has added a further style option to its AT 55 (all terrain) series of work boots. The new release is designated as Oliver Style Number AT 55-245Z and is a zip-sided work boot that has all the comfort and protective features demanded by workers on the farm, in mining and construction industry workplaces, at metal shops and factories, or any tough environment or job site where comfort and protection are the key considerations. Go to www.demm.co.nz/enquiry quote: D120705a

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operator error and improves the accuracy and repeatability of quick vibration screening. The meter also provides a severity scale for both overall vibration and bearing condition readings. Logged data can be easily uploaded into Excel to create trending reports. Go to www.demm.co.nz/enquiry quote: D120705

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Safety reference guide NHP are proud to announce the release of a comprehensive NHP Safety Reference Guide which includes a range of material to ensure you and your projects are safe. Complete with technical information on the company’s extensive range of safety products, whitepapers on various safety applications and information documents on international/local safety standards, the NHP Safety Reference Guide forms an invaluable resource for projects across all industries. It also includes example system designs for achieving different safety categories and a glossary of typical safety terminology. To register for your complimentary copy, visit nhp-nz.com/ safety. Go to www.demm.co.nz/enquiry quote: D120705b

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

0800 55 77 33

TAYLOR Bag & Sack Filling Systems

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FISCHBEIN Bag Stitching Equipment

SAXON Heat Sealers

GALAXY Conveyer & Palletiser Systems FULL RANGE OF CONSUMABLES & SERVICING ALSO AVAILABLE

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• PRODUCT WATCH

User-selectable motor, gearbox and brakes

New website launched

Small drives are used in a wide range of applications today such as automation, packaging technology and laboratory and medical technology. It is then obvious that users demand very customised characteristics. Hence ebm-papst St. Georgen have developed a drive family with a completely new design. A new 42mm diameter drive now supplements the range of products for applications with a low power requirement and a small amount of torque. The brushless, electronically commutated internal rotor motor is available with stator lengths of 20 and 40mm. This is how the small motor reaches outputs of about 45 or 90W at 110 or 220Nm of torque and a nominal speed of 4,000 rpm in each case. With that, the new motors offer a higher power density and almost double the torque with about 40 percent less mass compared to the predecessor type. The motor, whose introductory version was designed with

3M’s Occupational Health & Environmental Safety Division has launched a new website: www.3M.com/nz/PPESafety. The site’s online product catalogue enables visitors to quickly find information on 3M workplace safety solutions ranging from disposable and reusable respirators to earplugs and earmuffs, protective coveralls, welding helmets and communication headsets and much more. A major addition is the 3M Respirator Selection and Service Life software. By entering contaminants and their concentrations, this free software helps make the process of selecting a respirator faster and easier. The software can analyse more than 700 different chemicals and provide a record of your choices. It also offers an easy method for estimating service life of 3M respirator cartridges. Other resources include a download centre, product demonstration videos, FAQs and safety solutions for 13 major industries. Go to www.demm.co.nz/ enquiry quote: D120706a

an IP40 protection class, is produced for nominal voltages of 24 and 48 VDC. A rotor position indicator with three Hall-effect sensors is installed into the motor’s printed circuit board in the current version. The drive is thus equipped for operation with external, even customised, electronics. The drive energy is output via an 8mm-thick shaft. The ball bearings of the gearbox modules are designed especially robustly for higher radial loads on the gearbox output shaft, making them suited for applications with pre-tension, such as belt drives. Customer-specific variants are being prepared for other shaft diameters, flange geometry, a centring collar as well as modules for electronics, encoders and brakes. With that, a universal implementation of the new ECI 42 drives Go to www.demm.co.nz/ is possible. enquiry quote: D120706

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Wireless I/O for NI CompactRIO

National Instruments announced a new wireless gateway and two new measurement nodes that extend the capabilities of the NI wireless sensor network (WSN) platform and illustrate the company’s commitment to wireless measurement technology. With NI LabVIEW system design software, engineers can easily integrate wired and wireless measurement and control systems and deploy autonomous programs to WSN nodes that perform local control, data analysis and event-based alarming or notification. “Some of the world’s most challenging applications require a solution that combines both wired and wireless measurement and control systems,” said Jamie Smith, director of embedded systems product marketing for NI. “With the new WSN C Series gateway, NI is one of the only companies that can offer a complete, reconfigurable platform for these hybrid systems.” Go to www.demm.co.nz/enquiry quote: D120706b

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July 2012

• PRODUCT WATCH

A step forward in DRO technology

Connection to Profibus network

From their years of experience in digital readout (DRO) system manufacturing, Easson has achieved a high level of reliability and durability. Not only the electronics and mechanical system design are important, it is also essential that the system must be constructed with the highest possible specifications, quality materials and advanced production technology. The ES-12 is a step forward in DRO technology. Efficient production management and low overhead cost have allowed substantial savings and have made it possible, according to the manufacturer, to produce the ES-12 with the highest possible specifications and quality in material and components. The ES-12 DRO display has a colour graphic LCD screen and is programmed to allow for ‘full options’ and ‘all-in-one’ system. This makes it possible to select the required

The PowerFlex 750-Series Profibus DPV1 module from Rockwell Automation enables users to integrate the Allen-Bradley PowerFlex 750-Series AC drives with the Profibus network. The optional module mounts inside the PowerFlex 753 and 755 AC drives to save panel space and offers V1 services beyond the standard V0 services. Various tools can be used to configure the module and connected drive(s) including the Enhanced PowerFlex 7-Class HIM or drive configuration software such as DriveExplorer and DriveExecutive. Go to www.demm.co.nz/enquiry quote: D120707a

application (e.g. lathe, milling, EDM, drilling or grinding) during the set-up of the DRO. Also it allows for the selection of the number of axis and either 5µm and 1µm accuracy on each axis. The ES-12 series has been specifically designed for retrofitting. The many functions available like the non-linear error compensation, anti-vibration filter and speed axis display make it the ideal solution for any type of machine tool. Each preset program has its results displayed on the graphic LED screen. This allows the operator to see what the program will produce before any machining takes place. Go to www. demm.co.nz/enquiry quote: D120707

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BUILD IT Exactingly right – Every time –

•

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

Quality European Manufacturing • Motors • Gear Components • Control Technology

Final test.

High voltage motor test.

Painted to customer application requirement.

Individual components selected to specification for the gear unit.

Finished products ready for delivery.

Fast, customised assembly at purpose designed workstations.

New Zealand Assembled

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

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

24/7 Service backup

E&M212

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

INDUSTRIAL DRIVE TECHNOLOGY

• PRODUCT WATCH

Additions to the Threadmaster family

Seco has announced new additions to its Threadmaster family, bringing the benefits of its line of thread mills to a larger and more diverse range of applications. The new products include solutions

July 2012

A leap in performance

for hardened materials up to 60 HR, materials with tensile strength over 900 N/mm², small holes and complete drilling, chamfering and thread milling in a single operation. Drilling Threadmaster, or DTM, features a unique design that drills, chamfers and mills a threaded hole in one operation. Currently available for applications in cast iron and aluminium, the new tool mills threads using helical interpolation, it also drills and automatically chamfers the entry point when the tool reaches the bottom of the hole. DTM’s multi/function capabilities save time and money by reducing tooling inventory and minimising tool changes. Go to www.demm.co.nz/enquiry quote: D120708

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Sumitomo Demag, a leading manufacturer of plastic injection moulding machines, have continued to raise the bar on level of performance possible from injection moulding machines. According to the manufacturer, unerring accuracy and repeatability, combined with faster machine movements, and further improvement in energy efficiency are just some of the advantages customers will gain from the recently released SE EV series. Oliver Wolf of Tasman Machinery, the NZ agent for Sumitomo Demag, says, “Our customers have always appreciated the incredible accuracy, shot to shot repeatability, speed and energy efficiency of our machines. The SE EV series has taken quite a leap forward in all these facets of machine performance. The other change we are seeing with the EV series is the collaboration and integration of the Japanese and German thinking in terms of machine designs.” Wolf continues, “The new machine controller is a good example of this combined thinking. Also the high nozzle contact force is now a standard feature, which it always was on the German built machines, but not the Japanese machines.” The SE EV series is available from 18 to 180 tonnes. Go to www.demm.co.nz/enquiry quote: D120708b

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• PRODUCT WATCH

Fasco supported in NZ by CMG/Fasco NZ Ltd Fasco takes pride in having delivered the world’s most complete line of custom fractional horsepower motors and blowers for almost 100 years. These motors power thousands of products for a diverse line of markets. Plus, their expanding global presence, superior customer service and experienced staff can provide customers with the highest quality product at a competitive cost. In the years to come, Fasco will continue to develop and launch products to meet the requirements of their customers and the ever-changing marketplace. By listening to their consumers and combining this knowledge with their core expertise in key motor technologies, Fasco can continue to create customised solutions for the customers’ applications. The company staff their engineering department with the most experienced and imaginative designers who create value-added, innovative custom solutions. Each must be completely knowledgeable in the field and of course, fully capable of comprehending the customers’ needs and

developing the appropriate solutions. Over 100 engineers and technicians throughout the domestic and international facilities are devoted to comprehensive design assistance and rapid prototyping. This forwardthinking team also delivers customercentered testing including motor design and testing, vibration analysis, acoustics evaluation and analysis, and gas appliance

efficiency and emissions testing. Full-service design, development and testing teams have enhanced Fasco’s ability to serve their customers and fulfilled the goal of becoming one of the leading custom designers of FHP motors and blowers. 'Six Sigma' design has become a way of life at Fasco’s manufacturing facilities. This disciplined approach focuses on lean manufacturing and creates initiatives that drive process improvements throughout the company’s plants. Resource consolidation and product standardarisation allow Fasco to create a superior product in the most efficient way possible, permitting to pass the quality and savings on to their customers. Supported in New Zealand by main distributor Argon, based in Onehunga, Auckland, Fasco carry a very extensive range of both motors and blowers for the aftermarket. Argon have proudly sold and supported this product for over 20 years. Their expertise and stock support every customers’ needs. Go to www.demm.co.nz/ enquiry quote: D120709

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For the Most Demanding Industrial Markets

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

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AUCKLAND • ROTORUA • CHRISTCHURCH

1/06/2012 11:06:05 AM

• food processing industry

Slicing cheese with automated precision Incorporation of technological advances in farming and manufacturing has characterised the success of the New Zealand dairy industry. As the country’s biggest export earner, manufacturers continue to benefit from investing in technology to improve their productivity. New Zealand boasts a world-class dairy industry with annual exports in excess of NZ$11 billion. This success can be largely attributed to technological advances in both farming practices and manufacturing techniques. The key strengths of New Zealand’s dairy industry include its all-grass farming system, large-scale processing and high levels of research and development. With a reputation for providing clean, safe products that comply with rigorous health and safety standards, the New Zealand dairy industry is forecast to benefit from continued growth and productivity for many years. Cheese production is one of the most complex in the dairy industry involving a variety of processes to achieve the final product. Internationally renowned for products with a distinctive natural taste, recent years have seen a substantial

The cheese slicing machine has an advanced control system and comprehensive mechanical design.

increase in premium specialty cheese products manufactured in New Zealand. Automating processes in cheese manufacture can improve the productivity of the manufacturing plant to help meet increasing demand.

It’s all in the design The accurate control and customisation of the manufacturing processes is necessary for optimal large scale, quality cheese production. Designing manufacturing processes to produce consistent product

meet their specific requirements. CSL utilised the design capabilities of long standing system integration partner Integrated Automation Ltd (IAL) to develop a solution to meet the end-user requirements. Recent advances in motion control technology allow cheese slicing to be taken to a whole new level. The project requirement was to take an industry standard block of cheese and slice it to the specified dimensions and weight. When looking for products on the market that could achieve this, Integrated Automation Ltd decided to utilise the control processor capabilities of ControlLogix from Rockwell Automation.

Timing is everything

The Allen Bradley rotary servo motors meet the demanding requirements of high performance motion systems.

characteristics that meet customers' expectations, relies on the skills of a team of engineers and technologists. Advances in process and motion control technology has allowed processes that were historically manually operated in a cheese manufacturing plant to be automated – improving efficiency and safety. When an international cheese manufacturer decided to automate their cheese slicing processes they called on Cheese Solutions New Zealand Ltd (CSL), a leading New Zealand OEM machine builder, to design a system to

The challenge was to provide the customer with a complete natural cheese slicing production line that could take a 20kg block of cheese, pass it through a number of machines to break it down into smaller logs, and then slice the logs into the end product – a slice of cheese

The Rockwell Automation ControlLogix provides excellent processing capabilities.

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July 2012

•food processing industry that is 90mm by 90mm by 2.5mm thick. The crux of the solution lies in providing precise, high-speed synchronised motion control. An important part of this is having accurate control of the portioning process to provide that the product is cut accurately with minimal wastage. According to Stephen Cotter, Solutions Architect – Motion Control, Rockwell Automation, “While the rest of this plant utilises product solutions from Rockwell Automation, this new machine required additional motion control capabilities.” To deliver precise motion control, this solution utilised the new L73 processor which has faster processing capabilities and improved motion control. “It’s certainly the processor that will do the job because it’s up to speed to control the motion at the cheese slicing business side,” continued Cotter. Precise motion control and timing is critical to the success of this application. The log of cheese has to be indexed precisely because the slicing is performed with a rotating knife. Coordinating movement of the cheese with the rotating blade is critical. There is a finite period when the blade is not present during

which the cheese moves forward. The speed at which the cheese must move is dependent on the density, weight and size of slice required. To achieve this, ControlLogix required sample code with a particular CAM profile that was developed by the Rockwell Automation OEM team in Singapore. ControlLogix provided the single control platform with RSLogix5000 design and configuration software.

Cheese slicing precision “In addition to the advanced control capabilities required, building this machine also required a comprehensive mechanical design to ensure the machine’s mechatronic system is reliable enough to carry out the tasks of slicing the product,” said Donovan Ryan, Director, IAL. “There was no other choice but to go with the new L73 processor in this high-speed motion application; every millisecond was critical.” Safety considerations were paramount in this solution – the mechanical design of the cheese slicing machine provided that the rotating blade was protected from operator access at all times. The maintenance requirements were found to be minimal as the engineers were already

familiar with the Logix technology. The cheese slicer provided the customer with the flexibility to adjust the thickness of the cheese automatically. By checking the weight, the thickness of the slice can be adjusted automatically by changing the CAM profile to account for the density of the cheese. “This solution provided the customer with the ability to accurately perform to the required velocity with the ease of integration using RSLogix5000 motion control commands,” said Cotter. As consumer demand rises, automation and process technology is being utilised to increase productivity in the cheese industry. The benefits of automating the cheese manufacturing plant extend beyond the amount of product on the supermarket shelf. Establishing clean, efficient and automated processes minimises wastage of natural resources while providing industry with a way to meet increasing customer demands for quality dairy products. Article submitted by Rockwell Automation. Go to www.demm.co.nz/enquiry quote:

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D120710

NEW

SERIES The Driving Force In Pneumatics

KQB2

Metal One-touch Fittings

S/S Collet & FKM Seals

Electroless Nickel Plated Brass

•

Compact and light

•

More tube sizes added (ø3.2 (ø1.8”) and ø16 have been

• • • •

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

(Dimensions: Approx. 30% down - Comparison with KQBL06-01S)

added)

More configurations varied (17 models 9 models) Metric size x G thread added Applicable tube size (4mm - 16mm) Connection thread: M5 - G1/8, G1/4, G3/8, G1/2

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

• food processing industry

What is cleaning in place? CIP is a method of cleaning equipment without disassembly. The following article describes how it works and where you should use it. Cleaning in place (CIP) refers to the use of a mix of chemicals, heat and water used to clean machinery, vessels or pipe work without dismantling the plant. CIP has been around for about 50 years and is used in hygiene critical industries, including food, beverage, biotechnology and pharmaceutical, to clean primary (and some ancillary) plant lines. The process can be one shot, where everything goes to drain, or recovery, which recycles most of the liquid. Overall, CIP can be a very efficient way of cleaning. CIP should be used in any industry and plant where hygiene is critical; the process is usually an integral part of established automation systems. However expanded health and safety/food security compliance is set to make CIP more stringent – which is good, given a shiny surface on the outside of the plant is no

spores. A CIP process of at least 15 minutes of a suitable chemical (strength dependent on chemical supplier and product) is required to remove vessel soiling. The CIP process should optimally run between 50 degrees Celsius and 75 degrees Celsius, as there is no cleaning advantage to heating beyond 75 degrees Celsius.

Cleaning agents

guarantee of cleanliness on the inside. CIP is principally concerned with soil removal; however soil refers to anything that should not be present in a clean vessel and is therefore ‘soiling’ the vessel. Soil can cause tainting and can often be smelled. It may be visible (scale, foreign bodies) or invisible in the form of bacteria, such as E Coli or yeast

Commonly used chemicals for soil removal include Caustic Soda, Phosphoric and Nitric acids, Sodium Hypochlorite (Hypo) and Peracetic Acid (PAA). Caustic Soda is an alkali typically used at 0.5 percent to 2 percent volume. It reacts with fats in the soil to soften them for removal. One downside is that Caustic Soda is not effective for removing scaling. In addition, sequestriants are often added to keep soiling in solution. Phosphoric and Nitric Acids are used in detergent formulations for scale removal, often at lower temperatures than Caustic. These acids must be used with care as they can attack valve and pump seals. They are often used in dairies for one week in every six

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July 2012

•food processing industry weeks, to remove milk scale. Phosphoric and Nitric acids are frequently used after commissioning, to remove installation debris. Sodium Hypochlorite, usually called Hypo, is very inexpensive which offers a strong advantage. However, it is primarily used for disinfecting because its ability for soil removal is poor. The active ingredient of Hypo is chlorine (bleach). When concentrated, this can corrode stainless steel in and will attack seals and personnel. It will also taint the process if not carefully rinsed out, and is dangerous if mixed with acid as it will form poisonous chlorine gas. PAA is an equilibrium mixture of acetic acid and hydrogen peroxide. It is a powerful oxidising agent with an oxidation capacity higher than sodium hypochlorite and chlorine dioxide, and is comparable to the oxidative capacity of ozone. PAA at 75 mg/L is reported to successfully kill 100 percent of a 10(7) cell/ml yeast or bacterial population in 30 seconds.

CIP line and vessel cleaning When cleaning lines in process equipment using CIP, the correct fluid velocity must be achieved to obtain good cleaning. Laminar flow below velocity 1.5m/s does not give good cleaning characteristics; quite turbulent flow is instead required, at velocities between 1.5 to 2.1m/s. There is no gain at velocities above 2.1m/s. In cleaning vessels, two main methods are generally employed. The first one uses high pressure cleaning to remove soil by force, with the vessel surface being sprayed in a series of passes. The second method employs low pressure cleaning heads that rely purely on chemical action to remove the soiling.

CIP return The majority of problems with CIP can be attributed to poor CIP return. This causes excessive CIP times, excessive use of detergent and heat, and high effluent discharge. To overcome these problems, the system for return must quickly and efficiently return the cleaning solutions back to the CIP set. Critical in this is the choice of scavenge pump. Poor scavenge causes back-up of cleaning solution as well as poor cleaning of the lower part of the vessel. In contrast, effective scavenge allows fresh cleaning solutions to contact all vessel walls and carry away soil effectively.

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CIP optimisation Most CIP sequences are never altered following installation; they are usually set to ‘defaults’ which are set during commissioning. However, CIP operators can optimise their systems by monitoring a number of key parameters. These are: What temperature and concentration (conductivity) are the Caustic tanks set to? These are often set too high with no added benefit. Consider the pre-rinse – does it run clear and then keep going? Is the pre-rinse eliminating sufficient residue? Could it operate more efficiently? Caustic fill – how high are the return conductivity and temperature transmitters set? Keeping parameters as near as possible to the limiting effective temperature and pressure; higher parameters derive no benefit but cost in resource inputs. Intermediate rinse – is it removing Caustic solution and temperature prior to sterilisation? Optimise volume, velocity and time of rinse. Sterilisation – what strength is the sterilising agent and how long is the contact time? Avoid wasted resources by ensuring strength and contact are idealised. Finally, all changes resulting from the CIP monitoring process should be documented and validated, to meet statutory regulations and/or specific client requirements. Article by Chris Hoey, Managing Director & Regional Coach, Pacific, Bürkert Australia Go to www.demm.co.nz/enquiry quote: D120712

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• food processing industry

New range of HMIs for food and beverage

With the introduction of the new HMIGTO range, Schneider Electric has launched a range of stainless steel HMI touch screens and iPCs aimed at harsh environments such as food and beverage and pharmaceuticals. Aside

from the stainless steel bezel, the front panel is IP66K rated and all are conformally coated. The three stainless steel touch screens (5.7'', 10.4''and 12.1'') and 15'' Panel PC form part of a complete range of HMIs from the innovative 3.5'' STU which mounts via a standard 22mm pushbutton hole, to 15'' high resolution multimedia models. As with all Magelis HMIs, they can be used on a wide range of third-party PLCs, via serial and Ethernet ports, but offer closer integration when used with Unity-based PACs such as the M340 from Schneider Electric. The iPCs are available in three

ranges, all of which offer fan-less and diskless technology if required, XGA touch screens, serial, USB and Ethernet ports. The offer comprises of the Optimum and Universal, utilising the Atom based CPUs running Windows Embedded Standard 2009 and windows XP Pro respectively. The Performance range makes use of the powerful Core 2 Duo CPU range. The HMIs are programmed with the Vijeo Designer software and when used with Intelligent Data Service (IDS) the form part of an FDA CFR21 part 11 compliant system with data and operator actions being logged into a locked database. IDS also includes a powerful reporting system providing dashboards and scheduled reporting. The Magelis HMIs and iPCs have many certifications including UL, ATEX, FDA and Marine. Go to www.demm.co.nz/enquiry quote:

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D120714

˛ Certified for Automation The Magelis™ HMI and IPC Range

Schneider Electric (NZ) Ltd. 38 Business Parade South, East Tamaki, Manukau 2013 PO Box 259370, Botany, Manukau 2163 Tel: +64 9 829 0490 Fax: +64 9 829 0491

July 2012

Customer Care: 0800 652 999 Email: sales@nz.schneider-electric.com www.schneider-electric.com/nz

•food processing industry

Performance that comes naturally These specially formulated food-grade lubricants are effective under severe food processing operating conditions – from food acids and juices to by-products and temperature swings. The food-grade lubricants and greases fit perfectly into EcoSia, the premium performing line of environmentally-responsible products, represents PetroCanada’s commitment to developing lubricants and fluids that help reduce environmental impact. Many of the products within the EcoSia line are made from 99.9 percent pure, crystalclear base oils. That’s why these products retain their “fresh oil” properties longer and eliminate the impurities that impact performance. EcoSia products have been assessed to determine their impact on the environment. Based on the results, EcoSia products meet two criteria: • Inherently or readily biodegradable based on component or product data obtained using the Organisation for Economic Cooperation and Development (OECD) 301B testing guideline, or OECD 306 testing guideline (biodegradability in seawater). Not environmentally toxic based on the United Nations Globally Harmonised System (GHS) criteria. • EcoSia products cover a wide range of industries and applications, including hydraulic fluids, food grade lubricants, compressor fluids, drilling fluids and dust suppressant fluids. Petro-Canada’s Purity foodgrade lubricants are designed for many applications in food processing plants.

a Hazard Analysis Critical Control Point (HACCP) and GMP plan, and carry a full set of food-grade lubricant and grease credentials including NSF H1 lubricants with incidental contact requirements. According to the manufacturer, Purity FG

greases resist water washout, water jet spray and most sterilizing chemicals used in cleaning, better than many competitive food-grade greases. That reduces the downtime needed for regreasing. Go to www.demm. co.nz/enquiry quote: D120715

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Beyond today’s standards MAF C15/ NSF H1 food grade lubricants, ammonia refrigeration & industrial lubricants for gears, chains, compressors, hydraulics & greases call: THE CANADIAN OIL COMPANY LIMITED patdavis@canadianoilcompany.co.nz 09 837 1174 (fax 09 837 1708) www.canadianoilcompany.co.nz

• food processing industry

a safe mix

Hose reels for food processing Australian manufacturer ReCoila offers a range of stainless steel spring rewind reels for food processing, wash-down and manufacturing processes where hygiene is paramount. Available in a wide variety of sizes to handle pressures up to 400 bar, the SE Series of reels is strong, reliable and can be hygienically washed and cleaned when required. The reels are supplied either bare or with hose, from 3/8'' ID up to 1'' ID, and are suited to air, cold water or hot water. A heavy-duty mount enables the reel to be fixed to the wall, ceiling or under a work bench. ReCoila also supplies other reels that are well suited to the food processing industry including hand crank reels in stainless steel, and PVC spring rewind reels for hot water wash-down available with or without a fully insulated wash-down gun. Go to www.demm. co.nz/enquiry quote: D120716

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New earmuff for the food industry Honeywell create the perfect recipe for safety. We believe that providing the right personal protection in the workplace is an essential ingredient for building worker confidence and improving productivity in the food processing and handling industry. Honeywell Safety Products offer a complete range of PPE including earmuffs, detectable earplugs, respirators, eyewear, tunics, aprons and gloves – to suit specialised and general applications.

July 2012

Hygiene and comfort were high priorities in the development of the 3M Peltor H9A-02 food industry earmuff. This new earmuff helps provide the well-known attenuation and comfort of Peltor, along with unique features for noisy food processing environments (SLC80 26 DB Class 5). The H9A-02 combines a wide range of unique hygiene solutions for workers who often move between areas with considerable temperature differences. The special foam inserts make cleaning very simple and prevent the build-up of condensation and heat. The earmuff also has an entirely new head band cushion that is easy to clean and has no hidden crevices where bacteria can thrive. The earmuff is blue in keeping with the food and beverage industry’s recognised colour for safety products. Examples of typical applications for this earmuff include: • Baking, dairy and confectionery industries: 85-95dB(A). • Milling, drink production and meat industries: up to 100dB(A). • Glass bottling lines: 85-100dB(A). • Product impact on hoppers: 90-100dB(A). • Manually pushing wheeled trolleys/racks: up to 107dB(A). • Wrapping, cutting wrap, bagging etc: 85-95dB(A). • Milling operations: 85-100dB(A). • Blast chillers/freezers: 85-107dB(A). • Packaging machinery: 85-95dB(A). Go to www.demm.co.nz/enquiry quote: D120716a

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• Packaging and labelling

Ultimate Stretch Wrapping by Phoenix Stretch Wrapping (Shrink Wrapping as it is fondly referred to in NZ) has become a most important and cost effective form of packaging used for load containment. There are various types of LLDPE Stretch films available, either Cast or Blown, as well as pre-stretched and re-cycled films. The two methods of manufacturing film being; ‘Blown film’, where ‘blown’ refers to the manufacturing process, during which the film is blown like a soapy bubble, using heated resin, and the cast method of manufacturing film which combines multiple layers of resin, cast together, to produce a ‘Cast Film’. The science behind stretch film is ever changing. New technology allows us to test the accepted norms and it is critical know that one is buying the right film for the right application. Today it is estimated that cast film accounts for 85 percent of world film sales. Users prefer cast film due to its greater strength, consistency, high optics, quieter running, tear resistants and food safety characteristics. During design and manufacture it is critical to ensure the right blend of high end resins, and additives added between layers, produce a film with a high yield and elasticity for puncture resistance. Without this a good stretch film cannot perform on machines capable of high pre-sretch. Since its introduction PhoenixWrap 7 layer CAST Film (food grade) has gained momentum and proved to a force to reckon with against all major film distributors in New Zealand. Of primary importance is to get the right mix between the film and the equipment used to apply the film; this enhances the performance of the film by the effective use of high end resins and additives thereby increasing

both yield and puncture resistance. Without this, Stretch Film could not adequately perform the task required. This mixture of resins during casting and induced within the layers of the film is essentially where one film out performs the other. Since its introduction PhoenixWrap 7 layer CAST Film (food grade) has made significant market gains in the industry and has become the preferred option for many. Adequate stretching of these films is required to change the film economies. Further, the performance of the Stretch Wrapping Machine itself is to be maintained along with all equipment used ensuring optimal performance thus utilising the high yield stretch film. Most of the Stretch Wrapping equipment we have tested performs below acceptable levels, resulting in significant monetary losses through the wastage of Stretch Film. The importance of having the correct film and wrapping machine cannot be over-emphasised as it is this relationship that produces high film savings, and there for reducing the cost of packaging. All these need to be considered when choosing a film and machine combination; Wrap pattern, film force, film tension, film strength and memory effect in order optimise load containment, while reducing consumable cost, without compromising the load during shipping. The cost of the consumables can be dramatically reduced; savings of up to 65 percent when compared to wrapping a palletised load without prestretch. Manual Wrapping or using a tension or brake-post stretch method does not provide uniform stretch, will always cause

neck-down and is notoriously unreliable, leading to intermittent failure. Post stretch is a direct force to load tension that acts on the corners of the load causing it crush damage and can pull the layers apart during application. It is important to maximise pre-stretch while minimising post-stretch. Pre-stretch is achieved by threaded the film through a set of primary and secondary rollers in which the second roller rotates faster that the first thus creating stretch. Pre-stretch capability strengthens the film tensile strength & increases yield when applied over the load. One can observe the film tightening (like an elastic band) around the load soon after it has been applied. This is known as the

      

memory effect and is possibly the most important component of pre-stretch. This technology allows the wrapping a pallet load of empty cans without rep-strapping. Having to master the prestretch levels while varying film feed with the demand of the load at the same time keeping the tension constant is why Phoenix are world leaders in Stretch Wrapping Equipment. The Patented Phoenix Pre Stretch System - offers the most advanced 245-300% pre stretch, giving a pre-stretch ration of up-to 1:4, with less than 5% film neck down. Payback on Capital expenditure is easily achieved. Go to www.demm.co.nz/ enquiry quote: D120717

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• Packaging and labelling

Efficient packaging with MFC technology With the new KM-Flow, Witt is the first to offer a gas mixer with digital mass flow controllers (MFC) for packaging using a protective atmosphere in the food industry. Depending on the model, the KM-Flow mixes two or three gases for all types of packaging machines; whether vacuum, thermoforming, pillow bags or manually-sealed compartments. At the same time, the digital mass flow controllers assume the function of the proportional valves and pressure regulators that are so far found in practically all standard mixing systems in the international food industry. The digital mass flow measuring instruments are a major step technologically for the user, but a smaller one for Witt -The manufacturer has already been building MFC

systems for many years. “We typically use this technology for supplying burners in the glass industry,” confirms Sales Manager Martin Bender. “No other manufacturer in the food industry can demonstrate such practical experience as Witt. The KM-Flow is also certified according to ISO 22000 for food safety.”As a particular benefit for the user, Bender cites the easy operation that is now performed by touchscreen instead of the control dial commonly used previously. Freely programmable gas mixtures can now be selected at the touch of a button or by barcode reader, for example. The digital data-bus also makes evaluation of the measuring data easier. When it comes to technical precision and reliability when metering and retaining the selected mixing ratio, the MFC

technology is currently state of the art. A high level above the requirements for packaging purposes is also ensured with the conventional Witt measuring technology, states Bender. MFC devices are especially advantageous for users aiming for a fully-automatic inert gas packaging process with permanent monitoring and fault correction: In combination with an analysis instrument that continually measures the gas concentration in the package during the packaging process, the KM-Flow can adjust the gas ratio and gas mixture volume to optimise the process. The result: maximisation of the packaging quality along with a minimisation of the gas consumption. “This efficient packaging workflow can be ideally realised with MFC. The

optimised gas consumption helps to reduce costs and minimise the uncontrolled escape of CO2 protecting employees” stresses Bender. Besides the food industry, the KM-Flow with MFCs can also be used in further applications. Go to www.demm.co.nz/enquiry quote:

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D120718

Decorating containers with high-quality images C

CMY

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

July 2012

Moss from Reggio Emilla, Italy, have introduced their new plastic tube decoration system, Digitiube – Digital transfer machine. The Digitube encompasses a new transfer technology for decorating containers with high-quality images. The images are preprinted on a Xeikon printer at 1200dpi on rolled-up silicon

paper. The rolls are then used by the Moss Digitube machine to transfer the high-quality images onto the containers’ plastic substrate. This transfer is achieved by a combination of heat, pressure and perfect synchronisation. A lacquering device and optional UV drying feature improves the scratching resistance and appeal for the final product. Production costs are minimal, particularly on small runs, as offset plates and/or silk screens are not required. This provides manufacturers with fast turnaround, production flexibility and low set-up costs. Moss is represented in Oceania by HBM Plastics Technologies. Go to www.demm.co.nz/enquiry quote:

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D120718a

• Packaging and labelling

Packing fresh meat cost-effectively

With the R 515 machine, Multivac is bringing a new model of its highperformance thermoforming packaging machines onto the market, a model which is designed for the particular requirements of the fresh meat industry. Typical applications are large ham and fresh meat packs as well as wholesale and transportation packs. The R 515 is laid out for specific die formats and it offers all the advantages of the R 535 high-performance model. The fresh meat industry places special demands on the packaging of its products: this is frequently not required to appeal to consumers at the point of sale, but rather to protect the fresh meat during transport to the wholesaler or

processor. Cost effectiveness, output and hygiene are therefore right at the top of the list of requirements. Multivac fulfils the wishes of the industrial meat processor with the new R 515 machine model, which has the right price-performance ratio. The R 515 offers standard dies and format sets which are specially tailored to the fresh meat industry. The new machine model is designed for running flexible films, for example PA/ PE multi-layer films. The R 515 is also equipped with register mark control for running printed upper webs. In addition to vacuum packs, it is also possible to produce packs with modified atmosphere packaging (MAP). The machine cycle output is around

ten cycles per minute. Thanks to the HMI 2.0 user interface, even less technically proficient or trained operators can easily operate the complete functioning of the machine or line with the touch of a finger. The R 515 can be equipped with an optional jumbo film unwind for lower webs. This reduces machine downtime caused by roll changes. In addition to this, the R 515 offers an optional quick-change system for forming and sealing dies. This makes it easier to convert the machine to other formats. It is also possible to fit different types of labellers and marking systems. Like all Multivac machines, the R 515 is constructed in the Multivac hygienic design, it is compatible with the process-controlled clean-in-place system (CIP), and it can therefore be easily cleaned and disinfected on the inside and outside. The R 515 can be extended in a modular way and is suitable for the integration in automated packaging lines. Go to www.demm.co.nz/enquiry quote:

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D120719

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• Packaging and labelling

Protect anything and everything, anywhere

James Nilsson – Winchmakers using Sealed Air Instapak Quick RT foam packaging cushions to easily protect a Seawinch CH400, weighing 8kg, from damage during transport.

Sealed Air Instapak Quick RT foam packaging is an innovative and convenient packaging solution that allows a user to protect anything, anywhere and without start-up costs or specialist equipment. It provides users with a custom-fit protective cushion that is fast, easy-to-use and ideal for small-to-medium volume packaging applications. Specific businesses include manufacturers of electrical componentry, automotive and marine manufacturers, general componentry manufacturing, third party logistics, independent business owners, and warranty repair depots. The foam packaging is ideal for businesses that often have oneoff or small quantities of high-

value items needing protection e.g. prototypes, models or samples. Instead of the time and costs involved in designing oneoff, custom-made packaging, Instapak Quick RT foam packaging cushions can be used instead. One customer using this packaging solution is James Nilsson – Winchmakers who use it to protect winches during transport. “We now send all our goods, packed in the Instapak Quick RT foam packaging, safe in the knowledge that they will arrive at their destination in good condition,” explains Debbie, Director at James Nilsson – Winchmakers. Anybody can now produce protective foam cushions at any location easily, without the burden of capital equipment

or installation requirements associated with many packaging systems. By expanding up to 27 times their original size, the foam bags save valuable space. “Each Instapak Quick RT package comes packed neatly in a box for tidy storage,” explains Debbie, “making them the ideal on-demand packaging solution.” The foam packaging solution consists of a bag containing two liquid components. To create Instapak Quick RT protective foam cushions right out of the box, in three simple steps simply activate the components in the bag by manually pressing on the oval marked “A” to break the seal that separates the two components. After patting side “A” and side “B” 15 to 20 times, the proper mix is achieved. Before the foam begins expanding within the bag, the bag is placed into the shipping

July 2012

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D120720

Labelling standard UniCard materials The new Bluemark CLED from Phoenix Contact makes labelling standard UniCard materials for marking terminals, conductors, and devices as easy as printing on paper. There is a complete system comprising Bluemark CLED and notebook with preinstalled Clip Project planning and marking software so that you can start to print immediately – nothing to install, nothing to set up. Simply connect the devices via USB and start to print. With up to 10,000 labels an hour, state-of-the-art UV technology ensures fast and environmentally friendly printing. The solvent-free labelling fluid makes the Bluemark system suitable for clean room applications and ensures that labelling is extremely scratch-resistant and smear-proof. The extensive range of UniCard materials is available in various versions, colours and sizes for all applications involving labelling terminals, conductors, and devices. Bluemark CLED is part of the Marking system from Phoenix Contact. Labelling data is transmitted to the printer directly from the CAE system via the central Clip Project planning and marking software. Go to www.demm.co.nz/enquiry quote: D120720a

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container and the product nestled into the rising foam where it forms a custom-fit protective cushion around the product. The foam packaging reduces damage to items by providing superior cushioning, blocking and bracing and void-fill protection. The foam packaging also provides a tidy packaging solution that enhances the appearance of items being shipped. With six bag sizes, Sealed Air Instapak Quick RT foam packaging is extremely versatile, protecting a variety of products of almost any size, shape and weight. Debbie sums up Instapak Quick RT foam packaging: “They are quick and easy to use, no fuss, no mess, saving a lot of time and effort.” Go to www.demm.co.nz/enquiry quote:

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• machinery safety

Taking action for machinery safety The Department of Labour recorded 26 fatalities in the manufacturing sector between 2005 and 2010. And in the 2009 to 2010 year ACC approved just over 333,000 new claims from this sector. Almost 2500 claims received in that period of time were machinery-related. Editor Stefan Richter asked Tony Catterson, Pilz Safe Automation’s NZ Manager, where these alarming numbers come from and what to do about it. Statistics tell us that New Zealand is a quite dangerous place to operate a machine. Here are some incidents taken from recently-issued Department of Labour press releases: A female worker at a cheese processing factory was clearing a jam in a cheese packaging machine. Unaware that the machine was set to reactivate, she put her arm in to clear wrapping from clamps when they closed on her middle finger and amputated the tip. Her employer has been fined $50,000 and ordered to pay $12,500 in reparation. According to the Department of Labour it would have cost $500 to make the company’s two unguarded wrapping machines safe. A producer of snack and muesli bars has been fined $28,125 after an employee of a contractor had part of his finger amputated. The employee was trying to clear peels from an opening at the bottom of a peel dicer machine when his left index finger came into contact with the auger’s blade. His finger was amputated below the fingernail. The Department of Labour says that this injury could have been avoided if there had been a guard fitted at the bottom of the machine to prevent the employee’s fingers coming into contact with the blade. A sawmill employee was using a drop saw to cut regulated lengths of timber. The stopper on the machine kept moving resulting in longer pieces of timber than was required, and therefore needed trimming. While re-cutting the timber, the employee leaned over the machine to reach and remove the off-cuts. Unfortunately he lost his balance and stepped on the unguarded foot pedal, causing his right hand to become clamped in the drop saw. Neither the foot pedal nor the circular blade had any form of guarding, and the employee had not received adequate safety training for using the saw. His thumb,

July 2012

middle and ring fingers were amputated and his index finger was fractured.

My machine is safe – or is it? It’s a no-brainer that a machine can´t be safe when there are no safeguards in place. But even installed safeguards don’t necessarily cover all potential hazards throughout the machinery lifecycle. “Many people perceive a machine to be safe because it has a few safeguards on it. But when these safeguards don’t take into account the different environments a machine is being operated in they don’t fully protect people,” says Tony Catterson, NZ Manager, Pilz Safe Automation. In a lot of cases only the machine operator is taken into consideration. “But what about the maintenance staff doing the set-up of a machine? The maintenance guy might disable or bypass all the safeties that are on the machine to do the work he needs to do. In this case he isn’t protected at all. And sometimes those bypasses are left in place. People get complacent or just forget about it.” Another potential source of danger is people assuming a machine is safe only because they have bought it off an European manufacturer. “In Europe the machine might be equipped with automatic infeed and outfeed, and mainly produce one specific item, so that there are no frequent adjustments and no one is ever exposed to the corresponding hazards,” explains Tony. “But here in New Zealand the machine might be fed and unloaded

manually, and frequent change of products might require ongoing set-ups. So there are some safeguards in place, but they just don’t match the higher level of human exposure to potential hazards. People assume that just because a machine has a CE marking it’s going to be compliant. That’s a dangerous assumption.” Very often staff don’t fully understand why safeguards were installed in the first place, because the process hasn’t been documented properly. “Somebody had an accident or a near miss, and the company puts some safeguards on the machine, without going through the process of performing a hazard ID and a risk assessment, and then coming up with a combined approach of installing suitable safeguards and upgrading administration controls to work hand-in-hand with them,” says Tony. “Without this documentation process, nobody can remember why certain decisions have been made and understand how the new safeguards are going to impact on the workplace.”

Promoting safety in New Zealand Pilz New Zealand is swiftly approaching their tenth anniversary. “The market has changed quite a bit over the last decade,” recalls Tony. “When I started with Pilz ten years ago, people used to think it to be sufficient to just put an emergency stop on the machine. Safety requirements box ticked. But meanwhile companies are slowly recognising they do need to look at safety more closely. They are being pushed

• machinery safety

towards that topic from different directions.” The strongest promoter of machinery safety is the Department of Labour. The Health and Safety in Employment Act 1992 asks employers, machine designers, manufacturers, and importers to identify potential hazards, conduct risk assessments and make practical steps to improve safety. “Unfortunately many people still neglect doing a hazard ID and a risk assessment and prefer to get a quick fix to resume

production as soon as possible. People are aware of the obligations they have, but sometimes they don’t know where to turn to and what to do; they ignore it and put it into the too-hard basket. Others just think ´We never had an accident so we are not going to have one.` Anyway, the Department of Labour still find a large number of people not fully complying with the safety standards and regulations.” To change this situation, the Department has developed the Safe Use Of Machinery Project as part of the Manufacturing Sector Action Plan to 2013. This Sector Action Plan is one of five plans targeting sectors with consistently high levels of workplace injury, disease and fatalities – construction, agriculture, manufacturing, forestry, and fishing. The Safe Use Of Machinery Project aims at lifting the standard of machine guarding in New Zealand. Health and Safety Inspectors are focusing on

Making safety a high priority Protecting people from the harm production machines can potentially cause is a massive concern for manufacturing businesses, or at least it should be. Performing a search on ‘machine guarding’ on many top New Zealand news websites gives a long list of lamentable tales where safety has not been given the necessary level of priority, with the physical well-being of staff and the health of the businesses finances both having a heavy toll taken on them. However, smart business owners and production managers know that properly guarded machinery is prevention from having such severe negative effects on people and businesses, and when it comes to machine guarding, the Gratis Guard system from Autoline Automation offers a comprehensive, customised and failsafe solution. Gratis Guard is a modular system made from aluminium profiles and welded mesh or polycarbonate to fabricate a large range of guarding for a wide variety of applications. The system complies with the AS 4024 safety standards and allows easy upgrading or reconfiguring, with a 5mm hex key the only tool required for assembly, disassembly and reassembly. Hinges, handles, doors and other accessories are all part of the system and welded wire mesh and fastened mesh retainers provide a highly ridged panel. Go to www.demm.co.nz/enquiry quote: D120723

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raising awareness amongst employers and employees of the importance of machine guarding and checking that effective procedures and systems are in place to ensure the safe use of machinery in the workplace. “The manufacturing industry´s awareness of safety issues is also being increased by big companies such as Fonterra, Goodman Fielder, Bluebird and Progressive Enterprises. They are raising the bar in areas such as safety training and expectations as to what levels of safety must be installed on a new machine, and the smaller companies are following and starting to think about safety as well,” says Tony. “And there is also a greater awareness in the workforce; they expect to be properly protected from harm at their workplace. Many labourers have seen the levels of safety in various companies, and can tell when safeguards and standards are not up to scratch.” Pilz is another strong promoter of machinery safety in New Zealand. “Pilz has a background in machinery safety for such a long time, and we have always been a leader in safety technology,” says Tony. “More people at Pilz work in R&D than they do in sales and marketing. We were the first to come out with safety relays, a safety PLC, a safety fieldbus and also a safe 3D camera system to monitor the zone around a machine. But it’s not only about selling our products, we also have a passion for people to get their safety right.” Tony says that Pilz has discovered that quite often people don’t know what components they actually need or how to apply them properly. They might be buying components and installing them, but they are not working the way they should. “We have positioned ourselves as a partner of the industry, making sure companies are applying our products properly to achieve the desired results.

• machinery safety

More than a

magazine • Print • Website • Facebook • e-newsletter • Digital on-line

www.demm.co.nz 24

July 2012

Tony Catterson

Working with companies to understand how an accident could have possibly happened, we have seen the impact a fatality has on a workplace. Being able to offer a solution to keep them safe in future is very satisfying, and we are enjoying our job.”

Pilz’s safety related services The company Pilz is undergoing a transformation – from a vendor of safety components to a safety service and solution provider. “We offer customers to do the hazard ID and the risk assessment first. Then, based on the outcome, we come up with a comprehensive safety concept which takes into consideration every aspect associated with the machine operation, including the set-up, the maintenance and the cleaning. We assist with the detailed system design and implementation, and then we finally validate the safety system to prove that the installed safeguards are actually doing what they are supposed to do.” Another service offered by Pilz is safety training. “You can’t get trained in machinery safety in NZ. And even globally there’s very few places that offer specific training on that topic,” explains Tony. “If you are trained as a health and safety person, you are not trained about

the machinery, but about the processes. And the functional safety courses focus on process control of plants and equipment. So it’s left to the engineering staff to deal with machinery safety, but there is no training in the engineering degrees and the trade qualifications. We are having great success with our machinery safety training programmes.” Pilz works with many big companies and also with the Department of Labour. “Only last week I was doing a refresher training section for some of the Department´s inspectors. They also ask our advice on questions of machinery safety. And Pilz has actually just introduced a certified machinery safety expert course which is TUV approved. That’s something we are going to roll out globally. At the moment we are working on how to adapt this new course to the NZ framework.” According to Tony the immediate future of safety systems holds developments similar to those of standard control systems. “We can already achieve a lot of standard functionality in a safe control. In the future, safety systems are becoming more decentralised and user-friendly, easier to set up, and ready for plug and play. Motor controls are being equipped with more safety functionality. Improvements on our safe camera system will help detect a person quicker and stop the machine faster, so that the safeguards can be set up closer to the machine. To reliably and quickly stop the machine when something is not right, and to be able to find out what went wrong, it is very important for the safety system to provide a large amount of diagnostic information. The more information is available the faster any faults can be rectified saving machine downtime.” Go to www.demm.co.nz/ enquiry quote: D120722

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• fastenings

Securing your C-parts supply C-parts have a low purchasing value, but can often have high admin cost. Among the commonly encountered inventory problems of dealing with C-parts are stock outs and obsolete stock, excessive inventory, line stoppages, traceability of product, excessive expediting cost and paperwork, inconsistency/fluctuation in prices, material handling and inaccurate usage data. During the past two years, EDL Fasteners New Zealand has launched and grown a successful Company Division of Kanban and Inventory Management systems for medium and high volume users of fastener and consumable products. The EDL Kanban System can reduce labour costs and inventory levels and give the user security of supply. “This has been an absolute turnaround for the company

Kanban mobile unit.

with regard to productivity, with sales based around pack quantities rather than the traditional fastener sales of 12 bolts here and six nuts there,” says National Sales Manager Daniel Wright. The system has allowed EDL to streamline the order process through Electronic Data Interface and given the customer the opportunity to manage their demands through the EDL online portal. “Being the first to introduce such a comprehensive system in the New Zealand marketplace for this category of product has allowed us to quickly secure a good and strong customer base allowing us the opportunity to invest more in further improvements and additions to the computer package,” says Daniel. With over 100 customers now signed into the program nationally, the company is aiming to double this within the next twelve months. “At the rate we receive enquiries and install contracts, this is well within reach. Our more traditional business is now also changing to suit the fact that our higher volume users are moving over to these Inventory Managed Systems. We no longer have the need for a distribution warehouse in every city, so we are over the next couple of years changing these over to our new concept of Pick

Up Shop, allowing the small user access to our product range in smaller quantities and through a shop type concept,” says Daniel. The company’s new Dunedin Store opened in March and the new Penrose Auckland store opened at the end of June. “These shops are then supported by Major distribution warehouses in key areas around the country, shipping orders for next or sometimes same day delivery.”

Advantages of the EDL Solution • Reduced last minute ordering. • Reduced inventory levels. • Reduced stock obsolescence. • Improved housekeeping. • Certainty of pricing. • Detailed usage guide. • Clear identification of parts. • Minimised stock shortages. • No capital outlay for bins and racks. Go to www.demm.co.nz/ enquiry quote: D120725

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• MAINTENANCE MATTERS

The reliability toolbox Equipped with the right predictive maintenance tools, a reliability engineer can perform condition monitoring, predict impending machine failure and initiate the necessary changes to improve the reliability of a machine or plant. Clyde Volpe from the Vibration Institute Australia describes the most important tools in this reliability toolbox.

Vibration analysis Vibration analysis can be considered the cornerstone of any effective condition monitoring program. Art Crawford, the founder of IRD, has said that “no single measurement can provide as much information about a machine as the vibration signature.” Every piece of rotating mechanical equipment generates a characteristic vibration frequency. The vibration signature of a machine is a combination of the vibration frequencies of all parts of the machine. “Mechanical problems such as unbalance, misalignment, worn gears or bearings and looseness can cause this normal level of vibration to increase or become excessive and thus change the machine’s vibration signature,” says Clyde. “By measuring the three vibration parameters-displacement, velocity and acceleration, trending vibration change over time, and analysing the gathered data, it is possible to assess the severity and cause of a developing fault and predict the best time for the faulty component to be replaced.” Vibration analysis can be used with rotating equipment such as motors, pumps, fans, blowers, gear boxes, rollers, mills, crushers, turbines and compressors, but also with interconnected structures, static equipment and piping.

Ultrasonic monitoring Ultrasonic monitoring systems are an extension of the human ear. We are able to hear in a range from 20Hz to 20kHz; ultrasonic detectors can ‘hear’ frequencies

July 2012

ranging from 20kHz to 100kHz. Changes in these high-frequency ultrasonic signatures emitted by machines can provide the earliest signs of machine and bearing failure or lubrication problems. Ultrasonic sound travels through air and solid objects, but not through avacuum. “An ultrasonic gun is required to measure the either airborne or structure-borne high frequency signal,” says Clyde, “and then heterodyne that signal. That means the high frequency, which is inaudible to the human ear, is turned into a lower frequency that is audible to humans, like listening to a radio.” Operators can directly listen to the signals to search for leaks and faults, or the signals are measured in dBs. The data can also then be analysed and displayed as time-wave form or as spectrum. Clyde explains that there is no better technique than ultrasonic monitoring to find air and gas leaks. “A small leak over one year can cost you thousands of dollars. Compressed air is the most expensive product you have on your plant. It takes 9kW of energy to create 1kW of compressed air. If you have a little leak, it’s just money going right up into the atmosphere.” A high pressure leak in a pipe creates a turbulent flow and some high frequencies, which can be picked up by the ultrasonic gun. But it doesn’t work with a low pressure laminar leak. The high frequency emission of a leak is very directional, making it easy to pinpoint its precise source. The volume of the emission depends on the distance from the source. “The closer you get, the louder and softer the sound becomes,” says Clyde. “Ultrasonic monitoring is also a good tool to locate leaks in steam traps and valve seats, cavitation problems in hydraulic pumps, boiler tube and heat exchanger leaks and compressor valve leakage. Due to the fact that friction between surfaces creates ultrasound, lubrication problems and bearing faults can also be detected. Checking while lubricating is possible.” When it comes to electrical equipment, ultrasonic monitoring constitutes an important complement to thermography and can detect loose connections, corona discharges, arcing, and tracking. “Ultrasound is now a standard part of

condition monitoring programmes, the equipment is not expensive and it is not difficult to operate. It can be used to detect faults that other technologies can’t. The ultrasound signals are extremely directionalsudden changes can be heard in ultrasound first,” says Clyde. “The technique is useful in high noise environments and during peak production hours and can be integrated with other predictive maintenance technologies. Ultrasonic monitoring is a definite must for a reliability engineer.”

Thermography Machines and electrical equipment emit radiant energy (heat). An increased amount of emitted heat can indicate a fault condition. A thermal imaging camera measures the (invisible) infrared radiation within its field of view, calculates the temperature of the measured object and generates an image in which different colours represent the temperature distribution on the surface of the object. “The heat source may be inside the object. But the camera can only see the surface temperature. You can’t penetrate through a surface with thermography,” explains Clyde. “The temperature change over time is more important than the temperature itself. Comparing the temperature at selected points provides the best indication of severity. You should check your plant regularly with an infrared camera.” A lot of factors need to be considered to measure the accurate temperature with a thermal imaging camera. “When you are too far away from the object you are shooting the average temperature in a circle. Get closer and you can shoot the temperature of a spot.” An infrared camera detects all three forms of radiation: emission, reflection and transmission. “All objects emit, reflect and transmit heat differently. Therefore it is important to know the emissivity of an object. Surface properties determine the emissivity of an object,” says Clyde. “Black is a lot more emissive than silver, even on the same surface material. The emissivity of an object should be 0.6 or greater to obtain fairly accurate measurements.” Wind makes temperature measurements unreliable, and so does reflected sunlight. In mechanical applications heat can be generated by friction of defective parts, misalignment, wear, poor lubrication and misuse. Some examples: bearings, motors and pumps, couplings, steam traps, condensers, heat exchangers and piping. Loose, oxidised or corroded connections or component

• MAINTENANCE MATTERS malfunctions are responsible for increased temperatures in electrical applications such as transformers, circuit breakers, distribution panels, connections and cable trays.

Oil analysis Lubricants prevent metal-to-metal contact in a machine and protect against corrosive substances. “The lubricant is the life-blood of rotating equipment. It is essential that it is maintained in good condition; it must not be dirty or contaminated with water or dirt,” says Clyde. “Oil also reveals if there are any signs of wear within the machine. Samples should be collected routinely and then analysed either on-site or sent to the laboratory.” The laboratory can perform a variety of tests such as water, viscosity, elemental concentrations, degradation, acid levels, base levels, and particle counting for NAS or ISO cleanliness. “When you send an oil sample to the laboratory, it may only be tested for particles of up to 8 or 10 microns. If the particles are larger, the lab is going to miss them. The problem with this: When something initially wears it produces a large particle. The lab picks it up only when the particles become crunched up into smaller

pieces. The onset of wear is not well seen by this kind of test.” Clyde recommends having a wear particle analysis done to determine the condition of equipment based on the concentration of wear particles in the lubricant. “It is possible for oil analysis to detect a problem with a gearbox months before vibration analysis picks up the first signs of an impending failure.” Oil analysis alone is not suitable for determining the machine condition. “It can’t tell you if there is imbalance or misalignment. You have to do oil analysis and vibration analysis together,” says Clyde. But oil analysis is more important when it comes to reliability than vibration analysis. “Vibration analysis just collects data. It doesn’t make the machine live longer. But if I find something wrong in the oil, I can tell you to clean the oil, and the machine runs longer,” emphasises Clyde, “You need to concentrate on improving the ISO cleanliness across your plant, especially when you’ve got hydraulics,” explains Clyde and adds, “If you drop down by one ISO grade of cleanliness, you’ll increase the life of the gearbox or machine by 30 percent. If you want to improve the life of your machine, clean the oil.”

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Motor testing Motor circuit analysis and motor current signature analysis can be used to perform one-time troubleshooting or periodic testing to trend motor performance over time. Motor circuit analysis (MCA) measures resistance, impedance, inductance, phase angle and ground insulation to determine the condition of the electric motor circuits and detect electrical imbalances and insulation degradation. There are two major tests categories: online and offline. The former splits in two categories: current analysis and voltage analysis. MCA can detect cable and contact faults, winding shorts, poor connections, air gap and rotor faults and winding grounds and contamination. Motor current signature analysis (MCSA) is a non-intrusive method for detecting mechanical and electrical problems of AC induction motors. The motor current is recorded during operation and analysed in the frequency domain. Variations in the current signature can indicate issues such as phase unbalance, problems with rotor bars, faulty collector rings as well as dynamic and static eccentricity.

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• MAINTENANCE MATTERS

Who put the roo in the stew?

By Craig Carlyle.

I had the pleasure last month of being hosted by the Regency TAFE in Adelaide. TAFE (Technical and Further Education) is the equivalent of our own technical institutes so I was keen to discuss the reality of the Australian apprenticeship system with those at the forefront. Murmurings about adopting Australian systems appear regularly on the Kiwi horizon, so the opportunity to take a non spin-doctored look was not to be missed. South Australia and New Zealand share a decline in manufacturing and a malaise from officialdom to long-term investment in a strong trades base. The South Australian technical training ethos mirrors our bums-on-seats approach to training and technology. The numbers game approach to technical training provides the

July 2012

same outcomes as here, a lack of good quality entrants into the system and a sinking lid of experienced and sage tutors. I am surely no economist but I don’t get it. My recent travels through both “colonies” has provided many raw examples how both countries have grown and excelled on the back of their technical ability, from early settlers to young countries. Now we excel at exporting our commodities and overexcite ourselves about our tourism industry, (forgetting of course to consider the fate of other tourist-focused countries) because we can’t compete on labour rates. Yet other developed countries with strong manufacturing (and trades) roots don’t seem to take the same path and still value their trades and manufacturing

capability, for example. Japan, USA and Germany. My entirely unscientific study suggested that the warts in the Australian system are almost identical to ours and we would be foolish to hold the Australia system up as a holy grail unless we are prepared to deal with the same philosophical issues that both countries endure. On the good news front, it appears that changes are afoot in the New Zealand apprenticeship system. Changes that perhaps take us a step back towards a system that tradesmen claimed was never broken in the first place. How right or wrong my sources are is insignificant; the important point is that people at the bottom of the totem pole are sitting up and talking and the government is listening. Top stuff! Meanwhile, preparations continue for the Maintenance Engineering Society’s 2012 SKF National Maintenance Engineering Conference, to be held in November at the Distinction Hotel in Rotorua. This annual event, supported by official media sponsor DEMM Magazine, is unbeatable for providing inspiration and experience for attendees. The speaking agenda is firming up and while subject to final confirmation, the list of topics and speakers is exciting to say the least. Core technical subjects deal with preventative maintenance, infrared, hard facing, variable speed drives, earthquake impacts on heavy plant and pressure equipment and an investigation into the fatal Orewa boiler explosion, while we also check out lean manufacturing, asset life cycle costing, remuneration systems, human factors in health and safety and dealing with never ending change. The 2012 event will feature a renewed focus on pre-conference training opportunities with Novotel Lakeside Rotorua transforming

into a temporary education facility for the week of the conference. The aim is to bring together as many industry trainers as possible to the one venue and maximise the opportunity for attendees to leverage their presence at the conference proper. Already, SIRF Rt/RCA Rt have committed to a two-day RCA Problem Solving workshop, hosted by Bernie Piovesan, Eagle Bergmann are providing mechanical seal training, Waikato University will cover Ultrasonics, Maintenance Transformations will present sessions on maintenance management and health and safety and the ever-popular Ann Andrews will host a workshop on team management. Training is separate to conference attendance and is booked directly with the provider. Further sessions are in the pipeline, so check the conference website www.mesnz. org.nz/nmec for further details or contact the society with your training needs/solutions. The November 2012 Rotorua event, teamed with the Maintenance Engineering Trade Expo, will be bulging with attendees, exhibitors and speakers, all responding to the theme of “Lifting The Game”. Registrations are open for exhibitors and attendees and can be found on the website (www.mesnz.org.nz\nmec\) or by contacting Event Manager Leanne Powley on (09) 296 1333, conference@mesnz.org.nz. Check out the conference pricing – the SKF National Maintenance Engineering Conference boasts the cheapest attendance of any two-day+ event in the southern hemisphere. Attendance is only NZ$440 to $680 + GST pp for the conference. Craig Carlyle Secretary MESNZ

• MAINTENANCE MATTERS

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The SKF Remote Diagnostic Centre is a simple internet based technology to manage a Predictive (PdM) and proactive Reliability Maintenance™ programme. The process allows our clients to view the performance of the contract including, savings and justifying the need of the programme both technically and commercially. At SKF Reliability Systems, we have developed the right technologies and processes, to help establish & manage an effective condition based maintenance programme remotely for a specific plant at a lower cost.

SKF Proactive Reliability Maintenance™

The way to get more companies to take on apprentices is to provide management support – not money in the form of government subsidies, reveals a new study by Competenz, the Industry Training Organisation (ITO) for the baking, food and beverage manufacturing and engineering industries. A concerning 75 percent of companies in the metal, engineering and baking sectors do not hire

apprentices. This leaves just 25 convert non-apprentice hiring companies percent of companies in these sectors that hire a tradesperson, into apprentice with the job of educating newcomers hiring companies – by providing a pool of to their trade and imparting skills suitable candidates to recruit from, more to the next generation. And yet the help with supervising, and an online system benefits of up-skilling the workforce to track apprentices in real time. Small are significant both for industry as businesses in New Zealand are weak in a whole and individual companies. people management skills and are less likely “Skills convert immediately into to hire an apprentice – they have the most productivity increases and profitable to gain from a management intervention. improvement,” says John Blakey, Subsidies are easy – give a company money Competenz CEO. So why are 75 and hope they deliver – but they only percent of companies not hiring make a small difference in converting a apprentices? The study found that non-apprentice hiring company into an two thirds of companies in these apprentice hiring company. sectors do not currently hire a qualified Government subsidies such as Job Ops tradesperson – and cannot therefore hire with Training and Skills for Growth that an apprentice either. come with conditions can be deterrents for “You can’t take on an apprentice many businesses. The requirement to hire if you haven’t got the qualification someone off an unemployment benefit or yourself,” says John Blakey. “Otherwise the DPB, with low or no skills, is just taking the transfer of skills can’t effectively take on one issue too many for most companies. Remote Diagnostic Centre place. It’s a situation that perpetuates The message is clear. Without interventions, the low wage, low skilled economy.” Yet the number entering apprenticeships is likely while many companies are simply unable to remain static, a dedicated few training The SKF Remote Diagnostic Centre is a simple internet based technology to manage a Predictive (PdM) and to hire an apprentice due to not hiring a for the needs of the whole nation. But with Proactive Reliability Maintenance™ programme. The process allows our qualified tradesperson, 27 percent of these the right supports, more companies would clients to view the performance of the contract including, savings and non-apprentice hiring companies are in justifying the need of the programme be likely to take on an apprentice, enriching both technically & commercially. fact in a position to take on anAt SKF apprentice their own companies and building a more Reliability Systems, we have developed the right technologies – something that needs to happen if we are highly skilled, highly productive environment and processes, to help establish and manage an effective condition based maintenance programme remotely for to meet the expectation of school leavers for sector-wide. a specific plant at a lower cost. Go to www.demm.co.nz/enquiry quote: employment, and close the skills shortage D120729 gap. It is management support that will

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• MAINTENANCE MATTERS

More details with SuperResolution technology Testo is introducing the option of recording thermographic images using the patent-pending SuperResolution technology. This technology is available for all its current thermal imager range into the NZ market (series testo 875, 876, 881, 882, 885 and 890) via their sole agents, Eurotec. With the introduction of SuperResolution, the usable geometric resolution of the infrared image is improved by a factor of 1.6 – with up to four times more measurement values. For these high-resolution thermal images, which are conveniently available in the analysis software on a PC, additional real measurement values are recorded. Technologically, this is achieved by the combination of two technologies – SuperSampling and Deconvolution – which are exploited by the Testo thermal imagers by a complex algorithm. The micro movements made during a thermographic recording by every operator as a result of natural hand movement, are used for this purpose. This means that more thermal information can be seen on each infrared image, and thermal measurements can be conducted with more security. In practice, this means that the so-called ‘smallest measurable object’ becomes considerable smaller at the same distance between the thermographer and the measurement object, meaning the tiniest structures can be measured thermographically. With SuperResolution, considerably better analysis possibilities for

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thermographic recording in construction, industrial maintenance or development are presented – especially if very small or very distant measurement objects need to be recorded. In building thermography, the SuperResolution technology is perfect for visualising inadequate insulation, cold bridges or construction errors at a glance in the thermal image. Even when recording large building sections from a distance, the high level of detail allows construction defects to be detected, or energy losses in the heating or air conditioning of buildings to be analysed. SuperResolution thermal images are thus ideal for error diagnosis and maintenance on interior rooms or building shells. In preventive maintenance or production protection, defective components, faulty electrical connections

July 2012

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Portable data collector The real-time, multi-channel, Fast-Fourier Transformer (FFT) signal analyser and data collector from Allen-Bradley is used for predictive maintenance and machinery vibration diagnostics. The unit measures, processes, displays and stores a range of analysis functions. The data collector includes a high-performance computing platform running Windows CE 6.0, and a sunlight-visible colour LCD. It is suitable for harsh environments with a Mil 810 spec drop rating, IP65 sealing and an operating temperature range from -10 to +50°C. The combination of the Dynamix 2500 data collector with Emonitor software provides users with tools for predictive maintenance using noise and vibration analysis. The data collector can also be used in other applications such as balancing or bearing analysis. Go to www.demm.co.nz/enquiry quote: D120730a

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or mechanical damage can be detected from a safe distance using high-resolution SuperResolution infrared recording. Thanks to the high image resolution, the thermal image shows more relevant thermal details. This allows possible production or system downtimes to be prevented. In research and development, even the tiniest structures can be resolved thermally. The targeted analysis of heat distribution and development, eg. on circuit boards, is possible. With the thermal imager testo 890 and SuperResolution technology, infrared images in megapixel quality can be recorded. This allows tiny components up to a size of 0.07mm (socalled iFoVgeo) to be resolved and analysed in detail. Go to www.demm.co.nz/enquiry quote: D120730

• MAINTENANCE MATTERS

Measuring fastener strain or load quickly and precisely The latest evolution of an ultrasonic instrument that measures and records bolt strain or load is being introduced for safety and precision in fastening applications by global joint integrity specialist and engineering services company Hydratight. Boltscope II is an easy-to-operate, but very accurate, instrument that is particularly useful for verifying fabrication and manufacturing processes or confirmation on construction sites that local bolt tightening processes are in control. The instrument measures bolt strain using the well proven principle of measuring the time of flight of an ultrasonic signal. The signal is generated by a transducer and an advanced electronic clock measures the time taken to return to the transducer after reflection from the far end of the bolt or stud. The technology is also particularly applicable to bolts securing machinery, such as crushers in mines, quarries, turbines in energy and resources. Ultrasonics are

also highly useful in confined spaces where the use of a torque wrench is not possible without significant removal of components around the bolt in question, says The Commercial Leader of Hydratight in Australia, Mr Neil Ferguson. Boltscope firmware displays the load, stress or elongation of a fastener through operator setting and pre-loaded compensation data, clearly displaying the information on a large, easy-to-read screen. Built-in A-Scan wave-form displays help the user to place transducers correctly by verifying signal reception. Material and joint data can be uploaded and downloaded to a PC directly using the Stressware provided. The Stressware allows easy measurement analysis, as well as data reports and information to be saved for periodic comparisons. The unit works with all bolt tightening systems. It monitors the fastener during the tightening process to ensure accurate initial loading. Retained load in the

fastener can be monitored at any time.

Features include:

• Capacity to store up to 10,000 fastener measurements in up to 512 application groups. • Minimal application data required. • Easy-to-use interface, one menu deep, with direct access keys. • Measures reference length of fastener to better than four decimal places resolution. • Lightweight and compact. • Rugged design for production and site environments. • Measures fastener lengths up to 21 feet (6.4 metres). • Simultaneous display of fastener stress, elongation, load and time of flight. • Multilingual – English, French, German, Spanish, Italian and Russian. Go to www.demm.co.nz/enquiry quote: D120731

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Maintenance Best Practice - 5 Day Course. A bottom up approach to maintenance that will improve workplace culture and increase reliability. Maintenance & Reliability - 5 Day Course. Learn how to analyse and monitor plant to make positive changes to your maintenance practises. Planning & Scheduling for Planners - 5 Day Course. This course gives your planners the tools they need to increase productivity and reliability across the workplace. Introduction to RCM and HAZOPS - 1 Day Workshop. Learn what these processes are all about and how to lead and manage teams to implement them. August 27-31 Planning & Scheduling for Planners

September 24-28 Maintenance Best Practice

October 8-12 Maintenance & Reliability

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

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

Terminal blocks for a price-sensitive market Electro-technical systems for price-sensitive markets are usually produced directly on site since this allows for local companies to be competitive. The demand is often for economical, universal solutions – such as terminal blocks with bolt or screw connections. disconnect terminal blocks are also available. The terminal blocks meet the specifications in UL 1059 and IEC 60947-7-1. Tests pursuant to railway standard 50155 and Germanischer Lloyd have shown that they can be used worldwide.

Space-saving and versatile

Economical terminal blocks for price-sensitive markets – for global production of electro-technical systems.

The global increase in energy consumption means that switchgear equipment and systems for distributing energy have to increase in efficiency. In the interest of saving costs, many companies develop and produce in the countries and regions where

The Type RBO 8 terminal blocks provide diverse testing possibilities – additional safety is provided by anti-touch protection that can be snapped on.

July 2012

the products will be used later. Additionally, customers can often better identify with the products. Here, cost-efficient components are needed, some of which are subject to the approval requirements of the specific country.

Applications and market requirements Terminal blocks not only have to meet the specifications of various markets, but also those of various applications and industries. They are used in high, medium and lowvoltage systems, in energy generation, and in transformers. They are also important in telecommunications, shipbuilding, rail, and particularly in mechanical engineering. For all of these applications, Phoenix Contact has the RBO series with bolt connections and the RSC series with screw connections. Both series can be mounted directly or on a rail. For both series, measuring transducer

Thanks to their narrow shape, the open-style ring lug (RBO) bolt terminal blocks are suitable for switchgear systems in telecommunications, HVAC, and infrastructure. Conductors are connected using ring and fork-style cable lugs. Depending on the application, the terminal blocks come with rated cross-sections of 10mm² and 35mm². The rated voltage is 800V according to IEC and 600V according to UL. A maximum current of 57A is permissible with 10mm²; a maximum current of 125A is permissible with 35mm². There are single and multi-pole flange terminal blocks for direct mounting in control boxes, which can be connected together using engagement pins. Preassembled blocks are available for easy wiring. A bridging channel distributes potential. The RBO measuring transducer disconnect terminal blocks for direct and standard rail mounting are approved for a rated voltage of 800V according to IEC and 600V according to UL. The rated cross-section is 10mm² with a maximum current of 50A. The separating plate is anchored using a screw – this prevents unintentional switching. Standard screw bridges distribute potential via the bridging channel while isolator bridge bars are also available for switchable cross connections. The threaded bolts and current bars locked in the insulation housing are also beneficial. For applications requiring larger crosssections, the high-current connector from the RBO series with a rated cross-section of 70mm² provides an excellent solution. This terminal block, with a M8 bolt thread, is approved for a rated voltage of 1000V and a maximum current of 192A. A protective

prevent unintentional switching. All models have a central screw bridging channel for distributing potential.

Comprehensive accessories There is a comprehensive range of accessories available for both the RBO and RSC terminal block ranges. Fixed bridges are mounted in the bridging channel to distribute potential. Isolator bridge and switch bars for switchable cross connections between the individual terminal blocks are available, as are separating

Both the RBO series with bolt connections and the RSC series with screw connections can be mounted directly.

•

From turn and ground insulation, to high voltage machine coil insulation, it has to be OBA Dow Corning Products.

High Temperature Cables

cover can be optionally snapped on to provide contact protection, which has inspection holes in it to enable checks to be made. Connection rails are used for comfortable potential distribution.

Secure screw connection as an alternative

The product range for the compact RSC (ring lug screw) terminal blocks with a screw connection includes terminal blocks with rated cross-sections of 4mm² with a rated current of 32A, 10mm² with a rated current of 57A, as well as 35mm2 with a rated current of 125A. Blocks are easy to form in direct mounting using engagement pins. The threaded nuts and current bars are also locked in the insulation housing. The rated voltage of 800V according to IEC and 600V according to UL make the terminal blocks safe solutions for applications worldwide. The measuring transducer disconnect terminal blocks in the RSC 5 series are designed for a rated cross-section of 10mm² with a maximum current of 50A. They are permissible for a rated voltage of 800V according to IEC and 600V according to UL. The separating plate can be moved via a screw in order to

plates for separating neighbouring bridges. Separating plates can be inserted to avoid division losses, which is particularly important in tight spaces. The complete Phoenix Contact product range is supplemented with ring and forktype cable lugs. Crimping pliers, strippers, and cutters are available for assembling wires. Additionally, there are centre and side slots for easy labelling on all terminal blocks. Go to www.demm.co.nz/enquiry quote: D120732

The evenly assignable interior of the TKA55 can be modularly divided.

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• • • •

RECS (SIE VDE) - Rigid single core silicone insulated cable with tinned copper conductor. ECS (SIF - VDE) - Flexible single core silicone insulated cable with tinned copper conductor. MC-ECS - Multi core silicone insulated cable with tinned copper conductor ECSP - Single core silicone insulated reinforcing Braid with tinned copper conductor

• Silicoul 1.1 kV - Single core silicone insulated reinforcing braid with tinned copper conductor. • Silicoul 3.7kV - Single core silicone insulated reinforcing braid with tinned copper conductor. • Silicoul 6.6 kV - Single core silicone insulated reinforcing Braid with tinned copper conductor. • Silicoul 13.8 kV - Single core silicone insulated reinforcing braid with tinned copper conductor.

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Phone 0800 526 5533 email: orders@oba-ic.co.nz 33

Flexible cabling for energy, data and signal

The new Han PushPull cable-to-cable housings from Harting enable flexible cabling for the transmission of energy, data and signal to protection type IP65/67. They offer decisive advantages for device connection and the installation of switch cabinets and machines for machine and plant construction. It is rarely possible to allow for detailed concrete cable lengths in advance during the planning phase of a plant. When installing the plant, connectors that can be assembled on-site out in the field are a great help in this regard, as cables can be adapted to fit. In spite of this, there is still a requirement for pre-

assembled system cables in this environment. Users are looking to reduce the risk of errors, which can easily occur with untrained staff carrying out on-site assembly. This is where Harting cable-to-cable housings come to the rescue, meeting both requirements. They make it possible to use ex-works pre-assembled and individually tested system cables and flexible cabling and cable length extensions on site. If an existing tested system cable that has been pre-assembled in the works is not enough for cabling the plant, the appropriate additional extension cable can be used to ensure that plant cabling is completed to requirements and using optimal lengths. This means that users obtain tested system cables ex works with a functional guarantee, but also the required freedom for on-site

cabling. For the transmission of Industrial Ethernet and power supply, cable-to-cable housings with the appropriate contact inserts can be fitted for the Han PushPull family variant 4 (to IEC 61076-3-103) and 14 (to IEC 61076-3-1117). A bandwidth of up to 10 gigabits can be achieved with a reliable AWG 22-27 conductor cross section for the transmission of Industrial Ethernet. For power supply, using five contacts, up to 690V and 16A can be carried with a reliable conductor cross section measuring up to 2.5mm². Go to www.demm.co.nz/enquiry quote: D120734

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Routing cables in small spaces

Counter nut with 360 degree shielding

The new e-spool from igus is suitable for users looking for space-saving energy chains or requiring solutions that are more durable than cable drums. The system links two different energy chains in a unique way: a standard e-chain from the E2 or E4 series is routed via a spool and – thanks to the integrated return spring – always ensures the exactly correct length and tension of the energy chain. In its initial position, the chain compactly wound up. The twisterband connects the spool with the shaft bracket, which serves as the interface to the permanently installed cables. In classic cable drums this task is usually taken over by sliding contacts. The e-spool concept is far more flexible here, because in contrast to sliding contacts, cables for data, compressed air and fluids can be connected without interruption and be replaced or modified at any time. The twisterband TB 30 provides sufficient space for cable diameters of up to 16mm. If more space is required, the twisterband can route cables to both sides of the chain drum. These concrete advantages make the e-spool a complete modular replacement for classic cable drums. In addition, the e-spool can be just the solution where space is tight: additional space for storing the chain, as is the case with freely suspended or zigzag applications, is no longer required. The e-spool becomes a multidimensional solution when three-dimensional chains such as the igus triflex are used – in this case energy chains can supply in any direction. The e-spool can be used in lifting platforms, sorting lines, mobile cranes, platform applications or assembly or process cranes with grippers. Go to www.demm.co.nz/enquiry quote: D120734a

A plastic cable entry with 360 degree EMC shielding: What at first sounds like a contradiction is now becoming reality, thanks to an unconventional idea from Lapp. Instead of a brass cable gland, now all that is needed is a brass counter nut with active screen contact. A normal plastic gland can be used as a cable entry in the control cabinet. Product manager Andreas Bauer: “In a way, we put the cart before the horse and asked why the shield contact always has to be at the front in the gland.” The idea for the new Skintop Brush Add-On was born. Unlike in a normal brass cable gland, the highly flexible brass braids for the shielding are integrated into the much smaller counter nut. The new Skintop Brush Add-On is suitable for through-holes and offers many advantages: It can be removed at any time, can be fixed with a Skintop plastic gland, it is lighter, simpler and more flexible. In addition, the customer does not have to order an extra brass gland, but can use a plastic gland instead, which they will generally have in stock. For reliable 360 degree shielding, the space-saving Skintop Brush Add-On counter nut is absolutely sufficient. Go to www.demm. co.nz/enquiry quote: D120734b

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July 2012

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All-round protection for lines and hoses

The closed cable and hose carrier TKA55 efficiently protects hoses and lines right up to the connection area from intruding chips and dust.

Wood, metal or plastic chips entering into the cable space of cable and hose carriers can quickly result in costly problems. Carriers wear faster, the service life of the routed cables and hoses is shortened, and the availability of the entire machine or system is jeopardised. Tsubaki Kabelschlepp has developed a solution for these types of environments with

their cable carrier TKA55. The closed plastic cable carrier was awarded the Eco-Link label of excellence, and fulfils the very strict environmental compatibility standards of Tsubaki Group. An optimised sideband and a cover contour with minimised gap dimensions effectively prevents functional faults caused by chips and dirt entering into or sticking to the

cable carrier. The compact new surfaces make the cable carrier cover design fits seamlessly the ideal solution for long into one another and reaches travel lengths. Integrated noise over the sidebands to form a damping ensures that the compact, closed unit. They offer cable carrier is running silently secure hold even under severe and with low vibration at all mechanical stresses, e.g, when times. The closed cable carrier used with hydraulic lines. The by Tsubaki Kabelschlepp is smooth, dirt-repellent contour available in six interior widths of the sidebands with their between 50mm and 175mm. encapsulated stroke system prevents the intrusion of any foreign bodies. The covers can be opened and removed easily on the inside or outside to load the cable carriers. The interior of the TKA55 can be modularly partitioned with various divider solutions for even cable distribution. The evenly assignable interior of the optimised geometry of the chain The TKA55 can be modularly divided. links and a triple encapsulated stroke system allows the TKA55 Go to www.demm.co.nz/ to span extensive unsupported enquiry quote: D120735 sections. The integrated gliding

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

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

When you deal with SEW-Eurodrive, you are dealing with the `manufacturer’. Our huge range of quality European manufactured componentry is held in stock at our Auckland & Christchurch plants, ready for fast turnaround customised assembly. In tight economic conditions, getting it `right’ every time, is even more crucial. Contact us for advice, planning and drive calculations. AUCKLAND 82 Greenmount Drive, East Tamaki. Ph: (09) 274 5627. Fax: (09) 274 0165 PALMERSTON NORTH Ph: (06) 355 2165 CHRISTCHURCH 10 Settlers Crescent, Ferrymead. Ph: (03) 384 6251. Fax: (03) 384 6455 Email: sales@sew-eurodrive.co.nz • Web: www.nz.sew-eurodrive.com

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INDUSTRIAL DRIVE TECHNOLOGY

• SINGER

“A great acquisition for the country, the industry and Singer” Singer’s internationally experienced turbine boffin wants to share his knowledge with customers and employees. By Kevin Kevany. Steve Sands, the recently appointed Singer Central Region Maintenance Manager, stationed at Contact Energy’s Wairakei Power Station, Taupo, with more than 30 years in the ‘turbine and generation game’ internationally, could be said to be ‘the turbine mechanical expert Jeff Mclaren, CEO of the Singer Group, has been looking for a very long time’. Sands, a relatively new arrival in the country – he popped out for a ‘brief holiday’ and to catch up with a long-lost brother, who emigrated to New Zealand some 30 years ago – is yet another of those specialists-in-more-than-one-category, who are becoming sought-after players in the electrical industry. (We recently featured Singer’s Bill Mitchell, experienced electrician and professional thermographer in the 2011 year-end edition of Electrical Technology.) Mclaren’s commitment to maintenance as major factor in the profitability and sustainability of businesses – both for customers and the Singer Group, delivering its ‘powerful solutions’, which inevitably have a maintenance core to them – is well-known in the industry. “Extending the productive life of expensive equipment and, increasingly, gaining greater energyefficiency and thereby cost-efficiency has always been something I have championed with customers and employees, whether in boom or straightened times. “The fact that while we appear to have come through the GFC better than most in New Zealand, that doesn’t mean we are going to be released from the slow grind back to ‘better days’, over a number of years, which all the financial gurus are predicting for the world. So I was very happy to encounter Steve during his holiday and persuade him to join our Generation Services team, which under the leadership of Grant Morris is developing an excellent reputation for itself in tough times,” he says. Morris, a recognised electrical industry leader in the Waikato and central regions, has been the driving force in co-ordinating and integrating the expertise which Singer has built up over many years in the key

July 2012

Steve Sands (left) and Grant Morris

power generation area of the greater Waikato, where the Genesis Energy Huntly power station, the biggest gas/coal thermal plant in the country and the Contact Energy geothermal and hydro-electric plants create some unique challenges and require specialist expertise. “I’m personally thrilled to have Steve available, not only in terms of the here-andnow, but also in his ability to pass on those skills both to current and future clients’ staff, and to our own. For a number of years now, Singer has been both upping the skills’ levels of its apprentices and current staff, in response to client and industry demands, says Morris, who envisions Sands establishing the role of National Outages manager for the group, in time. Morris also points to the very successful apprenticeship scheme Singer is participating in, alongside Genesis Energy Training, which is attracting the cream of candidates in the mechanical and electrical fields – some 600 applicants for a handful of places in the first year alone – which he believes, over time, will set the benchmark for the generation industry, and provide a top-class talent pool. The company recently appointed Reg Soepnel to the role of Singer’s Generation Operations Manager – Genesis Energy as part of providing a greater range of top-end consulting services to the generation and gas reticulation sectors. But back to Sands. He is an Alstom Power man through and through. Lucky – or talented – enough at the age of 16 to be

selected for a mechanical apprenticeship offered in those days by that Rugby, UK company each year. He had to wait for his 20th birthday before the turbine mechanical fitter certificate was presented, as was the Alstom custom. He was already well-grounded in a broad cross-section of the industry, given Alstom operated in coal, gas, nuclear and hydro generation around the world. “We even got to do maintenance on Britain’s nuclear submarine and Hunter Killer fleet as part of Alstom’s specialist turbine team. The subs, which ran two turbines of the size we run for geothermal operations, had a particular vibration problem, so securing mountings took particular skills and focus. “It took a while to get used to the fact that you were always overseen by an armed guard. Probably good preparation for some of the sites I would be called upon to work on around the world in years to come,” he quips. By his late thirties, he’d gained a reputation for having such a broad knowledge of turbines across a huge range of power, application and range, that he was increasingly sent abroad to troubleshoot, often on his own, right across the US, China, most of Europe, South Africa, Malaysia, Australia, Thailand – although he never made it to New Zealand. Sands can keep you entertained too with stories about dealing with a stuttering translator during an emergency in China and the power of ‘sign language’. Or the perils and challenges of dealing with an

• SINGER

Grant Morris (left) with Steve Sands on a geothermal site.

apparatchik who insisted that he wrote all instructions on the floor in (readily-erasable) chalk and not on paper, so that in the event of something going wrong, the local supervisor would not be responsible, and would keep his job. Or the challenges of dealing with steam, superheated to 500 degrees C, which makes it invisible to the naked eye. He also has a legendary ability to be able to visualise problems, ask the right questions and provide accurate insights as to the likely causes over the phone; so that the correct gear and handling equipment can be assembled while he flies in for ‘the fix’. Sands can take you across virtually every scenario you can conceive of and he’ll list a dozen or so possibilities for things to go wrong – and then come up with a simple or temporary fix; the classical follow-up fix; and then spell out what should have been done to prevent it, way back when. The best part is that there isn’t a buzzword to be heard. And he will describe how you can use a foot-long plastic ruler to double-check the alignment at a particular place on a piece of equipment, before sliding the two parts together, rather than doing the ‘obvious’ and cause thousands of dollars of damage. The paragraph above, however, is a hint at one of his newly acquired skills, which Mclaren and Morris believe will be, as they say in the advert, ‘priceless’. When Alstom asked Sands a few years back to set up a training school for them, he decided, with a thoroughness that has marked his career, to qualify as a teacher, to ensure he was applying the correct techniques. Sands again: “I realised by the end of that qualification that we, as an industry, don’t do a very good job in passing on our skills and experience formally to those alongside us. Too often that is done very casually and often only partially on the job, in the pub or travelling between jobs. “While that has its place, the structured and formal methods which really succeed come from constant capture of what is being done currently, at every step along the way,

highlighting problems and making wellthought-through suggestions on how and why to improve a process, which just might have been ‘the way it’s done’ for a long time, but new technology, for example, might offer a better way. The nine guys I have with me on the Contact Energy sites at Wairakei and surrounds are already responding so well to these systems and disciplines that I’m stoked on what that is going to start delivering in the months ahead. “I remind them that we are privileged to work on a world-first site – Wairakei was the first geothermal plant of its kind anywhere in the world, commissioned in November 1958, and situated above a large geothermal system containing water at temperatures up to 240°C – and is an iconic symbol of New Zealand’s electricity generation system, not only in terms of its past but in its future. And indeed that is going to apply increasingly around the world, as a sustainable and natural source of power, we believe. “I’ve learnt a lot here in four tofive months and expect to carry on learning something new all the time. That’s what I want the lads to keep focussing on too,” Sands says. As his divisional boss, Morris notes,“at a time of a shortage of industry skills, Sands is a great acquisition for the country, the industry and Singer.”

The most reliable form of renewable electricity generation Geothermal energy involves harnessing the heat from under the earth’s surface and using that heat and steam to generate electricity. It is ‘the most reliable form of renewable electricity generation, regardless of the weather’. New Zealand has been a world-leader in the development of geothermal electricity generation for many years, and Contact Energy is a primary producer of New Zealand’s geothermal electricity. Their three geothermal power stations are located at Wairakei, Ohaaki and Poihipi Road. Together, they provide New Zealand with around five percent of total electricity production. Contact Energy has a geothermal development pipeline of over 400MW in place currently.

0800 474 643 www.singergroup.co.nz 37

Electrical machine safety Those who design new machinery or make electrical/control systems modifications to existing machine need to be aware of changes that have occurred with the Machinery Directive and standards that influence AS 4024:2006. Whilst not an AS/NZ standard, AS4024-1 2006 is viewed by DOL as “taking all practicable steps” as required by New Zealand Law. Now let’s test that in court! • AS 4024.1 is a derivative of BS 5108 & EN IOS 954-1. • EN 954-1 is now replaced by EN ISO 13849-1. • AS 4024.1:2006 contains information on hazard identification and details on carrying out risk assessment. It includes category information and explanations of principles of design and is widely used by New Zealand industry as the benchmark for health and safety design. Some of the most relevant, recognised standards for electrical machine safety are: • EN ISO 954-1 which has been replaced by EN ISO 13849-1. There was a transition period during which EN 954-1 remained current. On 28 December 2009 that transition period ended and EN 954-1 became obsolete, meaning that machine builders and system integrators will instead need to apply EN ISO 13849-1:2008 or, if more appropriate, the other functional safety standard for machinery, namely EN (IEC) 62061 ‘Safety of machinery – Functional safety of safety-related electrical, electronic and programmable electronic control systems.” • EN ISO 13849-1 “Safety of machinery, “Safety-related parts of control systems, Part 1: General principles for design” which has replaced EN 954.1. EN ISO 13849-2 specifies the procedures and conditions to be followed for the validation by analysis and testing of the safety functions provided; and the category achieved for the safetyrelated parts of the control system in compliance with EN 954-1 (ISO 138491), using the design rationale provided by the designer. This International Standard does not give complete validation requirements for programmable electronic systems and therefore can require the use of

July 2012

other standards. • EN/IEC 62061: “Safety of Machinery – Functional Safety of safety-related electrical, electronic programmable control systems” which is going to be integrated with EN ISO 13849.1 “Safety of machinery – Safety related parts of control systems.” • AS 61508 (parts1-7) Functional safety of electrical/electronic/programmable electronic safety-related systems. • Machinery Directive 2006/42/EC, Where machines have to comply with the Essential Health and Safety Requirements (EHSRs) listed in Annexure I of the directive.

What were the main reasons for revising EN 954-1? EN 954-1 has described the design of safety-related control circuits in the machinery safety sector since 1996. It is in use, but specifically contains no adequate requirements for programmable electronic systems. Other criticisms were that the relationship between risk level and category was not always plausible. Also, the general view was that probabilistic considerations ought to be included along with the safety aspects.

What has changed? A significant revision in EN ISO 13849-1 is the probabilistic approach to the assessment of safety-related control systems. The aim of the revision was to provide EN 954-1 with the probabilistic techniques urgently needed in order to assess modern circuits. The key step was to continue to use the proven categories but to also assess quantitative safetyrelated features. Performance levels (PL) have come into use; these are based on the categories and are described by the following parameters: • Category (structural requirement). • Mean time to dangerous failure (MTTFd). • Diagnostic coverage (DC). • Common cause failure (CCF).

The six steps for the design of the safetyrelated parts of a control system The introduction of EN ISO 13849-1 has also resulted in new procedural requirements for machine design. The design of the safety-related parts of a control system is an iterative process which is completed over several steps.

Step 1 – Define the safety function requirements First of all it’s necessary to establish the features required of each safety function. This step is the most important and sometimes the most difficult too. For safety gate guarding on a machine, for example, hazardous movements must be shut down when the safety gate is opened; it must not be possible for the machine to restart while the safety gate is open.

Step 2 – Determine the required performance level PL The greater the risk, the higher the requirements of the control system. The contribution of reliability and structure can vary depending on the technology used. The level of each hazardous situation is classified in five stages from “a” to “e”. With PL “a” the control function’s contribution to risk reduction is low, with PL “e” it’s high. The risk graph can be used to determine the required performance level (PLr) for the safety function.

Step 3 – Design and technical realisation of the safety functions The “safety gate interlock” safety function described in step 1 is realised through control measures. The safety gate interlock can implemented using a coded proximity switch such as the PSEN code. This provides the option to connect several safety gates in series without reducing the effectiveness of the monitoring functions. Coding also provides extensive manipulation protection. The sensors are evaluated using a multifunctional safety system

F1 S1 Start S2

F2 F3 F4

P1 P2 P1 P2 P1 P2 P1 P2

The risk graph can be used to determine the required performance level (PLr) for the safety function.

such as the PNOZ multi. The drive is shut down via two contactors with positive-guided contacts.

Step 4 – Determine and evaluate the performance level The safety function is broken down into three parts to determine the performance level that has been achieved: input, logic and output. Each of these subsystems contributes to the safety function. All the necessary performance data is available for reputable hardware such as Pilz, Sick Allen Bradley and Schneider to name but a few.

Step 5 – Verification This step determines the extent to which the achieved performance level matches the required performance level. The achieved PL must be greater than or equal to the PL r required by the risk assessment. This means a “green light” for the machine design.

Step 6 – Validation Alongside the purely qualitative requirements for the design of safety systems, it is also important to avoid systematic failures. Steps 5 and 6 are too often not completed and are an extremely important part of the process, in simple

Useful Links •IEC have published a series of FAQ’s related to Functional Safety: www.iec.ch/zonefsafety/ •Link to Sistema: www.dguv.de/ifa/ en/pra/softwa/sistema •Link to the Pilz PasCAL calculation tool: https://shop.pilz.com/eshop/ cat/en/EN/00013000317038/Utilitysoftware

a b c d e

Risk parameters

S = Severity of injury S1 = Slight (normally reversible injury) S2 = Serious (normally irreversible injury including death) F= Frequency and/or exposure time to the hazard F1 = Seldom to quite often and/or the exposure time is short F2 = Frequent to continuous and/or the exposure time is long P = Possibility of avoiding the hazard P1 = Possible under specific conditions P2 = Scarcely possible a, b, c, d, e = Estimates of safety-related performance level

terms it could be said: • Verification: Did we do what we meant to do? Involving lots of paperwork and analysis. • Validation: Did what we do work how we wanted it to? Test plan/testing.

Performance level safety software Sistema is popular for performing EN ISO 13849-1 performance level calculations, but some engineers criticise the way its results can be open to interpretation. Some English companies are now promoting Docufy Machine Safety to the UK market. While this is primarily a tool to aid compliance with the risk assessment aspects of EN ISO 12100:2010, it integrates with Sistema and, moreover, removes the ambiguity from Sistema’s results. The Sistema software utility provides developers and testers of safety-related machine controls with comprehensive support in the evaluation of safety in the context of ISO 13849-1. The tool enables you to model the structure of the safety-related control components based upon the designated architectures, thereby permitting automated calculation of the reliability values with various levels of detail, including that of the attained performance level (PL). The Sistema program is now available with selection of English language. Sistema may be downloaded and distributed to third parties free of charge. Relevant

parameters such as the risk parameters for determining the required performance level (PLr), the category of the SRP/CS, measures against commoncause failures (CCF) on multi-channel systems, the average component quality (MTTFd) and the average test quality (DCavg) of components and blocks, are entered step by step in input dialogs. Each parameter change is reflected immediately on the user interface with its impact upon the entire system. Users are spared time-consuming consultation of tables and calculation of formulae, since these tasks are performed by the software. The final results can be printed out in a summary document. Of course, if you are designing safetyrelated control systems to EN 62061 (IEC 62061) instead, then Sistema is of no help. However, the Pilz PAScal safety calculator can be used with this standard as well as EN ISO 13849-1, and it can import data for other manufacturers’ products in Sistema format. The Institute will be closely following the updating of AS4024:2006 in relationship with the implementation of EN ISO 13849.1 and the proposed integration of EN/IEC 62061 with EN ISO 13849.1

Allan Hill National secretary New Zealand Electrical Institute (Inc).

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

NZEI Inc. Auckland branch news Thanks to our National Secretary Allan Hill for a very interesting discussion and presentation on the systems used for the control of baggage handling from Africa to Spain to China and most points in between. Allan talked about the handling of checked baggage from the departure check-in process, where a ten-digit license plate number is tagged to the handle. The security screening process for bags from check-in, through the levels of surveillance of baggage with X-ray identification of suspect items, was interesting and included information on how the bag is tracked to the can that it is stowed in and can be unloaded if the passenger doesn’t board the aircraft. The routing of bags through screening and direction of the bag from the common reception belt to the make-up carousals/laterals, where the bags are loaded into the cans for loading onto the aircraft at very high speeds, was amazing. Power-point displays of photos and video clips showed the different methods of baggage transport from the standard belt conveyors with a maximum speed of 2.5m/s through to high speed inter-terminal systems running at up to 40km/h and tilt-tray sortation systems employing multiple linear motors. Minimising the cost of mishandled bags to the airline industry with correct and accurate routing is the prime objective.

Competency programmes refresher courses The EWRB has introduced new prescribed competence programmes for persons applying to uplift Board Practising Licences that took effect on 1 February 2012. Any person who wishes to uplift their practising licence after 31 January and whose refresher training is no longer current or is due to expire must attend a board-approved competence programme which includes instruction in electrical safety and approved instruction in cardio-pulmonary resuscitation and first aid. The Auckland branch of the NZEI Inc, who is an EWRB (Board) approved competence programme provider, undertook two competency programme/refresher courses in June; these refresher courses were free to our financial members. The refresher course on 7 June at the Birkenhead RSA attracted some 43

July 2012

Refresher course at the Birkenhead RSA.

The course at the MIT attracted 47 participants.

participants and the course on the 14 June at the Manukau Institute of Technology (MIT) attracted 47 participants. The refresher courses are facilitated by Mr Bob Hanham, a long/standing member of the NZEI Inc., who held the position of President of the Institute 2000 to 2001. Bob has held many roles in the Institute at branch, national level and his commitment to the Institute and electrical industry knowledge is much appreciated. The membership drive in the Auckland area by the executive committee has resulted in an additional twenty-one members in the month of May and June with interest in the NZEI Inc continuing to grow; enquiries are arriving by email, website enquiries and members contact with the industry. Joe Heappey (Interim) President Auckland Branch

www.standards.co.nz. On the home page click on the public comments tab, then the joint standards tab and then look for AS/NZS 3000 Amendment 2. Public comment can be directly made on line following the instructions on the standards website. Public comment closes 16 on July 2012, but due to the expected volume of public comments, it would very helpful if comments are received by the end of June 2012. The public comment will be considered at a meeting of the Joint EL-001 committee on 17 and 18 July 2012 in Sydney. It is expected that AS/ NZS 3000 amendment 2 will be published mid to late August 2012. Alan Cuthbert Wellington Branch Secretary

NZEI Inc. Wellington branch news May and June meetings The May and June meetings are competency courses for the renewal of EWRB practising licences. The last scheduled course on 7 June 2012 is full and it is not proposed to run any further courses until May/June 2013.

July meeting There will be a general meeting of the branch on 18 July 2012. There are a number of key events expected to be completed at the time of the meeting, so that branch members can be up dated on what changes these bring to the electrical industry.

August meeting

Due to a number of circumstances the August meeting is proposed to be cancelled, this is due to a number of circumstances. The confirmation of the cancellation will be advised late July /early August.

Standards news The amendment No 2 for AS/NZS 3000 is open for public comment, and close late June/early July. A copy of the public draft is on the Standards New Zealand website,

Changes to Standards and the Electricity (Safety) Regulations Electrical (Safety) Regulations 2010 The Energy Safety division of the Ministry of Economic Development (MED) issued an advanced copy of the draft Gas (Safety and Measurement) Amendment Regulations 2012 and draft Electricity (Amendment) Regulations 2012 for expert consultation on 2 May 2012. The draft regulations amend the Gas (Safety and Measurement) Regulations 2010 and the Electrical (Safety) Regulations 2010 (the “Principle Regulations”), respectively. The expert consultation review period closed on 15 May. This was a very, very short period to post the documents to the NZEI Inc members, receive comments and suggestions back to the National Office and submitted comment to Energy Safety. The NZEI Inc. has submitted comments and suggestions to the Energy Safety regarding the ESR amendment. The Minister of Energy and Resources has asked officials to progress the Draft Regulations so they can be considered by Cabinet in June 2012. It is proposed that the amended principle regulations will be effective on 1 July 2013.

AS/NZS 3000:2007 – Electrical Wiring Rules The Amendment 2 of AS/NZS3000 was released for public comment in Sydney on 14 May 2012 in line for the EL-001 meeting on 18/19 July 2012. The document was posted on the New Zealand Standards website on 14 May 2012 for public comment. The closing date for comments to the proposed amendment is 16 July 2012. To download a free copy of DR 3000A2, Amendment 2 to AS/NZS 3000:2007 Electrical installations (known as the Australian/New Zealand wiring rules), go to: www.standards.co.nz/draftstandards/joint-standards.

Report from the EL-001 and EL-042 of the joint standards committees as at 14 May 2012 • AS/NZS 3001 amendment No 1 Transportable Structures (In NZ this standard

covers connectable installations), is proceeding to publication, subject to NZ approval by the Minister of Energy and the Councils of Standards Australia and Standards New Zealand. Publication is expected to occur late May/early June 2012. The amendment will now mandate the removal of the neutral to earth links in caravans. This will be achieved by the removal of the link and the fitting of an RCBO when a warrant of electrical fitness is renewed. • AS/NZS 5033 Photo Voltaic arrays; the revised standard is preceding to publication subject to NZ approval by the Minister of Energy and the Councils of Standards Australia and Standards New Zealand. Publication is expected to occur late May/early June 2012.

• AS/NZS 3000 amendment No. 2 Australian and New Zealand Wiring Rules; the draft of

the amendment has been released for public comment on the Standards New Zealand website www.standards.co.nz on 14 May 2012, the closing date for comment is 16 July 2012. Due to the expected large volume of public comment, it would be of considerable assistance to the EL-001 committee if public comment was made at least two weeks before the closing date of public comments. All public comment received will be considered at an EL-001 meeting to be held on 18 and 19 July 2012. It is expected that, subject to

NZEl Inc. – General Cable Millennium Award

minor alterations only, that amendment 2 will proceed to publication, subject to NZ approval by the Minister of Energy and the Councils of Standards Australia and Standards New Zealand. Publication is expected to occur August or early September 2012.

Mr David Barnes, national branch member and the awards co-ordinator for the NZEI Inc, presented James Dodd (2012 General Cable Millennium award winner) with his registration certificate, NZQA certificate, and certificate of apprenticeship on Friday 13 April when he completed his apprenticeship. James was the Overall Apprentice of the Year from ETCO. During his apprenticeship, James completed all of his assignments and assessments on time, every time and scored marks in the 90’s for most of his work achieving competence first time around. James commenced his apprenticeship on 13 October 2008 and worked with five host companies during his three-and-a-half year apprenticeship. Each company he went to allowed him to acquire a new experience to provide a very well balanced range of practical skills. He worked with A.J. Beck, Mainline, Gael Switchboards, NZ Defence force and finally Advanced Building Services. On five separate occasions James served time with NZ Defence force acquiring specialist skills with various forms of engineering practices, disciplines, as well as serving our country in a period in April-May 2011 in Vanuatu. James’ modern apprenticeship coordinator, Victor Ostapowicz, is very proud of the achievements that he has made and can say that right from day one he has never been afraid of hard work. His positive “can do attitude” has meant he has had many opportunities to do well and this has all meant that the rewards have been worthwhile for everyone concerned. James has been offered full-time work with Advanced Building Services, which is the last host company that he has been working with whilst employed by ETCO. D Barnes, National Branch member and the Awards Co-ordinator New Zealand Electrical Institute Inc.

Coming into force of the amendments and revised standards It should be noted that an amendment or revised standard cannot come into force until Schedule 2 of the Electricity (Safety) Regulations 2010 has been updated to cover the issue date of the revised or amended standard. Amendment 2 of the Electricity (Safety) Regulations 2010 is currently being prepared and is expected to cover the amendment of AS/NZS 3001 and the revised AS/NZS 5033. However, the expected publication date of amendment 2 of AS/NZS 3000 means that this amendment may not be able to cover the proposed amendment 2 publishing date. The main points from a New Zealand point of view, is the amendment A of AS/NZS 3000 is currently covered and is in force. Amendment A covers new requirements for recessed luminaries, additional requirements for the use in RCDs in school classrooms and the need to cater for thermal insulation in ceiling, floor and walls of buildings, that may require the down-rating of the current rating of cables run in or near thermal insulation.

Other work in progress by EL-001 committee The revision of AS/NZS 3010, Generating sets, is about to commence. The current standard was last revised in 2004/2005, and requires considerable revision to cater for generating sets due the requirements of computer systems which require a continuous supply for operational reasons. It is expected that drafting of the revision will take until late 2012 before a public draft will be available. If any member has suggestions or would like to add input into the monthly newsletter, please contact me. We value people’s input and suggestions. Alan Cuthbert NZEI Standard committee member Wellington Branch Secretary

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Upgraded high-power converter

Semikron upgrades Semistack_RE, an IPM for renewable energy (RE). The new high-power converter for use in renewable energy applications such as wind and solar power installations will typically be used in synchronous and double-fed induction generators (DFIG) in wind turbines, as well as in central solar PV inverters. Semistack_RE is a water-cooled 3-phase converter that comes in B6CI 2-quadrant or 2 x B6CI 4-quadrant configurations in a bookcase-type mechanical design. Up to four converters can be connected in parallel and support applications of up to 6MVA. The Semistack_RE range is based on SKiiP 4, the latest generation of Semikron’s SKiiP intelligent power module family which integrates power components, driver and heat sink in a single case. The previous version, based on the 3-bay version of SKiiP 3, has a current capability of 1200A per module. The bigger 4-bay SKiiP 4 version has a current rating of between 1000A and 1400A. Thus, the maximum power carrying capacity of the Semistack_RE converter increases by 17 percent to 1,7MVA. Thanks to the very low inductance planar DC busbar of the converter and the internal bus bar construction of the SKiiP 4 the nominal DC voltage can be extended up to 1250Vdc even in short circuit conditions. The integrated new digital gate driver of SKiiP 4 provides a safe electrical isolation between primary and secondary side for all switching or control signals and even for the temperature signal. This allows omitting expensive circuits for electrical isolation for the user. The SKiiP driver features a CANopen setup and diagnosis channel – a first in a power module – which enables access to an error memory, meaning errors in the SKiiP 4 can be quickly identified and saved for later diagnosis. Go to www. demm.co.nz/enquiry quote: D120742

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July 2012

Measuring energy waste in electrical systems Fluke Corporation introduces the Fluke 430 Series II three-phase power quality analysers. According to the company, these units are the first tools to use a patented algorithm to measure energy waste and quantify its cost. The analysers help facilities reduce electrical power consumption and improve the performance and lifespan of electro-mechanical equipment by providing the return on investment (ROI) justification to mitigate power quality distortion. Previously, only experts could calculate how much energy was being wasted due to power quality issues. Utilities could calculate the cost but the required measurement process was beyond the reach of average electricians. With the new, patented Unified Power function of the 430 Series II, electricians, utility technicians, electrical engineers, field service technicians and energy consultants can automatically determine how much power is being wasted and calculate exactly what the extra consumption costs with a single handheld tool. In particular, the 430 Series II power quality analysers lets facilities assess the impact of new energy-efficient, electronically-driven systems from lighting to motor controls to HVAC. While these new models consume less energy as individual installations, they increase the level of power quality disturbance in the overall electrical system, increasing waste energy due to harmonics and reducing the total potential energy savings. The Fluke 430 Series II calculates the monetary cost of that waste

energy. Because of their simultaneous display-and-record capabilities, the threephase power quality analysers are very popular on the market, says the manufacturer. The updated 430 Series II models feature three new measurement functions as well as hardware, software and firmware improvements. New models have up to 32GB (8GB standard) memory, a swappable SD memory card and USB connectivity for longer power, energy logging and faster data download. Screen quality and battery life are both improved and the accompanying software has been redesigned to give users more options to analyse both power quality and power consumption. Both models are fully compliant with the stringent international IEC 61000-4-30 Class-A standard. Each one can monitor systems with up to ten power quality parameters on one screen and can record up to 150 parameters on four phases simultaneously, in accordance with the EN50160 standard, and are safety rated 600 V CAT IV/1000 V CAT III. Go to www.demm.co.nz/enquiry quote: D120742a

•

Termination panel offers space and cost savings The new Modular Industrial Patch Panel MIPP from Belden is a termination panel that offers significant space and cost savings. According to the company, it is the industry’s first panel able to manage both copper and fiber cables connected to active equipment such as switches. The MIPP is suitable for use in a wide range of industrial applications requiring maximum system reliability and flexibility, such as machine building, transportation, alternative power generation, power transportation and distribution, and oil and gas. Thanks to its modular design, installation is quick and easy, saving time and significantly reducing initial set-up costs, whilst at the same time contributing to greater reliability and easier and more efficient system management, requiring less maintenance. Due to their unique modular design and their compact dimensions, up to six individual MIPP modules can be combined in any permutation to create a large single patch panel. When required, each module can be easily removed or replaced for maximum flexibility. The MIPP provides the ideal connection between Belden cables and Hirschmann switches and is designed to have the same look and feel as the Hirschmann range of industrial switches. Go to www.demm.co.nz/enquiry quote: D120742b

•

Monitoring for enclosures

Rittal’s monitoring solution CMC, now available in version III, is also suitable for use in control cabinets and enclosures. The most important innovation is an integrated OPC (open packaging convention) server, which is compatible with around 99 percent of the most widely used control console systems. Also new is the change to serially connected sensors with CAN buses. The CMC III enclosure has also been completely redesigned: it now takes up far less expensive space in the server rack. The CMC III PU Compact differs from the full version in its smaller number of sensors or CAN-bus connection units, and it is not equipped with a SD card slot or a USB port for flash memory sticks. Rittal has completely redesigned its intelligent computer multi control (CMC) monitoring system, presenting the third generation of the system. While the predecessors used the common IT network protocol SNMP, an OPC server, standard in control console technology, is now integrated in the CMC III. The monitoring solution not only checks important data on temperature, humidity and voltage in the enclosure, it also provides effective opportunities for saving energy. High consumers of energy can be detected and replaced by efficient systems. Besides this, extensive and results-oriented analyses can be carried out so that the life cycles of the components used can be extended. In the case of out-of-spec measurement data, the CMC performs automatic countermeasures, informing immediately by email. The two most important functions – the temperature sensor for monitoring enclosure climate control and an infrared sensor, which ‘determines’ whether the enclosure door is open or closed – are already integrated in the central processing unit as defaults. Likewise, there are two digital inputs and one relay output present for small individual monitoring tasks. Furthermore, the CMC III can automatically control the enclosure light and climate control: If the door is opened, the light or the enclosure cooling system will be switched off. Other functions include a So bus for measuring energy use, while the monitoring of humidity, air flow, pressure difference, or voltage can also be

integrated, depending on the requirements. A 24 V DC power supply via terminals, or ‘power over Ethernet’ (PoE) are possible, or the system can be supplied with energy redundantly. One further innovation is the change to CAN (Controller Area Network) buses: These are integrated in the central processing unit and in Rittal’s intelligent sensors. Thus, unlike traditional I/O units, the CAN bus sensors are not connected individually to the central processing unit, but rather to each other in series. The processing unit of the third CMC generation can be mounted in the enclosure frame. Therefore it is ideally oriented to the enclosure door and does not require any space on the mounting plate. The optional control units, with up to 128 digital inputs and 64 relay outputs, can be fitted to the mounting plate by top-hat rail mounts. With the CMC III, network integration, as well as configuration and commissioning are performed comfortably with a laptop and a USB port. The user can choose between TCP/IPv4 and TCP/IPv6 as network protocols. Go to www.demm.co.nz/ enquiry quote: D120743

•

Inverter series for distributed applications Distributed automation applications place wide-ranging demands on drive systems. Optimal solutions will, by necessity, be those that fulfil the functional and cost needs for a specific application. Available in a wide range of performance grades and with many upgrade options, SK 200E series frequency inverters from Nord Drivesystems allow users to select customised solutions with features and costs that are tailored to their specific requirements. The modular inverter series is available in size 1 to 4 with a performance between 0.25 and 22kW, cost-efficiently covering distributed applications ranging from simple control tasks to complex positioning. Expansion options include external braking resistors and a separate 24V power supply for stand-alone control voltage operation. Furthermore, Nord provides I/O modules that allow for the detection and transfer of sensor and actuator signals as well as communication interfaces (with and without I/Os) for CANopen, DeviceNet, Profibus, Profinet and EtherCAT. Interfaces for the Industrial Ethernet standards Powerlink and EtherNet/IP are under preparation. Go to www. demm.co.nz/enquiry quote: D120743a

•

PowerFlex drives feature high voltage and output power Rockwell Automation has extended the power range of its PowerFlex 755 AC drives to 900kW and added 600/690 volt ratings. The new drives, designed for use in heavy industrial processes, provide users with increased flexibility, advanced diagnostics and a common DC bus option. The PowerFlex 755 is designed for applications ranging from simple variable speed and variable torque control to the most demanding systems requiring constant torque control. Applications include fans, pumps, mixers, compressors, conveyors and extruders. Like other PowerFlex 755 drives, this latest frame size includes an embedded Ethernet port and five option slots so that users can tailor it to their requirements. Optional modules include I/O feedback, safety, additional communications and an auxiliary power supply. A roll-out design allows easy access to the drive for fast installation and maintenance. The drive’s converter and control pod can remain in the unit while the inverter is rolled out ensuring that control wiring remains connected. In addition to the extended power range, a firmware upgrade for PowerFlex 755 drives will contain interior magnet motor control, which delivers increased application flexibility and high-energy efficiency. Also, a stop Ddwell feature helps prevent a motor from coasting to a stop; it allows users to preconfigure the motor to perform a controlled stop to help protect valuable motor investments. Go to www.demm.co.nz/enquiry quote: D120743b

•

• EVENTS

Coming events NZEI Inc. Auckland Branch, July Branch Meeting

26 July 2012, 7:30pm Delightful Lady Lounge, Alexander Park Raceway, Epsom, Auckland The NZEI Inc. Auckland Branch Committee have organised Mr John Sickels, the Registrar/Group Manager of the Electrical Workers Registration Board (EWRB) and Electrical Workers Licensing Board (EWLB), to come to Auckland to speak at the branch meeting regarding impending changes to the practicing license fees and other matters of importance to the electrical industry. All persons in the electrical industry are most welcome.

Zero Harm in the Workplace

30 July 2012 Sudima Hotel, Christchurch Airport Following on from the events held in Auckland and Wellington, the Zero Harm in the Workplace conference will be run in Christchurch for the first time in July. This event is a comprehensive one-day conference which tackles topics such as keeping safe in high-risk instances and understanding individual risk competence. www.conferenz.co.nz/zeroharm

2nd Water Infrastructure Investment & Planning Conference

30-31 July 2012 Amora Hotel, Wellington Water infrastructure is going through a period of change and development, and now is the time to discuss key issues in order to create the best solutions. This conference is a neutral environment where you can connect with peers and collaborate in order to achieve greater water security for all stakeholders. With a focus on investment and planning, know where the opportunities are for development and how to achieve success for projects in both rural and urban contexts. www.conferenz.co.nz/water

New Zealand Oil & Gas Exhibition 2012

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

Foodtech Packtech

25-27 September 2012 ASB Showgrounds in Auckland This biennial event gives you the opportunity to come face-to-face with the

experts behind the key innovations entering the New Zealand market. Foodtech Packtech will showcase the freshest ideas, latest technologies and the newest developments entering the food technology and packaging technology market. www.foodtechpacktech.co.nz/

Safety 2012 World Conference

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

54th ECANZ National Conference

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

2012 IEEE International Conference on Power System Technology (POWERCON 2012)

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

National Maintenance Engineering Conference 2012

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

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

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July 2012

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