Demm Engineering & Manufacturing June 2012 by Adrenalin Publishing Ltd

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

Robotic layer picker lifts safety, quality and productivity • Plastics industry update • Thermography in maintenance • Condition monitoring • SCADA manages processes efficiently Now including

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• CONTENTS

Editor's

note

Root causes My wife sees her dentist twice a year to have her teeth professionally cleaned. I dread the dentist pulling off his “I’m

so sorry but I have to drill” routine and try only to go when toothache makes me go. The missus usually ‘convinces’ me to accompany her at least once a year, but that’s another story entirely. Translated in the world of maintenance, I

preventive maintenance programme. Unfortunately there is no condition-based maintenance system for teeth yet, which

Plastics Industry

Materials Handling

Thermal Imaging

could tell you for example when the dental enamel in a certain area is worn out and needs attention. Predictive maintenance might give you warning of an impending failure, but it does not automatically lead you to the primary cause of an issue. After the dentist has wielded the drill, has your long-term dental health improved? After your thermal imager or vibration sensor has lead you to a faulty bearing, and you have replaced it, will your

symptoms. I have to make sure I don’t eat too many sweets, clean my teeth twice a day and use an interdental brush and floss. And only if condition monitoring is embedded in a reliability-centred maintenance strategy, which ensures the

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.

Maintenance Matters

This feature includes an introduction to Hazard and Operability studies and an elegant solution to difficult access problems.

Find out why Dominion Salt and Golden Bay Cement have won the EECA Awards 2012 and where the largest solar power plant of New Zealand is located.

serviced and lubricated, is it possible to increase its overall most (apart from healthy teeth). Learn more in this issue.

The latest developments in the world of thermal imaging. Includes new products, case studies and an interview with Wayne Ruddock, who is convinced that thermography is not WYSIWYG.

30 Electrical Technology

equipment is precisely balanced and aligned and properly reliability and availability. And that’s probably what you want

A smart robotic layer picker lifts not only pallets, but also safety, quality and productivity at Nestlé Australia’s national distribution centre.

“We are too busy collecting data,” says Clyde Volpe from the Vibration Institute of Australia and demands a maintenance approach that focuses on reliability.

“not necessarily” in both cases. For the sake of your teeth/ problem in the first place and fix the root cause, not only its

Discover how Coca-Cola Amatil manages to make and fill 16,000 bottles per hour at their new Christchurch plant.

22 Condition Monitoring

machine operate more reliable in the future? The answer is machine you should find out what might have generated the

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

gravitate towards reactive or run-to-failure maintenance, whereas my wife sticks to a more advanced and time-based

Product Watch

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

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

AdrenAlin publiSHinG ltd. 14c Vega Place, Mairangi Bay. P.O. Box 65 092 Mairangi Bay, Auckland, 0754. pHone: 64-9-478 4771 fAcSiMile: 64-9-478 4779 printinG: GEON ISSN 1172-4536 (Print) ISSN 2253-279X (Online) circulAtion: 10,287

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• PRODUCT WATCH

Designed for extreme cold environments The new 472LT and 722LT hoses from Parker Hannifin Corporation are engineered to work in temperatures as low as -70°F (-57°C) while maintaining high performance, thereby helping to reduce downtime and increase productivity for machines that operate in extreme cold environments. Specifically designed, tested and field-proven for highimpulse, heavy-duty applications, Parker’s 472LT and 722LT hoses are ideal for mining, drilling and construction equipment found commonly throughout northern Canada and the Arctic Circle. They are also suited for snow groomers, side booms, snowmaking machinery and cold storage applications in general. Immediately available in -4 to -16 sizes, the no-skive, two-wire braided 472LT hose is rated for high-pressure applications

that operate at up to 5,800 psi (40 MPa), and uses Parker’s standard 43 Series fittings. These fittings are offered in the widest range of end configurations available. Rated up to 4,000 psi (28 MPa), the no-skive, four-wire spiral 722LT is available in a wide range of sizes (-6 to -24), and incorporates a patent-pending spiral reinforcement construction that provides longer life in heavy-duty applications compared to standard braided hose. It also uses Parker’s 43 Series fittings, as well as the 71 Series (for size -24). Both hoses feature a half-bend radius, and are rated for applications with an operating temperature range of -70°F to 212°F (-57°C to 100°C). Go to www.demm.co.nz/enquiry quote: D120602

Edit o choi r's ce

Parker 472LT

Parker 722LT

•

Face milling cutter for smaller machines

Pressure sensors now also with IO-Link

Seco has introduced the Double Octomill 05, bringing the product family’s strong cost and performance benefits to smaller machines. This highly efficient and economical face milling cutter is available in diameters from 25mm to 125mm and provides optimal performance in applications requiring a maximum of 3mm depth of cut. The insert pockets of Double Octomill 05 incorporate a strong centre lock screw and grooves for axial and radial location pins, simplifying the mounting of inserts and ensuring maximum stability during operation. The pockets also feature an 8-degree negative angle to allow the use of double sided inserts, while the inserts themselves use a positive rake angle to minimise power consumption. Seco offers four insert geometries for Double Octomill 05, allowing the tool to be successfully applied across a wide range of materials. For applications requiring high surface finishes, a wiper insert with a 3.2 mm wiper flat can be incorporated to provide roughing and finishing in a single operation. All Double Octomill cutters make use of inserts that provide sixteen numbered cutting edges to minimise cost per edge and per part. The tools also feature pre-hardened cutter bodies to maximise tool life and performance. Go to www.demm.co.nz/ enquiry quote: D120602a

Process data or switch points – the user has the choice. The new robust pressure sensor from ifm electronic now communicates all data flexibly via switching outputs or IO-Link 1.1. Process data and diagnostic information are transmitted without problem using a standard cable. Even parameter setting of this PN7-type pressure sensor poses no problem using the IO-Link communication technology. An IO-Link master saves the parameters of the connected sensor and transmits them when the sensor is replaced by a device of the same type. This eliminates the need for a new parameter setting, which saves time and money. If the IO-Link function is not used, then the pressure sensor operates – as before – with two switching outputs (SIO mode) or a switching output and a diagnostic output. Furthermore, the sensor features a very high switch point accuracy and switching frequency and is extremely robust. According to the manufacturer the overloadprotected ceramic measuring cell even withstands more than 100 million switching cycles. Different versions with pressure ranges between -1 and 600 bar are supplied at a good price/ performance ratio. Go to www. demm.co.nz/enquiry quote: D120602b

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June 2012

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• PRODUCT WATCH

New tool holder for turning and milling applications Dimac introduces to the market the new WTO QuickFlex quick change system for turning and milling applications. QuickFlex combines an ER collet chuck and a quick change system in one tool holder. The systems come as a straight drill/milling unit and a right angle drill/milling unit, which makes them ideal for lathes with milling capability. “As a tool holder with ER collet chuck and quick change capability this system combines unique benefits,” explains Dimac Director Paul Fowler. “The unique advantage of QuickFlex starts with a minimal investment. The customer can clamp the cutting tools directly in the tool holder using a standard ER collet. That means you can start with a basic system at a small investment and later you buy quick change adapters when you would like to add the quick change function.” Another advantage is that the cutting tools can be pre-set while the machine is operating. Moreover, the time for tool changes is significantly reduced with the new and one-hand wrench (patent pending). Integral part of the QuickFlex system are two independent taper connections. The short taper, which is positioned just behind the thread for the QuickFlex adapter, provides radial centering and axial support of the adapter. Moreover, it protects the tool holder from chips and dirt. The radial bearing support for the adapter further back ensures high stiffness under load. As a result, permanent accuracy of the run-out is assured. The new one-hand wrench makes tool changes easy and quick. The wrench can be used to change ER collet nuts as well as the QuickFlex adapters and eliminates the cumbersome and ineffective clamping and releasing of nuts used in other tool change systems. Go to www.demm.co.nz/ enquiry quote: D120603

1 Tool holder, 2 QuickFlex chuck, 3 collet, 4 collet nut, 5 QuickFlex adapter, 6 one-hand wrench (patent pending)

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• PRODUCT WATCH

Accurate measurements of oxygen levels Michell Instruments has released details of the XTP601, the latest addition to its range of oxygen analysers. Based on the highly stable thermo-paramagnetic sensor, the XTP601 provides fast, accurate measurements of oxygen levels in various background gases. Capable of measuring Oxygen from 0-1% up to 0-25% and suppressed zero ranges, such as 90-100%, the analyser provides solutions for applications ranging from biogas plants to monitoring blanketing gases in oil tankers. The XTP601 is configurable to suit specific applications and budgets with three options: • Blind transmitter version (settings, controls and readings accessible via application software). • Transmitter with status LEDs (settings, controls and readings accessible via application software). • Full display analyser (settings and readings are accessible with on-screen controls or via application software). All of these options may be rated for either safe or hazardous area use. Hazardous area classifications are available for ATEX, IEC Ex with CCSAUS pending approval. The full display

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

version of the XTP601 has a touch screen interface to enable easy operation without needing to remove the lid. This means that users can calibrate, change settings and interrogate the instrument in the hazardous area without the need for a ‘hot permit’. Menus allow easy access to information on oxygen concentration; analyser status; a graph showing oxygen trends over a user-defined time period; alarm history; minimum and maximum concentrations and other parameters to aid diagnosis of plant conditions. Free software is available for the XTP601 to enable users to monitor, operate and calibrate any version of the instrument remotely via a PC or control system. Go to www.demm.co.nz/enquiry quote: D120604

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Serious sound The Sync Stereo Earmuff from Stanley features acoustical ear cup design, volume management technology and high-fidelity stereo sound, delivering the proper levels of hearing protection in hazardous noise environments. The earmuffs optimise new designs and technologies that provide both hearing protection and true listening enjoyment, without compromising on hearing protection or sound quality. The Sync can be used with a user's own MP3 player, mobile phone and other personal audio devices, making it ideal for use at work or at home. The technologically advanced acoustical bass chamber enhances bass sounds that are typically sacrificed in industrial stereo earmuffs, and there are no volume knobs or power switches to coordinate or batteries to replace. Featuring a SLC80 rating of 31dB Class 5, the Stanley Sync provides ideal consistent hearing protection and ensures appropriate attenuation in most industrial environments. The volume management technology manages sound levels reaching the user’s ear to a safe level, well within Standards Australia’s recommended 85dBA action level. With ear cup designs inspired by professional DJ models, the Sync’s sound quality is on par with other professional and high-end personal headphones, while the innovative air flow control technology provides higher attenuation across all noise frequencies. Go to www.demm.co.nz/enquiry quote: D120604a

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Coming up in the July issue SFood Processing Industry SPackaging and Labeling SMachinery Safety

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

Tel 09 263 7725 FAX 09 262 0970 10 Oak Rd, Manukau City 2241 Email sales@stratalign.co.nz 4

June 2012

SFastenings and Adhesives SCabling and Wiring Deadline editorial 8th June Deadline advertising 15th June

• PRODUCT WATCH

Low-cost combo pressure/temperature sensors

Bestech Australia presents the new pressure/temperature transducers AST20PT and AST 46PT for applications in hydrogen, oxygen, heavy oil processing, hydraulics, analysers, offshore, pipelines and ammonia systems. Both models

provide pressure and temperature dual outputs from a single process point which reduces process penetration points and leaks that are important considerations in critical systems. The pressure and temperature sensors generate two readings with power consumption of one sensor. Configured AST20PT stainless steel media isolated pressure/temperature sensor and AST46PT, explosion-proof pressure/temperature transmitter, are also suitable for low-power systems. Without compromising on the performance and incorporating a microprocessor-controlled design, both these transmitters offer high accuracy pressure and temperature measurements of ±0.1% and 1.0% linearity

respectively in various temperature ranges from -40°C to 125°C, while the AST46PT is offered in pressure ranges up to up to 20,000 PSI (1,400 bar), and the AST20PT is available in pressure ranges up to 45,000 PSI (3,100 bar). Both transducers can be constructed in a wide range of wetted materials with their one-piece body construction, including high-quality stainless steels and super alloys: 17-4PH SS, 316L SS, Inconel 718, Waspalloy, and Hastelloy C-276. The AST46PT is also CSAapproved for use in hazardous areas including Class 1 Div 1 Explosion proof Groups A, B, C and D, and for mining applications, Class 2 Div 1 Groups E, F and G. Go to www.demm.co.nz/enquiry quote: D120605

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Expanded tap range Dormer has further expanded its highperformance, multi-application threading programme with the introduction of numerous Titanium Nitride coated taps. Complementing Dormer’s existing bright finish and steam tempered multi-material ranges, the new taps provide significantly improved wear resistance and increased productivity. Available to DIN or ISO standard in both spiral point and spiral flute geometries, the versatile new taps will

be of interest to anyone performing threading operations in steel, alloy steel, stainless, copper or aluminium. The new surface treatment provides high hardness combined with low friction properties. This ensures considerably longer tool life and better cutting performance over uncoated taps. All spiral flute geometry taps feature a three-radii flute profile with a constant rake angle that facilitates the creation of narrow,

regular chips. This, combined with adequate flute space, results in negligible chip congestion. Ricky Payling, sales manager at Dormer Tools, said, “The optimum combination of coating, material and geometry used on these new taps results in low wear and, as a result, reduced cost per threaded hole.” Go to www.demm.co.nz/ enquiry quote: D120605a

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

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AADEMM20110607

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•

FISCHBEIN Bag Stitching Equipment

SAXON Heat Sealers

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

sales@aurora-nz.com

• PRODUCT WATCH

Ribbon blenders highly regarded

The Fresco blender’s double ribbon configuration moves products through, constantly circulating them from end to end, making it particularly good for blending minor additives in a mix. The agitator consists of an outer ribbon that moves the product from the ends to the centre while the inner ribbon moves the product from the centre to the ends. The agitator design lends itself to mixing low-density free-flowing products with a high degree of efficiency and accuracy. Various standard sizes are available to suit the batch size and bulk density of the material being mixed. Shafmounted and chain drive geared motors are available as required. The range of ribbon configurations include paddle, single, double or triple ribbons with either end or central discharge. When filling the blender, the operator can tip 25kg bags of various powders through the minors loading hatch or they can load via various lid configurations from bulk bags, mechanical conveyors

June 2012

Effective, intelligent and safe vacuum lifting

or pneumatic conveyors. Loss in weight or gain in weight from bulk bags or pneumatic hoppers is also common methodology for major ingredients. The lid is fitted with safety switches and is hinged supported by gas stays, providing the operator with full and easy access for cleaning between batches. Fresco blender can be fitted with a flush fit valve on the discharge feeding directly into a dust tight bulk bag fill head or a conveyor to processes downstream. Rotary sifters and magnets can also be incorporated into the system. Fresco’s standard range of ribbon blender sizes range from 150 litres up to 4,000 litres and can be constructed in mild steel, 304 or 316 stainless steel with finishes ranging from industrial to pharmaceutical. With standard features such as integral mounting feet, air purge lip seals, double ribbon and easy access, the Fresco ribbon blender can also be tailored to meet a specific requirement. Go to www.demm.co.nz/enquiry quote: D120606

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Stratalign Limited are New Zealand sales and service agents for two brands of European Vacuum lifters. Vaculex Vacuum Systems from Sweden and Fezer Vacuum Lifters from Germany are both among the world leaders in their fields. Vacuum is increasingly being recognised as the ideal method of lifting almost any item in a safe, gentle and effective manner. Steel sheets, timber panels, glass, bags/sacks, cartons, drums, and every other conceivable item, airtight or porous, can be moved around the production area single handedly with ease. The wide range of vacuum and mechanical gripping tools offers application-oriented systems and individual handling solutions for different goods. Because no up/down buttons are required for the balance function, the user has prefect control of the handling process without any physical effort. This increases productivity and also helps to maintain employee’s health. As a solution to a long standing challenge, Cabtec Ltd purchased a Fezer vacuum lifter from Stratalign, for processing sheets of board through a CNC machine. Prior to the purchase, the process had required manual handling, which in today’s environment, is not a sustainable option. More than one option for this solution was investigated by Cabtec with the decision being a vacuum lifter as the winning choice. Cabtec’s Peter Burgess recalls, “Vacuum lifter options were then investigated and an approach was made to Stratalign. Cabtec selected Stratalign as the winning supplier, based on their ability to provide the technical and professional advice, along with what Cabtec considered, a ‘top quality product for a competitive price’. This great investment has served Cabtec well and we would recommend these very good quality lifters to any prospective buyer. The ‘ease of operation’ is facilitated by the very smooth running bearings and movement points, integral to this structurally sound piece of kit.” Peter continues, “From the day the order was placed, the Stratalign team kept us updated with progress, to the day the machine was installed. The installation process was organised in such a way, by Stratalign, that it caused absolute minimal disruption to a very busy working environment during normal working hours.” Fezer’s range of units is broad. The VacuPowerlift tube lifters come with 5–150kg capacity and are suitable for steel, plastic, glass, sacks, cartoons, and finished product. VacuBoy lifters were designed for the horizontal transport, swiveling, and turning over of loads up to 2000kg, e.g. steel sheets/plates, aluminium sheets, glass. The VacuGiant is capable of horizontal transport up to 40 tonnes and swiveling up to 15 tonnes. The VacuCoil lifter handles paper and steel coils. The lifter series VacuPoro and VacuWood are suitable for porous workpieces and planks and gluelam beams respectively. Vaculex’s tube lifters are designed for lifts between five and 200kg. Since the suction foot is always dimensioned in accordance with the vacuum lift tube, the user does not risk dropping lifted items that are too heavy. If the weight is too much, the tube lift will simply not lift the article. This reduces the risk of personal injury Go to www.demm.co.nz/enquiry quote: and damaged goods. D120606a

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• PRODUCT WATCH

Cost-optimised electric toothed belt drive axis employs innovative design

Festo has entered the lowcost electric actuator market with the launch of a unique toothed belt drive axis which marries costoptimised design rules with precision engineering. The new ELGR toothed belt axis sets a new price-performance standard for the motion control industry. Designed primarily for applications

involving relatively short stroke lengths and low moments on the guide, such as pick and place tasks and transporting small masses, the new axis is also suitable for positioning, centring and pushing functions on conveyor belts, and for activating safety doors on processing machines. Unlike conventional toothed belt axes, which feature a full length profile, the ELGR axis is only supported at either end, and relies on the rigidity of the steel bearing guides to ensure straight line movement of the carriage. Both the support ends and the carriage are constructed from the same

BUILD IT Exactingly right – Every time –

extruded aluminum profile – an innovative asymmetric extrusion geometry facilitates the necessary offset – which further helps to minimise cost. Provided that system designers keep applied torsion and bending forces within prescribed limits, all Festo ELGR axes are capable of repeatable positioning accuracies of ±0.1mm and a very high in-service life – in excess of 5000 km of travel. ELGR axes are available with a choice of 35, 45 and 55mm wide profiles, and the moving carriage can be equipped with sliding bushings or with ball bearings for higher speeds and loads. Different models within the range offer stroke

lengths from 50mm to 1.5m and speeds up to 3m/s. The largest model can generate a feed force of up to 350N and accommodate payloads as high as 30kg. ELGR toothed belt axes are available as standalone products or as part of complete motion control solutions – they are fully compatible with Festo‘s range of stepper and servo motors, as well as the company‘s modular multi-axis system. The axes can also be used with any third-party motors; Festo can provide flange designs for these motors and even manufacture them if required. Go to www.demm.co.nz/ enquiry quote: D120607

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

Quality European Manufacturing • Motors • Gear Components • Control Technology

Final test.

High voltage motor test.

Painted to customer application requirement.

Individual components selected to specification for the gear unit.

Finished products ready for delivery.

Fast, customised assembly at purpose designed workstations.

New Zealand Assembled

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

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

24/7 Service backup

E&M212

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

INDUSTRIAL DRIVE TECHNOLOGY

• PRODUCT WATCH

New location improves efficiencies

CMG/Fasco Electric Motors NZ Ltd (NSF Accredited ISO9001) has just moved to a new building, located at 18 Jomac Place in Avondale, Auckland. “Having four operations in the Auckland area was a considerable cost and with the relocation we aimed at bringing these costs down. The benefits to our clients are important ones: faster delivery times and better stocks,” says Craig Keesing, Managing Director of CMG/ Fasco Electric Motors NZ Ltd. CMG/Fasco specialise in an extensive range

CMGNZ_DEMM_1112_01_OUTLINED.indd 1

June 2012

of electric motors, geared motors, variable frequency drives, soft starters and many other associated products. The company services industries as diverse as mining, petrochemical, automation, materials handling, fluid handling, air movement, agriculture and original equipment manufacturing. “Our operation is the largest in the Auckland area – if not in New Zealand – in its field, and after having moved to the new building we are better equipped to look after all types of business, ranging from supply to repair,” says Craig. “We do not only offer all standard products, but we also have the facilities to customise these standard products to meet our clients’ special requirements, from special paint finishes, to high specification motors for hazardous locations (Exn,Exe,Extd,Exd). Our range of high voltage motors adds to the extensive range available from 3.3, 6.6 and 11,000V up to 20,000kW and larger, in CACA and TEFC.” CMG also wanted to move their two rewind shops from Avondale and Otahuhu. “These shops have

benefitted from upgrading with better lifting and workshop equipment – we now have a Verissimo 10-tonne gantry system – and a better working environment.” The company is fully equipped to rewind all types of AC and DC units, as well as winding transformers, generators, welders and similar equipment using the highest quality insulation systems supplied by OBA NZ. The service division is also IANZ accredited to overhaul and repair ex-rated electrical equipment used in explosive atmospheres. Go to www.demm.co.nz/enquiry quote: D120608

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13/12/2011 11:06:01 AM

• PRODUCT WATCH

Synchronous jacking system lifts 6800 tonne walking dragline

When RCR Eagle of Gladstone Qld recently carried out maintenance to the base of a 6800 tonne Marion 8750 walking dragline, they chose Larzep as partners to supply a PLC controlled synchronous lifting system. This dragline,

which is believed to be the biggest in the Bowen Basin, was due for maintenance work. The challenge was to lift the dragline off its base in order to carry out the maintenance work and lower it again on completion of the work. The requirement was for

a modular system which allows up to three power packs to be connected to the PLC controlled by a single laptop computer. Larzep supplied 7 x 500T, 28 x 100T lifting cylinders and an electric powered pump with valving controlled electronically with a PLC with new software, enabling an operator to control the lift using simple mouse clicks on a laptop computer. The laptop enables all of the cylinders to lift and lower simultaneously within an accuracy of 1mm, regardless of the load on each cylinder. It also has progressive lift control which provides the ability to tilt the load. Linear and pressure transducers on each cylinder enable the operator to see clearly on the laptop screen, the displacement of

Hydraulic & Torque Tools

Ph: 09 636 2264

279 Mt. Smart Rd, Onehunga, Alk Akl

each jacking cylinder, as well as the hydraulic pressure in each cylinder in real time. Total mass and centre of gravity can also be shown. The operator is able to select a cylinder or group of cylinders and “dial-in” a distance for the cylinders to lift or lower. Larzep engineers were on site to supervise the commissioning of the new lifting system and provided training on the new equipment. Larzep was able to manufacture and deliver the new system to site within eight weeks of order placement. All hydraulic hoses for the project were of custom lengths and manufactured by Larzep at its Go to www. Hallam facility. demm.co.nz/enquiry quote:

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D120609

  

Sales Service Hire

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

Web: hytoolsnz.co.nz 9

• PLASTICS InduSTry

Cokin’ Say after me, as fast as you can: “Chish-Chish-Chish-Chish-Chish-ChishChish.” That’s the sound of a state-of-the-art bottling machine making and filling 16,000 bottles per hour at Coca-Cola Amatil’s (CCANZ) new Christchurch plant.

The beverage mixing unit with blow fill machine in background.

Installed during the current crop of earthquakes, its NZ$15 million’s worth of smart kit is securely bolted down to a reinforced earthquake-proof floor

Preforms moving from star wheel bottom left transfer to preheat wheel.

in a nine-million-dollar building repair and refit. The ‘blow fill’ moulding and filling machine is smaller than I expected. It would fit into a small house – labeling and packing excluded. Visually it’s a cross between a spacecraft, a CNC machining centre and a laundry. Stainless? Yeah. Computer controlled? Yeah (Siemens PLC). Each ‘Chish’ is

June 2012

a ‘Coke’ bottle blown to shape, filled and inspected. The system can handle all of the company’s carbonated soft drink products (Coke, L&P, Schweppes, Deep Spring, Fanta, Sprite, Diet, Zero and others) with rapid product changeover. The plant makes PET (Polyethylene Terephthalate) bottles that are the thinnest and lightest in the country. CCANZ estimates this will save up to 650 tonnes of PET per year (equivalent to 24 million 600ml Coke bottles) and also reduce energy, transport and packaging costs as well as reducing the carbon footprint of each bottle by about 20 percent. Other savings come from smaller caps and lighter labels. CCANZ has a pair of similar blow-fill lines in Auckland. The ‘blow fill’ method of making a plastic bottle begins with a pre-moulded caricature of one. It’s a small, thick-walled vial called a ‘preform’ with only the threaded neck being fully formed. These are transported through the process by the neck, firstly through an infrared

heating oven then to a heated mould where the softened plastic is expanded by compressed air to the shape of the mould. The mould opens, the new bottle is transferred to another section that cools it before it moves on to the filling station that injects the liquid content and installs the cap. Bottles travel around a number of horizontal wheels like carousels and are transferred between them via smaller ‘star-wheels’. At a blow fill rate of 16,000 per hour this happens at high speed. The wheels and bottles are a blur. The blowing wheel has eight mould positions. The fill and cap section has the largest wheel with over fifty stations with the filling taking about half a turn of it. The Krones Contiform S3 product line is of German manufacture. Machine operation and product are continually monitored – high speed vision systems analyse every bottle for shape, detail, concentricity, cap colour, fill level and other parameters and results logged. Any reject will be automatically ejected from the line. Touch screens and graphical displays at each module display pertinent process values such as pressures, temperatures and other parameters. The blow fill section is fully enclosed for hygiene, efficiency and noise

Bottle cooling

and safety control. Service doors are large with big windows for monitoring. Compressed air and cooling water used in the process is recycled, filtered and reused. The labeling and packaging section is also made by Krone. Once bottles leave the blow fill section they march down a long conveyor to a labeler then to a robotic section that herds them into the appropriate configuration for six-packs and other arrangements that are then robot stacked to pallets and shrink wrapped ready for distribution. From Krones’ website : “For carbonated soft drinks, percapita consumption in 2008 averaged 31 litres, ranging from 11 litres in Africa to 157 litres in North America… For the future, the strongest market development is predicted for Asia and the Middle East, plus North Africa, with growth of around one third.” Article by Geoff Anders Go to www.demm.co.nz/ enquiry quote: D120610

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Filled units march past with labeled product behind.

• PLASTICS InduSTry

Polyimides improve hot glass handling

Tecasint 2032, 3032 and 4131 materials are growing in popularity in the glass industry.

Polyimides can be used to increase productivity levels in the manufacture of glass bottles for the beverages, pharmaceuticals and cosmetics industries. The high temperature resistance and low thermal conductivity of these high-performance plastics offer major benefits for hot glass handling applications. Polyimides from the Tecasint product family are enjoying ever more popular use in the production of handling

equipment such as take-out tongs and deadplates. These materials can be economically produced and help to reduce the rejects quota. Non-melting polyimides from Ensinger offer excellent long-term thermal stability. Even when heated briefly to temperatures of up to 480°C, many Tecasint materials will not melt or even soften. Even in continuous operation, they retain their characteristic strength, dimensional stability and creep resistance. Manufacturers of perfume bottles and pharmaceutical glassware in particular make use of the graphite-modified Tecasint types in the 2000, 3000 and 4000 product ranges. Components produced from these materials are used for the unscrewing and onward transport of glassware at extremely high temperatures. Alongside extreme temperature resistance and low thermal conductivity, good resistance to abrasion and breakage is particularly significant for this type of application. Other

key requirements imposed on materials used in glass handling are mechanical strength and minimal oil absorption. In comparison to graphite, the property profile of Ensinger materials offers a particular range of benefits. The low thermal conductivity of types 2032, 3032 and 4121 prevents the formation of microcracks in the glass which can result from thermal shock during the handling processes. The excellent abrasion wear helps to extend the life of the components, and the toughness typical of this material helps reduce the formation of fractures during handling and production. Tecasint’s low oil absorption prevents the occurrence of print marks on the glass surface. Glass manufacturers also benefit from a reduction in the rejects quota and shorter downtimes, resulting in higher productivity. The material lends itself very well to machining, but without the creation of dust typically expected when cutting graphite. This reduces the level of stress on the cutting machine and the

amount of maintenance work required. For small batch sizes, moulded components produced from stock shapes are ideal. Tecasint 2000 and 3000 can be used to manufacture larger batch sizes, also making use of the more economical direct forming process. Go to www.demm. co.nz/enquiry quote: D120611

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Scrutinising bottles and containers The new NexGen Rotary Leak Inspection System, from ALPS (Air Logic Power Systems) is proving a popular choice with plastic bottle blow moulding, metal container, composite container and dispensing closure manufacturing companies worldwide, with more than 75 units sold since its recent launch. The system utilising encoder based timing and patented speed compensation technology performs functional tests on plastic containers and other products to ensure they seal and can hold pressure. The system eliminates issues particularly

related to current generation light-weight bottles that use recycled materials where there is an increased probability of ‘microleaks’. The NexGen seals and pressurises every container with a test probe – performing a decay timed pressure test – and can test from hundreds of milliseconds to several seconds on the container or closure depending on the level of testing required. It has a detection range from 0.1mm diameter. The NexGen machine is available in configurations from four to 30 heads, designed to meet specific speed and

sensitivity requirements and has a speed of up to 60,000 bph. They are ideal for lines ranging from 50 to 1000 cpm, and are currently being used on FMCG production lines worldwide for food, beverage, household cleaners, automotive products etc. Product changeover takes as little as ten minutes, with quick lock – no tool change parts and they have integrated air blow-off ejectors and standard reject verification. ALPS have installed leak inspection systems with nine of the top ten North American bottle blow moulding companies

and have an installed base of 10,000 plus leak testing circuits globally including their product range from the single head linear machines to the NexGen high speed rotary systems. Go to www.demm.co.nz/enquiry quote:

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• Plastics industry

Extrusion concepts on display

KraussMaffei Berstorff multilayer pipe head KM-RKW 34-400-IPC with internal pipe cooling technology

at the NPE 2012 in Orlando. On display was a KM-RKW 34-250 extruder with an internal pipe cooling (IPC) system. The IPC system is the answer to increasing demands of the fabricators

Krauss Maffei Extrusion, Munich, Germany, recently presented their extrusion concepts for increasing productivity and flexibility and optimisation of energy efficiency

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with regard to productivity increase, reduction in resource consumption and investment costs. “The high demand in North America confirms that we offer our customers a modern and efficient implementation solution for their specific requirements,” emphasises Matthias Sieverding, Extrusion Technology Manager at KraussMaffei Corporation in Florence (USA). The IPC technology shortens the cooling section by up to 40 percent because it uses ambient air, in addition to conventional external cooling, to cool the pipe from the inside. This allows fabricators to dramatically reduce acquisition costs and significantly reduce power consumption. The IPC system can produce thick-walled P/O pipes ranging from 110mm to 2500mm diameter. The KME 125-36 B/R model from the single-screw extruder series with the 36 L/D long processing unit has been successfully tried and tested worldwide for many years. Machines in this series are ideally suited to processing a large number of PO materials. They impress from a technical perspective with a series of advantages. The barrier screw concept thus

guarantees an optimum mixing process and eliminates thermal inhomogeneity. It provides high melt homogeneity at a low temperature, ensuring a top quality end product. The 36D single-screw series stands for cost-effective production combined with high specific melt throughputs. A compounding plant with one ZE 60 A UTX twinscrew extruder fitted with the EasyClean module was also exhibited. This design includes several individual components and improved features, which permit the cleaning time at the extrusion plant during product change to be reduced by up to 40 percent. The complete plant has a modular design – a special plant concept from KraussMaffei Berstorff in which the individual components of the line are combined to practical units with the dimensions of a sea container. Apart from considerably reduced assembly times at the construction site, the modular design also guarantees significantly reduced total construction costs because steel construction is not usually required and the provision of an easily converted room is sufficient. Krauss Maffei is represented in Oceania by HBM Plastics Technologies. Go to www.demm.co.nz/enquiry quote:

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June 2012

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• MATERIALS HANDLINg

Smart robotic layer picker lifts safety, quality and productivity An integrated robotic layer picking solution has transformed workplace safety and significantly improved the quality and productivity of mixed pallet assembly at Nestlé Australia’s national distribution centre (DC) at Arndell Park in Sydney’s western suburbs. The high volume DC stores and distributes several hundred stock keeping units (SKUs) from Nestlé’s consumer food and beverage, food service and pet food businesses.

Overview of the robotic layer picking module at Nestlé Arndell Park DC, with stock for orders flowing into the module on the left and completed orders exiting on the right.

The high demand for Nestlé’s leading household brands means most of the DC’s orders – around 80 percent – are distributed as full pallets. Picking the remaining 20 percent of orders – which are distributed in pallet layer and full case quantities – has involved the manual handling of around five million cases per year, creating a significant and ongoing occupational health and safety (OH&S) challenge. Nestlé’s innovative layer picking solution eliminates the need to manually handle around four million of those cases. The layer picking system achieves very high throughput rates thanks to logistics systems supplier Dematic’s FreePick Maximiser patented

software. By cross-matching orders and pairing those with compatible order profiles, FreePick Maximiser enables around 20 percent – in some instances up to 50 percent – of goods for orders to be distributed without them being physically picked.

A safer, smarter solution to picking and building layers Orders from Nestlé’s SAP warehouse management system are downloaded into Dematic’s PickDirector warehouse control system to initiate picking. Interfacing with FreePick Maximiser, PickDirector orders the stock required for layer picking in the sequence required to fulfil the next wave of orders. This is retrieved from

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• MATERIALS HANDLINg Building stable rainbow and sandwich pallets to order

The four-axis layer picking robot’s vacuum gripper head offers the maximum versatility in product handling, making it suitable for picking up to 80 percent of Nestlé’s SKUs held at the DC.

the adjacent bays of reserve storage by RF-directed forklift and loaded onto the induction conveyor spur. As pallets are fed into the layer picker, they are scanned, and the control system directs the operator to remove the required amount of stretchwrapping from the pallet. The pallet is then conveyed into the layer picker where it will go directly to one of four pick and put locations, or, if it is not immediately required, into one of eight buffer storage locations serviced by an automated pallet cart. While the software requests pallets to arrive at the layer picker in a particular sequence

to suit order assembly, the reality is that pallets occasionally turn up out of sequence. The buffer storage locations enable such pallets to be temporarily stored online within the layer picker until required. As new pallets of stock are fed into the system, the layer picker selects the required layers and transfers the stock to one of four customer order pallets. Any stock remaining on a pallet either forms the basis for another order via the system’s FreePick Maximiser software, or is returned to the adjacent reserve storage bays for use at a later stage.

With the supply chain running leaner, there is a general trend towards ordering smaller quantities of goods such as layers, rather than full pallets, or cases rather than layers. Many customers also require pallets to be built in a certain way to suit further processing. To maximise pallet building flexibility, the layer picking system has four order picking positions, which enables up to four orders to be picked concurrently. An empty pallet station accommodates the production of multiple layer sandwich pallets. The four-axis robotic layer picker is equipped with a dual bellows and vacuum-gripping head capable of handling up to 80 percent of Nestlé’s product range, covering a broad range of packaging types from cartons to bags and bottled beverages. When the robot is directed to pick up a layer, the bellows inflate and close around the product creating a seal. The vacuum exerts just enough pressure to pick up the layer, minimising the potential for product damage during handling. The vacuum gripper head offers the maximum versatility in product handling, making it suitable for picking layers from any pallet stacking

pattern, even those that have a hole in the middle. Completed orders are conveyed through the integrated layer picking system being checkweighed, stretchwrapped and labelled on the way, until they exit ready for collection and transport to despatch by forklift. Orders that require further case picks to be added to the layers exit the system, where a barcode label is attached prior to their retrieval by forklift. After the required case picks have been completed using the DC’s new voice picking system, the pallet is reinducted onto the system, checkweighed, stretchwrapped and labelled for despatch. Superior pallet build quality improves transport utilisation, with less handling damage and fewer returns.

Voice picking a sound solution for case picking The introduction of voicedirected computing has also improved the safety of Nestlé’s remaining manual case picking requirements. Nestlé’s forklift operators now wear a small headset and a lightweight, voice computer attached to their waist. The workers simply listen and respond to clear, verbal commands instructing them where to go and what to pick.

Making the most of picks for free FreePick Maximiser, patented software developed by Dematic, makes it possible for the robotic layer picking system to process stock for orders without ‘physically’ touching it, optimising productivity and system throughput. Using complex algorithms, it quickly analyses, cross-matches and resequences orders to generate the optimum order fulfilment sequence and maximise ‘free pick’ opportunities – where the picks required to fulfil one or more orders in turn leaves behind the stock required for another order, generating a ‘free pick’. The ‘FreePick’ concept can be used manually or by incorporating a robot to do the picking, and can be deployed in mixed case pallet, or mixed layer pallet picking operations. At Nestlé, FreePick Maximiser optimises productivity and throughput by enabling the layer picking system to process 20-30 percent more cases than are actually being physically picked by the robot.

Dematic has also implemented voice-directed computing at the Arndell Park DC to improve the safety and efficiency of Nestlé’s remaining case picking requirements.

June 2012

• MATERIALS HANDLINg

The layer picker has four order picking positions, which enables up to four orders to be picked concurrently, and eight buffer storage positions.

A significant advantage of voicedirected computing for order picking is that it leaves the user’s hands and eyes free at all times, making handling and picking cartons faster and safer.

Project outcomes • Eliminates the need to manually pick and handle 4,000,000+ cases/year. • Significantly reduces forklift operations and the OH&S risks associated with manual layer picking creating a safer workplace. • Integrated IT systems including SAP WMS, Dematic PickDirector WCS, FreePick Maximiser and Vocollect Voice Picking enable fast, accurate and reliable operations. • World first FreePick

Maximiser enables 20 percent – sometimes up to 50 percent – of case pick orders to be shipped without picking. • Superior pallet build quality for improved transport utilisation, less product damage and returns. • Reduces distribution operating costs. • Rapid payback: Estimated 3.5 year ROI. The ingenuity of the project was recognised by the Supply Chain and Logistics Association of Australia (SCLAA) at the recent 2011 Australian Supply Chain & Logistics Awards, with Nestlé winning the SCLAA’s Manufacturing Logistics, Storage and Handling of Materials, and Supply Chain Management Awards. Go to www.demm.co.nz/ enquiry quote: D120613

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FreePick Maximiser identifies that two orders require a total of five layers of the same SKU (2+3). Simply picking two layers from the donor pallet for the first order, leaves behind the three layers of stock required by the second order, creating a FreePick.

• MATERIALS HANDLINg

Simple steps to improve chemical safety work and all are preventable. Chemicals are used in 150,000 workplaces throughout New Zealand. But a lack of understanding of the harm chemicals can result in serious health problems from worker exposure. Common chemicals, such as petrol, LPG, paints and thinners have serious risks associated with them when they are not used properly, but because they are used so frequently they are often taken for granted.

Simple steps for the business owner As many as 1000 New Zealanders1 are thought to die every year as a result of occupational disease. Put in perspective, that’s three times our annual road toll. Many of these deaths are from longterm exposure to chemicals at

There are some simple steps that business owners can take to safely manage the chemicals in their workplace. The Environmental Protection Authority (EPA) believes that taking these simple steps will greatly reduce the risks from

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June 2012

working with chemicals. Prepare a list of all of the different types and amounts of chemicals used and stored at your workplace. Having a list also helps you to review whether you have chemicals that you don’t use. Getting rid of unwanted chemicals or reducing quantities may reduce your compliance needs and could therefore reduce costs. Make sure your chemicals are labelled and have a safety data sheet for each chemical. This is essential. If you don’t have a safety data sheet – ask your chemical supplier to give you one. Make sure that your staff are trained to use chemicals safely. The training should include what personal protective equipment must be worn and how to wear, clean and store it safely. Making sure your workplace is well ventilated is also important when using volatile chemicals, such as solvents. Have signs at your workplace to warn employees and visitors that chemicals are onsite and have an emergency management plan in place. Your emergency plan must be rehearsed with staff so that everybody knows what to do in the event of an emergency. You might need a location test certificate if you have flammable or oxidising chemicals at your workplace. This certifies that the place where the chemicals are used and stored is safely managed. For very hazardous chemicals you may also need an approved handler onsite. This is someone specifically trained to handle particular types of hazardous chemicals. Talk to a test certifier if you are unsure about what certificates you need. There is a list of test certifiers on the EPA website (www.epa.govt.nz). Ultimately, the health and safety of staff is the responsibility

of you, the business owner or manager. However, you can appoint someone else to be responsible for safely managing the chemicals at your workplace. That person doesn’t have to do everything themselves but needs to make sure that the things discussed above are done and safety precautions are in place.

Simple steps for the employee The responsibility for keeping safe with chemicals at work doesn’t just rest with the employer. Staff also have a responsibility. • Ask questions about the chemicals you work with. • Read the label and safety data sheet for the chemicals you use so that you understand the risks associated with those chemicals and know how to protect yourself. • Wear suitable personal protective equipment for the job. • Know what you need to do in the event of an emergency. Having employees and employers take these simple steps together is critical to preventing harm to people. Take the first steps to managing your chemicals safely today – someone’s life might depend on it. The EPA regulates hazardous substances under the Hazardous Substances and New Organisms Act 1996 and supporting regulations (HSNO). This legislation was previously administered by the Environmental Risk Management Authority (ERMA). ERMA was disestablished on 1 July 2011 and all functions were moved to the EPA. 1 Driscoll T et al. The burden of occupational disease and injury in New Zealand: Technical Report. NOHSAC: Wellington, 2004 Go to www.demm.co.nz/ enquiry quote: D120616

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• Thermal ImagIng

“Infrared thermography is not WYSIWYg” Thermography is a powerful and versatile predictive maintenance tool. However, Wayne Ruddock is convinced that only proper user training can unlock the full potential of this technology. DEMM: Can you describe the importance of infrared thermography in industrial maintenance? WR: Infrared thermography is the most versatile of the predictive maintenance technologies. It is the only tool that will give you fairly definitive results when looking for problems in electrical systems. It will identify three main problem areas. The main one is high resistance in relation to bad connections. For example, internal components such as contactors, fuses and fuse links to name a few. It will also identify areas of loading differences in the case of overloaded phases, imbalanced loading etc. An area that is receiving more attention lately is that of induced heating, due to its role in energy conservation. DEMM: And what about mechanical components? WR: Infrared is also a great mass screening tool for mechanical PdM inspections and will identify bearing issues as well as alignment problems in certain circumstances. The problem with this technology is that it will not give you a definitive cause for the overheating on a bearing. Imagine an overheated bearing. The cause cannot be determined from the infrared image. It could be overlubricated, it could be underlubricated, it could have a physical bearing defect, or it might even be an alignment problem. Infrared will only indicate that there is an abnormality, as all we see with an infrared camera is the radiated energy from the first 1/000 of an inch of the surface of the object being viewed. It is then up to the maintenance technician to invest more time on the problem and do further investigation with passive ultrasound or vibration analysis. Due to the expediency of mechanical inspections with infrared when compared to other testing methods, it can also be a viable mass screening tool to inspect motors and pumps as well. It can be used to identify overheating in equipment as compared to manufacturer specifications, as well as in comparative thermography looking at a number of pieces of equipment that are the same size doing the same job.

DEMM: What other applications can benefit from thermography? WR: Infrared is the best tool to identify and even quantify thinning or missing refractory insulation in furnaces, boilers and heaters in process type inspections. It will also identify missing or wet insulation in other insulated process vessels as well as pipe blockages etc, when there is a difference in temperature between the process and the ambient conditions. When considering facility maintenance, infrared will identify missing insulation, wet insulation, air infiltration and exfiltration, flat roof leaks on conventional flat roofs and a number of other structural and energy-related problems. DEMM: What other condition monitoring technologies do you need to complement thermography in order to set up a successful maintenance strategy? WR: To implement a successful and sustainable PdM programme it is necessary to employ all five condition monitoring tools, namely infrared thermography, vibration analysis, ultrasound, motor circuit analysis and oil analysis. To achieve maximum results with any condition-based monitoring programme it must be a part of an overall reliability centred maintenance programme. This programme should also have a computer package such as Maintelligence to bring all of the condition-based maintenance results together to give the manager of the programme the ability to see the health of each asset at a glance with the results of all the technologies tied together in one easy to access location. DEMM: What are the most common mistakes in connection with the use of thermal imaging cameras? WR: The biggest problem with the use of infrared thermography today is operator error. Many of the camera manufactures are now using terms such as fully automatic and on-screen temperature measurement, which does not give the true picture of how the technology actually works. This leads to erroneous conclusions and bad reports when it comes to equipment condition

“Proper training is the key to getting good results from infrared thermography.” Wayne Ruddock, Director Advanced Infrared Resources, wayne@infraredthermography.com

evaluation. Infrared thermography is not WYSIWYG. No infrared device in the world sees or measures temperature. You can get an accurate calculated temperature from a camera, but that only comes with proper manufacturer independent training and experience.

DEMM: What does the expert recommend to somebody thinking about buying a thermal imager for maintenance purposes? WR: Before buying an infrared camera one should understand how and why the technology works and then do an audit on their facility to determine the applications that are viable on your site. Once the audit is completed, they need to match the specification of the camera to their application needs. For example, many of the cheap infrared cameras on the market today are not suitable for doing certain electrical inspections due to an inappropriate instantaneous field of view (IFOV) value. Some cameras do not have a large enough temperature range to be suitable for some higher temperature applications. DEMM: Are there any important trends and/or developments in conjunction with thermographic cameras? WR: Due to the large drop in camera prices, infrared thermography has become a much more affordable tool in the field of predictive maintenance. The caution is that proper training is the key to getting good results from this technology. Organisations such as the NFPA in the USA have moved toward making infrared inspections of electrical equipment in industrial and commercial locations mandatory due to the high occurrence of electrical fires in the past.

• Thermal ImagIng

The top six places to look for energy losses in commercial buildings A considerable amount of energy loss is temperature related. Hot or cold air leaks from buildings are an obvious issue. That air took energy to heat or cool and when it dissipates due to a leak that energy is wasted. But many other systems and pieces of equipment also manifest wasted energy in terms of heat. With a small amount of training, most people can readily spot abnormal heat flow patterns with a thermal imager and follow the heat trail to energy waste. The technique works best when used by people who already possess a good working knowledge of the structures and systems being scanned and can better interpret the temperature variances they see on camera. Small, consistent changes can make a big difference in the profitability of any facility. Find problems fast, fix them, and win by realising the cost savings.

1. Building envelope “Building envelope” refers to the building structure as well as the climate controls within it. The envelope is what separates the outside environment from the inside, and it’s frequently imperfect. The problem with building envelope inspection is that the degree of temperature variance detected may often be very small, only a few degrees in some cases. The best time to scan is during a heating or cooling season, when there is a large difference in temperature. Similarly, beware of solar loading, wind, precipitation and other environmental factors, which could mask or

June 2012

distort potential problems. For instance, be careful to understand the direction and amount of heat flow when scanning an exterior wall if the sun is shining on it. • Roofs – wet roofing insulation loses much of its R-rating. This means heat can escape or enter the building much easier through wet insulating materials. In addition to looking for moisture issues, scan the roof surface and follow temperature differences to possible air leak entry/exit points. • Walls between conditioned and unconditioned spaces, including outside walls – due to the natural flow of air with different temperatures, significant air leaks tend to occur at the top and bottom of conditioned spaces, where air either enters or escapes a structure. • Construction joints and connections – for example, at floor slabs that extend outdoors, there are often heating or cooling losses by conduction through the slab. • Penetrations of the building envelope such as pipes, conduits and chimneys – un-insulated or unsealed gaps often exist around roof and wall penetrations. • Door and window frames and seals – locate air leaks around windows and doors caused by worn or missing seals.

2. Boilers Boilers are the heart of steam and hot water heating systems. • Refractory and insulation – thermal imaging makes the in-service monitoring and inspection of the condition of refractory linings for performance issues possible.

• Fan motors – as with motors in other applications, check for impeded airflow, electrical unbalance, overheated bearings and failing insulation. • Pumps – look for hot bearings, leaking seals and, as with fans, motor faults. • Valves – thermal imagers can identify blocked valves that are nominally open and leaking valves that are nominally closed. • Electrical connections – as with other kinds of systems, look for loose or corroded connections that increase resistance.

3. Motors and generators Electric motors are one of the biggest energy consumers in any facility. Overheating and malfunctioning motors and generators tend to indicate mechanical or electrical inefficiencies that lead to unnecessary energy use and sometimes even failure. Since generators are, in a sense, “reverse motors,” diagnostics are similar for both kinds of units. • Airflow – in fan-cooled motors, restricted airflow can cause general overheating often manifesting itself on the entire housing. • Electrical unbalance – a common cause, a high resistance connection in the switchgear, disconnect or motor junction box, can usually be pinpointed by an infrared inspection and confirmed using a multimeter, clamp meter or a power quality analyser. • Bearings – when thermal images reveal bearing housings with abnormally high temperatures, either

A thermal imager can spot abnormal heat flow patterns and thus reveal energy waste in buildings.

lubrication of the bearing or its replacement is often called for. Beware that over-lubrication can cause abnormal heating as well. • Insulation – look for higher than normal housing temperatures in areas associated with windings. For each 18 °F (10 °C) rise over the maximum rated temperature of a motor, approximately half the life of the motor is lost due to insulation failure. • Electrical connections – as with electrical connections in HVAC systems, look for loose or corroded connections that increase resistance. Heat losses due to high-resistance connections means that your energy is being given off as heat instead of being used for useful work.

4. Steam heating systems Today, steam systems are more common in industrial settings than commercial settings, but some commercial buildings still use them for central heating. • Steam traps – check traps

• Thermal ImagIng

using both thermal imaging and ultrasonic testing. Each technology works better than the other for certain traps and trap configurations. • Radiator coils – check for obvious steam leaks in radiators and at all visible pipe and joint connections. • Steam lines and valves – look for signs of leaks and blockages and for blow-by at valves that are supposed to be “closed.” • Condensers – look for leakage of outside air, which reduces the condenser’s vacuum, thereby decreasing its efficiency.

5. HVAC system The heating, ventilation and air conditioning (HVAC) system is usually one of the biggest energy consumers within a facility. • Ductwork and registers – even the highest-rated HVAC system wastes energy without a well-sealed duct system. With thermal imaging, one can see the thermal pattern of air loss or gain in ducting and also monitor registers to determine whether heating or cooling output is optimal. • Fans and blowers – these mechanical elements are, of course, motor driven. In fans and blowers, mechanical imbalance will manifest itself in overheated bearings and other components. Thermal images of these systems can also identify shaft misalignment in couplings between the motor and fan. • Electrical connections – loose or corroded connections increase resistance at the connection point, resulting in increased energy costs. • Compressors and coils – regular inspections of the compressors and coils can also help reduce energy costs. A malfunctioning compressor can have a different thermal signature than a properly-

We measure it.

HVAC is one of the biggest energy consumers within a facility.

operating one. If coils are blocked, or cooling fins are clogged, improper airflow and heat exchange can take place. This can greatly impact system efficiency, and also further reduce component lifespan.

6. Electrical system Many people don’t realise that electrical systems can actually waste money. As components degrade and resistance increases, waste occurs. • Distribution panels – check for unbalance in circuits and loose and corroded connections at breakers, contacts, fuse clips and buss work. • Transformers – be aware that if the temperature of one electrical leg on a transformer is significantly hotter than the others, that leg may be failing. • Lighting control circuits – check all wiring splices and connections at fuses, switches, in panels, and at the fixtures. Be aware that thermal imaging can also be used to monitor low-voltage control circuits. Thermal imagers have come down so far in price that most facilities can recoup the cost of purchase in terms of energy savings within six months. Plus incorporating infrared inspection into regular maintenance provides significant efficiencies and helps identify and prevent expensive failures. Go to www.demm.co.nz/enquiry quote:

NEW SEE MORE : THE NEW THERMAL IMAGERS FROM TESTO

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

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

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

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

Article submitted by Fluke

• Thermal ImagIng

Two new thermal imagers from Testo

The testo 876 comes in classical camcorder design.

With the thermal imagers testo 876 and testo 882, the German manufacturer is introducing two new models to the market (NZ distributor: Eurotec Ltd). The new models are already the third generation of imagers from the measurement technology specialist Testo, who entered the thermography market in 2007. Daniel Auer, Director of Product Management Infrared Measurement Technology: “Testo combines consistently strong technology with innovation. We relied on this strength in the development of our thermography solutions too – and have been very successful with it, as the past years have proven. With the new products,

we are again establishing technical standards – in order to again be able to offer our customer even more added value.” The testo 876 is the company’s first thermal imager in classical camcorder design. The light, 900g imager is equipped with a rotatable display. This makes thermography possible even in difficult-to-access places, opening up completely new opportunities, especially in professional industrial thermography: Due to the fact that the display can be rotated by up to 180 degrees, it is even possible for the user to work above their head without any problems. For users from the

fields of building thermography as well as industrial maintenance and servicing, this also means a security plus: Parts of buildings or industrial systems which are difficult to access can thus be thermographed from a different angle – and the exchangeable lens ensures optimum attention to detail. Thanks to its low weight and easy operation, the testo 876 adapts optimally to the requirements of the thermographer – for fast and versatile work. As the first Testo thermal imager with a 320 x 240 pixel detector, the testo 882 promises a high detail of accuracy without the necessity of an exchangeable lens. Equipped with a 32° lens, the new model offers the user all image details at a glance, ensuring fast, uncomplicated and precise work. Just as with testo 876, security is also paramount with the testo 882. It allows even the smallest faults in difficultto-access places or dangerous zones in industrial systems to be identified precisely and reliably – from a safe distance. With the detector size of 320 x 420 pixels, the testo 882 also fulfils the current standards of building thermography.

Case study: Thermographic mould and humidity measurement

Testo thermal imagers calculate the humidity value of each measuring point.

June 2012

Testo thermal imagers calculate the humidity value of each measuring point using the externally determined ambient temperature and air humidity as well as the measured surface temperature. And on the display the user is immediately able to detect what is invisible to the naked eye. Humidity in building interiors often leads to wide-ranging problems. Structural defects and inappropriate user behaviour can result in the formation of mould. Testo thermal imagers can be

used in many areas: • Locating thermal bridges. • Detecting air leaks. • Detecting cracks in the masonry. • Gas leak detection and location. • Energy consultancy. It is particularly important for moist areas on walls and ceilings to be made visible. This is because the earlier one detects the risk of mould developing, with its associated risks to health and equipment, the sooner it is possible to do something about it. Scientific studies have shown that humidity values of approximately 80 percent RH are required for mould to grow. Xerophilic fungi even grow from approximately 65 percent RH. Testo thermal imagers reveal sites at risk of mould, such as ceilings, walls or corners, directly on the camera display: points at risk are displayed in red, points not at risk appear green. One glance is all it takes to be assured that you are in the clear. No need to spend time on elaborate and complex calculations of humidity values or make a written note of them. Simply input the ambient temperature and air humidity into the thermal imaging camera, and the thermal imaging camera will take care of the rest and calculate the relative surface humidity value for each measuring point. In addition, an external wireless humidity sensor can be connected to the testo 881 and testo 882 models and can be used to transmit the ambient parameters to the thermal imaging camera. There is no need to input the readings manually. Thus, the continuous data transmission makes calculating humidity values even easier and more reliable. Go to www.demm.co.nz/enquiry quote:

•

D120620

• Thermal ImagIng

Thermal camera for maintenance inspections

The E30 is equipped with a 2 Megapixel visual camera to reference the exact position of the problem.

Flir Systems has unveiled its latest E30 thermal imaging camera – the latest addition to its E-Series range for electrical and mechanical maintenance inspections. The new E30 is equipped with a 2 Megapixel

visual camera which enables the operator to clearly reference the exact position of the identified problem with a visual image. By pressing just one button the camera stores the thermal image and the visual image simultaneously. A LED lamp at the front of the camera ensures good quality visual images can be taken in darker environments. Just like all E-Series cameras, the E30 is equipped with a laser pointer to help the user to associate the hot spot on the thermal image

An internal winding problem as seen with the IR camera.

with the real physical target in the field. The state-of-the-art uncooled Vanadium Oxide micro bolometer detector produces clear thermal images of 160 x 120 pixels. Temperature differences as small as 0.1˚C become clearly visible on a crisp thermal image. The E30 can measure temperatures between -20˚C and +350˚C. The Flir E30 is built tough and rugged to face up to everyday use in harsh environments and applications. The vital inner core is well protected (IP54 rated). Extremely easy-to-use, all buttons for controlling the E30 are right underneath your fingertips. The large 3.5” LCD touchscreen shows clear thermal images and allows access to all camera features. Every E-Series thermal imaging camera comes with Flir Tools software which

Overheated connection.

delivers thermal images directly from the E-Series to a PC and for basic reporting and analysis of your findings. Go to www.demm.co.nz/ • enquiry quote: D120621

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•Condition Monitoring

“We are too busy collecting data” Condition monitoring as such does not improve the reliability of a machine. But it can provide the necessary data to identify and deal with the root cause of a problem. Editor Stefan Richter talked to Clyde Volpe from the Vibration Institute of Australia about reliability maintenance.

DEMM: While teaching vibration analysis here at the MIT you mentioned that you don’t particularly like the term condition monitoring. Why is that? CV: Condition monitoring is an old technique we used to do to collect overall values from machines, like overall vibration or overall temperature and then trend them. If they went up we would then often plan to change the machine. Because of this CM is perceived by many engineers and managers as the collection of a value and trending it like a temperature reading or an overall vibration reading. When we are measuring these parameters with simple overall value measurement devices though we can only tell that the condition has changed, but not why it has changed. Today we have much more sophisticated analysers to do this and they are capable of much more than

June 2012

focus to one of reliability, but this will require substantial changes to the tradition CM approach. It’s time we moved on with a new approach and embraced the change.

those simple devices of past days. These are referred to as predictive maintenance tools, they are way more powerful and can isolate the actual problem by indicating if it is unbalance or misalignment, soft foot, a bearing outer race fault or loose foundations, for example. We can use these tools to predict what is actually wrong and what has caused it, and not just report that the vibration or temperature is increasing, which actually tells you nothing about the specific problem. By definition, condition monitoring and predictive maintenance are not the same thing. However, knowing the condition of a machine and predicting an impending failure does not improve the reliability of the machine. Knowing when a machine is going to fail is great, but you have not extended its life. Very often the fact that we are ‘doing condition monitoring’ holds us back from going forward and analysing the gathered data and ultimately finding and dealing with the root cause that is responsible for the failure in the first place. That’s why I don’t like the term CM. Very often we are just too busy doing condition monitoring and collecting data and miss the bigger picture which is to raise the reliability.

DEMM: Could you expand on that? CV: We ought to ask ourselves: What factors are affecting my reliability and what do I have to do to improve it? That’s precision or reliability maintenance. The word precision implies that something is done correctly, properly, precisely. This kind of maintenance focuses on things like precision balancing and alignment, soft foot correction, setting up proper foundations for machinery, correct lubrication, proper servicing and repairs, etc. When you merely gather machine data you’re not doing reliability maintenance. But you have to monitor the condition of the machine anyway, because if you know its condition, you can plan the adequate response to solve the cause and not just the problem. Detecting an increased vibration level of a bearing is a problem, and installing a new bearing might solve it for a while. But what caused it in the first place? Could it be misalignment, imbalance, or bad lubrication practises? When the data is collected, analysed and interpreted correctly, predictive maintenance can point to the root cause of a problem and offers the reliability maintenance engineer a powerful toolkit to do his job properly.

DEMM: What should we be doing then? CV: Reliability maintenance, that’s what we should be doing! The biggest thing holding us back is our resistance to change. We need to change from our present condition monitoring

DEMM: What exactly is contained in this reliability toolbox? CV: A reliability maintenance engineer needs tools to do his job, much like a mechanic needs tools to do his. His tools should include

the whole technology group: vibration analysis, oil analysis, infrared thermography, ultrasonics, laser alignment, precision balancing, etc. The more the better. There isn’t one tool that’s going to fix everything. A reliability maintenance engineer with only a computer in front of him is hopeless, all he can do is calculate reliability, but he can’t improve it. This toolbox will give him the tools to drive up reliability, which in turn drives availability, which is ultimately what we want. The better he knows how to use these tools, the better a position he will be in to help achieve this. But the tools need to be utilised properly and to their full capabilities. Some companies buy really good vibration analysers and use them as data collectors – they are more simply using them as a condition monitoring tool. The engineer has to determine all the ways in which existing equipment can fail and choose the predictive maintenance technology from the toolbox that can detect the respective failure mode. If there is a lot of electrical equipment, vibration analysis is probably not the best predictive tool to use. If you have lots of gearboxes, I would be using vibration and oil analysis. Are there lots of electric motors? You should consider doing motor voltage and motor current signature analysis together with vibration analysis. If there are a lot of motors and fans, I would focus on vibration analysis balancing and alignment. The equipment ultimately determines the suitable reliability maintenance tool you should use.

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• Condition Monitoring

DEMM: Is reliability maintenance the predominant form of maintenance in Australia and New Zealand at the moment? CV: It depends on the industry type. For example, the mining industry in Australia is heavily investing in this concept and reaping massive rewards for their efforts. But for many of the others, unfortunately I have to say no condition monitoring is still their focus; that said, the last two years have seen a real positive change towards this idea. Many ANZ companies are cutting the maintenance budget rather than investing in predictive maintenance, or worse still, things are still done on the old philosophy of condition monitoring and one or two parameters measured and trended. It is also not very conducive to improving reliability when these technologies are only applied to a small number of machines. Many companies just dabble in predictive maintenance, but expect big results from their half-hearted efforts. Very often the management is happy to have maintenance staff run around the plant taking vibration readings, trending these readings and then inform them if there is a problem with a specific bearing. There is no interest in identifying the cause. In these cases condition monitoring is merely used as a failure prediction tool. There is no improvement of reliability. Simply measuring a machine does not make it run longer, the same as going to see your doctor and having him measure your heart beat doesn’t make you live longer There are those people who take care of their bodies, eat well, do exercise, and see their doctor regularly. Others don’t do any of that at all. Some companies monitor their machines and assets for signs of trouble and practise reliability maintenance, others don’t. And then they wonder why they can’t compete in the marketplace…

June 2012

DEMM: What exactly needs to change in your opinion to improve reliability? CV: We need to make changes, nothing big or new really. We just need to be more precision focussed and carry out our work with this in mind. Training your people to fit bearings correctly, lubricate correctly, align correctly must be the end goal. Companies need to step up from where they are now, and strive to acquire quality data that’s worth analysing. When we take good care of our machines, they will perform more reliably. Manufacturers need to make sure their assets have been correctly specified and checked before they are actually put into production. If condition monitoring – which is the term we use for collecting the data and trending it – detects a potential problem, doing root-cause failure analysis is the right response, based on the data collected with the reliability maintenance toolbox. In that way manufacturers can find out why their equipment failed and implement the changes so that it won’t fail again. DEMM: Who is to drive the change towards reliability maintenance? CV: The new reliability engineers, these newly graduated creative bright engineers that want to make changes, are the guys I want involved. They still have the energy and desire to do it better, and will only get bored with the traditional reliability models. Whenever I am teaching a class and have a reliability engineer on the course I watch them get excited. Most leave with a renewed vigour to go out and change the world. Let’s face it, they are our only chance. If not an engineer then don’t be afraid to use that bright fitter or mechanic, etc, that works with precision; promote him to this position and skill him up. In fact the best I know of in the business come from these roots.

Locating the leakage China Steel uses NI PXI and LabView to build an air leakage detection system for sintering pallets. Iron manufacturing plants supply the steel industry with molten iron and raw materials. Coke, a solid carbon fuel and carbon source used to melt and reduce iron ore, and sinter, also needed for blast furnace iron manufacturing, are supplied by the coke furnace and the ore-sintering plant, respectively. The ore-sintering plant produces sinter as the raw material for blast-furnace iron making. During the primary processing procedure, the raw materials – iron ore, flux (such as limestone), and coke breeze – are made into pellets by adding water to the mixing cylinder and mixing evening, and then sent in their specified mixture ratios to the sintering machine for calcination. After the agglomerated sinter has been crushed and filtered, the five to 50mm sinter pellets are sent to the blast furnace as the primary raw material for iron making.

Difficulties encountered in the sintering plant The sintering permeability ( JPU) is an important indicator for testing the agglomeration status during the agglomeration process. The permeability status during the manufacturing process is ultimately determined by the ventilation quantity of the air exhaust system. In the air exhaust system, the sintering machine comes into the most direct contact with the raw materials and is the easiest location for gas leaks to occur. The sintering machine structure is made up of many sintering pallets with sealing devices located in front and behind each one. These devices come into contact with a hard metal plate at the bottom of the pallet beam and the side of the bellows. To prevent rubbing against the sharp sintering charge during the sintering process. (which results in scratching and air leakage, expansion space is required. If the sintering machine pallet has a leak), ventilation decreases, which causes difficulties in forming the pellets and decreases sinter output. An intact sintering pallet uses less electricity and has a lower system fan load because it does not have any leaks. A pallet with a leak requires the fan to rotate at a higher speed to maintain a certain amount of ventilation, so the motor driving the fan provides a higher drive current and wastes more energy. To increase the productivity of our sintering plant, we needed an effective way to test for the air leakage sources and analyse the leakage data as the basis for regular overhaul and replacement of the sintering pallets.

Past methods for leakage testing In the past, we used manpower to perform air leakage tests during the sintering machine operations. Under conditions where a lot of dust and noise (approximately 90 to 110dB) were present for extended periods of time, personnel had to make judgments based on what they could see and hear. However, tracing the source of a leak can be very difficult because leaks can occur at different points such as the charge level or the pallet. In addition, the degree of noise made by the leak is not necessarily related to the amount of air leaked. It is difficult to judge if a leak is serious by simply listening to the leak. Moreover, manual test results are difficult to quantify and record and cannot be used as a reliable reference for sintering pallet overhaul. To increase the test rate and prevent health risks to personnel under extended exposure to these poor working conditions, we wanted to establish an automated air leak testing system that allows

â&#x20AC;˘ Condition Monitoring

personnel to conduct immediate testing and monitoring of the air leak status of all sintering pallets by operating the system in an electrical room. We also wanted to use this system to carry out signal analysis and data recording as the basis for future sintering pallet overhauls. The value of information technology (IT) lies in the ability to analyse problems qualitatively and quantitatively to visualise the problem. To establish an air leakage testing system, we needed to know how to identify the air leak, how to identify the nature of different leaks and quantify the extent of their effect, and how to select the pallets most in need of maintenance based on considerations of planned maintenance and work capability.

reliability. NI provides a variety of reliable, modular hardware that targets each different measurement need and pairs LabView with the various toolkits. With this solution, we quickly developed a highly flexible, highly integrated customised system that fully met our needs and considerations. This system combines a sound array, radio-frequency identification (RFID) technology, and the NI PXI platform to provide an excellent solution for an automated air leakage testing system. We developed regulations for optimised testing using an acoustic pressure microphone based on air noise to test the pallet leakage status. At the same time, we used an array framework to fully test the leakage status of each part of the pallet, coupled with an NI PXI chassis, an NI

Developing a solution

PXI-8106 embedded controller, and an NI PXI-4472 dynamic data acquisition (DAQ) module to collect data. We used LabView as the development platform to accelerate the feasibility of inspection, verification, and the implementation method as well as to test the stability of the system. By providing immediate pallet leakage information and proper maintenance, we saved energy, reduced carbon emissions, increased production, and increased product quality.

Test results We installed the complete automated

PXI and LabView for machine condition monitoring

Before we chose a signal acquisition and analysis platform, we considered factors such as the usability of the platform programming language, computation capability, hardware communication, and long-term

Minimise Downtime

Increase Reliability

Improve Productivity

Maintenance Training Centre A crucial part of good maintenance is to develop a culture of maintenance best practice in the workplace. Skills4Work Maintenance Best Practice course will enable your tradespeople to understand what constitutes best practice and how to apply it.

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Foundation course for adopting international maintenance best practice. How to structure your maintenance to improve workplace culture and increase reliability. Part of Level 5 National CertiďŹ cate in Mechanical or Electrical Engineering. Leads to unit standard 26564 Apply knowledge of Business Centred Maintenance (BCM).

How to take your organisation through the 4 stages of Maintenance Excellence: Reactive Predictive Preventative Proactive How to use the building blocks of Maintenance Excellence for improved reliability and productiity. From the importance of precision maintenance and planning to the use of tools such as Reliability Centred Maintenance (RCM).

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• Condition Monitoring

test system in our top sintering plant to test and record the leakage status of each pallet. After repairing the 20 pallets with the most serious leaks based on the measurement data, we acquired favorable results. The average production quantity prior to periodic repairs was 6205 tons per day; after periodic repairs, the average output was 6292 tons per day, an increase of approximately 87 tons per day and an output rate increase of 0.65 percent. Because the sintering pallet system operates 24 hours per day – except during periodic repairs – we repaired only 20 pallets and markedly increased the output. While maintaining a fixed output, decreasing the leakage of the sintering pallets with the intention of increasing effective ventilation can decrease the load on the sintering pallet fan and thereby decrease the propulsion current needed by the propulsion fan motor.

The energy expended prior to repairs was 3282 kWs/h compared with 3245 kWs/h expended after repairs, resulting in an average annual savings of approximately ¥ 540,000 (more than $5,500 USD) per year in electrical costs. Throughout the entire sintering process, each kilowatt-hour produced 0.637kg of carbon dioxide; after using the system, the carbon dioxide discharge amount decreased by approximately 198 tons per year. Moreover, low air leakage increases the percentage of passing sinter. Thus, the amount of sinter that needs to be recovered decreases, which reduces recovery costs and avoids power costs incurred by resintering. Moreover, the sintered ore is the primary raw material for blast furnace molten iron. When an inadequate quantity of sintered ore is provided for

Now you can with pm-online a New Zealand developed multi site, multi industry, service and planned maintenance software (accessed via the web from any computer worldwide). pm-online has been designed to streamline service and planned maintenance administration so you and your contractors can get back to work and earn more income by reducing your paperwork.

At its core pm-online: • Organises your servicing and planning maintenance schedules, • Allocates work to employees and contractors, • Uses a single point of work completion input (no paper work or back office), including photo/image capture for offsite assessment, work audits and reports. • Provides pre-authorised maintenance and automated work authorisation requests at point of inspection/identification, • Enables multi device input and access from PC, laptop or handheld in either office or field locations.

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•

How many expensive repairs and maintenance surprises have you experienced this year? Too many? Here’s how you might be able to avoid those surprises, innovate and save money. The company pm-online has developed an automated, paperless “cloud” computer based system designed for businesses that manage and/or schedule planned maintenance checks on buildings, equipment and systems. The system has two distinctive components: a maintainable web based database available 24/7 and a mobile device based interface used to perform scheduled tasks on site, the results of which are uploaded instantly back to the web database. The system has been designed specifically with the customers’ needs in mind. It is fully automated, eliminating paper and replacing it with an electronic audit trail. It also eliminates errors, prevents incorrect tests being performed and invalid test results. All tests are performed to a plan and compliance with all NZ Standards. pmonline documents all systems to be maintained under a contract. It documents and displays the frequency of all tests, when they will be done and by whom. A barcode ensures the integrity of the planned maintenance system and that each piece of plant and system on site is uniquely identifiable. The system prompts to ensure all tests are completed by the due date. Test results are accessible by the user and their team at the click of a mouse. The system makes also sure all parties are alerted to remedial actions required to rectify any failed system components. Go to www.demm.co.nz/enquiry quote: D120626

June 2012

and support for the system development and assisted us in accelerating development and testing the viability of our green energy engineering solution. With the pallet air leakage testing system, sintered ore product quality and output are markedly increased and we will use this technology in other sintering plants in the future. Our solution has provided effective, substantial help in increasing personnel safety, saving energy, decreasing carbon emissions, and increasing output. Article by Dr. Wang Chih-Chung, Automation & Instrumentation System Development Section, Steel & Aluminum Research & Development Dept., China Steel Corporation (Taiwan). Go to www.demm.co.nz/ enquiry quote: D120624

Planned maintenance online

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the blast furnace, we have to externally purchase coking coal pellets as a substitute for the raw material. In the past, the sintered ore-to-pellet ratio used during the smelting process was approximately 78 to 22 percent. After conducting the periodic repairs, the amount of sinter provided by the sintering plant increased markedly, and the sintered ore-to-pellet ratio has reached 82 to 18 percent. We calculated that the increased output efficiency of using sintered ore instead of pellets is approximately ¥ 18 million per year. Furthermore, we improved the combustion efficiency using sintered ore as the raw material over pellets and increased sintered ore and blast furnace outputs, which conserved energy used by the blast furnace and lowered overall steel production costs. NI engineers provided service

•

• MAINTENANCE MATTERS

More power to the little guys! It is encouraging to read in the media the exploits of MESNZ chairman Barry Robinson and his latest innovation to supply the electrical requirements of his Drury engineering operation with solar power. (see page 40). SAFE Engineering demonstrates how even a small business can mix new technology with sustainability, financial responsibility and leadership and come out a winner on all fronts. It is not just the large companies that can make great gains in energy efficiency if they focus on it. The SAFE Engineering solar power story is a sage reminder of the history and inventiveness of kiwis and maintenance engineers. We are very good at finding ways to improvise and improve and as technology evolves, the ability to innovate increases more, not less. A good example of the application of new technologies and materials was demonstrated to me last year by Vyan Reddy at NZFI in Hamilton with the innovate cladding solution of his boiler house. Suffering from a variety of issues from the unclad structure, Vyan clad the building in clear vinyl. The result has to be seen to be appreciated; thermally efficient, visually clear, natural lighting, easy to install and maintain and cost effective. Innovation and attitude is not just restricted to physical assets; in the past month I have had the pleasure of working with the engineering departments of three mediumsized companies who are striving to lift their game. While the industries are dissimilar,

By Craig Carlyle.

the determination of these engineers to match 2012 processing capability with 2012 maintenance management professionalism is heartening and their can-do attitude assures me that they will succeed. These are examples of continuous improvement and innovation that should be shared amongst engineers, a goal that is at the core of the Maintenance Engineering Society (MESNZ). These success stories are just the tip of the iceberg and the challenge for the society is to provide the forum for the exchange and interchange of stories to our member engineers. Standing back and observing the success stories in engineering, energy efficiency, processing and change management gains the reader some respect for the huge potential that we still demonstrate in NZ industry. While the society puts a lot of work year-round into supporting engineers and creating opportunities to share experiences, the big event on the calender is the SKF National Maintenance Engineering Conference. This annual event, supported by official media sponsor DEMM Magazine, is unbeatable for providing inspiration and experience for attendees. The November 2012 Rotorua event is well supported by suppliers providing an amazing range of solutions for the inquisitive. Established and respected conference exhibitors such as Eagle Burgmann, Eurotec, Hydralink, ITW, John Brooks, SGS, SKF, Skills 4 Work and Stevenson’s will this year rub elbows with a

variety of new exhibitors such as 2 Degrees Mobile and People Passion. Matching the steady growth of electrical engineers in MESNZ and the national conference, industry suppliers Fluke and HV Power are also welcome new additions to the event. 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 and the preconference activities are entirely free! Details of all the MESNZ activities are available on the society website, www.mesnz.org.nz. As a resource for maintenance engineers, you would agree MESNZ is a busy little society, but not too large that we do not welcome your call to listen to your issue or ideas. Email, call, or better still, see you at the National Conference! Craig Carlyle Secretary MESNZ

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• MAINTENANCE MATTERS

Intro to Hazard and Operability (HAZOP) studies

Hazard and Operability (HAZOP) studies were initially introduced by ICI in the United Kingdom in the 1960s, but the technique only started to be more widely used within the chemical process industry after the Flixborough disaster in 1974. This chemical plant explosion killed twentyeight people and injured scores of others, many of those being members of the public living nearby. Through the general exchange of ideas and personnel the system was then adopted by the petroleum industry, which has a similar potential for major disasters. This was then followed by the food and water industries, and Hazop’s have now gained widespread acceptance across many differing industries. A Hazard and Operability (HAZOP) Study is a structured and systematic examination of a planned or existing process or operation in order to identify and evaluate, then eliminate or mitigate

June 2012

problems that may represent risk to health, safety, environment, community, equipment, or prevent efficient operation. In the context of existing plant, the application of a HAZOP study will be used to ensure change as a result of asset improvement does not have an undesirable effect (in that the change might introduce risk). A HAZOP study may also be carried out on existing plant to identify modifications that should be implemented to reduce risk and operability problems. The application of a HAZOP analysis will also be used as a tool during the design phase of Life Cycle Asset Management to identify and design out risk. The HAZOP study procedure involves taking a full description of a process and systematically questioning every part of it to establish how deviations from the design intent can arise. Once identified, an assessment is made as to whether such deviations and their consequences can have a negative effect on the safe and efficient operation of the plant. If considered necessary, action is then taken to remedy the situation. All industrial plant is designed with an overall purpose in mind. It may be to produce a certain tonnage of cut timber per year, to produce a specified amount of dairy product, or to process and dispose of a certain volume of effluent. While that would be considered to be the main design intent of the plant, it would also be considered a secondary intent to carry that out as efficiently and safely as possible. With this in mind, equipment is designed

and constructed in such a way that when it is all assembled and working together, it will achieve all the desired goals. However, in order to do so, each item of equipment, each pump and length of pipe work, will need to consistently function in a particular manner. It is this manner which could be classified as the ‘design intent’ for that particular item. In all but the simplest of plants, it is too much to expect any HAZOP study team to deal with all aspects and operations in the process simultaneously. Therefore, large systems must be broken down into logical areas of study and a specific point (known as a node) chosen to consider the design intent for the area we are studying. With continuous plant, one usually progresses from upstream to downstream, with services such as drains, vent headers, instrument air, cooling water, etc. being considered separately and last. Once a logical order for studying the plant has been determined the HAZOP process then goes on to look at how certain parameters such as temperature, flow or pressure could deviate from the norm. The team carrying out the HAZOP study then consider the consequences of the deviation and the possible cause or causes, plus any existing indicators or safety processes that may already be in place. The final element of the process is to decide on the most appropriate action to eliminate or mitigate the potential hazard. The process of carrying out a HAZOP study is essentially to use the experience of the team in a structured way to brainstorm potential failures or hazards and to consider actions to remedy those. This requires committing considerable resources to the process in the form of experienced personnel. However, the resulting knowledge, obtained by working through the process will not only identify potential hazards but will also identify operating problems. This can lead to a clear return on the investment in the form of productivity improvements beyond the obvious benefit of eliminating hazards. Phil Hurford is the Manager of the Skills4Work Maintenance Excellence Training. For information on training for maintenance staff, contact Phil at p.hurford@skills4work. org.nz or visit www.skills4work.org.nz.

• MAINTENANCE MATTERS

Rent a spider

At first sight, the appearance of a Spider Lift elevating work platform in action gives the impression that it might be better suited to a science fiction movie. Not so, actually it is much more likely to become something of a lifesaver to anyone contemplating a difficult access problem. Over the last few years, Auckland based access equipment company, Access Solutions Ltd has been closely considering the possibility of adding such a product to its range of rental options. As a result the company has recently purchased two Spider Lift EWP’s through New Zealand distributor and long-term business

partner, Youngman Richardson & Co. Ltd. To date the Spider Lift has been a largely unknown quantity but overseas experience has proven that the machines are gaining popularity with hire operators, contractors, councils, electrical authorities, aborists and general maintenance companies. “Whilst we have been examining the market potential for some time, it was vitally important that we proceed with somebody who could be relied upon to provide an efficient nationwide support and parts backup,” says Access Solutions Managing Director, Michael Biddick. “In Youngman Richardson & Co Ltd we found the perfect partner. We were also impressed with the wider range of product options that are available, including some larger spider lifts that may be considered in the future.” The recently delivered Spider Lift 15.75 and 18.90 are mid-range models that are suited to a wide range of applications. With its huge outreach, yet super compact dimensions, there’s just nowhere that the Spider Lift EWP can’t go. The extra-long four stabiliser legs make it ideal for steep terrain, difficult to access building applications and tall, hard to prune trees. A variable track width provides additional stability when the Spider Lift is in motion. When the job calls for an interior operation, dual power hydraulic pumps provide the ideal solution. Inside where space is at a premium, the Spider Lift EWP reduces down, once the

tracks are retracted, to a super compact size, making it possible for it to be driven to the site through a domestic doorway with ease. The Spider Lift EWP also has non-marking tracks to allow the machine to operate without damaging interior flooring. Benefits for the operator include superior noise reduction and greater visibility. Remote controls also allow the operator to control all functions from within the basket as well as from the ground. The platform can be quickly and simply detached with the removal of a single pin. The lightweight Spider Lift can be easily transported on a trailer and can be set up for the next job to save time before unloading. Access Solutions is a wholly-owned New Zealand company and has for the last 11 years concentrated most of its activities within the Auckland region. “That’s about to change,” says Michael Biddick. “We are now in the process of taking the business nationwide with the opening of branches in Wellington and Christchurch in the very near future. Along with the equipment rental side, Access Solutions has an aluminium manufacturing side to the company that supplies its own scaffolding products via the Oldfields scaffold brand. They also have a full scaffold service team of certified scaffolders with the ability to provide innovative solutions and top quality service. Go to www.demm.co.nz/enquiry quote: D120629

•

SKF Reliability Systems Excellence in Reliability Solutions

SKF Integrated Condition Monitoring SKF Reliability Systems hardware and software components are specifically designed to make it easier to collect, analyse, use and share machine condition data. From hand-held to hard wired to wireless, SKF has a complete, fully integrated range of condition monitoring tools and technology to help our clients. • Basic hand-held tools • Portable Data Collectors and Analysers • On-line Surveillance and Protection • @ptitude Asset Management System • Baker Electric Motor System diagnostics • Thermography • Laser Alignment and Geometric Measurement

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

• Proactive Reliability Maintenance • Engineering Solutions • Remote Diagnostic Centre

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

www.skf.co.nz 29

Enhancing the core: Improved SCADA in a collaborative operations management environment intensive. The emphasis today is on reducing programming and installation time to help speed up commissioning or upgrade. To do this at minimal risk, operations are looking for standardisation and the ability to reuse modules and libraries when configuring or upgrading.

Sustainability

The SCADA solution Vijeo Citect provides operations staff the visibility and control needed to manage processes efficiently. In the picture: Uddevalla Bridge, Sweden

Intensified cost pressures, compliance requirements and competition are raising the level of risk that organisations have to manage today. This in turn increases performance demands on operations staff. Some of the higher demands that they have to address in relation to their operations management solutions include the following topics.

Transparency With competition in process and commodity markets intensifying at a global level, there is a greater sense of urgency to streamline decision-making processes. To do this, operations staff are looking at how best to leverage SCADA for operation-wide visibility, draw actionable information, link it with business systems and deliver insight in a usable and digestible form.

Operational efficiency Monitoring and control

June 2012

tools that help raise productivity and lower maintenance and downtime costs have a direct positive impact on profitability of total operations.

Reliability and openness Process operations are increasingly looking for open solutions that facilitate seamless integration with different proprietary systems. Reliability is also critical, since at most operations, downtime cost increases exponentially with time since spill over impacts are wider than immediate productivity and revenue losses.

With increased compliance requirements toward greater transparency in all operational aspects, process operations are looking for solutions that meet these expectations cost-effectively. Energy management and efficiency Increasing population and expanding cities demand more power, water and infrastructure. In these industries, effective energy management is a tool to significant operational savings.

Ease of use As process complexity increases, the number of process variables to be tracked

Flexibility Of increasing importance is the need for scalable systems (so they can be reconfigured depending on changing needs and return on investments).

Engineering productivity The process of deploying operations management solutions is time and effort-

Bottling line

and analysed increases as well. To help prevent being overwhelmed with the depth and breadth of process data, organisations are seeking simplified and easier-to-use interfaces for the operations management systems.

PlantStruxure To address all of these challenges, organisations are changing work practices and adopting a much more holistic view of operations management solutions. The key questions now are not simply about how best to react to key process events, but more about how to be proactive in leveraging control systems for the health of the total enterprise. To help them do that, organisations are increasingly looking for complete, open and integrated solutions that are built from best practice. One such solution is Schneider Electricâ&#x20AC;&#x2122;s PlantStruxure â&#x20AC;&#x201C; a collaborative operations and monitoring solution

• SCADA

that provides industry and infrastructure organisations actionable insight to optimise operations and improve energy management. Comprising an integrated and standards-based system from field device to manufacturing execution system (MES), PlantStruxure has at its heart the SCADA solution Vijeo Citect that provides operations staff the visibility and control needed to manage processes efficiently while raising productivity and reducing risk. SCADA is more than just an event-driven process control system. By virtue of its ability to span operations and draw data from device level, its ability to connect with data repositories and its ability to generate actionable insight for business systems, SCADA is the core control solution that

facilitates system visibility, stability and optimisation.

Vijeo Citect V7.20 Features in V7.20 of Vijeo Citect aim to make SCADA simpler to engineer, smarter to use and more secure to maintain. Simpler to engineer with the server-side online changes feature, alarm, trend and report configurations can be changed without having to restart servers. Significantly, while reloading to the appropriate server, only changes are reloaded, thus leaving undisturbed the rest of the alarms, trend and reports, while at the same time reducing system traffic. Vijeo Citect can now integrate the video feed from Pelco surveillance cameras directly onto process displays. What this enables users to do is monitor critical processes, equipment and materials so

that they improve security, safety and process control and heighten the accuracy of condition assessment to ensure better-prepared maintenance or intervention in the case of an incident. Additionally, server-to-server authentication is now an added layer of protection for networked control systems. As operations consolidate and globalise, plants have new sections added on, existing areas expanded or modified and in the process, operations systems become larger and hold more data. Server-side online changes enable this to happen without the risk of operator error or downtime. Live video on SCADA screens direct from IP cameras located across key sites is likely to gather momentum since it provides a quick and intuitive add-on

to traditional process and security data assessments. Enriched tag information that adds richness and context to process data should help operators read this data more accurately. Graphic enhancements and the improved look and feel of templates will not only improve engineering efficiency for quicker project design, but will also simplify the user experience. All together, the focus on enhancing the core is expected to deliver richer operational and business benefits through easier and secure deployment, enhanced analysis and security and an improved user experience. Article submitted by Schneider Electric Go to www.demm.co.nz/ enquiry quote: D120630

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

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

• SCADA

The top five missed opportunities with HMI alarms and events Discover hidden but powerful features of your human-machine interface software that help you save time and ease troubleshooting. Interacting with alarms is one of the basic functions your operators expect from their human-machine interface (HMI) software. However, if you’re only using the standard alarming functions, your operators might be missing out on lesser-known features that could help you save time and ease troubleshooting. We examine five FactoryTalk alarms and events functions that are often overlooked but could be helpful to operators.

1. Associated tags In an HMI system, it’s useful to have additional system information associated with an alarm for streamlined reporting and more effective alarm handling. An alarm can be associated with up to four tags that are recorded in the alarm history log and also embedded in the alarm messages visible in an alarm summary or banner. By associating tags to include process data with event information and alarm messages, operators can receive relevant information automatically that describes what the system’s environment looked like when the alarm was triggered. For example, if you have a pump alarm associated with a flow-meter output value, a tank weight, and two process valves, you’d typically have to review trending data and activity reports to understand what might have contributed to an alarm becoming active. With associated tags, you get all pertinent information in one transaction which saves time

June 2012

and effort because it eliminates the need to run multiple reports and correlate the data in separate databases.

2. Alarm commands Addressing the cause of an alarm in a time-efficient manner is a top priority for operators. However, an HMI system that correctly identifies alarm conditions does no good if the operator still has to click through multiple screens and open new programs to access the controls needed to correct the problem. Recent advancements allow new HMI software applications to be configured to execute a command when the user double-clicks on the alarm in the alarm summary. For instance, an operator can double-click an active alarm and have the appropriate screen displayed for them to take corrective action. This is especially effective in a large HMI system where the operator must have access to a process screen or device faceplate to understand the area of concern before taking action.

3. Preconfigured control-status alarms HMI software should be tightly integrated with plantfloor controls and enable you to capture additional data beyond alarm and event information. Collecting data related to environmental factors, such as problems with controllers and other equipment, can help operators better understand what is happening in the system. Newer HMI applications incorporate preconfigured control-status alarms that indicate when an issue with a controller or its connection arises. In addition, operators should be able to

run reports showing in-depth detail regarding the conditions of the alarm. For example, with preconfigured control-status alarms, when an operator sees that data isn’t updating into its system, he can review the alarm summary and immediately see that the controller is in program mode and not run mode. This saves the operator time because he’s no longer trying to figure out if something needs correction.

4. Alarm classes When viewing many different alarms, it can be a time-consuming task to group like alarms together. Effectively organising alarms in an alarm summary or report can be simple when using alarm classes in some applications. The alarm class is a text string of up to 40 characters that operators enter when configuring an alarm. At run time, the value of the alarm class is recorded in the alarm history log, and the content is filtered based on the value of the alarm class. This enables you to easily sort or filter your alarms by function including, whether for valves that fail to open or close, pressure, temperature, equipment running or tank levels.

5. Remote alarm annunciation and escalation The last often underutilised alarm-and-event function provides operators with remote access and control capabilities. Specter Instruments, a participating Encompass Product Partner in the Rockwell Automation PartnerNetwork, incorporates a FactoryTalk alarms and events subscriber plug-in for its Win 911 product. With remote alarm annunciation and escalation a FactoryTalk system notifies

operators of alarms via text to speech (calling an operator’s cell phone), text pages, email or through voice-over TAPI modem. If the operator can’t be reached, the Win 911 product can use the escalation function if the nominated response rate is exceeded. For example, if the system gets no response when an operator is contacted, the system will escalate to the line supervisor. If the line supervisor doesn’t respond, the system will escalate to the plant manager, and so on until someone is reached who can address the alarm. Because the system is contacting people at home, it also gives employees the ability to remotely acknowledge and address the alarms. Poorly managed alarms and events can be disasters waiting to happen. Use these hidden tools and start streamlining your alarm management. Article by Tony Carrara, FactoryTalk View SE Product Manager, Rockwell Automation. Go to www.demm.co.nz/ enquiry quote: D120632

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Uncover more hidden alarm and event capabilities Visit these websites to discover more alarm and event opportunities: • Key features presentation of FactoryTalk Alarms and Events on SlideShare: http:// slidesha.re/x4b4Jm. • FactoryTalk Alarms and Events photos on Flicker: http://bit.ly/xOiUGG. • Rockwell Automation Manufacturing Intelligence: http://discover. rockwellautomation.com/hmi.

AS3000:2007 – Electrical wiring rules cause knock-on action to AS/NZS 3000. The Amendment 2 of AS/NZS3000 will be released for public comment in Sydney on 14 May 2012 in line for the EL-001 meeting on July 18/19 2012. The document should have been published on the Standards New Zealand website on Thursday 17 May 2012. Public comment received will be considered at a meeting in Hobart mid-April 2012. It is expected that AS/NZS 3000 amendment No. 2 will be published mid-May 2012. The EL-001 meeting will be discussing AS/NZS 3001 Transportable Structures (Connectable installations) proposed amendment No. 1 to clarify requirements for AU and NZ. The public comment document is expected to be released late Jan 2012 for one month. Public comment is expected to be small and publication expected late February 2012. The NZ only amendment A will be revoked when the amendment No. 1 is published. AS/NZS 3002, Shows and Carnivals; A proposal for some minor alterations has been received, if action for amendment proceeds, publication mid-2012. AS/NZS 3003, Patient Treatment Areas, this new standard was revised and published recently by another joint committee, but will

It is expected that the changes necessary will to be covered by amendment 2 of AS/ NZS 3000. AS/NZS 3004 series, Marinas and Boats; Some revision work proposed, but needs an approved Standards AU project to complete, approval is expected to be mid-2012. Publication expected late 2012/early 2013. AS/NZS 3008.1.2, Current ratings of cables. Requires minor technical corrections to some tables, these are expected to be published mid-2012. As the result of recent experimental testing carried out in Australia, the “totally surrounded with thermal insulation” values need to re-checked and modified as necessary. AS/NZS 3010, Generator sets; Extensive and major revision work has commenced, has an approved Standards AU project to complete, publication expected late 2012/ early 2013. AS/NZS 3012, Construction and Demolition sites; Minor technical correction proposed, publication expected mid to late 2012.

Electrical (Safety) Regulations 2010 The Energy Safety division of the Ministry of Economic Development (MED) issued

BUILD IT Exactingly right – Every time –

an advance copy of the draft Gas (Safety and Measurement) Amendment Regulations 2012 and draft Electricity (Amendment) Regulations 2012 for expert consultation on the 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 the 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 then submit comments 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 the 1 July 2013. Allan Hill National secretary New Zealand Electrical Institute (Inc).

• 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

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

INDUSTRIAL DRIVE TECHNOLOGY

NZEI Inc. – Auckland branch news A technical visit to Cuthbert Stewart Ltd (CSL) at their premises in Takapuna on the 12th of April was welcomed by the Auckland Branch of the NZEI with an excellent display of the company’s products. Geoff Thompson spoke about the range of surge protection devices (SPDs) available from CSL and the necessity to select the appropriate device for the point in the installation and the location according to the AS/NZS1768. The class C2 for industrial mains or overhead mains, C1B for distribution boards, or class A for final circuits.

Surge protection devices and methods Several companies make surge suppressors intended for phone lines and ISDN lines. Some are in-line connectors with modular plugs. Others are hardwired at the demark point. The main methods of protection are series and shunt. Series devices typically plug directly into the line between the equipment and the demark attempting to block incoming surges before they reach your equipment. Shunt devices attach in parallel with the line. They try to direct the surge away from the equipment by providing a better path to ground. Some devices combine both methods of protection.

For AC power lines Power conditioning and backup is fast becoming a requirement for many sensitive electronic devices including computers, audio processors, mission critical components and any device that relies on clean power for a CPU controlled device. Many of the home backup power devices even include RJ jacks for network and/or modem protection. Larger commercial types of power backup provide better protection that the smaller consumer devices. They have a better reaction time and offer better line filtering. Some of the very large installations tend to work in a “hot” mode where they are constantly online and commercial power is merely maintaining a charge on the batteries. A good surge suppressor should have some kind of an alarm system. This is because once a surge suppressor has done its job typically they are no longer any good and should be replaced. The technology behind some suppressors is that there are special components inside that get destroyed during a major lightning strike. The deadly force of the lightning is dissipated while components themselves are being destroyed. If a series device fails “open”

June 2012

it will prevent power from passing to your device. A shunt device may fail as well but unless it shorts the power to earth you might not know if the device is still protecting your equipment. This is the reason for some type of alarm or indicator informing the user of a failed status. Better surge suppressors have a longer useful life, but after so many lightning strikes they may fail. Power backup devices or uninterruptible power supplies (UPS) convert DC power supplied from batteries to AC power. Smaller units tend to provide just enough power to ride out a short duration power outage. The concept is to ride out the outages until power restores or provide enough time to shut down your equipment. More sophisticated UPS units can monitor their status and automatically shut down the protected equipment should a power outage occur. Small to medium UPS units tend to be preferred where there is a backup generator installed, such as a transmitter site. This works well when commercial power is lost and the UPS carries the load until the backup generator comes online.

Things to consider about UPS devices Some of the smaller and older UPS units provide little to no surge suppression. Many people buy these devices thinking that they are also protected from power surges. It is best to check the manufacturer’s specifications. Commercial AC power out of the outlet is typically a pure sine wave. Most UPS devices do not produce a pure sine wave output but a modified alternating square wave. Most equipment with switching power supplies and analogue power supplies can tolerate this modified sine wave but there is some equipment that cannot. Some of the more sophisticated UPS units do not tolerate “dirty” power. Dirty power is considered to be power that might be off frequency, with various spikes and sags within the waveform, and/or lower or higher voltage levels. Older and poorly maintained generators may not provide clean-enough power to the UPS units for them to switch from their batteries back to commercial/ generator power. Eventually the UPS will drain its batteries and your equipment is no longer powered. Some of the better UPS units allow adjustment of the AC line tolerance parameters. If the UPS has this feature you

may need to experiment with the settings to get them to work properly in your situation. Also dirty power has been known to cause some of the cheaper UPS units to lock up their CPU’s and prevent the unit from passing any power.

For RF devices Suppression of lightning and surges for RF follows the same principles for dissipating surges in power lines.

Grounding Proper grounding is essential to maintaining equipment safety. Many facilities employ a grounding system that is very intricate. The idea is to provide a central grounding point for all audio and broadcasting equipment to maintain a common ground. RF lines entering buildings from antenna structures would typically have copper strap bonded to the outer conductor and shunted to the common ground to help divert the major surge away from their equipment. Equipment racks in engineering rooms, studios, and transmitter sites are also tied into this common ground system to maintain the same potential. Dedication to proper AC and ground wiring techniques can ensure minimal risk to one’s equipment due to a surge and also can reduce incidents of ground loops and hum in your facility. Good studio grounding techniques are essential to minimise the damage of a lightning strike. With the proper grounding of your studio equipment and AC power ground, you stand a much better chance of surviving a lightning strike. Instead of losing the entire studio, you may only lose one or two specific items. With adequate surge protection, the damage to the specific item(s) will ideally be minimal (if any). There are a great number of technical papers, books, methods and philosophies on grounding. It is recommended you research the subject further and contact a vendor experienced in this field for any grounding recommendations to your facility.

Old fashioned tricks For years, computer technicians have talked of tying knots (usually three) in the power cords of the computers as lightning protection. They report that in really bad lightning strikes, the power cords with knots were totally destroyed… but the computer was perfectly fine. The only cost incurred was for a new power cord. Others have used

ferrite beads and looped the cords through these. Some people report the same results doing the same trick with phone lines.

Conclusions/recommendations Put the surge protection circuits close to the equipment. If possible, tie the ground of the line suppression unit to the common ground or the chassis of the protected equipment. Use a very short lead (4-6”) between the suppression module and the equipment. Establish a common ground in your facility and make the attempt to route all your grounds to that point. Choose UPS units suited for your application, making sure they can handle the equipment they will power. Check for features and options and verify the surge protection ratings. Always check your unit for faults especially after a major storm. All telephone and cables related to their equipment could experience a double lightning strike, from both the power lines and telephone lines/cable into the premises in the attempt to find its way to ground or earth. This can destroy the equipment. So protect all cabling into you equipment.

Upcoming meeting for the Auckland branch The Auckland Branch Committee have arranged for Mr John Sickels, the Registrar/ Group Manager of the Electrical Workers Registration Board (EWRB) and Electrical Workers Licensing Board (EWLB) to come to Auckland on Thursday 26th July 2012 to speak at our Branch meeting regarding impending changes to the Practicing License fees and other matters of importance to all of us in the Electrical Industry. The venue will be at the Delightful Lady Lounge at the Alexandra Park Raceway, Greenlane. For further information on this meeting please Contact Allan Hill Phone +64 021 613 448. Mr John Brothers Auckland Vice President Secretary & NZEI Inc Vice President

NZ Electrical Institute Inc. A.W.gooder Award Peter Robertson achieved the top mark in the 2010 EWRB Electrical Inspectors Exam and received the NZ Electrical Institute (Inc.) A.W. Gooder Award. The award consists of a framed certificate and an engraved bronze medallion. The icing on the cake for Peter was a cheque for $200 from the NZIE Education Trust. He left a job in electrical wholesaling to pursue an apprenticeship in electrical engineering. That was seven years ago and six years later he has not only completed his electricians exams and unit standards but also completed the exams needed to become an electrical inspector. Studying by correspondence at the Open Polytechnic and attending Block courses at Bay of Plenty Polytechnic, Peter’s schedule required organisation to ensure that all assignments and the paperwork for sign-off of the “on job” unit standards were completed. Having gained his electricians qualification he decided to study for the Electrical Inspector exam. All of the directors of ESP Technologies that Peter works with were most supportive and the weekly trips to the evening classes at Bay of Plenty Polytechnic were by company van. During his studies to become an inspector he “has mixed with and learned from like-minded people in the industry,” he said “it demands attention to detail and an intimate knowledge of 36 electricity standards.” The directors of ESP Technologies are most supportive of the Advanced Trade Certificate, of which the inspector exam is the first quarter, as they have only one inspector and having the depth of knowledge of an inspector maintains the highest standards needed for the diversity of work that the company carries out from the schools and high tech milking machines to extra safety involved in medical installations. Peter has written Joe Heappey, NZEI Awards Convenor procedures to put in place systems to ensure the best 2011 with Peter Robertson of ESP standard of installation, service and advice are offered to Technologies their customers.

NZEI Inc. – Schneider Electrical Award

The NZEI Inc.- Schneider Electrical Award was presented to Carson Cox on March 8, 2012 for gaining the best aggregate of marks in the EWRB exam nationwide. Carson's marks were 94 percent for the regulations examination and 91 percent for the Theory Examination. Carson’s marks were equal with one other candidate but as Carson was the youngest he won the award. The award was made at a morning tea function at Connetics Christchurch. This is the third time that a Connetics apprentice has received this award, following Steve Duggan in 2002 and Shaun McConnell in 2005. Carson intends to study further after completion of his registration as an electrician. He will be supported in this by his company.

EECA Awards honours innovative energy use Two large regional manufacturing plants have been honoured in this year’s EECA Awards. Dominion Salt, alongside engineers Aurecon New Zealand, won the Innovation Award for an ingenious project that expanded capacity without increasing energy use at the company’s Mt Maunganui plant. And Whangarei-based Golden Bay Cement won the Renewable Energy Award for its long-term project

June 2012

to substitute coal with locally-sourced bioenergy. Winners in nine EECA Award categories were unveiled at a ceremony in Auckland on 23 May. Combined, the EECA Awards entrants have saved or generated energy worth more than $600m, and have saved or avoided more than 1.7m tonnes of CO2 emissions. The Supreme Award, presented by Minister of Energy and Resources Phil Heatley, went

to Air New Zealand for energy-saving initiatives that have saved more than $540m in fuel costs.

Dominion Salt – Fisher & Paykel Innovation Award winner In 2009 Dominion Salt started a major upgrade of its existing vacuum plant to increase the production of food grade and pharmaceutical grade salt. The objective was to cost-effectively increase production

Dominion Salt won the Fisher & Paykel Innovation Award.

by at least 50 percent, or 20,000 tonnes a year, with the focus on manufacturing higher-grade pharmaceutical salt, for which export demand was growing. Before the upgrade, the plant was having to run continuously to cope with demand. The solution involved expanding an existing three-effect vacuum crystallising evaporator into a new five-effect evaporator in such a way that the existing three effects could continuously manufacture pharmaceutical salt, and the two new effects continuously manufacture food-grade salt. Aurecon’s project involved the installation of new salt crystal evaporation plant, a crystal separation centrifuge, a salt dryer, packing equipment and other utilities including a replacement steam turbine generation set. The new facility increased plant capacity by 63 percent to 76,000 tonnes of salt a year. It has also reduced energy consumption per tonne of product by 33 percent, and improved overall plant energy efficiency by 48 percent. This was achieved in two ways: • By incorporating two new effects into the original three-effect salt crystallising evaporator, and using vapour from the new steam-heated first effect to heat the following effects in a multiple-effect configuration. • By the use of higher energy waste streams, such as waste condensate, to pre-heat the incoming cool air to the new fluid bed dryer. This design modification meant the new dryer required 50 percent less steam than the existing dryer. The expansion has given Dominion Salt a significant competitive advantage in export markets, as its production costs are lower. It has decreased CO2 emissions by more than 3,000 tonnes. It has also helped with the training of plant operators as the 3-D AutoPlant

modelling that Aurecon carried out using laser scanning was used by Dominion Salt maintenance and operations staff to evaluate equipment accessibility and operation. The EECA Award judges described the Dominion Salt upgrade as “an exceptional engineering project.” “It was clever to get two products out for the price of one, without increasing energy costs. This is an example of an established industry applying innovation to existing technology, that over-delivers on productivity targets.”

Golden Bay Cement – Right House Renewable Energy Award winner In 2004 Golden Bay Cement started substituting the coal used in its cement kiln with locally sourced wood, including demolition and construction waste. This remained at a relatively low level of around 10 percent until mid-2008, when the company completed a capital upgrade on its kiln and carreid out a process trial which highlighted the opportunity to use more even more biofuel as a substitute for coal. The plant is now running on an average of 30 percent wood energy, and has plans to boost that further to 45 percent. This is saving Golden Bay around $3m a year in energy costs, and reducing annual CO2 emissiosn by 58,000 tonnes, which also means lower ETS charges. Golden Bay Cement’s annual thermal energy usage is up to 2.8PJ – the project has made it possible to use around 0.8PJ of biofuel as part of that. When it first examined the feasibility of biofuel substitution, Golden Bay Cement got design and supply options for a new fuel feed system from international experts that estimated the project costs at $5 million. The company then did an internal review, and with an innovative design that included using recycled material, managed to complete the project for only $1.5 million. The project also involved changing the operating characteristics of the kiln to take account of the energy required to drive off moisture and the impact of the introduced energy, on the chemistry of the final product. Outside the wood processing industry, which is traditionally a very high bioenergy consumer, Golden Bay Cement is one of the first industries in Northland to use wood biofuel for process heat. According to international

Golden Bay Cement is the Right House Renewable Energy Award winner.

benchmarking, the company is now one of the largest users of wood energy in the global cement industry. The judges said that in its large-scale use of biomass for heat, Golden Bay Cement was showing leadership as a major industry outside of the traditional wood processing sector. “This project should be an exemplar for non-traditional users of biomass such as the dairy industry. It’s an innovative use of local resources, with reduced waste to landfill as a bonus.” Also recognised at the Awards was SCA Hygiene Australasia, highly commended for its conversion to geothermal steam from natural gas; and Life Technologies Christchurch, commended for its heat recovery and other projects that have reduced diesel use at the site by 50 percent. Go to www.demm.co.nz/enquiry quote: D120636

•

EECA Awards winners at a glance Dominion Salt / Aurecon • Plant capacity: 76,000 tonnes per year. • Capital investment: $15m (upgrade was needed to meet growing demand). • Energy savings: $500,000 per year (expected to rise to $900,000 when full capacity reached). • CO2 avoided: 3,371 tonnes. • Energy saved over life of the project: 17,550 MWH.

Golden Bay Cement • Capital investment: $1.5m. • Energy savings: $3m per year. • CO2 savings: 210,269 tonnes. • Bioenergy generated over life of the project: 653,333 MWH.

HOW TO STOP YOUR FANS SUCKING PROFITS OUT OF YOUR BUSINESS Improving the energy efficiency of your pumping and fan systems can save thousands of dollars a year. But too often these savings aren’t realised because the opportunities are not obvious. An energy audit can show you where you can make improvements – and lock in savings. When a world-leading manufacturer of Medium Density Fibreboard engaged an EECA Business approved provider to audit their fan systems, they identified a great opportunity. The energy audit recommended an upgrade to motor controls which resulted in a 51% reduction in energy use, equating to a cost saving of around $127,000 annually, and a two year payback. What’s more, the project reinforced the company’s reputation for sustainably developed products. And because production was not impacted, management gained the confidence to pursue further energy efficiency initiatives resulting in more cost savings. EECA Business is offering funding towards pumping and fan system audits and grants to help implement energy efficiency projects.

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

Ogilvy/EEC2294

New Zealand’s largest solar power plant Many consider global warming to be a threatening fact, for others it is just a myth. However, businesses throughout the industrialised world are implementing policies and principles of sustainability with renewable resources. South Auckland Forging Engineering Ltd (S.A.F.E Ltd) in Drury has now risen to the challenge of sustainability by installing the largest photovoltaic solar electricity generating array in New Zealand. The official opening of the 68kW solar plant by Dr Paul Hutchinson, MP for Hunua, took place on Friday, 27 April 2012. S.A.F.E Ltd operates a heavy forging plant, a large heat treatment facility, machine shop, metallurgical laboratory and training programme all on its one three-hectare site, to provide a ‘one stop shop’ integrated manufacturing service. With drop-hammers and forging presses to 1200 tons, S.A.F.E Ltd produces specialised, customised, high-integrity product for most industries in New Zealand. Innovation and capacity expansion is a continual

development at S.A.F.E Ltd, with a new process for Titanium forging and extrusion currently under construction. The solar generation project was launched as a result of S.A.F.E Ltd’s management questioning how to reduce the ever-increasing electricity bill. Changing to a different supplier was investigated, but would only have decreased the bill by two percent. After further research and getting a number of quotes, the economic advantages of installing solar panels proved convincing. But cutting the energy bill was not the only motivation for going solar. Barry Robinson, General Manager, S.A.F.E. Ltd: “I don’t believe in things such as carbon tax and the Emissions Trading Scheme, but I am an absolute green!” How can that work? “I am asking myself: Do we do the right thing for our environment when we pay the carbon tax, or do we just do it to feel better? Does the carbon tax really and significantly reduce CO² emission, or does it only shift production to countries without any emission control, with our planet being much

S.A.F.E Ltd in Drury possesses the largest photovoltaic solar electricity generating array in New Zealand.

worse off? S.A.F.E. walks the talk and does what matters to keep the environment clean. We have spent a lot of money to install NZ’s largest solar power plant, because we are passionate about our community – our local community, our NZ community and the global community.” Barry says that S.A.F.E. absolutely believes in sustainability, and the triple bottom line of financial, social and environmental sustainability. “We forge products in steel, aluminium and copper, and soon hopefully titanium. All these metals are indefinitely recyclable. We give back to our community in many ways. We help run the non-profit

Maintenance Engineering Society of NZ, we actively support community organisations, and now we run a chunk of our plant on solar energy. When I see our machinery operating and think that the energy required is coming from the sun it really amazes me. We pride ourselves on walking the sustainability talk.” As part of the opening programme the attendees could witness a hot-forging demonstration in the company’s forging shop. “Hot forging is the strongest and often the most economic method of making a metal product. Steel is heated up to about 1200 degrees Celsius by electromagnetic induction NZ’S LARGEST ABC

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

Barry Robinson, the company’s General Manager, demonstrates the hot-forging process.

and plastically deformed with a forging press,” explains Barry, and adds, “We also conduct metallurgical investigations here, and we do trainings courses for engineers. We are currently building a new analytical laboratory which will be home to a full-time metallurgist. And for some years we have been contributing to a titanium powder project, which has the potential of adding considerable value to titanium products made in NZ rather than just export the resources we have here in NZ. We are planning to extrude titanium powder into solid products.” A major advantage of this solar installation is that S.A.F.E Ltd is able to contribute towards sustainable industry in New Zealand, without it being a huge ongoing financial burden to the company. There has been a significant financial investment required (about 250,000 NZD), but there is also a measurable return on investment that is well within the life-span of the solar array. “S.A.F.E Ltd looks forward to progressively innovating

in order to secure the future sustainability of the company and its customers,” says Barry. The 68kW solar array was planned and installed by Ramarama-based What Power Crisis Limited. It features 360 photovoltaic panels from ZG Cells with a maximum generation of 62.4kW. Six inverters change this electricity from DC to AC power required for S.A.F.E Ltd’s heat treatment furnaces, forging plant and CNC machines. Any surplus electricity is fed into the National Grid to be on-sold by Meridian Energy. The solar panels are ground-mounted rather than roof-mounted, and positioned at a 30 degree angle for maximum efficiency. Obviously solar panels will produce more electricity in summer than in winter, but the solar array is forecast to meet 70 percent of S.A.F.E Ltd’s electrical requirements over a 12-month period. A payback period of eight to nine years, and a return on investment of around nine percent is expected. There are a lot of variables still to be measured and there is some risk associated with increasing lines charges, coupled with reduced buy-back rates. “Meridian Energy has gone some way to reducing the risk with a two-year contract to buy back surplus electricity at the same rate as S.A.F.E Ltd purchases it from them,” says Barry. Go to www.demm.co.nz/enquiry quote:

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Logger series testo 174

Logger series testo 175

Logger series testo 176

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

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

D120640

An elegant way to connect a circuit board Han-Fast Lock delivers rapid user-friendly circuit board connection technology. Without the need for additional components, Harting now makes it possible to connect Han connectors to circuit boards with ease and flexibility. The Han-Fast Lock circuit board connector seamlessly meets the requirements of high currents, is easy to handle and comes in a space-saving size. During development, both technical requirements and optimised processing were the focus of attention. This was the only way to optimise overall circuit board production costs and minimise device costs. Han-Fast Lock makes circuit board production easy. It is easy to connect up to 60A current to a circuit board. But only Han-Fast Lock makes it possible to create contacts in a compact,

flexible and easy way. Only one contact point is needed to make the connection. Conductor lines are through-plated and given a drill hole and supporting point. Device manufacturers have access to pre-assembled system solutions. For example, the Han Q 4/2 connector with pre-connected litz wires and circuit board contact can be supplied as a pre-tested system and connected to the circuit board. Litz wires measuring up to 10mm² can be used with the Han-Fast Lock contact. The pre-assembled contact is fitted to the prepared circuit board and the pin provided is engaged to lock the circuit board. It is extremely easy to use and comparable to any commercially available snap connector. Go to www.demm.co.nz/enquiry quote: D120642

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Redundancy with zero switchover time

Hirschmann has extended its product program to include Ethernet switches from the new RSP family. These are especially designed for use in the field-level networks of power supply companies, but they also can be used in any situation where uninterrupted communication is required, for instance for mechanical engineering projects or drives for production facilities. These extremely robust fanless switches have eleven ports, three of which can be used for SFP transceivers. These support Fast (100 BASE-FX) or – optionally – Gigabit Ethernet (100/1000 BASE-

June 2012

FX). The remaining eight ports can be used either for 100 BASE-TX or as a combination of four SFP transceivers and four TX ports. Additional features of these switches include comprehensive management, diagnostic and filter functions plus a variety of redundancy methods and markedly expanded security mechanisms. In addition to the standard configuration, Hirschmann also offers a version that supports highly precise synchronisation compliant with IEEE 1588v2, plus PRP (Parallel Redundancy Protocol) and HSR (High-availability Seamless Redundancy).

This means that, for the first time, it is now possible to implement networks that guarantee uninterrupted data communications with the attached systems and can thus – in the case of the electricity supply industry – guarantee reliable power supplies to end customers at all times. These switches, which comply with the standards and approvals of IEC 61850 3, IEEE 1613, EN 50121 4, NEMA TS2 and cUL 508, are remarkable for their high vibration resistance and extensive resilience to magnetic fields and electrostatic discharges, and can also withstand ambient temperatures in the range -40°C to +70°C. The supply voltage may be either 24/48 V DC or 60/120/250 V DC and 110/230 V AC. Redundancy methods such as PRP, HSR and PRP/HSR Redundancy Box, RSTP, MRP and Fast MRP ensure a high level of network availability. The supported security mechanisms include authentication, radius, role based access, port security, SSHv2; HTTPS and SFTP. The switch status can be monitored locally using indicator contacts while detailed information can be displayed via a standard web browser. The integrated SNMP interface offers an additional centralised management function that makes it possible to use network management software such as Industrial HiVision. Go to www.demm.co.nz/enquiry quote: D120642a

•

Platform for embedded monitoring of both worlds. The devices also feature built-in analog I/O so engineers can take advantage of the company’s analog expertise in addition to their application-specific circuitry. The devices’ low-cost, small form factor; built-in I/O; realtime processor; and FPGA provide an ideal platform for embedded monitoring and control applications in industries such as medical and energy. Go to www.demm.co.nz/enquiry quote: D120643

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National Instruments has announced four new NI Single-Board RIO board-level embedded devices featuring a real-time processor, Spartan-6 field-programmable gate array (FPGA), analog and digital I/O and more built-in peripherals for custom embedded control and monitoring applications. The new devices provide engineers with off-the-shelf FPGA and real-time processor technology through NI LabVIEW while maintaining the custom I/O often required for high-volume deployments through the option of a RIO

Mezzanine Card connector. The connector provides direct access to FPGA digital input/ output (DIO) lines and certain processorspecific functions for mating custom daughter cards. NI Single-Board RIO alleviates the effort of designing an entire system from scratch so designers can focus on the custom parts of their applications, such as the I/O. With the new devices, engineers can achieve the shorter time to market of an off-the-shelf system along with the I/O customization offered by in-house designs, providing the best

Stand by me Distributed throughout New Zealand by Youngman Richardson & Co. Limited, Pramac generators have a range of mains failure stand-by compatible products that are designed and proven to meet a wide variety uses from domestic to industrial and farming applications. Manufactured in Spain and the USA, Pramac Generators are one of the world’s largest producers of quality generators. With models from 6kVA to 2000kVA and powered by engines such as Yanmar, Perkins and Deutz, these generators are factory fitted with automatic mains failure (AMF) control panels and offer full LTS (load transfer switches) boxes as off the shelf options. The Pramac generator P series is available in both single and three-phase models. Both units have a silenced canopy that lifts up for easy inspection and at only 70 dba at 7m, is very easy on the ears. The overall size of the Pramac P series is 1451mm long, 650mm wide and 975mm high and they weigh in at 325kg. These particular models have a maximum output of 10.6kVA and a

continuous output of 10.0kVA with a voltage of 230V, 50Hz for the single phase model and 400/23V, 50Hz for the three phase. The company also stock a smaller LPG/Natural Gas model which has proven to be an ideal stand-by generator. This model has sound dampening and a weatherproof enclosure, high temperature protection and battery condition monitoring. Larger models are available up to 200kVA ex stock which are designed for use mainly on major construction sites and other industrial applications. Go to www.demm. co.nz/enquiry quote: D120643a

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Contactor select app now available

Selecting contactors and overloads for three phase electric motors is made easy with the Contactor Select App from NHP. By simply selecting the motor voltage and kW, the Contactor Select App will display the motor FLC (Amps) and suggest which contactor and overload to use. The Contactor Select App selects from NHP’s premier Sprecher + Schuh brand, with contactor and overload selection made easy by providing users with the exact product number and product photo of the contactor or overload they need, as well as easy access to NHP’s 0800 NHP NHP sales number and website. Useful for designers and electricians as a handy pocket reference tool, the Contactor Select App calculates full load current of three phase motors and allows correct product selection and overload settings to be made. While it is now available on the iTunes App Store and on Android devices, it is also available in a web friendly version at nhp-nz.com. Go to www.demm.co.nz/ enquiry quote: D120643b

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• EVENTS

Coming events EEA Conference 2012

20-22 June 2012 SkyCity Convention Centre in Auckland The Electricity Engineers’ Association Conference and Trade Exhibition is the premier power engineering event for the New Zealand electricity supply industry. The aim of the conference is to provide a national forum for engineering practitioners and technical experts to examine and discuss industry issues, developments and technologies in the field of power engineering. www.confer.co.nz/eea/index.htm

Smart Electricity World 2012

02-04 July 2012, Crown Casino, Melbourne, Australia In 2012, Smart Electricity World is co-located with The Utility Show and Electric Vehicles World. Meet senior level executives from Australasia’s electricity and EV industries at this innovative series of events exploring the energy supply chain. This is a must-attend event for anyone involved in the electricity supply chain, or exploring our electric vehicle future. www.terrapinn.com/2012/smart-electricity-world/

Best Practice in Industrial Compressed Air Systems

06 July 2012 University of Waikato, School of Engineering, Hamilton Attendees will be able to leave with a basic capability to identify system efficiency opportunities and work confidently with skilled service providers to realise the energy efficiency opportunities available. Contact: jamesn@waikato.ac.nz, www.energyefficiencynz.com

New Zealand Oil & Gas Exhibition 2012

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

Foodtech Packtech

25 to 27 September 2012 ASB Showgrounds, 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 Organization. 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

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

June 2012

LOOKINg FOR NEW BuSINESS AND SALES ENQuIRIES? Contact Frank Atkinson Email / frank@adrenalin.co.nz DDI / (09) 477 0362

ROTORUA 7-8 NOVEMBER g The forum-based open networkin ers. ine eng ce conference for maintenan

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E V A S 05 $ 1,5 SPECIAL PRICE $

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Unit D/38 Highbrook Dr, East Tamaki 46

June 2012

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6_DEMM_010612

Specifications & Prices are subject to change without notification. All prices exlude G.S.T. Valid until 30-06-12